RWH ROTARY SCREW COMPRESSOR UNITS
INSTALLATION - OPERATION - MAINTENANCE
070.620-IOM (DEC 12)
Page 2
Contents
MAINTENANCE
GENERAL INFORMATION ................................................. 23
NORMAL MAINTENANCE OPERATIONS ........................... 23
GENERAL MAINTENANCE ................................................ 23
COMPRESSOR SHUTDOWN and START-UP .....................23
GENERAL INSTRUCTIONS FOR REPLACING
COMPRESSOR UNIT COMPONENTS ......................... 23
OIL FILTER .......................................................................24
STRAINER - OIL PUMP ....................................................24
STRAINER - LIQUID INJECTION .......................................25
COALESCER FILTER ELEMENT(S)...................................... 25
CHANGING OIL ................................................................ 25
PUMP DISASSEMBLY .......................................................26
PUMP ASSEMBLY ............................................................27
THRUST BEARING ADJUSTMENT .....................................28
INSTALLATION OF CARBON GRAPHITE BUSHINGS .......... 28
TROUBLESHOOTING THE PUMP ...................................... 29
MAINTENANCE SCHEDULE .............................................. 30
PREVENTATIVE MAINTENANCE ......................................30
RECOMMENDED MAINTENANCE PROGRAM ....................30
VIBRATION ANALYSIS ......................................................30
OIL QUALITY AND ANALYSIS ..........................................31
OIL SAMPLING PROCEDURE ............................................ 31
OPERATING LOG .............................................................. 31
MOTOR BEARINGS .......................................................... 31
GREASE COMPATIBILITY .................................................. 31
NLGI GREASE COMPATIBILITY CHART ............................. 31
TROUBLESHOOTING GUIDE .............................................32
ABNORMAL OPERATION
ANALYSIS and CORRECTION ....................................32
PRESSURE TRANSDUCERS - TESTING ............................. 33
PRESSURE TRANSDUCERS - REPLACEMENT ...................34
CAPACITY LINEAR TRANSMITTER - SLIDE VALVE ........... 34
VOLUME RATIO CONTROL TRANSMITTER - SLIDE STOP
.. 34
TEMPERATURE SENSOR ..................................................35
OIL LEVEL TRANSMITTER ................................................ 35
TROUBLESHOOTING THE RWH COMPRESSOR ................ 37
THE PUMP SYSTEM ..................................................37
THE OIL SEPARATION SYSTEM .................................38
THE HYDRAULIC SYSTEM .........................................38
MOTOR and BARE COMPRESSOR REPLACEMENT ...........39
SAE STRAIGHT THREAD O-RING FITTINGS ASSEMBLY
PROCEDURE .............................................................39
SHUTDOWN DUE TO IMPROPER OIL PRESSURE
(HIGH STAGE and BOOSTER) ....................................39
COMPRESSOR PORT LOCATIONS .................................... 40
SAMPLE P & I DIAGRAM .................................................. 43
PROPER INSTALLATION OF ELECTRONIC EQUIPMENT IN
AN INDUSTRIAL ENVIRONMENT ...............................46
FORMS ............................................................................51
INDEX .............................................................................. 58
PREFACE............................................................................ 3
DESIGN LIMITATIONS ......................................................... 3
JOB INSPECTION ............................................................... 3
TRANSIT DAMAGE CLAIMS ............................................... 3
COMPRESSOR and UNIT IDENTIFICATION ......................... 3
COMPRESSOR IDENTIFICATION ........................................4
INSTALLATION
FOUNDATION ....................................................................5
RIGGING and HANDLING .................................................... 6
CHECKING MOTOR/COMPRESS OR ROTA TION .......................6
COMPRESSOR/MOTOR COUPLING INSTALLATION ............. 6
COUPLING ALIGNMENT PROCEDURE ................................. 7
HOT ALIGNMENT OF COMPRESSOR/MOTOR ...................... 9
OIL PUMP COUPLING ......................................................... 9
HOLDING CHARGE AND STORAGE.....................................9
OIL CHARGE ...................................................................... 9
OIL HEATER(S) ...................................................................9
OIL FILTER(S) ................................................................... 10
THERMOSYPHON OIL COOLING .......................................10
LIQUID INJECTION OIL COOLING (Optional) ...................... 11
LIQUID LINE SIZES/RECEIVER VOLUME ............................11
WATER-COOLED OIL COOLING (OPTION AL) .................... 11
ECONOMIZER - HIGH STAGE (OPTIONAL) .......................12
ECONOMIZER LOAD BALANCING ..................................... 13
ELECTRICAL ..................................................................... 13
MOTOR STARTER PACKAGE ............................................13
CURRENT TRANSFORMER (CT) RATIOS ........................... 15
MINI MUM BURDEN RATINGS ...........................................15
CONTROL POWER REGULATOR ....................................... 15
OPERATION
OPERATION and START-UP INSTRUCTIONS .................... 16
TDSH COMPRESSOR .......................................................16
COMPRESSOR LUBRICATION SYSTEM .............................16
CONTROL PUMP OIL SYSTEM ......................................... 16
FULL TIME PUMP SYSTEM ............................................... 17
COMPRESSOR OIL SEPARATION SYSTEM ....................... 17
DISCHARGE BUTTERFLY CONTROL OIL SYSTEM .............17
COMPRESSOR HYDRAULIC SYSTEM ...............................17
VOLUME RATIO CONTROL ............................................... 18
COMPRESSOR OIL COOLING SYSTEMS ........................... 18
SINGLE-PORT LIQUID INJECTION ................................... 18
DUAL-PORT LIQUID INJECTION ....................................... 18
QUANTUM
™
LX EZ-COOL
™
LIQUID INJECTION
ADJUSTMENT PROCEDURE ......................................19
SUCTION CHECK VALVE BYPASS ..................................... 21
LOW AMBIENT OPERATION ............................................. 21
BALANCE PISTON PRESSURE REGULATOR ...................... 21
INITIAL START-UP ........................................................... 21
INITIAL START-UP PROCEDURE .......................................22
NORMAL START-UP PROCEDURE ....................................22
VFD SKIP FREQUENCIES ..................................................22
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