Intermech BBR-6015-2 Manuale utente

Compressor Service Manual

Customer :

Company Origin Energy

Address 1 King William Street

City/State Adelaide, South Australia

ZIP Code 5000

Phone +61 8 8217 5211 (reception)

Fax +61 8 8217 5768 (reception)

Email Address [email protected]

Site Location East Perth Bus Depot, Kensington Street,

East Perth, Western Australia, 6004

Product Compressor BBR- 6015-2 Vol. 2 (J1563)

Model No CO-BBR-6015-2

Serial No R4837; R5081

INTERMECH LTD.

88 Leonard Road, Penrose

PO Box 12284, Penrose

Auckland, New Zealand

Ph 64 (9) 525 2220

Fax 64 (9) 579 3900

Email [email protected]

REVISIONS RECORD

Revision Date Changes / Additions Issued

1 March,2006 New edition

Table of Contents

1GENERAL.....................................................................................................................................6

1.1 INTRODUCTION.......................................................................................................................6

1.1.1 Compressor General Arrangement -(BBR-6015-2)..........................................................7

1.1.2 Compressor GA – X-Section (BBR-6015-2) .....................................................................8

1.1.3 Compressor Parts List - (BBR-6015-2) ............................................................................9

2SAFETY.......................................................................................................................................10

2.1 GENERAL SAFETY ................................................................................................................10

2.2 MAINTENANCE SAFETY........................................................................................................11

3COMPRESSOR SPECIFICATION..........................................................................................13

3.1 MODEL.................................................................................................................................13

3.2 DESIGN SPECIFICATION........................................................................................................13

3.3 MANUFACTURER’S PLATE & LABEL INFORMATION.............................................................13

3.3.1 Specification Plate..........................................................................................................13

3.3.2 Cylinder Identification Plate ..........................................................................................14

3.3.3 Suction Identification Plate ............................................................................................14

3.3.4 Discharge Identification Plate........................................................................................14

3.3.5 Warning Plate.................................................................................................................15

3.3.6 Rotation Plate.................................................................................................................15

3.4 CLEARANCES .......................................................................................................................15

3.4.1 Original Running Clearances.........................................................................................15

3.4.2 Piston Ring Side Clearances / End Gaps........................................................................16

3.4.3 Piston to Cylinder Clearances........................................................................................18

3.4.4 Torque Settings...............................................................................................................18

3.4.5 Rhino Compressor Tools ................................................................................................20

3.5 OPERATING PROCEDURES ....................................................................................................21

3.5.1 Start Up Check List Contents .........................................................................................21

3.5.2 Package Details..............................................................................................................21

3.5.3 Prior to Starting..............................................................................................................22

3.5.4 After Starting ..................................................................................................................23

3.5.5 Maximum Allowable Working Pressure .........................................................................23

3.6 LUBRICATION.......................................................................................................................24

3.6.1 General Description.......................................................................................................25

3.6.2 Oil Specification.............................................................................................................25

3.6.3 Before Starting................................................................................................................26

3.6.4 Top Up With Oil .............................................................................................................26

3.6.5 Primary Starting.............................................................................................................26

3.6.5.1 Priming the lubrication system using priming pump...........................................................27

3.6.6 Oil Filter.........................................................................................................................28

3.6.7 Lube Oil Pressure Adjustment........................................................................................28

3.6.8 Oil Relief Valve Setting...................................................................................................28

3.6.9 Compression Cylinder Injection Lubrication System .....................................................29

4MAINTENANCE........................................................................................................................30

4.1 GENERAL .............................................................................................................................30

4.2 OIL PUMP (CRA-357) & OIL PUMP HOUSING (CRA-352-1)................................................31

4.2.1 Oil Pump Housing Drawing (CRA-352-1) .....................................................................31

4.2.2 Oil Pump Housing (CRA-352-1) Parts List....................................................................32

4.2.3 Oil Pump Assembly Drawing (CRA-357).......................................................................33

4.2.4 Oil Pump Assembly (CRA-357) Parts List......................................................................34

4.2.5 Oil Pump Relief Valve Drawing (CRA-333)...................................................................35

4.2.6 Oil Pump Relief Valve (CRA-333) Parts List .................................................................36

4.2.7 Disassembly – Oil Pump Housing..................................................................................37

4.2.8 Disassembly – Oil Pump Relief Valve ............................................................................37

4.2.9 Disassembly – Oil Pump.................................................................................................37

4.2.10 Assembly – Oil Pump.................................................................................................38

4.2.11 Oil Pump Relief Valve................................................................................................38

4.2.12 Assembly – Oil Pump Housing (CRA-352)................................................................39

4.3 RHINO CRANKCASE (CRA-3603).........................................................................................40

4.3.1 Rhino Crankcase Drawing (CRA-3603).........................................................................40

4.3.2 Rhino Crankcase Drawing (CRA-3602).........................................................................41

4.3.3 Rhino Crankcase (CRA-3603) Parts List........................................................................42

4.3.4 Rhino Crankcase (CRA-3602) Parts List........................................................................42

4.3.5 Taper Lock Bearing Housing Assembly Drawing (CRA-3640)......................................43

4.3.6 Taper Lock Bearing Housing Assembly Parts List (CRA-3640).....................................44

4.3.7 Rhino Crankcase Filler Bowl Drawing (CRA-820)........................................................45

4.3.8 Rhino Crankcase Filler Bowl (CRA-820) Parts List ......................................................46

4.3.9 Disassembly – Crankshaft (CR-3253) ............................................................................47

4.3.10 Assembly – Crankcase (CRA-3603)...........................................................................48

4.4 DRIVE END BEARING HOUSING / MECHANICAL SEAL ASSEMBLY (CRA-356)....................51

4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356 RevB)...................51

4.4.2 Mechanical Seal Housing (CRA-356) Parts List............................................................52

4.4.3 Disassembly / Assembly - Mechanical Seal....................................................................53

4.5 CONNECTING ROD ASSEMBLY .............................................................................................55

4.5.1 Connecting Rod Assembly Drawing (ROA-8525)...........................................................55

4.5.2 Connecting Rod Assembly Parts List (ROA-8525).........................................................56

4.6 CROSS HEAD CYLINDER/PISTON (CYXA-6003)..................................................................57

4.6.1 X-Head Cylinder Assembly – (CYXA-6003)...................................................................57

4.6.2 X-Head Cylinder Parts List– (CYXA-6003)....................................................................58

4.7 CROSS HEAD CYLINDER/PISTON (CYXA-6004)..................................................................59

4.7.1 X-Head Cylinder Assembly – (CYXA-6004)...................................................................59

4.7.2 X-Head Cylinder Parts List– (CYXA-6004)....................................................................60

4.7.3 Disassembly - Cross-Head Cylinder/Piston ...................................................................61

4.7.4 Assembly - Cross-Head Cylinder/Piston ........................................................................61

4.8 1ST/2ND STAGE CYLINDER/PISTON / PISTON ROD ASSEMBLY .................................................63

4.8.1 Cylinder Assembly – X-Section (CYA-6046-3)...............................................................63

4.8.2 Cylinder Assembly – Exploded View (CYA-6046-3).......................................................64

4.8.3 Cylinder Assembly (CYA-6046-3) Parts List..................................................................65

4.8.4 Cylinder Head Assembly Drawing - (HEA-6000)...........................................................67

4.8.5 Cylinder Head Parts List – (HEA-6000) ........................................................................68

4.8.6 Disassembly – 1st / 2nd Stage Piston...............................................................................69

4.8.7 Reassembly 1st / 2nd Stage Cylinder................................................................................69

4.9 3RD / 4TH STAGE CYLINDER/PISTON/PISTON ROD ASSEMBLY...............................................71

4.9.1 Cylinder Assembly – X-Section (CYA-3015-1)...............................................................71

4.9.2 Cylinder Assembly – Exploded View (CYA-3015-1).......................................................72

4.9.3 Cylinder Assembly (CYA-3015-1) Parts List..................................................................73

4.9.4 Piston Rod Assembly Drawing (ROPA-3280) ................................................................75

4.9.5 Piston Rod Assembly (ROPA-3280) ...............................................................................76

4.9.6 Piston 3.0” x 1.5” Assembly Drawing (PIA-3015-2) .....................................................77

4.9.7 Piston Assembly 3.0” x 1.5” Parts List (PIA –3015-2)..................................................78

4.9.8 Disassembly – Final Stage Cylinder / Piston .................................................................79

4.9.9 Disassembly – 3rd Stage Cylinder / Piston......................................................................79

4.9.10 Assembly- 3rd / 4th Stage Cylinder / Piston.................................................................80

4.10 ROD SEAL HOUSING ASSEMBLY SEA-3503.........................................................................82

4.10.1 Rod Seal Housing Assembly 3.00”– (SEA-3060).......................................................82

4.10.2 Rod Seal Assembly 3.00”– (SEA-3060) Parts List.....................................................83

4.10.3 Disassembly...............................................................................................................83

4.10.4 Assembly....................................................................................................................83

4.11 COMPRESSOR VALVES .........................................................................................................85

4.11.1 Removal .....................................................................................................................85

4.11.2 Installation.................................................................................................................85

Table of Figures

Figure 1 Plan and Elevation of Four-Stage Compressor ____________________________________7

Figure 2 X-Sectional Plan `A-A’_______________________________________________________8

Figure 3 Specification Plate _________________________________________________________13

Figure 4 Cylinder Specification Plate__________________________________________________14

Figure 5 Suction Identification Plate __________________________________________________14

Figure 6 Discharge Identification Plate ________________________________________________14

Figure 7 Warning Plate_____________________________________________________________15

Figure 8 Rotation Plate_____________________________________________________________15

Figure 9 Compressor Tools__________________________________________________________20

Figure 10 Oil Circulation Schematic __________________________________________________24

Table of Tables

Table 1 Specification Chart__________________________________________________________13

Table 2 Original Running Clearance __________________________________________________15

Table 3 Piston Ring End Gaps _______________________________________________________16

Table 4 Piston Ring Side Clearances __________________________________________________17

Table 5 Piston to Cylinder Clearances _________________________________________________18

Table 6 Torque Settings_____________________________________________________________19

Table 7 The Maximum Allowable Working Pressure ______________________________________23

Page 6 of 85

1 General

1.1 Introduction

The Rhino compressor has been developed specifically for CNG/NGV with

the following features :

 Gas tight pressurised crankcase, up to 40 bar (600 psig).

 Hoerbiger valves for specific performance and reliability.

 Double row spherical roller main bearings.

 Heavy duty crankcase.

 High strength crankshaft, 100-80-3 ductile iron, 89mm (3.5" journals).

 Full flow, filtered, pressurised lubrication.

 Generous integral cross-head piston bearing surface.

 Standardized design, 22 - 200 kW (30 - 270 hp), 0.5-30 bar, (8 - 435psig)

inlet pressure.

 High quality oil flooded mechanical crankcase seals.

 Double acting two, three or four stage design.

 Exclusive low friction cylinder treatment.

Intermech Ltd. BBR-6015-2 Compressor Service Manual

Page 7 of 85

1.1.1 Compressor General Arrangement -(BBR-6015-2)

Figure 1 Plan and Elevation of Four-Stage Compressor

Intermech Ltd. BBR-6015-2 Compressor Service Manual

Page 8 of 85

1.1.2 Compressor GA – X-Section (BBR-6015-2)

Figure 2 X-Sectional Plan `A-A’

Intermech Ltd. BBR-6015-2 Compressor Service Manual

Page 9 of 85

1.1.3 Compressor Parts List - (BBR-6015-2)

Item

Number Part Number Description Quantity

1 CRA-3603 Crankcase Assy. 1

2 LUB-BBR-SB-6015 RHINO Compressor Lubricator Assembly 1

3 CYA-6046-3 6" x 4.5" Cylinder Assembly 1

4 CYA-3015-1 Cylinder Assy. 3.25" x 1.5" (MT Valve Plates) 1

Intermech Ltd. BBR-6015-2 Compressor Service Manual

Page 10 of 85

2 Safety

2.1 General Safety !!! WARNING !!!

COMPRESSED GAS IS A HIGHLY DANGEROUS

SUBSTANCE

READ AND UNDERSTAND THIS SECTION OF

MANUALS

IT IS ESSENTIAL FOR THE SAFE OPERATION

OF EQUIPMENT

2.1.1. Systems must be entirely vented before repair or maintenance is carried

out.

2.1.2. The installation, operation, maintenance and repair shall be carried out

only by qualified personnel and in accordance with the corresponding

regulations for operation and safety.

2.1.3. No smoking or naked lights within 10m of any gas installation.

2.1.4. Do not adjust, remove or bypass any protective device.

2.1.5. Rotating machine parts represent a special danger. Covers and guards

must not be removed whilst the machine is operating.

2.1.6. Persons operating the compressor should use hearing protection.

2.1.7. Do not store flammable materials e.g. oily rags near the compressor

unit or engine drive.

2.1.8. Supply pipework and other components, which may not be included in

scope of supply, must be suitable for the respective working pressure.

2.1.9. If necessary they have to be tested and protected by a pressure-

unloading device.

2.1.10.Electrical cable must be Flameproof and must not be linked, or allowed

to contact rotating parts.

Intermech Ltd. BBR-6015-2 Compressor Service Manual

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