Leroi Om Rotary Screw Manual1
Leroi Om Rotary Screw Manual1
Leroi Om Rotary Screw Manual1
Installation Operations
Maintenance and Service Guide
Rotary Screw Compressor
Models:
HG10
HGF10
HG12
HGF12
HGS17
HGSF17
HG17
HG24
LG30
LGL30
Table of Contents
Safety Information and Warnings________ _________________1
Protecting Your Compressor Before Service_________________2
Identifying Your Compressor_____________________________3
Understanding Your Compressor_________________________4
The Compressor System______________________________5-6
Oil Flow and Orifice Sizing____________________________7-10
Variable Vi Adjustment______________________________11-13
Versatrol (Capacity Control)__________________________14-15
Oil and Related Items_________________________________16
Installation________________________________________17-18
Installation Component Location________________________19
Operation and Preventive Maintenance____________________20
Service Procedures - Components_____________________21-29
Rebuild Kits_________________________________________30
Website____________________________________________31
Contact List_________________________________________32
Service Diagnosis____________________________________34
Warranty___________________________________________35
DURING
SHIPPING,
IT
DOES
NOT
PROVID
ADEQUATE
PROTECTION FOR STORAGE.
compressor.
Oil-flooding provides cooling, lubrication and sealing in the compressor. The oil
must be cooled using either water
or air in a heat exchanger that is properly sized for all operating conditions.
Geared units (Figure 1) come standard with integral gearing to increase or dec
rease the speed internally, allowing
for direct connection with standard drivers. The drive (input) shaft is an integra
l extension of the male rotor.
Compressors with gears use an independent input shaft, commonly referred to
as a jackshaft, mounted on roller
and/or special deep groove ball bearings. The gear mounted on the jackshaft dr
ives the gear mounted on the male
rotor and the male rotor meshes with and drives the female rotor.
Figure 3 shows the direction of th
e rotor rotation and
compressor at the
This is required to prevent the carry over of liquids into the compressor. Filtration is ofte
n necessary, especially in vacuum
installations, to prevent debris (e.g. iron sulfides) from getting into the compressor.
Gas/Oil Separator
The gas/oil separator is a key component of the compressor
system. The separator shoul
5
d be designed to handle the
coalescing filter are sized properly to insure optimum gas and oil separation. The separat
Oil Filter
or also acts as the oil reservoir (oil
It is extremely important that the oil injected into the compressor be as clean as possible
sump), with the oil collecting in the bottom.
. The oil filter should be generously
Oil Cooler
sized to handle full oil flow, and should have a filter element that will remove particles do
The oil cooler is an air-cooled or water-cooled heat exchanger that is sized to suit the
wn to 10 micron. If the compressor
size (capacity) of the compressor being
is in an application where continuous operation is important or where the filter will get d
cooled. The cooler should be designed to handle the worst operating condition, which is
irty in a short period of time, it is
usually based on the lowest suction
recommended that a dual filter arrangement be used.
pressure and the highest discharge pressure. However, the oil flow plays a critical role in
Instrumentation and Controls
determining the heat rejection of the
The compressor has operating limitations that must be monitored. Protective devices are
oil cooler.
required to the protect the
Minimum Pressure Valve
compressor from experiencing a catastrophic failure. These include, but are not limited t
The minimum pressure valve is recommended to maintain a minimum pressure in the ga
o high temperature and pressure, as
s/oil seperator. It is especially
well as liquid level switches in the suction scrubber where there is a potential for large a
important to use this device when the possibility exists that the system pressure may no
mounts of liquid in the gas stream.
t be suficient to maintain pressure in
the seperator to achieve adequate gas/oil seperation.
2.
Provides a seal between the cylinder and rotors to reduce gas slippage.
3.
LeROI gas compressors have an oil injection manifold that distributes oil su
pplied by the pump or pressure
diferential. The orifice creates a restriction. A smaller orifice results in a gre
ater restriction, which forces
more oil to the bearing and less oil to the rotors. The goal is to create a pro
per balance in the compressor
for reliable operation.
also important to note that you may need to create an orifice in the event y
our desired size is in between
manufacturer available sizes.
Temperature/Viscosity/Press
ure
Refer to Figure 7 for temperature and pressure methods and locations.
o
Temperature/Viscosity/Pressure (Conti
nued)
For Most Situations:
o
40 F
Instrument
Infrared (IR)
temperature
gun
Pressure gage or
transducer 1
Pressure gage or
transducer 2
Data
Location
a. oil injection
(A) pipe
temperature
(B) pipe
b. gas discharge
temperature
c. discharge bearing(C) tube (goes
oil drain temperature
down on some
models)
d. gas inlet pressure(D) inlet pipe
e. oil injection
pressure
(E) injection
manifold
performance program to
resize
s
disch & oil i
njection tem
p
N
o
more than 40 F?
D
less than 30 F?
No
C
Is diff
betwee
n beari
no
ng
oil drai
n & oil
injectio
n
OR Is
oil inje
ction
pressur
e less t
han 60
PSI
OK
by changing cooler or
Smalle thermostat
Yes
r pump
Yes
or orific
Install smaller injection
e is
require orifice.
d. Us
e perfo Note: When gas disch
rmance
pressure is below 60 PSI it
progra
may not be possible to
m to re
achieve 60 PSI oil pressure,
size
even with the smallest orifice.
This is acceptable if the
bearing oil drain temp is
Reduc
within spec.
e oil inj
ection t Install larger injection
orifice.
emp
pressure?
10
Variable VI Adjustment
Variable Vi is used to minimize the power required by the compressor. It
does not change flow
directly, but can allow an increase in flow through more eficient use of powe
r. Vi is the volume
compression ratio of a compressor: V1 / V2. The internal Vi of the compress
or is determined by the size
of the discharge port. A small port causes gas to be released later in the co
mpression cycle resulting in a
higher internal Vi, while a larger port allows the gas to be released earlier in
the cycle resulting in a lower
internal Vi. The ideal Vi for an application can be calculated if the inlet and
discharge pressures and k
(Cp/Cv) of the gas are known.
The compressor makes the most eficient use of power when the internal Vi e
quals the ideal Vi. For
example, if the internal Vi is high but the ideal Vi is low, the gas is compresse
d to a pressure greater than
the external pressure prior to being released. On the other hand, if the intern
al Vi is low but the ideal Vi
is high, gas momentarily flows backward into the compressor and is recompressed. Both of these
scenarios result in wasted energy.
The standard discharge housings of the HG17, HG24, LG30, and LGL30 com
pressors have a 4.4 Vi
port, but are fitted with four valves that can be opened to increase the total s
ize of the discharge port, so
that the following internal Vis can be achieved.
Instructions
T
w.
11
P1 and P2 must be in PSIA, and be at the compressor inlet and discharge flang
es. Be sure to
account for package pressure drops, which decrease the inlet pressure
and increase the
discharge pressure at the compressor flanges. As a quick reference, fo
r a typical natural gas
with k = 1.26, the pressure ratios that correspond to available internal
Vis are:
Vi
4.4
3.0
P2 / P1
6.5
4.0
1.9
2.2
Since there are three available internal Vi settings, each must cover a
range of ideal application
Vis:
Figure 8:
Compressor discharge end sho
wing four
ial locknut-
thread protectors.
Compressor models may also ha
ve an oil
alves on the
left.
Figure 9:
Remove locknuts with wrench b
efore
making adjustments.
It is not necessary to remove th
e outer
are being
adjusted.
The model represented in the fi
gure has a
12
Figure 15
HG17 showing
four Versatrol
pockets. HG24
arrangement is
the same
(Pockets 2 and
are under the
compressor)
Figure 16
LG30 showing
four Versatrol
pockets. (Pockets
on HG17 and
HG 24 are on the
other side)
to prevent
jamming the valve.
13
14
Plumbing:
15
Start-Up:
Oil Filter:
Check after first 100 hours. Change once a month if continuously
operated or every 1000
hours otherwise. Filter must be changed with every oil change.
At the minimum a diferential pressure is recommended for the oil fi
lter. A diferential gauge
with an alarm is advised.
Viscosity:
The packager/user is responsible for selecting oil that is compatible
with the gas, and can
maintain minimum viscosity at the operating conditions. The recom
mended viscosity is 15
centistokes regardless of the operating conditions. The minimum vis
cosity is 13 centistokes
regardless of the operating conditions.
Oil viscosity greater than 15 centistokes can afect performance, es
pecially horsepower.
Analysis:
Oil should be analyzed on a regular basis. Oil should be checked
once a week for the first
month, with at least two of those samples being analyzed. If the firs
t month of samples is
okay then the analysis can be reduced to once a month. Increases i
n water content and metals
should be watched closely. All reputable oil suppliers and manufact
urers will analyze oil
samples at no charge.
Recirculation: It is important that the oil recirculates at least two times per
minute, especially with heavier
hydrocarbon and water saturated gases. This keeps the oil tempera
ture higher, thereby
reducing the possibility of hydrocarbons condensing and afecting t
he viscosity of the oil, or
having water condense and cause lubrication problems.
Strainer:
When there is an oil pump, it is recommended that a Y-strainer be
installed between the
separator and the suction to the pump
It is recommended that a Y-strainer be installed downstream of
where the oil leaves the
discharge bearing retainer, and where it is injected in the casing. T
his will reduce the
possibility of a catastrophic failure if a bearing fails on the discharg
e end.
Coalescing: The coalescing element in the gas oil separator should be
monitored with a diferential
pressure gauge. This element should be changed as required. It sho
uld be checked at least
once a year. It is important that the filter element have enough surf
ace area to remove oil
from the gas stream.
Gas Filtration: Gas filtration is recommended. Particulate in the gas stream can
contaminate the oil and
cause premature failure.
16
Installation
The compressor and prime mover must be mounted on a rigid frame so that
the drive, piping, etc. are
not subject to strain and/or misalignment. Mounting holes are provided to s
ecurely attach the
compressor.
The mounting surface must be a smooth, level surface that will support the
weight of the compressor
and handle the associated vibration. Shims must be installed between the fr
ame and the mounting
surface to eliminate strain on the frame.
Adequate airflow for cooling must be provided. Uncontrolled recirculation (f
rom unit to other source)
of hot air must be prevented. Refer to figure 17 for a typical installation.
17
Installation (Continue
d)
Drive:
Several types of drive couplings may be used. However, direct flexibl
e and universal joint types are
recommended. When using a direct flexible coupling follow the coupl
ing manufacturers
instructions. As a general rule, for this type of coupling, the alignme
nt should be as near in line
as possible. In any case, coupling misalignment may not exceed 1/32
parallel and/or 2 angular
misalignment. Refer to figure 18.
THE DR
IVE
NG
ING, SHAFT,
MUST BE
ED BY A
LE GUARD
ELD. ALL
S AND
S MUST BE
CE WHEN
Figure 18
COUPLI
(COUPL
BELTS)
COVER
SUITAB
OR SHI
GUARD
SHIELD
IN PLA
OPERATING THE
UNIT
Figure 19
18
Separator out:
check valve) must
mum pressure valve.
mum number of
d securely.
Provisions must be made to mount and connect other
components in this
ture sensing devices,
etc.
Comp Instrumentation: Pressure gauges should be provided to monitor t
he pressure drop
(restriction) across the oil filter element, separator ele
ment, and oil cooler.
A single gauge for each is recommended, with a manif
old and shut of
d outlet) pressures.
sure readings.
19
3.
Check the compressor oil reservoir fluid level. Add oil as necessary
to the correct level. Do not
overfill.
4.
Make certain adequate ventilation and cooling water, if required, is
provided.
5.
Start the unit by actuating the electrical controls or starting the
engine following the equipment
manufacturers instructions.
6.
Observe the unit for leaks, unusual noise, vibration, etc. (Shutdown
the unit and correct as
required.)
7.
Observe all instrumentation for proper readings.
Shut Down:
1.
Preventive Maintenance:
1.
Ensure the oil is properly maintained per the Oil and Related Items
section of this manual.
2.
Visually inspect the entire unit for leaks, loose hardware, etc. as
often as feasible. Correct as
required.
3.
Service all equipment (filters, moisture separators, etc.) following
the manufacturers
instructions.
4.
Drain water (condensate) from the oil reservoir. Close the drain valve
securely when oil appears.
5.
Check the compressor oil reservoir level. Add correct type of oil as
required. Do not overfill.
6.
With the unit running, observe the oil pressure gages and compare
readings (filter in-filter out)
A diference in pressure readings of 15 PSI or more indicates that th
e filter element must be
renewed.
7.
With the unit running observe the gas pressure gauges and compare
readings. A pressure drop
across the separator element of 15 PSI or more indicates the separat
or element is restricted. If
the restriction is caused by dirt or other foreign matter, renew the se
parator element.
Oil saturation can cause excessive restriction across a separat
or element. Always
check the separator drain tube and line for restriction, the ch
eck valve (installation
and condition) and clean or renew the drain line filter before
condemning a
separator element.
8.
Remove surface dirt and dust from the oil cooler and after cooler.
20
Compressor Service:
The compressor for these units is serviced only as a complete assembly using
a new or factory rebuilt
compressor. Parts available for field service include the input shaft rotary oil
seal and the seal retainer
gasket or o-ring seal.
Input Shaft Seal Replacement:
The compressor input shaft rotary seal may be replaced as follows, Refer to
Figure 21:
I. Make certain the unit cannot be started and system has all pressure rem
oved.
II. Remove any coupling guards and/ or shields.
III. Clean the front of the compressor thoroughly to prevent dirt from enterin
g the
compressor.
IV. Disconnect the drive coupling.
If the compressor or prime mover must be unfastened f
rom the frame, save
and mark all mounting shims if any, for reuse.
NOTE: Always verify Seal Kit P/N by referring to appropriate compres
sor assembly / parts
drawing.
The seal kit includes:
(1) Rotary shaft seal assembly (1) 100 grit silicon carbide emery cloth
(1) Technical / Service Bulletin TSB0802 (1) Tube P80 Rubber Lubricant
Emulson
The following procedure is to be used for installing all rotary face type shaft seal
s:
Follow the maintenance manual procedure for the specific unit being serviced, to
expose the rotary seal retainer.
Disconnect the lubrication line (tube) from the seal retainer or bearing retainer (
depends on unit model).
NOTE
THE FITTING INSTALLED IN THE SEAL OR BEARING RETAINER OR THE OIL
PASSAGE IN
THE RETAINER, WHICH DELIVERS OIL TO THE SEAL, MAY BE RESTRICTED
OR ORIFICED.
INSPECT THIS FITTING AND OIL PASSAGE AND THE ATTACHING LINE (TUB
E) TO MAKE
CERTAIN THE ORIFICE IS CLEAN AND THAT THE TUBE HAS BEEN CORRECT
LY INSTALLED
(NO EXCESSIVE FITTING CRUSH).
21
Remove the seal retainer and seal assembly as described in the maintenance manu
al
for the unit being serviced. Discard the old seal parts. (Figure 1)
Clean the seal retainer and seal cavity in the bearing retainer thoroughly. (Figure
2)
To protect the exposed shaft bearings from dirt, dampen a lint free rag and clean c
ompressor oil and insert the
rag into the bearing retainer cavity.
Inspect the shaft surface for nicks and burrs. If found, remove them with a fine file
or stone. Remove any sharp
edges from tapers or chamfers on the shaft. (Figure 3)
22
On the shaft area, where the seal is to be located, polish the shaft using a number
100 grit silicon carbide emery
cloth (P/N 204-2385). Wrap a strip of emery cloth around the shaft. Grasp the
emery cloth and use a rotary
motion to polish the shaft. (Figure 4)
Carefully remove the oil dampened rag from the bearing cavity with a wiping moti
on.
Dampen a lint free rag with a non-hydrocarbon solvent (suggest acetone, nail
polish remover, or equivalent) and
carefully remove any remaining dirt from the shaft. Make certain the shaft is oil a
nd dirt free. (Figure 5)
WARNING
SOLVENTS SUCH AS ACETONE MAY BE TOXIC WHEN INHALED. ALWAYS USE I
N A WELLVENTILATED AREA.
Carefully remove the new seal from the wrapping, check for any damage, and wip
e
clean.
CAUTION
CHECK THAT THE SEAL FACE IS LOCATED IN THE RETAINER WITH THE LAPP
ED FACE
OUTWARDS, AND TAKE CARE THAT THE FACE DOES NOT DROP OUT OF THE
RETAINER
WHEN HANDLING AND FITTING THE SEAL. HANDLE THE SEAL ASSEMBLY WI
TH GREAT
CARE. DO NOT TOUCH THE SEAL INSERT OR CARBON RING POLISHED FACES
.
Lubricate the steel face insert seal ring (o-ring) and seal retainer counter bore
with P80 Rubber
Lubricant
Emulsion (P/N 204-2386). (Figure 6)
Protect the polished side of the seal insert using the paste board seal protector fur
nished with the seal assembly
and push the insert into the seal retainer until it bottoms in the counter bore.
CAUTION
DO NOT TOUCH THE POLISHED FACE OF THE SEAL INSERT WITH FINGERS, R
AGS, ETC.
Apply a film of P-80 on the gas end shaft and on the inside diameter of the flexible
section of the seal assembly.
23
CAUTION
TO MAKE CERTAIN THAT THE FLEXIBLE SECTION OF THE SEAL ADHERES TO T
HE SHAFT
IN THE CORRECT LOCATION, IT IS NECESSARY TO COMPLETE THE ASSEMBLY
ONCE
STARTED.
Lubricate the carbon ring section of the seal assembly with clean compressor oil.
CAUTION
DO NOT USE OTHER TYPES OF OIL OR GREASE.
Make certain all parts and supplies (gasket, sealer, etc.) are available before beginn
ing final assembly.
Without touching the polished area of the carbon seal ring install the seal assembly
(spring, etc.) on the shaft.
(Figure 8)
Apply sealer (or install gasket on the seal retainer) as described in the instruction m
anual for the unit being
serviced.
Immediately install the seal retainer and attaching capscrews to the bearing retaine
r mating surface. Tighten all
capscrews securely. (Figure 9)
After installation is completed allow the seal to sit without rotating the shaft for app
roximately 30 minutes.
Complete reassembly of drive coupling, guard, etc. following instructions provided i
n the manual for the unit
being serviced.
24
25
Service ProcedureComponents
6.
17.
Reinstall the minimum pressure valve on the receiver-oil reservoir
cover. Use a good grade of pipe
thread sealer on all pipe threads. Tighten securely. Do not over tighten
.
18.
Reconnect the service piping to the valve using pipe thread sealer on
the pipe threads. Tighten
service piping securely. Do not over tighten.
26
Service Procedure-Components
(Continued)
Changing Minimum Pressure Valve Spring
This section contains the instructions to replace a high-pressure spring in a
minimum pressure valve with
a low-pressure spring.
High Pressure
Cover Spring
Body
Low Pressure
Spring
Piston
Spacer
Stack
p of the body.
acers shown in
27
Service Procedure-Components
(Continued)
Changing Minimum Pressure Valve - Continued
28
Service Procedure-Components
(Continued)
Oil Separator Service
3. Disconnect the separator drain line and remove the drain tube from th
e separator. Mark the position
of the receiver-reservoir cover to aid in correct assembly.
4. Remove the separator cover to receiver-reservoir attaching capscrews
(nuts) and remove the cover.
5. Remove the separator element by lifting it out of the reservoir.
6. Clean the cover and reservoir cover mounting flange. Make certain all
traces of gasket material are
removed.
If the gaskets do not have grounding
staples, install two large copper clad
staples in each gasket.
7. Inspect the new element gaskets to make certain the electrical ground
ing staples are installed.
8. Reinstall the separator element in the receiver-reservoir.
9. Reinstall the reservoir cover, correctly positioned, with attaching caps
crews (nuts) and tighten
securely.
10. Reinstall the separator drain tube and fitting.
The drain tube must extend into the separator
element far enough to touch the bottom of the
element. If the tube is not long enough to touch
bottom, obtain/make a new tube.
11. Reconnect the separator drain line.
MAKE CERTAIN THE DRAIN LINE
FILTER AND CHECK VALVE ARE
CORRECTLY INSTALLED
12. Reconnect the service piping to the minimum pressure valve. Use a qu
ality pipe thread sealer on all
pipe threads. Tighten securely. Do not over tighten.
29
Rebuild Kits
Please refer to the engineering print below to order a rebuild ki
t for your unit.
(Check the Website for latest revision.)
30
Website
LeROI-RCT has a website that contains useful tips, features, sizing
information, and technical data. We
encourage using and exploring the website to learn what tools are available t
o you. Visit us at
www.leroigas.com
Fax: 937-492-3424
Engineering / Email:
Technical
Support / Website
[email protected]
Ron Keen
Note: All warranty claims now submitted via the web. Visit
Phone: 937-498-2558
Accounting
www.leroigas.com.
Fax: 937-492-3424
Email:
Amanda Young
Phone: 937-498-2638
Fax: 937-492-3424
Email: [email protected]
31
Contact List
Below is a list of contacts in case you need any assistance. In order to provid
e you with the latest
USA
32
MALFUNCTION
PROBABLE CAUSE
REMEDY
High Discharge
Temperature
1.
1.
2.
3.
4.
5.
6.
1.
2.
3.
CANADA
2.
3.
4.
5.
6.
1.
1.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
6.
2.
3.
4.
5.
Excessive Oil Consumption
1.
2.
3.
4.
5.
6.
7.
7.
34
Manufactured
LeROI-RCT warrants its rotary screw compressor products and parts to be in
compliance with
their respective specifications and free from defects in materials and workmanship
during a
warranty period ending the earlier of (i) 12 months after the product start up date
, or (ii) 18
months after the original date of shipment of the product by LeROI-RCT.
Remanufactured
LeROI-RCT warrants its remanufactured rotary screw compressor products and parts
to be in
compliance with their respective specifications and free from defects in m
aterials and
workmanship during a warranty period ending the earlier of (i) 90 days after the prod
uct start
up date, or (ii) 9 months after the original date of shipment of the product by LeROIRCT.
LeROI-RCT's only obligation under this warranty will be, at its election, to repair or
replace any
part determined to be non-conforming or defective during the applicable warran
ty period,
including ground freight (Domestic USA only for overseas warranty) for the gas end.
Labor to
change out the gas end is not covered. THIS WARRANTY DOES NOT COVER CORR
OSION.
THE OWNER/USER ASSUMES ALL OTHER RISKS, IF ANY, SUCH AS THE RISK
OF ANY
DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGES A
RISING
OUT OF THE USE OF, OR INABILITY TO USE, THE COMPRESSOR OR ANY PART.
THIS WARRANTY IS MADE IN LIEU OF THE WARRANTIES OF MERCHAN
TABILITY,
FITNESS FOR PARTICULAR PURPOSE, AND ALL OTHER WARRANTIES, EXPR
ESS OR
IMPLIED, AND MAY NOT BE VARIED OR EXTENDED EXCEPT IN WRITIN
G BY AN
AUTHORIZED OFFICIAL OF LeROI-RCT.
Rotary Compression T
echnologies
211 East Ru
ssell Road
Sidney, O
hio 45373
Phone: 93
7-498-2555
Fax: 937
-492-3424
www.sales@l
eroigas.com
www.ler
oigas.com
ised 8-10-07
35
36
Rotary Compression Te
chnologies
211 East Rus
sell Road
Sidney, Ohi
o 45365
Phone: 937498-2555
Fax: 937492-3424
sales@leroi
gas.com
www.leroi
gas.com
37