Intermech BBR- 3516 User manual

Compressor Service Manual
Customer :
Company
Address
City/State
ZIP Code
Phone
Fax
Email Address
Site Location
Product Compressor BBR- 3516 Vol. 2 (J1705)
Model No CO-BBR-3516
Serial No
INTERMECH LTD.
88 Leonard Road, Penrose
PO Box 12284, Penrose
Auckland, New Zealand
Ph 64 (9) 525 2220
Fax [phone]
Email [email protected]

Compressor Operation & Maintenance Manual Page 2 of 79
Revisions Record
Revision
No.
Date Description of Revision
August, 2006 First edition
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 3 of 79
Table of Contents
1GENERAL.....................................................................................................................................6
1.1 INTRODUCTION.......................................................................................................................6
2SAFETY.........................................................................................................................................8
2.1 GENERAL SAFETY ..................................................................................................................8
2.2 MAINTENANCE SAFETY..........................................................................................................9
3COMPRESSOR SPECIFICATION..........................................................................................11
3.1 MODEL.................................................................................................................................11
3.2 DESIGN SPECIFICATION ........................................................................................................11
3.3 MANUFACTURER’S PLATE & LABEL INFORMATION.............................................................11
3.3.1 Specification Plate..........................................................................................................11
3.3.2 Cylinder Identification Plate ..........................................................................................12
3.3.3 Suction Identification Plate ............................................................................................ 12
3.3.4 Discharge Identification Plate........................................................................................ 12
3.3.5 Warning Plate.................................................................................................................13
3.3.6 Rotation Plate .................................................................................................................13
3.4 CLEARANCES .......................................................................................................................13
3.4.1 Original Running Clearances.........................................................................................13
3.4.2 Piston Ring Side Clearances / End Gaps........................................................................14
3.4.3 Piston to Cylinder Clearances........................................................................................16
3.4.4 Torque Settings ...............................................................................................................16
3.4.5 Rhino Compressor Tools ................................................................................................ 18
3.5 OPERATING PROCEDURES ....................................................................................................19
3.5.1 Start Up Check List Contents..........................................................................................19
3.5.2 Package Details..............................................................................................................19
3.5.3 Prior to Starting..............................................................................................................20
3.5.4 After Starting ..................................................................................................................21
3.5.5 Maximum Allowable Working Pressure .........................................................................21
3.6 LUBRICATION.......................................................................................................................22
3.6.1 General Description .......................................................................................................23
3.6.2 Oil Specification .............................................................................................................23
3.6.3 Before Starting................................................................................................................24
3.6.4 Top Up With Oil .............................................................................................................24
3.6.5 Primary Starting .............................................................................................................24
3.6.5.1 Priming the lubrication system using priming pump........................................................... 25
3.6.6 Oil Filter......................................................................................................................... 26
3.6.7 Lube Oil Pressure Adjustment ........................................................................................26
3.6.8 Oil Relief Valve Setting................................................................................................... 26
3.6.9 Compression Cylinder Injection Lubrication System .....................................................27
4MAINTENANCE........................................................................................................................28
4.1 GENERAL .............................................................................................................................28
4.2 OIL PUMP (CRA-357) & OIL PUMP HOUSING (CRA-352-1)................................................29
4.2.1 Oil Pump Housing Drawing (CRA-352-1) .....................................................................29
4.2.2 Oil Pump Housing (CRA-352-1) Parts List ....................................................................30
4.2.3 Oil Pump Assembly Drawing (CRA-357) .......................................................................31
4.2.4 Oil Pump Assembly (CRA-357) Parts List...................................................................... 32
4.2.5 Oil Pump Relief Valve Drawing (CRA-333)................................................................... 33
4.2.6 Oil Pump Relief Valve (CRA-333) Parts List..................................................................34
4.2.7 Disassembly – Oil Pump Housing .................................................................................. 35
4.2.8 Disassembly – Oil Pump Relief Valve ............................................................................ 35
4.2.9 Disassembly – Oil Pump.................................................................................................35
4.2.10 Assembly – Oil Pump.................................................................................................36
4.2.11 ............................................................................................................................................36
4.2.12 Oil Pump Relief Valve................................................................................................ 36
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 4 of 79
4.2.13 Assembly – Oil Pump Housing (CRA-352) ................................................................37
4.3 RHINO CRANKCASE (CRA-3603).........................................................................................38
4.3.1 Rhino Crankcase Drawing (CRA-3603) .........................................................................38
4.3.2 Rhino Crankcase Drawing (CRA-3602) .........................................................................39
4.3.3 Rhino Crankcase (CRA-3603) Parts List........................................................................40
4.3.4 Rhino Crankcase (CRA-3602) Parts List........................................................................40
4.3.5 Taper Lock Bearing Housing Assembly Drawing (CRA-3640) ......................................41
4.3.6 Taper Lock Bearing Housing Assembly Parts List (CRA-3640).....................................42
4.3.7 Rhino Crankcase Filler Bowl Drawing (CRA-820)........................................................43
4.3.8 Rhino Crankcase Filler Bowl (CRA-820) Parts List ......................................................44
4.3.9 Disassembly – Crankshaft (CR-3253) ............................................................................45
4.3.10 Assembly – Crankcase (CRA-3603)...........................................................................46
4.4 DRIVE END BEARING HOUSING / MECHANICAL SEAL ASSEMBLY (CRA-356)....................49
4.4.1 Drive End Bearing Housing / Mechanical Seal Drawing (CRA-356 RevB)...................49
4.4.2 Mechanical Seal Housing (CRA-356) Parts List ............................................................50
4.4.3 Disassembly / Assembly - Mechanical Seal ....................................................................51
4.5 CONNECTING ROD ASSEMBLY .............................................................................................53
4.5.1 Connecting Rod Assembly Drawing (ROA-8525)........................................................... 53
4.5.2 Connecting Rod Assembly Parts List (ROA-8525) .........................................................54
4.6 CROSS HEAD CYLINDER/PISTON (CYXA-6003) ..................................................................55
4.6.1 6” Cross Head / Cylinder Drawing (CYXA-6003) .........................................................55
4.6.2 6” Cross Head / Cylinder (CYXA-6003) Parts List........................................................56
4.6.3 Disassembly - Cross-Head Cylinder/Piston ...................................................................57
4.6.4 Assembly - Cross-Head Cylinder/Piston ........................................................................57
4.7 1ST STAGE CYLINDER/PISTON / PISTON ROD ASSEMBLY ......................................................59
4.7.1 Cylinder Assembly Drawing (CYA-3500-3)....................................................................59
4.7.2 Cylinder Assembly (CYA-3500-3) Parts List ..................................................................60
4.7.3 Disassembly ....................................................................................................................62
4.7.4 Assembly .........................................................................................................................62
4.8 ROD SEAL HOUSING ASSEMBLY ..........................................................................................65
4.8.1 Rod Seal Housing Drawing (SEA-3503).........................................................................65
4.8.2 Rod Seal Housing (SEA-3503) Parts List .......................................................................66
4.8.3 Disassembly ....................................................................................................................67
4.8.4 Assembly .........................................................................................................................67
4.9 2ND / 3RD STAGE CYLINDER/PISTON/PISTON ROD ASSEMBLY ................................................68
4.9.1 Cylinder Assembly Drawing (CYA-3216-4)....................................................................68
4.9.2 3.25”x 1.625” Cylinder Assembly (CYA-3216-4) Parts List ..........................................69
4.9.3 Piston 3.25” x 1.625” Assembly Drawing (PIA–3216-2)...............................................71
4.9.4 Piston 3.25” x 1.625” Assembly (PIA–3216-2) Parts List .............................................72
4.9.5 Disassembly – Final Stage Cylinder / Piston .................................................................73
4.9.6 Disassembly – 2nd Stage Cylinder / Piston ....................................................................73
4.9.7 Assembly- 2nd / 3rd Stage Cylinder / Piston ..................................................................74
4.10 ROD SEAL HOUSING ASSEMBLY SEA-3250.........................................................................76
4.10.1 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 1)......................................76
4.10.2 Rod Seal Housing Assembly Drawing (SEA-3250: Sheet 2)......................................77
4.10.3 Rod Seal Housing Assembly (SEA-3250) Parts List ..................................................78
4.10.4 Disassembly ...............................................................................................................78
4.10.5 Assembly ....................................................................................................................78
4.11 COMPRESSOR VALVES .........................................................................................................79
4.11.1 Removal .....................................................................................................................79
4.11.2 Installation.................................................................................................................79
Table of Figures
Figure 1 Plan and Elevation of Three-Stage Compressor____________________________________7
Figure 2 Specification Plate _________________________________________________________11
Figure 3 Cylinder Specification Plate __________________________________________________12
Figure 4 Suction Identification Plate __________________________________________________12
Figure 5 Discharge Identification Plate ________________________________________________12
Figure 6 Warning Plate_____________________________________________________________13
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 5 of 79
Figure 7 Rotation Plate _____________________________________________________________13
Figure 8 Compressor Tools__________________________________________________________18
Figure 9 Oil Circulation Schematic ___________________________________________________22
Table of Tables
Table 1 Specification Chart__________________________________________________________11
Table 2 Original Running Clearance __________________________________________________13
Table 3 Piston Ring End Gaps _______________________________________________________14
Table 4 Piston Ring Side Clearances __________________________________________________15
Table 5 Piston to Cylinder Clearances _________________________________________________16
Table 6 Torque Settings_____________________________________________________________17
Table 7 The Maximum Allowable Working Pressure ______________________________________21
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 6 of 79
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-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 7 of 79
Figure 1 Plan and Elevation of Three-Stage Compressor
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 8 of 79
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-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 9 of 79
2.2 Maintenance Safety
!!! WARNING !!!
COMPRESSED GAS IS A HIGHLY
DANGEROUS SUBSTANCE.
BEFORE DISMANTING ANY PART OF
THE COMPRESSOR, ENSURE THAT THE
UNIT IS COMPLETELY DEPRESSURED
2.2.1. Maintenance and repair may be carried out only on the shutdown and
entirely vented compressor unit. If necessary isolate all storage
systems and blow-down all condensate traps and heat exchanger
collectors. Open all manual drain valves.
2.2.2. Isolate the equipment electrically by pad-locking the main switch in the
"OFF" position and fixing a corresponding warning sign.
2.2.3. Only use original spare parts and recommended products for
maintenance and repair works on the compressor unit.
2.2.4. Never do work that will produce heat, like welding near oil or gas
systems. Before working on oil or gas tanks empty them and clean
them carefully eg. by a steam jet or purge with nitrogen.
2.2.5. During maintenance and repair work observe strict cleanliness. Keep
impurities away, by covering dismounted parts and free openings with
a clean rag, paper or adhesive tape.
2.2.6. After having finished the works be sure that no tools, loose parts or
cleaning rags have been left on or in the compressor unit, or near the
engine air cleaner.
2.2.7. Do not use easily flammable solving agents for cleaning of parts, until
the unit has cooled thoroughly. After the use of solving agents
carefully rinse the parts and clean them with compressed air.
2.2.8. Be very careful, use eye protection, when working with compressed air
for cleaning equipment.
2.2.9. After modification or repair work on pressure vessels and safety
equipment, such as relief valves, all work must be tested and accepted
by the inspection authority concerned.
2.2.10. The switchboard may be opened only by qualified and authorized
persons. Even if the main switch is set to the "OFF" position, the poles
of the switch and feed cables of the terminal strip are alive. Therefore
do not touch anything on the switchboard, and do not carry out work,
with the mains current supply is not disconnected. Before starting
work check if the system is entirely free of power.
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 10 of 79
2.2.11. Do not touch bare wires and live (current-carrying) parts, when the
electrical system is energized.
2.2.12. After modification or repair work to compressor, and before power is
supplied to machine, always manually turn compressor over by hand to
ensure compressor is running free.
2.2.13. Intermech takes no responsibility for personal injury or damage on the
unit, caused by the non-observance of the safety precautions during
handling, operation, maintenance or repair of compressor units or other
equipment.
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 11 of 79
3 Compressor Specification
3.1 Model
This package utilises the BBR-3516 compressor.
First stage 3-1/2” Double Acting cylinder
Second stage 3-1/4” Single Acting cylinder
Final stage 1-5/8” Single Acting cylinder
3.2 Design Specification
DESCRIPTION IMPERIAL UNITS
STROKE 3.25 inches
ROD LOAD, COMPRESSION 10,000 lbs
ROD LOAD, TENSION 10,000 lbs
FRAME HORSEPOWER to 270 hp
MAX. INTERNAL PRESSURE 600 psi
WEIGHT, APPROXIMATE 1900 lb
RPM to 1800 rpm
OIL PUMP CAPACITY 6 gpm @ 1600rpm
SUMP CAPACITY 4.5 gallons
Table 1 Specification Chart
3.3 Manufacturer’s Plate & Label Information
3.3.1 Specification Plate
Figure 2 Specification Plate
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 12 of 79
3.3.2 Cylinder Identification Plate
Figure 3 Cylinder Specification Plate
3.3.3 Suction Identification Plate
Figure 4 Suction Identification Plate
3.3.4 Discharge Identification Plate
Figure 5 Discharge Identification Plate
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 13 of 79
3.3.5 Warning Plate
Figure 6 Warning Plate
3.3.6 Rotation Plate
Figure 7 Rotation Plate
Note : Rotation direction is anti-clockwise looking at the compressor from the oil
sight glass side.
3.4 Clearances
3.4.1 Original Running Clearances
Original Running Clearances Minimum Maximum
Connecting rod thrust (side clearance) 0.010” 0.015”
Crankpin bearing (con-rod big end) 0.002” 0.004”
Connecting rod bushing to wrist pin 0.0015” 0.0035”
Crosshead to wrist pin 0.0015” 0.002”
Oil pump impellor assembly end clearance 0.003" 0.005"
Crosshead to guide 0.007” 0.010”
Drive end metering plate to crankshaft 0.002” 0.004”
Table 2 Original Running Clearance
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 14 of 79
3.4.2 Piston Ring Side Clearances / End Gaps
Min Max Min Max Min Max
Straight Cut 0.004 0.014 0.042 0.052 0.011 0.021
45º Cut 0.003 0.013 0.030 0.040 0.008 0.018
Straight Cut 0.004 0.014 0.046 0.056 0.012 0.022
45º Cut 0.003 0.013 0.032 0.042 0.008 0.018
Straight Cut 0.004 0.014 0.049 0.059 0.013 0.023
45º Cut 0.003 0.013 0.035 0.045 0.009 0.019
Straight Cut 0.006 0.016 0.082 0.092 0.020 0.030
45º Cut 0.004 0.014 0.058 0.068 0.014 0.024
Straight Cut 0.006 0.016 0.089 0.099 0.022 0.032
45º Cut 0.004 0.014 0.063 0.073 0.015 0.025
Straight Cut 0.006 0.016 0.096 0.106 0.023 0.033
45º Cut 0.004 0.014 0.068 0.078 0.016 0.026
Straight Cut 0.006 0.016 0.103 0.113 0.025 0.035
45º Cut 0.005 0.015 0.072 0.082 0.017 0.027
Straight Cut 0.007 0.017 0.116 0.126 0.028 0.038
45º Cut 0.005 0.015 0.082 0.092 0.019 0.029
Straight Cut 0.007 0.017 0.123 0.133 0.029 0.039
45º Cut 0.005 0.015 0.087 0.097 0.021 0.031
Straight Cut 0.008 0.018 0.129 0.139 0.031 0.041
45º Cut 0.005 0.015 0.091 0.101 0.022 0.032
Straight Cut 0.009 0.019 0.163 0.173 0.038 0.048
45º Cut 0.006 0.016 0.115 0.125 0.027 0.037
Straight Cut 0.010 0.020 0.176 0.186 0.041 0.051
45º Cut 0.007 0.017 0.125 0.135 0.029 0.039
Straight Cut 0.011 0.021 0.216 0.226 0.050 0.060
45º Cut 0.008 0.018 0.153 0.163 0.035 0.045
Straight Cut 0.012 0.022 0.223 0.233 0.052 0.062
45º Cut 0.008 0.018 0.158 0.168 0.036 0.046
Straight Cut 0.012 0.022 0.230 0.240 0.053 0.063
45º Cut 0.008 0.018 0.163 0.173 0.038 0.048
Straight Cut 0.014 0.024 0.270 0.280 0.062 0.072
45º Cut 0.010 0.020 0.191 0.201 0.044 0.054
Ring Gaps
Peek
Ring Material
3.5
Cast Iron
1.5
1.75
Clylinder Size
8.5
3.75
10
6.5
6
4.5
4.75
8
8.25
4.25
1.625
Carbon Teflon *
3.25
3
Table 3 Piston Ring End Gaps
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 15 of 79
Side Clearance
Table 4 Piston Ring Side Clearances
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 16 of 79
3.4.3 Piston to Cylinder Clearances
Clearances Minimum Maximum
Crosshead piston to guide 0.008" 0.010"
8.0" - 10.0" Dia cylinder 0.035" 0.040"
6.0" - 6.5" Dia cylinder 0.030" 0.035"
5.0" - 5.25" Dia cylinder 0.025" 0.030"
4.125" – 4.75" Dia cylinder 0.020" 0.025"
3.5" - 4.0" Dia cylinder 0.018" 0.022"
2.75" – 3.25" Dia cylinder 0.015" 0.020"
2.0" – 2.5" Dia cylinder 0.013" 0.018"
1.25" - 1.75" Dia cylinder 0.016" 0.025"
Table 5 Piston to Cylinder Clearances
3.4.4 Torque Settings
Torque Settings Size Type Torque ft-lb
Piston Nut (8” to 8-1/2” Piston) 1-1/8” - UNF 150
3" - 3-1/2" Piston 1" – UNF - 200
Piston Rod to Crosshead Lock Nut 1" – UNF Rod 300
Piston Rod to Crosshead 1" – UNF - 300
Final Stage Cylinder to C.E.Cylinder ¾" – UNC Stud 125
Final Stage Cylinder to C.E.Cylinder ¾" – UNF Stud 106
Final Stage Head ¾" – UNF Stud 140
Cylinder Head. 10" ¾" – UNF Stud 96
Cylinder Head. 6" Thru 8" ¾" – UNF Stud 96
Crosshead Cylinder To Crankcase ¾" – UNF Stud 105
Compression Cylinder To Crosshead
Guide
¾" – UNF Stud 112
Crankcase Inspection Cover 5/8" – UNC Cap Screw 92
Valve Lantern Jacking Screw 5/8" - UNF Socket Set Screw 80
Crankcase Mounting Bolts 5/8" - UNC Hex Bolts 80
Cylinder Head. 4-½" thru’ 3-1/2” 5/8" - UNC Cap Screw 51
Final Stage Discharge Valve Cover ½" – UNF Cap Screw 50
Cylinder Head. 3-1/4" thru’ 3” ½" – UNC Cap Screw 51
Valve Covers ½" – UNC Cap Screw 45
Oil Filter Housing ½" – UNC Cap Screw 53
Split Flange Clamps ½" – UNC Bolt 45
Conrod Bearing Cap ½ " - UNF Cap Screw 62
Drive Bearing Housing ½" – UNC Cap Screw 45
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 17 of 79
Torque Settings Size Type Torque ft-lb
Oil Pump Housing to Crankcase ½" – UNC Cap Screw 45
Final Stage Piston Retaining Nut ½" – UNF - 30
Rod Seal Housing to Cylinder ½" – UNF Cap Screw 45
Rod Seal Housing to Cylinder 7/16" - UNF Cap Screw 40
6-1/2” First Stage Piston 7/16" - UNF Cap Screw 27
Tandem Piston (5-1/4") to Crosshead 3/8" – UNC Cap Screw 25
Tandem Piston (3" to 3-1/2") to Piston
Rod Lock Bolt
3/8" - UNF Cap Screw 27
Split Flange Clamps 3/8" - UNF Cap Screw 20
Gudgeon Pin End-CapRetaining Bolt
Nut
3/8" UNF Bolt / Nut 30
Mechanical Seal Retainer 5/16 " -UNC Cap Screw 15
Bearing Cover Plate 5/16" - UNC Cap Screw 15
Oil Pump Housing Seal Cover 5/16" -UNC Cap Screw 15
Oil Pump Retainer 5/16" –UNC Cap Screw 17
Final Stage Piston Retaining Plate 5/16" – UNC Cap Screw 22
Piston “Power Nut” Locking Screw
(10” Piston)
5/16” – UNF Grub Screw 12
Rod Wiper Retainer Plate 5/16” – UNF Cap Screw 18
Piston Rod Balance Nut Lock Screw
(Power Nut type)
5/16" UNF Grub Screw 12
Piston Rod Balance Nut Lock Screw
(Standard Balance Nut)
¼" UNF Grub Screw 6
Piston Rod Locking Screw ¼" UNF Grub Screw 6
Table 6 Torque Settings
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 18 of 79
3.4.5 Rhino Compressor Tools
Figure 8 Compressor Tools
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 19 of 79
3.5 Operating Procedures
!!! WARNING !!!
COMPRESSED GAS IS A HIGHLY DANGEROUS
SUBSTANCE.
BEFORE DISMANTLING ANY PART OF THE
COMPRESSOR ENSURE THAT THE UNIT IS
COMPLETELY DEPRESSURED
3.5.1 Start Up Check List Contents
3.5.2 Package Details
Compressor Model :
Serial Number :
Motor/Engine Model :
Motor Rated Speed :
Packager :
Package Unit Number :
Date Package Shipped :
Start Up Date :
Commissioning Engineer :
Customer :
Location :
Local Service Agent :
Local Service Agent
Telephone Number :
Intermech Ltd. BBR-3516 Compressor Service Manual

Compressor Operation & Maintenance Manual Page 20 of 79
3.5.3 Prior to Starting
Yes No
1 Do you have the Intermech Manual(s),
special tools & spares?
2 Check the Performance Data Sheet for
design limitations; eg Rod loads, RPM,
discharge temperature.
3 Check the Performance Data Sheet for
optimum running conditions.
4 Set the Fault Switches according to
these conditions.
5 Have all the Intermech Pre Start-up Checks,
as outlined in the Commissioning Procedure,
been carried out?
6 Has the Electrical Pre Start-up Checks, as
outlined in the Commissioning Procedure,
been carried out?
7 Is the Installation complete to the satisfaction
of the Commissioning Engineer?
8 Has the Warranty Document been completed?
9 Are the customer & operators familiar with the
equipment's Operating Instructions?
10 Check that no damage has occurred to the
Package during transportation.
11 Is the correct grade and quantity of oil available
on site (at least 20 litres - 5 imp. gallons)?
12 Check the oil level in the compressor.
13 Has all the lubrication oil pipework been primed
with oil?
14 Is there Methanol or Isopropyl Alcohol available
on site (at least 20 litres - 5 imp. gallons)?
15 Check the coupling bolt torques.
16 Has the compressor coupling alignment been
checked (maximum allowable tolerance 0.005"
(0.127mm)? Record dial indicator readings:
17 Has the gas inlet pipework been cleared of dirt,
slag, rubbish, etc?
18 Check the Cooler Fan for obstructions.
19 Has the Compressor been turned over by hand
p
rior to initial start-up?
OD
FAC
E
DIAL
INDICATOR
ALIGNMENT
RUN OUT
Intermech Ltd. BBR-3516 Compressor Service Manual