CENTAC Field Service Manual

Section 9 Page Date 2-28-1997 Supercedes 3-25-1995

SECTION 9 COUPLINGS

Page 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3J

Title

Date of Issue

Lubricated Coupling Maintenance 12-27-1994 Dry-Type Coupling Maintenance 3-25-1995 Coupling Greases 1-6-1995 Coupling Greases (Cont d) 1-6-1995 Coupling Greases (Cont d) 1-6-1995 Section 1: Description Coupling Greases (Cont d) 1-6-1995 Section 2: Ingredients Coupling Greases (Cont d) 1-6-1995 Section 3: Physical Data Coupling Greases (Cont d) 1-6-1995 Section 4: Fire and Explosion Coupling Greases (Cont d) 1-6-1995 Section 5: Reactivity Hazards Coupling Greases (Cont d) 1-6-1995 Section 6: Health Hazards Coupling Greases (Cont d) 1-6-1995 Section 7: Special Protection Information Coupling Greases (Cont d) 1-6-1995 Section 8: Special Protection Information

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Section 9 Page Date 2-28-1997 Supercedes 3-25-1995

SECTION 9 COUPLINGS (Cont d)

Page 4 4A 5 5A 5B 5C 5D 5E 5F 5G 5H 6 Title Date of Issue

Procedure to Install a Coupling 1-8-1995 Procedure to Install a Coupling (Cont d) 1-8-1995 Reverse Indicator Alignment Method 2-28-1997 Reverse Indicator Alignment Method (Cont d) Setup 2-28-1997 Reverse Indicator Alignment Method (Cont d) Reverse Indicator Basics 2-28-1997 Reverse Indicator Alignment Method (Cont d) Procedure 2-28-1997 Reverse Indicator Alignment Method (Cont d) Procedure 2-28-1997 Reverse Indicator Alignment Method (Cont d) Coupling Alignment Chart 2-28-1997 Reverse Indicator Alignment Method (Cont d) Coupling Alignment Chart 2-28-1997 Reverse Indicator Alignment Method (Cont d) Diagram 1 2-28-1997 Reverse Indicator Alignment Method (Cont d) Diagram 2 2-28-1997 Procedure for Removing a Coupling 3-25-1995

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Section Page Date Supercedes

9 1 12-27-1994 8-30-1991

LUBRICATED COUPLING MAINTENANCE

Recommended maintenance procedures for lubricated couplings: 1. Use an acceptable grease. 2. Hand pack the coupling with grease between the hub and sleeve. 3. Use only a hand-pump grease gun. 4. When greasing the coupling with a hand-pump grease gun, the grease connections should be placed in a horizontal position. The connection opposite the fitting should be open to atmosphere. 5. After greasing with a hand-pump grease gun, move the coupling sleeve back and forth axially between the motor and compressor to remove excessive grease to prevent hydraulic lock. 6. Follow the manufacturer s recommendations for time intervals for maintenance and inspection. 7. When inspecting a coupling, make sure the sleeves slide freely over the hubs, the teeth are in good condition and the o-rings are in good condition.

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Section Page Date Supercedes

9 2 12-27-1994 8-30-1991

DRY-TYPE COUPLING MAINTENANCE

Recommended maintenance procedures for dry-type couplings: 1. Inspect the coupling annually. 2. Inspect the rollers to make sure they rotate freely between the hub and sleeve. 3. Insure the sleeve moves freely. 4. It is good practice to use a very thin film of grease on the rollers for ease of assembly.

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Section Page Date Supercedes

9 3 1-6-1995 8-18-1994

COUPLING GREASES
In the Spring of 1994 Centac Division released a synthetic grease for lubricated couplings. The grease is CENLUBE-SG, part number C1951, and is sold in case quantities of 10 tubes per case. The following specification sections of CENLUBE-SG can be used for reference and comparison for obtaining an alternative grease. ASTM TEST NLGI Grade Texture Thicker Type (soap base) % Soap Base Fluid Type Operating Range Operating Speeds Cone Penetration, mm Unworked Worked, 60X Worked, 10,000X Worked, 100,000X Dropping Point, F Base Oil Viscosity SSU @ 100 F SSU @ 210 F Viscosity Index Timken OK load, lbs. TEST RESULTS 1-1/2 - 2 Butterfly Aluminum Complex 7 Multi-Temp Synthetic -40 F to 500 F All Speeds 292 293 295 294 520 593 78 130 100

D-2265 D-2161

D-2509

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ASTM D-2596 TEST Four Ball EP Test load wear index, kg. weld point, kg. Four Ball Wear Test scar diam., mm, 40 kg. 1200 rpm, 165 F, 1 hr. Copper Strip Corrosion Water Washout % loss @ 104 F % loss @ 175 F Oil Separation, %

Section Page Date Supercedes

9 3A 1-6-1995 8-18-1994

TEST RESULTS 65.2 400

D-2266

D-4048 D-1264

0.6 1A 11 7 0

D-1742

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9 3B 1-6-1995 8-18-1994

SECTION 1: DESCRIPTION
Anti-friction Bearing and Coupling Grease - EP Synthetic MLGI No. s 1-1/2 & 2 DOT Hazard Class: Non-Hazardous Chemical Family: Aluminum Complex Grease

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9 3C 1-6-1995 8-18-1994

SECTION 2: INGREDIENTS
Components: Base Oil (multi-synthetic) Synthetic additives with ISO-Paraffinic diluents Aluminum Benzoate Hydroxy Complex Soap Base The precise composition of this mixture is proprietary. A more complete disclosure will be provided to a physician or nurse in the event of a medical emergency. This product contains no hazardous substance within the definition of OSHA Regulation 29 CFR 1910.1200.

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9 3D 1-6-1995 8-18-1994

SECTION 3: PHYSICAL DATA

Boiling Point C/F Pour Point C/F Vapor Pressure mm Hg @ 20C Evaporation Rate Units Solubility in Water Specific Gravity Units Appearance Odor mild) 274C (535F) not applicable 0.01 max. 0.01 max. none 0.89 buttery and soft grease odor (very

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9 3E 1-6-1995 8-18-1994

SECTION 4: FIRE AND EXPLOSION

Flash Point C/F Extinguishing Media 450F Dry Chemical, Foam, CO2, Water Fog Positive pressure, selfcontained breathing apparatus should be enclosed or

Special Fire Fighting Procedures worn in confined spaces. Unusual Fire and Explosion Hazards

None

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Section Page Date Supercedes

9 3F 1-6-1995 8-18-1994

SECTION 5: REACTIVITY HAZARDS

Stability Conditions to Avoid Incompatibility (materials to avoid) Hazardous Decomposition Products Hazardous Polymerization Stable Extreme heat and open flame Strong Oxidizers

Carbon Monoxide, Hydrogen, Aldehydes, smoke and fumes Will not occur

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Section Page Date Supercedes

9 3G 1-6-1995 8-18-1994

SECTION 6: HEALTH HAZARDS

Acute Overexposure No significant adverse health effects are expected upon short term exposure. Repeated and long time skin contact for persons hypersensitive to petroleum products may cause redness and irritation of skin. National Toxicology Program: NO I.A.R.C. Monographs: NO OSHA: NO 5 mg/m3 for synthetic lubricants

Chronic Overexposure

Chemical Listed as Carcinogen or Potential Carcenogen Threshold Limit Value

EMERGENCY AND FIRST AID PROCEDURES 1. Inhalation Vaporization is not expected at ambient temperatures, so there should be no problem. Wash with large quantities of water for 10-15 minutes. Wash with soap and water. Low order of toxicity. Do not induce vomiting: call physician.

2. Eyes

3. Skin

4. Ingestion

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Section Page Date Supercedes

9 3H 1-6-1995 8-18-1994

SECTION 7: SPECIAL PROTECTION INFORMATION

Respiratory Protection used. Ventilation Normal ventilation is all that is required. None required, but may be used. None required, but glasses may worn. Wear protective apron to protect clothes. None required. In enclosed areas, breathing equipment may be

Protective Gloves Eye Protection be Other Protective Clothing or Equipment

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Section Page Date Supercedes

9 3J 1-6-1995 8-18-1994

SECTION 8: SPECIAL PROTECTION INFORMATION

Precautions to be taken in away Handling and Storage Normal precautions: keep from flames, sparks or ignition sources. Do not weld or use torch on the container or near container. None required. Scoop up grease and return container. To prevent slipping while walking , clean oily spot by wiping with rags and applying soaking compound. Dispose according to current local, state and federal regulations.

Other Precautions Steps to be Taken in Case Material is Released or Spilled

Waste Disposal Methods

NOTE: This information is furnished without warranty, representation, inducement or license of any kind, except that it is accurate to the best of Ingersoll-Rand s knowledge or obtained from sources believed by Ingersoll-Rand to be accurate, and Ingersoll-Rand does not assume any legal responsibility for use or reliance upon same. Customers are encouraged to conduct their own tests. Before using any product READ IT S LABEL.

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Section Page Date Supercedes

9 4 1-8-1995 8-18-1994

PROCEDURE TO INSTALL A COUPLING

When installing a new coupling on a shaft, the following should be observed prior to heating the coupling: 1. Diameter of shaft 2. Diameter of coupling bore 3. Depth and width of keyway in shaft and depth and width of keyway in coupling. Also inspect for burrs, nicks, etc. and remove or smooth both the coupling and shaft as necessary. The diameter of the shaft should be measured with outside mics. The inside bore of the coupling should be measured with inside mics or calipers using the same outside mics for checking that were used to check the shaft. The coupling inside diameter should be 0.0005 to 0.00075 per inch of diameter smaller than the shaft diameter. The width of the keyway in the shaft should be slightly smaller than a standard key so that the key has to be filed to fit snugly in the shaft keyway. Relieve key on all corners. The keyway in the coupling should be 0.001 to 0.003 wider than they keyway in the shaft so that the key slides freely through the coupling keyway. If there are any discrepancies in keyway sizes, a step key must be made.

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9 4A 1-8-1995 8-18-1994

The sum of the depths of the keyways must be greater than the thickness of the key by at least 0.010 . If any discrepancies exist, file the key thickness to provide a minimum of 0.010 clearance at the top of the key when the coupling is installed. If any portion of the key protrudes behind the coupling, it should be stepped so that the keyway in the shaft is filled but the key does not protrude out of the shaft behind the coupling. After all checks have been made and the key properly fitted and installed in the shaft, a gauge should be made 0.003 larger than the shaft diameter. This gauge can be made from a piece of welding rod tapered at the ends so that it fits nicely into the coupling (when hot) without giving a false indication. Bolt a stop bar across the face of the hub to prevent the hub from sliding too far on the shaft. A small drilled piece of flat bar bolted to the puller bolt holes serves this purpose. The coupling should be either heated in a controlled temperature oven with a heat ring or a heating blanket. If these methods are not available, the use of a large heating torch (preferably a rose bud) may be used, but is not recommended, due to personnel hazard and carbonization of the coupling in the hot oil. Heat the coupling uniformly until the gauge made fits freely into the coupling. Quickly install it on the shaft before the coupling cools. Allow the entire assembly to cool. An air stream directed on the coupling and shaft will speed the cooling process and prevent heat from spreading to the bearing or seal area. Never use water when the coupling or shaft are hot, since distortion may occur.

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Section Page Date Supercedes

9 5 2-28-1997 1-8-1995

REVERSE INDICATOR ALIGNMENT METHOD

Introduction
The Reverse Indicator Alignment Method is an alignment method which uses two dial indicators spaced 180 apart, mounted to rigid brackets, as shown in Diagrams 1 & 2. One bracket is attached to the shaft of the compressor while the other bracket is attached to the shaft of the driver. The indicator attached to the bracket on the compressor shaft is positioned over the driver shaft so that the indicator plunger contacts the coupling hub. The indicator attached to the bracket on the driver shaft is positioned over the compressor shaft so that the indicator plunger contacts the coupling hub. Readings from the indicators are used to calculate the amount of movement required to obtain the desired vertical offset. Specific vertical offset is different for each model Centac. The Reverse Indicator Alignment Method is used for spacer coupled units. Centac CV units normally do not require alignment of the coupling hubs as the alignment is controlled by the flange surfaces of the gear case and motor "D" flange.

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Set-up

Section Page Date Supercedes

9 5A 2-28-1997 1-8-1995

The Centac is normally equipped with a limited float, gear type coupling with a spacer between the driver and compressor shafts on motor driven units. Turbine driven units are supplied with the same type coupling without the limited float feature. "Float" of a coupling is typically referred to as the amount of axial movement allowed. The total axial float on motor driven units is limited to approximately 3/16". This limiting is accomplished by two phenolic discs. There is one phenolic disc located in each end of the coupling spool. During installation of the unit there are typically two alignment checks performed - rough alignment and final alignment. Rough alignment is performed for the purpose of leveling the unit in preparation for grouting. Rough alignment may be performed simply by the use of a good straight edge. It is important to insure the shafts are close to insure final alignment can be accomplished with minimal effort. Typically, rough alignment is satisfactory when the shafts are parallel and vertical offset is within 1/16". Final alignment is performed for the purpose of operation. Final alignment will be performed using the Reverse Indicator Alignment Method. When performing final alignment the distance between the shafts is determined from the information provided on the General Arrangement Drawing. On units with sleeve type bullgear bearings the bullgear must be positioned in the middle of the available axial float. A motor shaft must be positioned to allow operation on its' loaded magnetic center when coupled to the compressor. Typically magnetic center and mechanical center of a sleeve bearing motor are the same. Many motors use sleeve style bearings but without a thrust surface for controlling axial float. Motors with sleeve bearings typically have 1/2" axial float. NOTE: Be sure the bullgear anti-rotation bolt is removed.

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Reverse Indicator Basics
The following basic steps should be followed: 1.

Section Page Date Supercedes

9 5B 2-28-1997 1-8-1995

Lock out and tag the starter panel breaker or the turbine steam supply block valve. Confirm the unit is properly leveled and grouted. Recheck the unit base bolts to insure they are tight. Check the driver feet and the driver base pads to insure they are clean and free of burrs. All shims must be clean and free of burrs. Stacks of shims of varying thickness are recommended for alignment. Whenever possible, replace stacks of thin shims with two or three thick shims to avoid spongy shim stacks. Insure the driver mounting bolts are of proper hardness. A grade 5 or higher strength bolt is recommended. Washers used with the mounting bolts are recommended to be at least 1/4" thick to prevent bending when the bolts are tightened. If not ordered with the original equipment jacking bolts should be installed to aid in horizontal alignment. The time involved to add jacking bolts is easily recovered by reducing the amount of time required for movement of the motor. The jacking bolts should be completely loose during final alignment readings. The indicator brackets must be designed to be rigid and bolted securely to the coupling hubs. Brackets which are not rigid will cause inaccurate readings and result in incorrect alignment. The oil should be warmed to 100-110F and circulating during alignment. The cooler casing supports on the CII design should be in contact with the cooler casing with the oil at 110F. On all models it is recommended to circulate water through the air and oil coolers.

2. 3. 4.

5.

6.

7.

8.

9.

10.

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9 5C 2-28-1997 1-8-1995

Reverse Indicator Alignment Method Procedure

The following steps should be followed when performing alignment: 1. Position the driver and compressor shafts to obtain the correct shaft spacing specified on the General Arrangement Drawing. On motor driven units the motor shaft must be positioned in the magnetic (mechanical) center of its' available axial travel. A turbine shaft must be positioned on mechanical center of its' available axial travel. Mount the rigid indicator brackets to the coupling hubs. Install the indicators onto the rigid brackets. Position the indicator pointers 180 from each other. Check the driver mounting bolts to insure they are tight. Loosen the driver foot bolts one at a time. Observe the indicator dials for any change in the readings. A change of more than 0.002" indicates a condition commonly referred to as "soft foot". The amount of change observed indicates the amount of shim thickness required to correct the soft foot condition. Install the shims necessary and tighten the loosened bolt before proceeding to the next foot. Take a set of readings of each indicator and record. A set of readings consists of four positions of the shaft and are normally located at 0, 90, 180, and 270 of a circle. Typically the 0 position is either the 12:00 or 6:00 location with reference to a clock and is dependent upon which location from which it originates. NOTE #1: Both shafts must be rotated together to keep the indicator readings 180 apart. NOTE #2: Readings recorded during the procedure will be total indicator readings (T.I.R.). Actual offset will be 1/2 the T.I.R. readings. 5. Loosen the mounting bolts and adjust the horizontal readings. The horizontal readings are normally the 90 and 270 positions. Move the motor to obtain the same readings on each indicator. Tighten the mounting bolts. Take another set of readings and record. Again, be sure to rotate both shafts together to keep the indicators 180 apart.

2.

3.

4.

6.

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7.

Section Page Date Supercedes

9 5D 2-28-1997 1-8-1995

With the readings recorded from step #6 calculate the amount of movement required, if any, to obtain the correct vertical alignment for the specific model Centac. The change is achieved by adding or removing shims from between the motor feet and motor base pads. Take another set of readings and record. Make corrections as necessary. This is commonly referred to as a "Cold Alignment". Once achieving the alignment desired the coupling can be assembled and the unit operated. Follow recommended assembly procedures for the specific coupling installed. Operate the unit for a minimum of 4 hours at full load. It is not always feasible to achieve full load operation during the initial test run. A condition as near to full load as possible is recommended. After completion of the minimum 4 hour operation at full load stop the compressor and recheck alignment. The readings recorded should be zero, or near zero. This is commonly referred to as "Hot Alignment". Once completing the Hot Alignment the driver should be doweled. When doweling a motor the use of tapered dowels with pulling nuts is recommended.

8.

9.

10.

11.

12.

Upon completion of assembly of the coupling the unit can be placed in normal operation.

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COUPLING ALIGNMENT CHART

Section Page Date Supercedes

9 5E 2-28-1997 1-8-1995

The coupling alignment chart is used to locate a specific model Centac which requires alignment before startup. The chart indicates alignment readings for specific model Centacs by total indicator reading (T.I.R.) and actual reading. The chart is specific for the reverse alignment procedure and indicates only vertical offset for motor driven units. Turbine alignment values should always be 0.000" vertical alignment with the compressor and turbine at operating temperature. All readings are "plus" dial indicator readings. "Plus" readings are obtained with the compressor indicator "zeroed" and the indicator pointer originating at the top of the compressor hub. The motor indicator is zeroed with the indicator pointer originating at the bottom of the motor hub. Model Number Compressor Hub T.I.R. Actual 0.020" 0.020" 0.030" 0.050" 0.060" 0.010" 0.010" 0.010" 0.010" 0.010" 0.010" 0.018" 0.020" 0.010" 0.010" 0.010" 0.010' 0.015" 0.025" 0.030" 0.005" 0.005" 0.005" 0.005" 0.005" 0.005" 0.009" 0.010" 0.005" 0.005" Motor Hub T.I.R. Actual 0.028" 0.028" 0.037" 0.066" 0.076" 0.010" 0.010" 0.010" 0.010" 0.010" 0.010" 0.018" 0.020" 0.010" 0.010" 0.014" 0.014" 0.0185" 0.033" 0.038" 0.005" 0.005" 0.005" 0.005" 0.005" 0.005" 0.009" 0.010" 0.005" 0.005"

0C 1C 2C 3C 4C 1ACII 2ACII 2CC 1CII 2CII 3CII 5CII 6CM 5CCH 6CCH

Tolerances should not exceed +/ 0.002" T.I.R. All values listed are for cold alignment. Models 0C, 1C, 2C, 1ACII, 2ACII, 2CC, 1CII, 2CII, 3CII, 5CCH, 6CCH will be setup similar to the example in Diagram 1. All other models will be setup similar to the example in Diagram 2.

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9 5F 2-28-1997 1-8-1995

The distance between shaft dimension is obtained from the General Arrangement (G.A.) drawing. Always refer to the specific G.A. drawing for each compressor. Note: API units usually require a different alignment value. It is common for the driver for a API unit to be set low to the compressor. Typically a cold alignment of the driver low to the compressor 0.005" is normal. These units must have a hot alignment performed to make any necessary corrections before doweling of the motor.

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Section Page Date Supercedes

9 5G 2-28-1997 1-8-1995

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Section Page Date Supercedes

9 5H 2-28-1997 1-8-1995

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Section Page Date Supercedes

9 6 3-25-1995 1-8-1995

PROCEDURE FOR REMOVING A COUPLING

#1 HEATING TORCH 1/2 TO 3/4 PLATE PULL BOLT @ 1 DRIVE SHAFT SLEEVE

ATTACHMENT BOLTS HUB

KEY

#2 HEATING TORCH

Figure 9.6.1 Coupling Pulling Method Note: Quickly heat coupling hub to 300 to 400F (150-204C). Two oxy-acetylene torches with Rose Bud tips work best for rapid heating. Use one torch by sweeping over the keyway. The other sweeps on the bottom and sides. Turn the puller Pull Bolt to remove the coupling. Keep the flame off of the hub teeth.

DANGER !
SEVERE BURNS MAY RESULT FROM IMPROPER USE OF OXY-ACETYLENE TORCHES. USE SAFETY GLASSES AND HIGH TEMPERATURE GLOVES WHEN REMOVING COUPLING WITH FLAME TORCHES.

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