Instruction manual
Model SCF-6 Centrifugal Compressor
Atlas Copco Comptec LLC
46 School Road
Voorheesville, NY 12186 USA
[Link]
Printed Matter No. 9497 1590 07
Revision 04, 09/07
GENERAL INFORMATION AND DATA
Atlas Copco recommends that the owner of this compressor record pertinent data below for future
reference. Please direct enquiries about your model SCF-6 compressor to the Parts and Service
Centre and include the machine serial number.
Ownerʼs Machine Number: ________________ Atlas Copco Serial Number: ________________
SCF-6
Model: __________ ___ Delivery Date: _____________ First Start-up Date: ________________
DESIGN CONDITIONS
Type of Gas ___________________ Flow ______________________ ACFM __________________
Inlet Pressure ___________________ (_______) Inlet Temperature ____________ (Deg._____)
Discharge Pressure ______________ (_______) Discharge Temperature _______ (Deg._____)
Atlas Copco Comptec LLC
Parts and Service Centre
46 School Road
Voorheesville, NY 12186 USA
Phone (518) 765-3344, Fax (518) 765-4889
[Link]
2
GENERAL DESCRIPTION SAFETY PRECAUTIONS
Atlas Copco model SCF-6 centrifugal compressors *** WARNING ***
feature an overhung, open-type impeller and inlet Centrifugal compressors have high speed rotating
shroud in a nodular cast iron housing. The impeller is components and can cause fatal injury. Only qualified
mounted on a high speed pinion shaft that is personnel should be allowed to install, operate and
supported by two tilting pad bearings. maintain this compressor and the associated
The pinion is driven by a single-step speed increasing equipment. To protect personnel from injury, the
gear supported by two sleeve bearings. The gears are proper safety precautions contained in this manual
manufactured from hardened steel and ground to must be followed.
AGMA Q-13 standards. The gearbox features a flange • Use proper care and procedures in handling, lifting,
for mounting to a gas turbine and is horizontally split in installing, operating, and maintaining the
the pinion plane to allow easy inspection of bearings equipment.
and seals as well as removal or installation of the • Do not touch energized circuits or rotating parts.
complete rotor assembly. • Wear proper hearing protection when in close
proximity to machinery with high noise levels.
• Do not bypass or render inoperative any
RECEIVING safeguards or protective devices.
All Atlas Copco model SCF-6 compressors are • Periodically check safety devices.
subjected to mechanical integrity testing at the factory • If gas piping downstream of the compressor must
and are shipped completely assembled and ready for remain pressurized while maintenance is being
installation and operation. Unless otherwise specified, performed on the compressor, be sure that a blind
they are shipped without special shipping preparation. flange has been installed to prevent inadvertent
Upon receipt, the compressor should be carefully back-flow of air through the machine. Do not rely
inspected and any damage claims filed immediately on a check valve.
with the carrier. Then promptly notify: • Do not remove any compressor parts, including
ATLAS COPCO COMPTEC LLC guards, shields, screens, caps, or plugs before
Parts and Service Centre Manager relieving pressure from the system. Oil or air under
46 School Road pressure can cause severe injury, or death.
Voorheesville, New York 12186 • Do not operate the compressor at pressures and
Tel. (518) 765-3344 speeds above its rating.
Fax (518) 765-4889 • To avoid electric shock, disconnect all power
The compressor has been shipped without oil. During sources from the machine and accessories before
manufacture, test and preparation for shipment, basic performing maintenance. Safe maintenance
procedures were observed to protect against rust and practices with qualified personnel are imperative.
corrosion. As a result, a film of rust inhibiting oil • Ground electric components and the machine in
remains on the parts during shipment. accordance with national electrical codes and
If the compressor has been exposed to low consistent with sound local practice.
temperatures, it should be unpacked only after it has • Do not leave loose items (for example, tools, rags,
reached the temperature at which it will be installed. or machine parts) on the compressor or gear
assembly prior to start-up.
• Do not use flammable solvents to clean parts.
• Keep dirt out of exposed openings by covering
them with clean cloth or kraft paper.
• Do not touch hot portions of the equipment; for
example, the compressor housing.
The owner, lessor, or operator of the compressor is
hereby notified and forewarned that failure to observe
common safety precautions, whether or not
specifically stated herein, may result in injury to
personnel or damage to equipment.
3
DESCRIPTION OF SCF-6 SEAL OPERATION
Process gas pressure at the discharge is decreased Oil is prevented from entering the process first by a
along the impeller labyrinth teeth to Port “B” which is slinger ring on the high speed shaft which slings off
internally ported back to process suction. Pressure at the majority of the oil coming from the inboard bearing,
Port “B” is then further reduced across a second set of then draining from Port “E” to Port “F.” If some oil
labyrinth teeth to Port “C” which is internally ported to does get past the slinger and enters the oil seal, it can
the 1-1/2" npt breather on the gear cap. This flow of be drained out after the first oil seal tooth back to Port
gas also flows across a single labyrinth tooth to “E” and again to Port “F.” As a further backup, oil can
prevent oil migration down the shaft to Port “D.” Port also be drained out from Port “D” being assisted by
“D” is connected to customerʼs vent 3 and drain process gas flow as described in previous paragraphs.
through liquid level trap to customerʼs oil reservoir.
COMPRESSOR START UP
Prior to starting the turbine, the following check list may cause the impeller to become separated
must be verified for atomizing air compressor start-up. from the compressor shaft.
START-UP CHECK LIST 3. To prevent accumulation of condensate verify that
the pre-cooler low point drain is not plugged and
1. 200°F (93°C) is the minimum allowable compressor
that there are no low points downstream of the pre-
inlet temperature. Atlas Copco recommends an
cooler where condensate could collect.
inlet temperature 15 to 20°F (8 to 11°C) greater
than the dew point. The pre-cooler drain must remain open at all
times during operation.
NOTE: The dew point at 155 psia (11 bar A) is 195-
Any low points must be drained before start-up to
200°F (90-93°C). At maximum inlet pressure of
prevent damage to the compressor.
155 psia (11 bar A) and an inlet temperature of
215°F (102°C), adequate superheat will be 4. To prevent impeller and housing erosion by solid
available. particles, the blowdown line from the cyclone
separator should remain open.
2. Failure to maintain the specified compressor inlet
conditions will result in the following problems: 5. Adequate oil supply pressure and temperature must
be provided to the compressor before starting the
a. A temperature too low will cause excess water
turbine:
to be blown across the high pressure buffer seal
and will cause rapid erosion of the seal, followed 26 - 30 psig (1.7 - 2.1 bar g)
by excessive leakage. 100°F min. (38°C)
145°F max. (63°C)
b. Small droplets of water at high inlet velocity will
cause impeller erosion. Warning: If the compressor is tested on a customer
test skid, i.e. not connected to turbine, the inlet
c. Slugs of water from low points in the air supply
pressure should simulate the turbine start-up speed vs
system can cause abrupt failure of the
inlet pressure profile or it may be started at an inlet
compressor.
pressure of 3-4 psig. Then, once the compressor
d. Inlet temperatures in excess of 250°F (121°C) reaches design speed, inlet pressure should be
gradually raised to the required design pressure.
6. Blow down compressor inlet piping and compressor
housing insuring that no condensate has
accumulated prior to start up.
NOTE: In the event of atomizing air compressor problems or failure, an Atlas Copco service technician must be
contacted and the failed unit sent to Atlas Copco, Voorheesville, NY for service.
7
MAJOR MAINTENANCE Place two 3/4"-10 guide pins (at least 8" long) 180°
Before performing major maintenance on your Atlas apart on a horizontal plane in the holes from which the
Copco model SCF-6 centrifugal compressor, refer to bolts were removed in the previous step.
the “Gearbox and Compressor Housing Assembly Remove the remaining two bolts holding the shroud
Drawing” and appropriate “Bill of Material.” (Bills of and entry flange to the compressor housing.
Material are identified by Assembly Number. The Remove the entry flange and shroud from the
compressor housing being careful not to damage the
impeller by hitting it with the shroud. If the entry flange
COMPRESSOR does not remove easily, there are three 5/8"-11
MODEL SERIAL NO.
tapped holes that may be used as jacking bolt holes.
CAPACITY ACFM m3/h (Remove the entry flange and shroud evenly with the
INLET PRESS. ABS. PSIA BAR(a) jacking bolts.)
INLET TEMP. °F °C
DISCHARGE PRESS. ABS. PSIA BAR(a)
Once the shroud with entry flange has been removed,
RATED SPEED COMPR. RPM store it in a safe place. Do not place it on the floor
WEIGHT TOTAL LBS kg where it might be damaged.
COOLING WATER FLOW GPM l/s
INLET WATER TEMP. °F °C
Do not attempt to remove the impeller from the shaft.
MAX INLET WATER PRESS. GAGE PSID BAR(e) This is a pressed fit and is not designed for field
ASS’Y. NO. [Link]. assembly. Rotor removal will be covered later in this
CUSTOMER P.O. NO. procedure.
CUSTOMER ORD. SHT.
STG 1 STG 2 STG 3 STG 4
MAX. WKG. PRESS. PSIG
BAR(e) GEAR CAP REMOVAL
MAX WKG. TEMP. °F Remove any vents and seal connections that would
°C hinder gear cap removal.
ATLAS COPCO COMPTEC LLC Remove the inspection cover from the gear cap by
SCHOOL RD., VOORHEESVILLE, NEW YORK 12186, USA removing the twelve 1/2"-13 bolts from the inspection
cover.
Typical compressor data plate. NOTE: Model SCF-6 compressors (assembly number
806 993 G01-G99) have four bolts that are
appropriate Assembly Number can be found on the longer and that are used to hold the gear cap
compressor data plate.) to the gearbox as well as to hold the
For the purposes of these instructions, it has been inspection cover to the gear cap.
assumed that the compressor has been removed from Remove all bolts holding the gear cap to the gearbox
the turbine and has been securely mounted to a stand and all bolts holding the gear cap to the compressor
or work bench. The compressor can be mounted to a housing.
stand using the four bolt holes of the oil drain flange.
Remove the two dowel pins aligning the gear cap and
The following operations are explained:
gearbox.
• Shroud with entry flange removal Rig the gear cap to an overhead hoist.
• Gear cap removal
• High speed bearing, seal and rotor removal The recommended method of rigging is to place two
• Low speed bearing and drive gear removal 1/2"-13 eye bolts in the two upper corner bolt holes
• Inspection from which the inspection cover was removed. Then
• Reassembly use straps placed through the eye bolts and attach
them to the overhead hoist to support the gear cap.
SHROUD AND ENTRY FLANGE REMOVAL After checking to insure all bolts have been removed,
Remove all but two of the 3/4" bolts and belleville slowly lift the gear cap, keeping it as parallel to the
washers, items 38 & 39, holding the shroud and entry gearbox as possible. If the gear cap sticks to the
flange to the compressor housing. gearbox, tapping the gear cap should loosen it. Do
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BILL OF MATERIAL BILL OF MATERIAL
ASSEMBLY # 0806993G06, GBOX & COMP HSG ASSY SCF-6H ASSEMBLY # 0806993G07, GBOX & COMP HSG ASSY SCF-6H
GE #302A1537P01 and P10 GE #302A1537P05 / 102T1384P005
ITEM PART NO. DESCRIPTION QTY UM ITEM PART NUMBER DESCRIPTION QTY UM
001 0806991G01 GEARBOX ASSY, FINISHED MACH 1.00 EA 001 0806991G01 GEARBOX ASSY, FINISHED MACH 1.00 EA
002 0806984002 COMPRESSOR HOUSING 1.00 EA 002 0806984002 COMPRESSOR HOUSING 1.00 EA
003 0806977001 FLANGE, ENTRY 1.00 EA 003 0806978002 ENTRY FLANGE 1.00 EA
004 0806994G06 ROTOR ASSEMBLY 1.00 EA 004 0806994G01 ROTOR ASSEMBLY 1.00 EA
005 0806979G01 GEAR, DRIVE 1.00 EA 005 0806979G01 GEAR, DRIVE 1.00 EA
006 0413012G02 SEAL, OIL, SPLIT 1.00 EA 006 0413012G02 SEAL, OIL 1.00 EA
007 0413011G02 SEAL, AIR/GAS 1.00 EA 007 0413011G02 SEAL, AIR/GAS 1.00 EA
009 0806830001 NAMEPLATE 1.00 EA 009 0806830001 NAMEPLATE 1.00 EA
010 0806992004 SHROUD, VOLUTE 1.00 EA 010 0806992001 SHROUD, VOLUTE 1.00 EA
011 0420211001 SHIM WASHER, LAMINATED 4.00 EA 011 0420211001 SHIM WASHER, LAMINATED 4.00 EA
013 0800180000 CAP, PLASTIC 2.00 EA 013 0800180000 CAP, PLASTIC 2.00 EA
014 0803622003 JOURNAL BRG 1.00 EA 014 0803622003 JOURNAL BRG 1.00 EA
015 0806998001 JOURNAL BRG 1.00 EA 015 0806998001 JOURNAL BRG 1.00 EA
016 0800024000 JOURNAL BRG 2.00 EA 016 0800024000 JOURNAL BRG 2.00 EA
017 0800087000 BREATHER 1.00 EA 017 0800087000 BREATHER 1.00 EA
018 0800931000 PIPE PLUG 1.00 EA 018 0800931000 PIPE PLUG 1.00 EA
019 0800758000 SPRAY NOZZLE 1.00 EA 019 0800758000 SPRAY NOZZLE 1.00 EA
021 0417013001 COVER, END 1.00 EA 021 0417013001 COVER, END 1.00 EA
022 0806995G01 COVER, GEARBOX 1.00 EA 022 0806995G01 COVER, GEARBOX 1.00 EA
024 0803610001 SHIM, THRUST BRG RETAINING 1.00 EA 024 0803610001 SHIM, THRUST BRG RETAINING 1.00 EA
025 0800661000 NIPPLE, PIPE 1.00 EA 025 0800661000 NIPPLE, PIPE 1.00 EA
026 0564000026 TEE, PIPE 1.00 EA 026 0564000026 TEE, PIPE 1.00 EA
027 0402025002 SEAL PLATE 1.00 EA 027 0402025002 SEAL PLATE 1.00 EA
028 0409058014 SCREW, STUD 4.00 EA 028 0409058014 SCREW, STUD 4.00 EA
029 0800766000 NUT, HEX 4.00 EA 029 0800766000 NUT, HEX 4.00 EA
030 0420095202 PIPE PLUG 1.00 EA 030 0420095202 PIPE PLUG 1.00 EA
031 0800714000 PIPE NIPPLE 1.00 EA 031 0800714000 PIPE NIPPLE 1.00 EA
032 0686610401 PIPE PLUG 4.00 EA 032 0686610401 PIPE PLUG 4.00 EA
037 0802316000 KEYSTOCK 1.75 IN 037 0802316000 KEYSTOCK 1.75 IN
038 0801959001 WASHER, BELLEVILLE 16.00 EA 038 0801959001 WASHER, BELLEVILLE 18.00 EA
039 0801307000 SCREW, HEX HEAD 16.00 EA 039 0801307000 SCREW, HEX HEAD 18.00 EA
041 0801277000 SCREW, HEX HEAD 8.00 EA 041 0801277000 SCREW, HEX HEAD 8.00 EA
042 0801280000 SCREW, HEX HEAD 1.00 EA 042 0801280000 SCREW, HEX HEAD 1.00 EA
043 0801171000 SCREW, DRIVE 4.00 EA 043 0801171000 SCREW, DRIVE 4.00 EA
044 0801959002 WASHER, BELLEVILLE 9.00 EA 044 0801959002 WASHER, BELLEVILLE 9.00 EA
047 0802177000 O-RING 1.00 EA 047 0802177000 O-RING 1.00 EA
048 0801116000 O-RING 1.00 EA 048 0801116000 O-RING 1.00 EA
049 0801124000 O-RING 1.00 EA 049 0801124000 O-RING 1.00 EA
050 0801125000 O-RING 2.00 EA 050 0801125000 O-RING 2.00 EA
051 0801115000 O-RING 1.00 EA 051 0801115000 O-RING 1.00 EA
052 0802954000 COUPLING, PIPE 1.00 EA 052 0802954000 COUPLING, PIPE 1.00 EA
053 0800179000 CAP, PLASTIC 1.00 EA 053 0800179000 CAP, PLASTIC 1.00 EA
054 0417079001 RING, PILOT 1.00 EA 054 0417079001 RING, PILOT 1.00 EA
055 1420030117 WASHER, LOCK, SPLIT 4.00 EA 055 1420030117 WASHER, LOCK, SPLIT 4.00 EA
056 1420030189 INSERT, THREADED 4.00 EA 056 1420030189 INSERT, THREADED 4.00 EA
057 0801282000 SCREW, SOCKET HEAD CAP 6.00 EA 057 0801282000 SCREW, SOCKET HEAD CAP 6.00 EA
059 0800181000 CAP, PLASTIC 1.00 EA 059 0800181000 CAP, PLASTIC 1.00 EA
067 3455058906 PIPE PLUG 2.00 EA 067 3455058906 PIPE PLUG 2.00 EA
18
BILL OF MATERIAL BILL OF MATERIAL
ASSEMBLY # 0806993G08, GBOX & COMP HSG ASSY SCF-6L ASSEMBLY # 0806993G10, GBOX & COMP HSG ASSY SCF-6
GE #302A1537P04 / 102T1384P004 GE #302A1537P09
ITEM PART NUMBER DESCRIPTION QTY UM ITEM PART NUMBER DESCRIPTION QTY UM
001 0806991G01 GEARBOX ASSY, FINISHED MACH 1.00 EA 001 0806991G01 GEARBOX ASSY, FINISHED MACH 1.00 EA
002 0806984002 COMPRESSOR HOUSING 1.00 EA 002 0806984002 COMPRESSOR HOUSING 1.00 EA
003 0806978002 ENTRY FLANGE 1.00 EA 003 0806977001 ENTRY FLANGE 1.00 EA
004 0806994G02 ROTOR ASSEMBLY 1.00 EA 004 0806994G08 ROTOR ASSEMBLY 1.00 EA
005 0806979G01 GEAR, DRIVE 1.00 EA 005 0806979G01 GEAR, DRIVE 1.00 EA
006 0413012G02 SEAL, OIL 1.00 EA 006 0413012G02 SEAL, OIL 1.00 EA
007 0413011G02 SEAL, AIR/GAS 1.00 EA 007 0413011G02 SEAL, AIR/GAS 1.00 EA
009 0806830001 NAMEPLATE 1.00 EA 009 0806830001 NAMEPLATE 1.00 EA
010 0806992001 SHROUD, VOLUTE 1.00 EA 010 0806992006 SHROUD, VOLUTE 1.00 EA
011 0420211001 SHIM WASHER, LAMINATED 4.00 EA 011 0420211001 SHIM WASHER, LAMINATED 4.00 EA
013 0800180000 CAP, PLASTIC 2.00 EA 013 0800180000 CAP, PLASTIC 2.00 EA
014 0803622003 JOURNAL BRG 1.00 EA 014 0803622003 JOURNAL BRG 1.00 EA
015 0806998001 JOURNAL BRG 1.00 EA 015 0806998001 JOURNAL BRG 1.00 EA
016 0800024000 JOURNAL BRG 2.00 EA 016 0800024000 JOURNAL BRG 2.00 EA
017 0800087000 BREATHER 1.00 EA 017 0800087000 BREATHER 1.00 EA
018 0800931000 PIPE PLUG 1.00 EA 018 0800931000 PIPE PLUG 1.00 EA
019 0800758000 SPRAY NOZZLE 1.00 EA 019 0800758000 SPRAY NOZZLE 1.00 EA
021 0417013001 COVER, END 1.00 EA 021 0417013001 COVER, END 1.00 EA
022 0806995G01 COVER, GEARBOX 1.00 EA 022 0806995G01 COVER, GEARBOX 1.00 EA
024 0803610001 SHIM, THRUST BRG RETAINING 1.00 EA 024 0803610001 SHIM, THRUST BRG RETAINING 1.00 EA
025 0800661000 PIPE NIPPLE 1.00 EA 025 0800661000 PIPE NIPPLE 1.00 EA
026 0564000026 TEE, PIPE 1.00 EA 026 0564000026 TEE, PIPE 1.00 EA
027 0402025002 SEAL PLATE 1.00 EA 027 0402025002 SEAL PLATE 1.00 EA
028 0409058014 SCREW, STUD 4.00 EA 028 0409058014 SCREW, STUD 4.00 EA
029 0800766000 NUT, HEX 4.00 EA 029 0800766000 NUT, HEX 4.00 EA
030 0420095202 PIPE PLUG 1.00 EA 030 0420095202 PIPE PLUG 1.00 EA
031 0800714000 PIPE NIPPLE 1.00 EA 031 0800714000 PIPE NIPPLE 1.00 EA
032 0686610401 PIPE PLUG 4.00 EA 032 0686610401 PIPE PLUG 4.00 EA
037 0802316000 KEYSTOCK 1.75 IN 037 0802316000 KEYSTOCK 1.75 IN
038 0801959001 WASHER, BELLEVILLE 18.00 EA 038 0801959001 WASHER, BELLEVILLE 16.00 EA
039 0801307000 SCREW, HEX HEAD 18.00 EA 039 0801307000 SCREW, HEX HEAD 16.00 EA
041 0801277000 SCREW, HEX HEAD 8.00 EA 041 0801277000 SCREW, HEX HEAD 8.00 EA
042 0801280000 SCREW, HEX HEAD 1.00 EA 042 0801280000 SCREW, HEX HEAD 1.00 EA
043 0801171000 SCREW, DRIVE 4.00 EA 043 0801171000 SCREW DRIVE ALL 4.00 EA
044 0801959002 WASHER, BELLEVILLE 9.00 EA 044 0801959002 WASHER, BELLEVILLE 9.00 EA
047 0802177000 O-RING 1.00 EA 047 0802177000 O-RING 1.00 EA
048 0801116000 O-RING 1.00 EA 048 0801116000 O-RING 1.00 EA
049 0801124000 O-RING 1.00 EA 049 0801124000 O-RING 1.00 EA
050 0801125000 O-RING 2.00 EA 050 0801125000 O-RING 2.00 EA
051 0801115000 O-RING 1.00 EA 051 0801115000 O-RING 1.00 EA
052 0802954000 COUPLING, PIPE 1.00 EA 052 0802954000 COUPLING, PIPE 1.00 EA
053 0800179000 CAP, PLASTIC 1.00 EA 053 0800179000 CAP, PLASTIC 1.00 EA
054 0417079001 RING, PILOT 1.00 EA 054 0417079001 RING, PILOT 1.00 EA
055 1420030117 WASHER, LOCK, SPLIT 4.00 EA 055 1420030117 WASHER, LOCK, SPLIT 4.00 EA
056 1420030189 INSERT, THREADED 4.00 EA 056 1420030189 INSERT, THREADED 4.00 EA
057 0801282000 SCREW, SOCKET HEAD CAP 6.00 EA 057 0801282000 SCREW, SOCKET HEAD CAP 6.00 EA
059 0800181000 CAP, PLASTIC 1.00 EA 059 0800181000 CAP, PLASTIC 1.00 EA
067 3455058906 PIPE PLUG 2.00 EA 067 3455058906 PIPE PLUG 2.00 EA
19
Instruction manual
Model SCF-6 Centrifugal Compressor
Atlas Copco Comptec LLC
46 School Road
Voorheesville, NY 12186 USA
[Link]
Printed Matter No. 9497 1590 07
Revision 05, 08/12