PG-2143-C July, 1989 DRESSER-RAND Instruction Supplement SUPPLEMENT TO RDS, HOS AND HHE INSTRUCTION BOOKS (Forms PG-642-D, PG-1028-A, PG-2127-A and PG-2017-A) A frame oil pressure relief valve that is not field adjustable is now being installed on all Dresser-Rand RDS, HOS and some HHE compressors. All reference to field adjustment on page 2-3 of forms PG-642-D and PG-1028-A should be ignored. Aliso, Figure 2-3 in forms PG-642-D and PG-1028-A (Frame Oil Pressure Relief Valve) does not depict the new valve. Sectional drawings of both the new and old valves appear below. The description of operation and setpoint for the new valve is essentially unchanged, the only difference between the two valves being that the spring retainer is pinned in place (on the new valve, thus preventing tampering with the relief valve setpoint This new valve is not field adjustable, nor is it field repairable. If the valve malfunc- tions, please order a new valve using the part number contained in the compressor parts list. urceno ‘A-vALvE soDY = ear C— REGULATING SCREW = LocknuT — UPPER SPRING PLATE SPRING LOWER SPRING PLATE ‘CURRENT VERSION VERSION TP-1606-A Frame Oil Pressure Relief ValvePG-2387 March, 1987 DRESSER-RAND nstruction Supplement COMPRESSOR FLYWHEEL Installation and Removal instructions GENERAL A flywheel may be supplied on compressors that are direct-driven by an induction motor. ‘The flywheel is mounted on the portion of the compressor crankshaft that extends from the frame and is connected to the driver with @ coupling as illustrated in Figure 1. The flywheel ‘normally is removed from the unit for shipment to the compressor site. it must be installed on the machine as described in the following instructions, s VIEW AA CAPSCREW POSITION TO LOOSEN TAPERED BUSHING. VIEW BB CAPSCREW POSITION TO TIGHTEN TAPERED BUSHING SEE COUPLING ASSEMBLY DRAWING FOR COUPLING INSTALLATION DIMENSIONS. AAND 6 - [F DRIVE SHAFT ‘COMPRESSOR SHAFT TP-1346-A Figure 1. Compressor Flywheel and Drive CouplingInstruction Supplement FLYWHEEL INSTALLATION 1. Inspect the flywheel! bore, tapered bushing diameters and the portion of the crankshaft where the flywheel will be mounted. These surfaces must be clean and free of all foreign substances such as paint or dit. Carefully remove nicks, burrs or other surface irregularities with a mill file or a fine hone CAUTION Use no lubricants in this installation. 2. Assemble the tapered bushing and flywheel as illustrated in Figure 1. Loo: capscrews and lockwashers into this assembly (see view B-B in Figure lubricate the capscrew threads. 3. With the key properly located in the crankshalt keyway, slide the flywheel and bushing assembly onto the crankshaft so that the face of the bushing is flush with the end of the crankshaft (unless otherwise indicated on the certified Flywheel Assembly drawing). If it is dificult to slide the bushing onto the shat, wedge a screwdriver blade into the saw cout to relieve the fit. Check to be certain the capscrew heads are to the outside with the flywheel in its installed position 4, Tighten the bushing capscrews evenly and progressively to the torque value given in Table | Table |. Bushing Torque Values Bushing Capscrews Torque Value Foot- Size No, Thread Pounds Nm M 34-10 225 305 5 N 718-9 300 406 w 1118-7 600 813© Instruction Supplement 5. Mount the flanged coupling half on the flywheel and assemble the coupling. See the ‘separate Coupling Installation instructions provided by the coupling manufacturer. FLYWHEEL REMOVAL If it becomes necessary to remove the flywheel from the compressor crankshaft, use the following steps: 1. Disconnect the drive coupiing, remove the flanged coupling half from the flywheel and move the driver as required to provide space for pulling the flywheel. WARNING ‘The flywhee! may unexpectantly come off the crankshaft when the tapered fit is broken free. To prevent injury to personnel, the flywheel must be adequately supported and restrained before proceeding with the following removal procedure. 2. Loosen and remove the capscrews and lockwashers that attach the bushing flange to the flywheel hub. 3. Insert the same capscrews in the tapped removal holes provided in the flywheel hub and progressively tighten each one against the bushing flange until the flywheel is loose on the bushing. (See view A-A in Figure 1.) 4 Remove the flywheel and tapered bushing from the crankshaft. if the bushing will not slip off the shaft, wedge a screwdriver blade in the bushing saw cut to relieve the fit; the bushing can then be easily removed. PG2387PS.TXT/PG Forms Disk #5JAMES MAUDE & CO. LIMITED > ‘Zecistared OMmce: Forest Road. Mansfeld = ——= Netuingham NG1 4aX Tel: 0625 26558, Telex: 578169 MAUDE G Fax: 0623 21575 CHECKED TO ORESSERRAND Spex, LO.OTT BO Ne EREIEICATE CF PTA comroruance 1g BST SAN CSTVER: Dresser Rand Painved post MPROKED 8 Sas FETT: Gass> FEB 20 199 As ORDER WO: < ed 866259C >) . MOCERIAL: TR 60,000-30 ~ Cae dhion January 1995 me CHEMICAL ANALYSIS urs Dae come oon | W/m c Ja | me | s 208 | 1.76 [oes BL 2 10.050 |0.032 2Cran Kehatt co tse ‘APPROVED BY. Sold to: ELLWOOD CRANKSHAFT& Date: JULY 6 1995 MACHINE CO P.O. #: HS95-1645/2025 2727 FREEDLAND ROAD Shop Order#: 5-3124 HERMITAGE PA 16148 Specification: 65,001 ED.03 Drawing #: F-25493 REVC Grade and Description: 4140 CRANKSHAFT-R.T. Heat! | Ingot | ingot Order #| Serial#| ingot# | size_| Weight Product Size 1 eT iat ‘TENSILE TEST RESULTS: TENSILE TEST DIA. 505" ____________BRINELL RESULTS Yield 7] vw YW] vw Strength Tensile | Elong EquoTip Serial# | TestLoc | .2%offset_| Strength | in2” |RA% BRINELL O17 406,000. 430,000 21 61 __| 262-268-271-267-272-274 i IMPACT RESULTS: TEST SIZE: 10mmx10mm Test Serial# | TestLoc | Temp. | Ft tbs. | % Shear Lateral Expansion ——— “DURING MANUFACTURING, TESTING AND INSPECTION, THIS PRODUCT HAS NOT COME IN DIRECT CONTACT WITH — MERCURY OR ANY OF ITS COMPOUNDS, NOR WITH ANY MERCURY CONTAINING DEVICE EMPLOYING A SINGLE BOUNDARD OF CONTAINMENT. MATERIAL MANUFACTURED IN ACCORDANCE WITH ECF QUALITY POLICY MANUAL EDITION 3 DTD 11/1193 ‘CONFORMING TO MIL.J-45208A AND ISO-002-1987. MELT METHOD: ELECTRIC FURNACE VACUUM DEGASSED LADLE REFINED CAPABLE OF MEETING MAG, PARTICLE PER 21, 109-00 IN FINAL PART CAPABLE OF MEETING SONIC 21,305-00 IN PINAL PART Signed mY ms ‘CERTIFICATION CLERKELLWOOD CRANKSHAFT (343 AND MACHINE CO. Ez 2727 Freediand Road Hermitage, PA 16148 12047-0250 FAX: 412/947-0054 sve00/247-1828 NON DESTRUCTIVE TEST RECORD CUSTOMER: Dresser-Rand Com ADDRESS 100 Chemung Stree: Painted CUSTOMER ORDER NUMBER | DRAWING? JOB # (Fapph CPSCGBBSB720 25493 Rev. C GRADE OF STEEL MATERIAL SUPPLIER .D. # | MILI 4140 5-3121-01-7 DESCRIPTION ECM LD. # Crankshaft 0-2025-01-2 ULTRASONIC DATA SPECIFICATION: 21, 305-00 ED 2 INSTRUMENT: SM 90D Automation Industries, Inc. TRANSDUCER: Aerotech Gamma Series METHOD: Contact MHZ: 2.25 | SIZE: 1" "40CR) WAVE: Longitudinal STANDARD: 100% FSH REFERENCE HOLE. RMS: 63 COUPLANT: SAE 30 REMARKS: RADIAL - No recordable indications found AXIAL - No recordable indications found Reported by. DS D. Dunstan, ECM Levit II creo Toon sep, (S100 MUG TO INGENERAL CONFORMANCE: ‘APPROVED BY. MAGNETIC PARTICLE DATA SPECIFICATION: _21,109-00 ED 2 EQUIPMENT: Magnaflux Corp. Type KCH-3D ‘CURRENT: 3000 Amps max. PARTICLES: MI-Glo 810 SURFACE RMS: 16 REMARKS: Revealed no recordable indications Reported ty: L/peLacrre ded acetZee2DNiliam D. Dunstan, ECM Level I ECMQANDT TBIoe 13-05 10:18 FAX 212 922 3810 YOEST-ALPINE NY Con Rods — i ‘VORST-ALDTUE STEEL PRODUCTS COMPODATION SOE. 42 staat Baw York, WT. 10265 rest Mew York, Sue 8, 1998 ATO an teary COUT ‘DRRSSER-RARD COMPANY Building 14, Floor 2 Painted Post, W.¥. 14870 — ome ov meres 3/u afecr t me. ov sumcss: P.O. @ vasc# 3250020/ aco: 1478. ~kow/3,280--kow formanax #: see 3/a, cr Gee ia ts i pars 3s Erstren-wore: 1use/ene? = aeane Guvores bs «61/478 cayoesraae Dear Maxy: | mclosed please find the mspectiin certificates 464.406 and # 64.407 in duplicate for the above quoted shipisints.° The material was transported to your plant by your trucker after clearing customs. ‘The respective invoices # 01/0697539 and $ 01/069755e for the above captions sateriel vera sex to your Asoouts Payeble Departoent. Dimpatch-totar #: 1250/36356 and 1150/36357. FZ cjeocoronnernoy O/7 ‘alae Administrator UN eas 150 siamo INGENERAL CONFORMANDE TO_ Ruste: see above. || apPROVED AY ZZ0613-08 0:10 FAN ana 082 3810 OrsT ALPEN? MF =a i ==. : 4350/1313 (sen) roo 878796¢ 1250025 = FieweLsranges, 1594-0 = | = = =] = ean 66.037 (3/2/93) = ows ‘Commas Arayae Ube! grate / Capea cara 3) a2,s| me | 43 | 690 |, 20,0 a2 |; 22.5] 53] <8 ea ‘i Spec. 29.000-00 (7/14/94) normalieed, quenched and'teagered, stress selleved omyering tenpecerures 630°C semmped vith 558 Ops inna. 2540/02"—" ‘SehrembockXe Heads Tape rire I EMPIRE STEEL CASTINGS, INC. Box 139 Reading, Pa. 19603 Vv itatenzat, centtrscaazol Customer: Twesser Rand Serial No. Customer Order No. Pattern No mane23 Cex > Shipping Date: _6/26/95 to Spectfivation: _ ASTM A216-89 Gru R1830 % ) CHEMICAL COMPOSITION Vi cupsrcay, coNPOSEEION a As No. C ~ Mn P v s sf mi a No Cu__Other Piece es = ve MECHANICAL PROPERTIES Yiela Ultimate Elongation R.A. Impact Ber (psi) ms (3) CFT/1) (ILS) 79,000 26 45.5 SPECIAL PROCEDURES xT Pr RT We1a Heat Treat Procedure Procedure Procecure Procedure Proceaure RT performed on castings Empire Steel Castings, Inc., we hereby certify Q.a.Manager, ff~ Pursuant to laboratory tests conducted at Rl that a31 requirements of the stated specifica~ tinn have been met. oa METALLURGIE4.5" byl &% le! SENT BY:ST. MARYS FOUNDRY, INC: @-23-95 i 6:12AM i 41930682604 OR QUALITY CONTROL:# 2 MEEHANITE® AND DUCTLIRON® CASTINGS 1S 9002 CERTIFIED + caneermnemon nna sonve, SERRE on waaay ante ‘ 8 S scoeece+ CERTIFIED TEST REPORT - ae eee aye a a eS CASTDATE: @6\09\1995 MEATS 7e018 ) NATESPEC: G1901-01 RRV: O86 ove MECHANICAL TESTING CHEMICAL AWALYSTS ee eee Prana oes ; SILICON: 2.56 -“SULPHUR: 010 TEKSILE (Lesvsumm1 gga > Puospuonuc, —@.¢22..GunonruMs vreLo (essary: 4887 nrcKeL: "e180 noLYBDEKUN: ELONGATION (9: 2 COPPER: 295 ALUNTHUR: CASTING HARDNESS «BHKD 1 s ‘TETAMIUN: @.0@% MAGNESIUM: 0.051 TEST BAR RARDMESS (BK) 1149 U7 Saree: 11H 2.003 & ses HEAT TREAT TIMES & TEMPS ‘se tee CHARPY IMPACT VALUES ver HEAT Tor F TEMP (F)r °7@° BREAKING ENERGY (FT/LES) RATES FUR SamPcet: a . 38 WOLD: ours WO sores: ceecuto oa sess (A, COW O1 Coot\ates F/aR Max aT SPEC: Ramon \p \ Saat F AUG 2.31995 SSG CST PRAS IN GENERAL CONFORMANCE TO, “_ authorized Agent. ay 1931 oat RCA foregoing ia limited based on material and/or specifications fi Glient and excludes any varrentiem as te the fitness of the material. U SO pee rrrrreree rare seta errant eereerer3.5 Cylon fy [of 4 JUL 24 "95 LAESTAM ELLUOOD CITY FORGE QUAL DEPT Pa i , EE A A A ~ ¢<* TEST REPORT Ru oe i aR 18/29/1994 | Ou "cout @ STW ALLOY STEELS COMPANY SoA: Ms CASTLE & 22. & sjoe weer 73K ether 26000 MILES ROAD ‘ cuLCAGO IL 60628 BEDFORD HEIGHTS» == Oh“ autus i aaa TEE = oe ts000 b. 750" MTP RE stress Ret TAC-33590 5 PART NUMBER: Grave: 4182 DH CA-AL Ne IMIL-8-1222H AM! GR_B7 3.1.1 ONLY ASTM AN3W-90A CLASS SC) FORESSER-RAND 65,007 10TH ED JGASTH £281-79¢84) eset No = ge ote = Pe is od ats wore: AB “AL cu 93583 sN1 97 5018 1030.26 13.71.03" 419 032 «1H 2 sominy 1 2 3 4 S 6 7 8 91011 1213 14 15 16 18 20 24 28 32 Gr Size Bree oh sf st se se of se 38 752 a5 Fle Fas 1 2S OT 8G 38 eS 22: preter: Stamped vith Heat Code; NCB, Hardness 4B SURFACE 285 - 8 Off Yield Tenaite Elong Ai MID RAD. 269 fmunber «Set. PST. PSE XR SURFACE 288 : "02 $1,800 126,000 1919 56-9 MED RAD. 205 '2) 108,000 y 102 87,000 121,800 20.9 54.0 : 12 99,000 @ yfiere test stiatactory. - placrserch meet $3, 3, -C3. wihis materiel vas melted and produced tn the UNITED STATES of AMERICA. Gf rena asrena xr svcren vo wun oe SE i at LOS Povcmass oa aoe Marumt roples no erowD To weceons ‘Serena Samana comnron woes on a OAM ARES, 2 AAA AOE MEARE REA NE RUA EAE AEE EE AEE A nara carly that te sore ta ae core a contac Inne marae of Copperaetl Stel Comoe Lanpl Hi ‘s i Raene Suerte OO eS es ts sess aa sa ne ele se