CECO Maintenance course

1/
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BCL / PCL MAJOR MAINTENACE

2/
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Maintenance
• Front head and rear head flanges connected to casing by stud bolts
• Front head flange connected to casing by shear ring of traditional
design, casing bell type
• Front head flange connected to casing by shear ring of modern
design, casing bell type
• Accident; compressor bundle removing (shear ring disassemble)
• Modern PCL design
• Old PCL design
• Labyrinth Seal Clearance
• Tool for Horizontal Removing/Fitting CO/CE 2BCL 800-1000
• Rotor centering relative to diaphragms
• Rotor Axial float calculation
• Thrust bearing thickness calculation

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MAJOR INSPECTION FOR BARREL COMPRESSOR
Disassembly of parts
Outside the centrifugal compressor
• Removal of coupling cover
• Removal of coupling spacer
• Alignment check
• Removal of coupling hub

On the centrifugal compressor

• Disconnection and removal of instrumentation
• Removal of piping
• Removal of bearings covers
• Removal of bearings
• Removal of thrust collar
• Removal of seals
• Removal of suction head flange
• Removal of bundle
• Bundle opening
• Removal of the rotor
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MAJOR INSPECTION FOR BARREL COMPRESSOR
Cleaning and inspection
Parts to be inspected on site
• Coupling spacer
• Instrumentation
• Piping
• Bundle
• Rotor

Parts to be replaced
• Seals
• Pads
• O-rings
• Labyrinths

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MAJOR INSPECTION FOR BARREL COMPRESSOR
Re-assembly of Parts
On the centrifugal compressor
• Installation of rotor and clearance check
• Bundle closing
• Installation of bundle
• Installation of suction head flange
• Installation of seals
• Installation of thrust collar
• Installation of bearing
• Installation of bearing cover
• Installation of piping
• Installation and connection of instrumentation

Outside the centrifugal compressor

• Assembly of coupling hub
• Alignment check
• Assembly of coupling spacer
• Assembly of coupling cover

6/
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Front head and rear head flanges connected
to casing by stud bolts

7/
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Front head and rear head flanges connected to casing by
stud bolts
Conceptual disassembly
procedure is:
• Disassemble couplings,
bearings, and DGS both
ends
• Disassemble front head
and stud bolts
• Disassemble internal
bundle from casing

Note: rear head flange may

remain in place

8/
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Front head and rear head flanges connected to casing by
stud bolts
Conceptual disassembly
procedure is:
• Disassemble couplings,
bearings, and DGS both
ends
• Disassemble front head
and stud bolts
• Disassemble internal
bundle from casing

Note: rear head flange may

remain in place

NOTE: Coupling flange bolts

• pay attention they do not fall in the lube oil drain header
• put temporary, a rag or plate on the oil drain hole of coupling

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Front head and rear head flanges connected to casing by
stud bolts

Front head stud

bolts disassembly

Remove the nuts from the reference studs of the casing head, and
screw on them the guide pins, supplied with the standard
assembling tools
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Front head and rear head flanges connected to casing by
stud bolts

Front head stud

bolts disassembly

Remove all stud bolts nuts. Install jack screw in the casing head and
tighten evenly to force casing head out

11 /
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Front head and rear head flanges connected to casing by
stud bolts

Front head stud

bolts disassembly

Front head
disassembly

Adjust hoisting equipment, draw or put the casing head and lower it
carefully to floor resting it on wooden blocks

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Front head and rear head flanges connected to casing by
stud bolts

Front head stud

bolts disassembly

Front head
disassembly

Adjust hoisting equipment, draw or put the casing head and lower it
carefully to floor resting it on wooden blocks

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Front head and rear head flanges connected to casing by
stud bolts

Front head stud bolts

disassembly

Front head
disassembly

Withdraw rotor/diaphragms
bundle assembly as indicated
in the dwg
Diaphragm bundle
disassembly “Assembly/disassembly
rotor/diaphragms bundle”

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Front head and rear head flanges connected to casing by
stud bolts

Front head stud bolts

disassembly

Front head
disassembly

Lower bundle to floor resting it

on wooden blocks
Diaphragm bundle
disassembly

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Front head and rear head flanges connected to casing by
stud bolts

Front head stud bolts

disassembly

Front head
disassembly

Remove the union bolts of the

diaphragms and withdraw the suction
diaphragms, that is manufactured in a
Diaphragm bundle
piece. Remove the union bolts and
disassembly dowels from the components
manufactured in two halves.
Adjust hoisting equipment and
carefully raise upper halves and lower
them on suitable supports. 16 /
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Front head and rear head flanges connected to casing by
stud bolts

Front head stud bolts

disassembly

Front head
disassembly

Remove the union bolts of the

diaphragms and withdraw the suction
diaphragms, that is manufactured in a
Diaphragm bundle
piece. Remove the union bolts and
disassembly dowels from the components
manufactured in two halves.
Adjust hoisting equipment and
carefully raise upper halves and lower
them on suitable supports. 17 /
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Front head and rear head flanges connected to casing by
stud bolts

Front head stud bolts

disassembly

Front head
disassembly

Diaphragm bundle
disassembly

18 /
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Front head and rear head flanges connected to casing by
stud bolts

Prepare two hardwood supports having the

same height and a wide enough base. Make
Front head stud bolts two “V” notches where the rotor will rest for
disassembly the installation in the journal bearing zone.
Protect these two “V” notches with lead or
other soft material such as a rag.

Front head
disassembly

Diaphragm bundle
disassembly

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Front head and rear head flanges connected to casing by
stud bolts

Wrap rope slings or plastic covered wire slings

around shaft at each end. Carefully lift the
Front head stud bolts rotor in good balance, guiding it by hand, to
disassembly avoid damaging the labyrinths. Lower the rotor
carefully to the hardwood supports.

Front head
disassembly

Diaphragm bundle
disassembly

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Front head and rear head flanges connected to casing by
stud bolts

Front head stud bolts

disassembly

FOR THE WEIGHT OF CASING,

HEAD, BUNDLE AND ROTOR
Front head
disassembly REFER TO THE WEIGHT TABLE IN
THE ASSEMBLY DRAWING

Diaphragm bundle
disassembly

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Front head and rear head flanges connected to casing by
stud bolts
Lifting the rotor (typical sketch)

Keep the rotor in good balance, guiding it by hands to avoid damaging on the
impellers or labyrinths at lifting or during lowering. Remember to use a water-level to
lift the rotor in a balanced position.

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Front head and rear head flanges connected to casing by
stud bolts

23 /
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Front head and rear head flanges connected to casing by
stud bolts

Bundle disassembly

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Front head and rear head flanges connected to casing by
stud bolts

Note: tool for bundle assembly

 nr. 1 cradle for BCL size < 400 and PCL size<600
 nr . 2 cradles for BCL size >400 and PCL size>600

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Front head and rear head flanges connected to casing by
stud bolts

26 /
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Front head and rear head flanges connected to casing by
stud bolts

Counter casing Diaphragms

Bundle open with rotor on lower half

Bundle open
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Front head and rear head flanges connected to casing by
stud bolts
Diaphragms

Counter casing

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Intermediate, Centrifugal Compressor

Front head flange connected to casing by

shear ring of traditional design, casing

bell type
(high pressure compressors)

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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Conceptual disassembly
procedure is:
1. Disassemble bearings,
couplings and DGS both ends
2. Disassemble end gasket
3. Disengage shear ring
4. Remove front head
5. Disengage internal shear ring
6. Disassemble internal bundle
from casing

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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Shear ring disengage

Head flange disassembly

Inner shear ring disengage

Inner bundle disassembly

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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Traditional solution for /c, /d, /e BCL type compressors

To flare
P measurement
buffer N2
O rings

teflon “C” rings

energized with an
elycoidal internal spring

But this solution has the disavantage of a very heavy head flange with major
difficulties for the ass/diss and the possibility to lock one or more sectors of
the shear rings.
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

34 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

35 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

36 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Device for

fitting/removing
head flange SOS 78600/3

37 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Fitting

Fitting shear ring in the casing

38 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Positioning of shear
ring in the casing
Fitting

Items 6, 7, 8 are
fitted on the two
shear ring sectors at
the top

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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Fitting

Fit on the gasket item (C) and (D)

correctly as shown
For fastening of bracket (9) use
de correct screw of main flange
Position the lifting eyebolt (E) in
the center of gravity, drill and fix
the screw (W)
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Fitting

Fitting the main flange

41 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Fitting

Fitting head flange in the

casing

Mount the main flange, fit the

brackets (Z) fixing them to the
casing with screw (W) use the
n° 4 screws (15) to push the
main flange fully home

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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Fitting

Check the reference value

“X” on the assembly drawing

43 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Fitting
Remove the screw (15) fit the
rods (D) and nuts (C)
Use the nuts (7) to put the
shroud rings in their working
position
Since is necessary to ensure
that the main flange is home
against the shroud rings and
casing (to avoid kickback
during compressor start-up),
the main flange mast be
moved back. To do this it is
necessary to act on the n° 4
tie rods (C) using the nuts (D)
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

45 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)
Bundle assembly / disassembly in / from casing

Inner bundle disassembly

Casing and Head flange

46 /
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Front head flange connected to casing by shear ring of
traditional design, casing bell type (high pressure compressors)

Bundle
assembly/disassembly tools
by means of jacks

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Bundle assembly/disassembly tools

48 /
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Bundle assembly/disassembly tools

49 /
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Bundle assembly/disassembly tools

50 /
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Bundle assembly/disassembly tools

51 /
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Bundle assembly/disassembly tools

52 /
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Intermediate, Centrifugal Compressor

Front head flange connected to casing by

shear ring of modern design, casing

bell type
(high pressure compressors)

53 /
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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)
Conceptual disassembly
procedure is:
1. Disassemble bearings,
couplings and DGS both
ends
2. Disassemble head flange
positioning screws
3. Disassemble shear ring-
outer ring
4. Disassemble shear ring-
inner ring
5. Disassemble front head
6. Disassemble internal
bundle from casing

54 /
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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)
Conceptual disassembly
procedure is:
1. Disassemble bearings,
couplings and DGS both
ends
2. Disassemble head flange
positioning screws
3. Disassemble shear ring-
outer ring
4. Disassemble shear ring-
inner ring
5. Disassemble front head
6. Disassemble internal
bundle from casing

55 /
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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)
Conceptual disassembly
procedure is:
1. Disassemble bearings,
couplings and DGS both
ends
2. Disassemble head flange
positioning screws
3. Disassemble shear ring-
outer ring
4. Disassemble shear ring-
inner ring
5. Disassemble front head
6. Disassemble internal
bundle from casing

56 /
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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)
Conceptual disassembly
procedure is:
1. Disassemble bearings,
couplings and DGS both
ends
2. Disassemble head flange
positioning screws
3. Disassemble shear ring-
outer ring
4. Disassemble shear ring-
inner ring
5. Disassemble front head
6. Disassemble internal
bundle from casing

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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)

Advantages
 Forged casing more light
and with a reduced
maximum diameter
 Easy to disassemble
assemble the head flange
and the shear rings
 Avoid to lock one or more
sectors of shear rings in
their seats during the
movement to fit or
remove them

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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)
To flare

Buffer gas N2 Dp instrument

O-rings
“C” seal rings
energized by an
internal spring

Note:
 The N2 buffer system is afterwards the flare
 Measurement of pressure inside the chamber between the two C – rings
 In the old design all the seals were afterwards the shear rings
59 /
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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)

Head flange axial positioning

screws disassembly

Outer shear ring sectors disassembly

60 /
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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)

Inner shear ring sectors

disassembly

Front head disassembly

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Front head flange connected to casing by shear ring of
modern design, casing bell type (high pressure compressors)

Inner bundle disassembly

62 /
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Accident occurred
during compressor bundle removing
(shear ring disassemble)

GE Oil & Gas TTS_TA_030

Accident occurred during compressor
bundle removing (shear ring disassemble)
GE Oil & Gas TTS_TA_030

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Accident occurred during compressor
bundle removing (shear ring disassemble)

Machine : BCL405C
Location : Off Shore Platform
Activity: Compressor bundle removal
Event: Shear ring shoot away during disassemble
Reason (Causes): A chamber inside the machine was still pressurized
Root Causes: 1- Internal O-ring wrongly installed in a past work
2- incorrect procedure followed by manpower
Reference drawing: SOS94060 – SW56444 – SW 57700

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Accident occurred during compressor
bundle removing (shear ring disassemble)
BCL405C

Dwg n° SOS94060
66 /
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Accident occurred during compressor
bundle removing (shear ring disassemble)

67 /
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Accident occurred during compressor
bundle removing (shear ring disassemble)

68 /
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Accident occurred during compressor
bundle removing (shear ring disassemble)
1- Internal O-ring wrongly installed
Between compressor casing and main head
flange are installed n°2 “C” O-Ring at item 35E
external and 34E internal, (see SOS94060).
In a past maintenance work the internal ring 34E
was mounted incorrectly in a reverse way (see
picture below) so that process gas leaked
through it creating a pressurized chamber
between the two o-rings; that area remained
under pressure even once the compressor
casing was completely depressurized.
Due to the chamber geometrical shape the gas
trapped inside applied an axial force towards the
head flange and the shear rings, sticking the two
together and making the last hard to be
removed.

69 /
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Accident occurred during compressor
bundle removing (shear ring disassemble)
2- incorrect procedure followed
The personnel involved on the diaphragms
bundle removal didn’t use a correct procedure.
Shear rings can be taken out pretty easily once
their lock screws are loose, if the ring seems
stuck or very hard to get out stop any activities
and investigate the reasons. The TA’s on site
didn’t realized that there was still a residual
axial force and decided to remove the rings
using an hydraulic tool.

70 /
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Accident occurred during compressor
bundle removing (shear ring disassemble)
3- Consequences
On Personnel : Nobody was injured but
witnesses suffered severe shock
On Material : Minimal damages, screws and
thrusting screw twisted, shear ring dented
Potential : Extreme potential danger to
personnel safety

71 /
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Accident occurred during compressor
bundle removing (shear ring disassemble)
4- Suggestion and corrective action
A. Pay attention during bundle assembling in
order to install correctly all compressor
components
B. During dismantling , ensure that there aren’t
any pressurized gas pocket once the
compressor is depressurized
b. to verify that ,open all casing drain

In this compressor a vent flanged (marked XLII

and XLIII on section drawing) were provided on
top of the case, so potential remainder gas can
be vent through this flanges opening (in safe
conditions)

If you find any problem on main flange-

shear ring-bundle removing, don’t force
your action but look for possible causes
and in case of doubt ask to Florence!

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Front head flange connected to casing by shear ring of
modern design, front head, diaphragms bundle and
rear head connected together in a single piece

cartridge PCL type

73 /
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PCL modern design
Casing head

Shear rings

74 /
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PCL modern design

Head and rear flange axial

positioning screws disassembly

Outer ring sectors disassembly

75 /
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PCL modern design

Inner ring sectors disassembly

Inner cartridge removal

76 /
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PCL modern design
Shear ring and cartridge disassembly

77 /
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PCL modern design

Cartridge disassembly

Note: the bearings and the seals haven’t to be disassembly from the bundle
78 /
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PCL modern design

Diaphragms bundle disassembly

79 /
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Front head flange bolted to casing in old design

PCL type

80 /
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PCL old design

• Remove the house bearings rear and front connections

• Remove the bearings connections to the juctions box 81 /
• Remove the bearings and the seals GE /
PCL old design

• remove the stud bolts from the front flange

Note: 82 /
the rotor is supported by an hydraulic jack tool at the front end and a false bearing at the rear end
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PCL old design

• remove the front head flange

83 /
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PCL old design

• finally remove the bundle with the rotor

84 /
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BCL bundle removal

85 /
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BCL head flange removal

86 /
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BCL head flange removal

87 /
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BCL bundle removal

88 /
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BCL bundle removal

89 /
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BCL bundle removal

90 /
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BCL bundle removal

91 /
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BCL bundle removal

92 /
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BCL bundle removal

93 /
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BCL bundle removal

94 /
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BCL bundle and Rotor on load bay

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Diaphragm bundle disassembly for barrel compressors

96 /
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Diaphragm bundle assembly

97 /
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Diaphragm bundle assembly for barrel compressors

Assembly general procedure

note:
It is made performing the operations of disassembly but in the opposite order
In particular take the following measures:

1) Blow carefully air into all parts to be assembled

2) When the machine is about to put into operation, remove the protective oil from
the rotor
3) Replace correctly the dowel pins of the two halves of diaphragms bundle
4) Position the rotor in the lower half bundle and reassemble the upper half bundle
5) Reassemble the suction diaphragm (this is manufactured in a piece)
6) Before fitting the rotor diaphragms bundle into the casing clean the internal
surface of the casing and the external surface of the diaphragms.

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Diaphragm bundle assembly for barrel compressors

7) Replace the “o” rings if they are damaged

8) To fit the bundle make use of the suitable equipment refer to
“Assembly/disassembly rotor/diaphragm bundle” drawing
9) Insure that the shims, especially those for the thrust bearing, are correctly fitted
10) Check that all parts are thoroughly clean and lubricated
11) When assembling the coupling guard, be sure that no foreign matter has remained
in the oil drain hole and that the oil inflow tube to the coupling is properly
assembled, paying attention that the outlet holes are towards the coupling teeth

THE CASING HEAD FLANGE LOCKING BOLTS SHOULD BE TIGHTENED TO A TORQUE VALUE
SHOWN IN TABLE ON “PROCEDURE FOR TIGHTENING CASINGS”

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Diaphragm bundle assembly for barrel compressors

100 /
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Labyrinth
SealClearance

101 /
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Labyrinth Seal Clearance

• Lateral clearances
• Vertical clearances

102 /
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Labyrinth Seal Clearance

BCL compressor, before checking labyrinth seal clearances it is needed:

1) Place lower half diaphragm assembly horizontally

on a saddle shaped support
2) Level lower half assembly with a precision level
and lock it to the support with brackets
3) Assemble two half rings (called false labyrinth) on
diaphragms bundle in place of labyrinths at both
ends of the bundle
4) Position the rotor on half bundle and let the rotor
supported by the two half rings (false labyrinths)
5) Position axially the rotor making the impellers
outlet channel center coincide with the diffuser as
shown in assembly drawing

false labyrinth

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Labyrinth Seal Clearance

104 /
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Labyrinth Seal Clearance

Which diaphragms you choose to center the rotor?

The nr.4...

105 /
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Labyrinth Seal Clearance

Check of labyrinth seal clearance

Side clearances
a) Gauge, by means of feeler
gauges, the labyrinth seal
side clearances
b) Two values (one for each
side) are taken for each
labyrinth and added to each
other

The results is then compared with the relevant value on the

“Diametral clearance table”

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Labyrinth Seal Clearance

Labyrinth Seals
Lateral
Clearance
Check

Filler gauge

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Labyrinth Seal Clearance
Vertical clearances

a) Remove the rotor from the lower half diaphragm assembly

b) Some pieces of lead wire shall be arranged transversally in the bottom of the
lower half-rings of labyrinth seals
c) Place now the rotor in the original position, paying attention it is centered

DO NOT LET THE ROTOR SLIDE AXIALLY, OTHERWISE

THE LEAD WIRES GET DAMAGED

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Labyrinth Seal Clearance

d) Place, on the rotor top, in the zones of the labyrinth seals of the upper half-
assembly, some pieces of lead wires as indicated at point b)
e) Install upper half diaphragm assembly on lower half. Install split-line cap
screws and tighten
f) Then remove the split-line cap-screws and lift the upper half assembly
g) Remove the rotor
h) Remove the lead wires that now are shaped as the free space between the
labyrinth seal and the relevant rotor part
i) Measure by a micrometer screw gauge the flattening made by the labyrinth
seals on the lead wires
j) Now add the values of upper and lower clearances of the same labyrinth
and compare the result with the value indicated in the “Diametral
Clearances table” for each labyrinth seal ring. The seals, whose clearances
complies with the established value but have the blades slightly rounded or
dented, can be restored by a tool of the same type as those used for the
lathe having the profile like that included between two seal blades.

SHOULD THE VALUES TAKEN BE HIGHER

THEN ALLOWED CLEARANCES
110 /
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Labyrinth Seal Clearance

111 /
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Replacement of

labyrinth seals

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Replacement of labyrinth seals
Replacement of labyrinth seals

Usually the labyrinth seal rings are supplied in two halves (in four sections these of
bigger compressor) and with the clearances already established, therefore no
adjustment is required.
However it is advisable to always check the clearance again.

To remove and then replace the labyrinth seal rings act as follows:

1) With a hammer or a brass bar (or another equivalent soft metal) whose section is smaller
than that of the half-ring, beat on one of two sides of such a ring to let it rotate and therefore
come out. First beats shall be light to avoid deforming the half ring
2) In the event, after the first beats, the half ring does not begin to slide, put in its housing some
penetrating oil and let it soak for some hours

DO NOT FORCE, BY ANY TOOL, THE SEAL

RING HOUSING SHOULDER, PARTICULARLY
ON THE CENTER LINE
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Replacement of labyrinth seals

114 /
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Replacement of labyrinth seals

3) The half ring removed, clean the housing carefully by thinners and scrapers and blow air in
4) Introduce the new half-ring in the relevant housing. The half-ring is shaped in order that no
positioning mistake is allowed
5) Should the half ring not fit owing to its different bending in respect of its housing, rest it
upside-down on a plane and beat slightly on the top to increase the relevant bending radius
(To reduce the bending radius it will be necessary to beat on one end)

SHOULD THE HALF RING NOT FILL WELL, DO

NOT FORCE IT
IN THESE CASES IT IS ADVISABLE TO REMOVE
AND ADJUST IT WHERE THERE ARE CLEAR
FORCING TRACES

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Replacement of labyrinth seals

6) The labyrinth seal half ring just replaced shall be marked with the same numbers as those
removed and therefore as those of the half-casing (or half diaphragm assembly)

THE HALF-RINGS ASSEMBLED ON THE

UPPER HALF PART ARE FIXED ON THE
CENTER LINE THROUGH SCREWS
TIGHTENED ON THE RELEVANT HALF
DIAPHRAGMS

THEREFORE THE HALF-RINGS TO BE

REPLACED SHALL BE MILLED ON THE
CENTER LINE DURING THE
ASSEMBLING OPERATION, SO THAT
THEY HAVE THE SAME SPOT-FACING
AS THOSE REMOVED (MARK ON THE
NEW HALF-RINGS THE SAME NUMBER
OF THOSE REMOVED)
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Replacement of labyrinth seals

117 /
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Replacement of labyrinth seals

118 /
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 Tool for Horizontal Removing/Fitting

CO/CE 2BCL 800-1000

See spec. SSO0667745

119 /
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Tool for Horizontal Removing/Fitting CO/CE 2BCL 800-1000

A – Install 4 adapter stools on the electric motor

baseplat and fit them to the holes as shown in the
drawing

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Thrust bearing side
A - Remove the cover (1M) on the thrust
bearing side, by loosening screws
B – Remove the oil splash rings positioned
between the cover and the joint
C – Disassemble the joint according the
apposite spec (before removing the joint on
the collar side, fit the cap to the shaft)

D – remove cover (12M) on the instrument box by unscrewing the screws and remove the gasket
(13M)
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Thrust bearing side

A – Disassemble probes (11S) on

the thrust bearing side, by means
of keys
B – Disconnect and remove the
thrust bearing external
thermoelement cables from the
instrument box
Pay attention :
The thermoelements don’t have to
be removed from the bearings

C – Loosen screws (3E)

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Thrust bearing side – Flange removal

D – Screw columns 2(D) into the bores

from where screws and their relative
washers have been unscrewed
E – To lift the flange, fit an eyebolt
complete with a shackle into the
threaded bore.
F – Unscrew the remaining locking
screws of the flange

G – Use two pullers (4G) to detach flange, then pull it out by making
it slide along columns. Do this by keeping the flange lifted.

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Thrust bearing side – Thrust collar removal
A - Straighten the safety plate (9Y) by using
the special tool according to spec. SOS86540

B – Unscrew collar nut (8Y) by means of the sector key

C – Disassemble the collar (10Y) by means of the lifting

tool, the handling tool and the screws according to
spec. SOS78177

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Thrust bearing removal
A – Disconnect thrust bearing
internal thermoelements connections
from terminal board and remove
them from the instrument box.

B – Remove ring (12Y) and

disassemble ring (11Y) in two halves.

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Thrust bearing side

C – Screw columns (2D)

D – Assemble puller (4D) for detaching the flange
E – Take off the flange by making it slide along columns

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Thrust bearing side – Journal bearing removal
A – Disconnect the journal bearing thermoelement
connections from terminal box; do the same with
vibration probe connection
B – Loosen screws (2E) and their relative washers
(15E)

C – Screw columns into the holes from

where screws were taken off

D – Unscrew the remaining locking screws of the shoe

journal bearing.
E – Screw the two pullers (4G) into appropriate holes.
F – Fit lifting tool (9G) into the threaded bores, by means
of the suitable screws.
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Thrust bearing side

A – pull out the Journal bearing by making it slide along columns, by means of two pullers

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Thrust bearing side A – pull out the stop ring by using the handling tool
B – Disassemble locking ring in four parts by means
of puller, which is fit into the suitable hole.
Do this by pulling out one sector at a time, removing
the two lateral sectors first.

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Thrust bearing side

A – Pull out the separation ring by making the cage slide along the columns until it
comes out the head flange.

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Thrust bearing side

A – Straighten safety plate by acting on

special tool in compliance with spec SOS86540
B – Unscrew ring nut (13Y) by means of the
key (21D)

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Thrust bearing side

A – After having unscrewed the ring nut, pull it out.

B – Pull out the bushing by means of pullers.

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Thrust bearing side – oil seals removal

133 /
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Thrust bearing side – oil seals removal

A – Pull out the oil seals by making the cage slide along the columns until they come out the
head flange.

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Thrust bearing side – end seal removal

B - After remove the end seal (1C) by means of pullers.

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Thrust bearing side – end seal removal

special nuts

clamping screws

A – fit the special nut (52G 51G) onto the tie rods (after
having disassemble the locking nuts 20E). These nuts
permit to push the head flange so as to remove the
clamping screws (6A) and as a consequence to
disassemble the ring in four part.
B – disassemble the blocks (4A) and their relative
screws.

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Thrust bearing side – sector ring removal

A – Fit lifting tool into the suitable

holes of sector ring.
B - Disassemble the sector ring by
means of lifting tool. To do this, pull
out one sector at time starting from
the lateral sectors, then the sector
on the top and finally the sector
downward.

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Thrust bearing side – sector ring removal

A – Remove locking screw (30E) and

disassemble the ring in 4 parts (2A)
B – Fit lifting tool (9G) into the suitable
holes of sector ring (2A)

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Thrust bearing side – Flange removal
A – Fix the lifting bracket (7G) on the head flange (1E); tighten screws (27G) 135Nm; assemble tie rods (19E),
nuts (52G), shims (62G 63G) and reassemble block (4A)
B – Assemble special equipment (3G) onto lifting bracket [spec SSO0667261]
C – Lift the head flange up to the indication marked on the equipment plate
C – Now act on nuts (52G) to pull out the head flange

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Thrust bearing side – Bundle removal

A – Fix the brackets to the casing by means of screws

B – Connect brackets with the pillar

by means of screws

C – level the brackets by

inserting shims between
the adapter stools

D – Fit guides onto casing by means

of screws

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Thrust bearing side – Bundle removal

141 /
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Thrust bearing side – Bundle removal

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Thrust bearing side – Bundle removal

B – Now, support the diaphragm

bundle with the crane by means of
the extraction bracket and ensure
that the inner casing and the
guides are not in contact.

A – Install 2 hydraulic cylinders RCO41037 on the supports.

Start pump RCO10329 until the diaphragm bundle comes
out of the casing of about 330 mm.
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Thrust bearing side – Bundle removal

A – Go on with the extraction until the diaphragm

bundle comes out of the casing of about 600mm in
order to permit the assembly of sliding equipment
(5G) as spec. SSO0667225.

B – Tithten screws with a torque of

135Kgm. Connect the 2 hydraulic
cylinders RCO41036 with manifold
RTO36599

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Thrust bearing side – Bundle removal

C – Start pump RCO10329 until the diaphragm

Bundle touches the brackets. During this
operation, close the two cocks which connect
the balancer jacks.

stop blocks

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Thrust bearing side – Bundle removal
D – Go on with the extraction
of the diaphragm bundle, until
it reaches stop block on the
brackets. Do this by
displacing the hydraulic
cylinder supports when the
latter stop running.

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Thrust bearing side – Bundle removal

A – Lift the diaphragm bundle

by means of four eyebolts

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Thrust bearing side – Bundle removal

A – put the diaphragm bundle on

the cradles previously prepared.
B – Remove the external gasket
C – Disassemble the two sliding
equipments (SSO0667225) in order
to assemble the lifting stakes
fitted with the screws tighten with
a torque of 135Kgmm.
D – disassemble the extraction
bracket.

Lifting stake

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Rotor removal

A – Lift the upper half diaphragm bundle

fitted with bridge crane with 2 hooks, B – Pull out the rotor by means of balance
rotate it of 180° and put it on the cradles (As RB000104).
previously prepared.

WARNING
During handling rest the rotor in the
journal bearing or sleeve collet zone
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Rotor removal and check clearances
A – Assemble half rings to check the clearance
between the rotor and the seals.
B – Insert the rotor in the diaphragm bundle by
means of the balance
C – After having checked the clearances, remove the
two half rings and reassemble the labyrinth seals.
D – Reassemble the new rotor and the bundle in the
compressor by following the steps of the previous
procedure in the reverse way and by means of the
Half rings same special tools.

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Rotor removal and gasket assembly

151 /
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152 /
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153 /
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154 /
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155 /
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156 /
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Rotor centering
relative to diaphragms

157 /
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Rotor centering relative to diaphragms

The relative position of the thrust collar and

the thrust bearing assembly determine the
axial position of the rotor within the
diaphragms.

This relative is adjusted with thickness rings

located on either side of the thrust bearing
assembly.

If it is necessary to change a rotor or/and

diaphragm bundle, then the correct center
position must be established.

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Rotor centering relative to diaphragms

1) Check that the lower diaphragm bundle half is completely assembled and
horizontal.

2) Carefully lower the rotor, guiding it by hand, into lower diaphragm bundle half
and set it on labyrinth halves. The rotor should be axially positioned to obtain
optimum impeller - diffuser passage alignment.

Clearances

Clearances
159 /
see Clearance table GE /
Rotor centering relative to diaphragms

1) Check that the lower diaphragm bundle half is completely assembled and
horizontal.

2) Carefully lower the rotor, guiding it by hand, into lower diaphragm bundle half
and set it on labyrinth halves. The rotor should be axially positioned to obtain
optimum impeller - diffuser passage alignment.

Diffusers width

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Rotor centering relative to diaphragms

3) Measure distance between shaft end and No-Drive face of bundle. Take two
values, +/- 0.05 mm, 180° apart and record the average value.

4) Assemble the diaphragm rotor bundle and fitting it into the casing.

5) Set rotor to center position using dimension established in step 3 above. Measure
+/-0.05 mm distance from shaft end to face of casing on Drive End and record the
value.

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Rotor centering relative to diaphragms

6) Install the head flange. Using value taken in step 5 above, set rotor to center
position. Measure +/- 0.05 mm, the distance from the shaft end to the face of the
head flange and record the value.

7) Install oil seals or dry mechanical seals, install journal bearings and thrust
bearing using existing thickness rings.

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Rotor centering relative to diaphragms

8) Force rotor against outboard thrust assembly. Measure the distance, +/- 0.05 mm,
between shaft end and the head flange outer face.
9) Compare this value with that taken in step 6 above. When rotor is against
outboard thrust assembly, it should be in the center position, +/-0.1 mm. If it is
not, the outboard thickness ring must be adjusted. This will alter thrust bearing
clearance, therefore adjustment of the inboard thickness ring may required.

Thickness rings must be surface ground. Do

not shim. If additional thickness is required,
grind new rings from blanks.

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Rotor Axial float calculation - BCL
type A – labyrinth end seal fitted on the flange (old type)

1) With the bundle open in two half (outside the casing) align diaphragm with
impeller (as previously explained in the procedure) in order to establish the
zero position of the rotor
2) Measure the total float. Suppose that you find NDE 4mm and DE 4,5mm
3) According the specification value in the ass. dwg: NDE 2mm and DE 2.5mm
are the min axial float required

4.00 mm Displacement 4.50 mm

Suction NDE Discharge DE

2.00 mm Minimum float 2.50 mm

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Rotor Axial float calculation - BCL
type A – labyrinth end seal fitted on the flange (old type)

4) Assembly the internal bundle in the casing, assembly the head flange and
interpose between the casing and the flange 5mm thickness
5) Move the rotor completely towards NDE, set the zero on the dial indicator
6) Move the rotor (4mm) versus DE, (working position)
7) Now reset the dial indicator and move versus DE, store the new value
(3.8mm)(due to the contact with the rear flange labyrinth)

4.00 mm Displacement 4.50 mm

Suction NDE Discharge DE

4.00 mm Displacement 3.80 mm

Suction NDE Discharge DE

2.00 mm Minimum float 2.50 mm

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Rotor Axial float calculation - BCL
type A – labyrinth end seal fitted on the flange (old type)

8) DON’T touch the dial indicator, remove the thickness from the front head
flange and tighten the stud bolts until final torque value
9) At this point move again the rotor versus NDE store the new value (3.5mm)

4.00 mm Displacement 4.50 mm

Suction NDE Discharge DE

4.00 mm Displacement 3.80 mm

Suction NDE Discharge DE

3.50 mm Displacement 3.80 mm

Suction NDE Discharge DE

2.00 mm Minimum float 2.50 mm

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 Exercise

Discharge DE Suction NDE

Actual axial displacement with the old shims installed: 0,02 mm

Required (e) 222.44 mm Old Shim inactive side (b):13.90 mm

Obtained (e’) 221.70 mm
Old Shim active side(a): 4.90 mm

Thrust bearing clearance min 0.25 mm max 0.35 mm

What are the values to add or remove from the shims?

We can machine the old ones?

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 Exercise

Discharge DE Suction NDE

Actual axial displacement with the old shims installed: 0,02 mm

Required (e) 222.44 mm New Shim inactive side (b):12.93mm

Obtained (e’) 221.70 mm
New Shim active side(a): 5.64 mm

Thrust bearing clearance min 0.25 mm max 0.35 mm

What are the values to add or remove from the shims?

We can machine the old ones?

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Old type shaft end labyrinth
It is avisable to compare
the thickness between the
old and the new
labyrinth

Head Side that

Flange may be
machined

Rotor
@zero
position

gap

171 /
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 New type shaft end labyrinth external fitting
Head Head
Flange Flange

Rotor Rotor
@zero @zero
position position

gap

B Gap= A-B

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Rotor Axial float calculation - BCL
type B – labyrinth end seal external fitting
1) Start with the rotor centering position in the diaphragm bundle
2) Introduce the bundle in the external casing, assembly the front head flange (also with the shear
rings) without any thickness interposition on the flange
3) Move the rotor completely vs NDE set zero the dial indicator. Move the rotor vs DE in order to have
the previous value of the zero position (vs NDE of 4mm)
4) At this point set zero on the dial indicator and move the rotor vs DE, a lower value vs DE will be find
that’s due to the fact that the rotor will touch the statoric part of the end seal on the balancing
drum
5) The new value for example will be (instead of 4,5mm DE) 3mm DE and 4 mm NDE
6) Move again the rotor in the zero position

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Rotor Axial float calculation - BCL
type B – labyrinth end seal external fitting

Note: if the gap between the rotor and the flange is 20 mm the end laby has a
thickness of 17,5 mm, on the DE i will find a value of 2,5mm of total float.
On the NDE for example if i find a gap between the rotor and the flange of 21mm
and the thickness of the end laby is 17,5 mm the float vs NDE will be of 3,5mm.

The Gap should not be less then minimum axial

displacement value.
For some machine the minimum acceptable gap
(D.E. only) is specified on the dwg.
Update the axial displacement values simulating
the installation of both (one by one) shaft end
labyrinths.

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BCL compressor – thrust bearing thickness
determination
For the alignment, the rotor was Faces to be aligned. For the offset
seating on dummy Discharge tolerance refere to the dwg.

Diaphragm
labyrinths placed on bottom half Where not specified has to be considered
diaphragms bundle 3-5% of the diaphragm gap

Rotor locking
device

Thrust bearing
clearence

Impeller Non active Active side

side

collar
DE SHAFT NDE

Dial
Gauge

Reference
Measure

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Exercise 1 (example) – thrust bearing
thickness calculation

Actual Thrust
bearing
clearance=0,45mm
Old shims:
Non active Active side
3,82 mm active side
side 6,18 mm non active side
DE collar NDE
-0,34 NDE
+0,34 DE
@ zero rotor position
dial gauge setting 5,00
Min clearance according the specification
0,30 mm
5,34 In the non active side i have to consider
0,45-0,30=0,15 mm to add

New shims:
(3,82-0,34)mm = 3,48 mm active side
(6,18+0,34+0,15)mm = 6,67 mm non active side

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Exercise 2 – thrust bearing thickness
calculation

Actual Thrust
bearing
clearance=0,40mm
Old shims:
Non active Active side
3,82 mm active side
side 6,18 mm non active side
DE collar NDE

Min clearance according the specification

@ zero rotor position
dial gauge setting 5,00
0,30 mm

5,15

177 /
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Exercise 2 sol. – thrust bearing thickness
calculation

Actual Thrust
bearing
clearance=0,40mm
Old shims:
Non active Active side
3,82 mm active side
side 6,18 mm non active side
DE collar NDE

Min clearance according the specification

@ zero rotor position
dial gauge setting 5,00
0,30 mm
In the non-active side i have to consider
0,40-0,30=0,10 mm to add
5,15

New shims:
(3,82-0,15)mm = 3,67mm active side
(6,18+0,15+0,10)mm = 6,43mm non active side

178 /
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Exercise 3– thrust bearing thickness
calculation

Actual Thrust
bearing
clearance=0,18mm
Old shims:
Non active Active side
6,45 mm active side
side 4,20 mm non active side
DE collar NDE
Min clearance according the specification
0,30 mm
@ zero rotor position
dial gauge setting 5,00
New shims:

4,61

179 /
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Exercise 3 sol. – thrust bearing thickness
calculation

Actual Thrust
bearing
clearance=0,18mm
Old shims:
Non active Active side
6,45 mm active side
side 4,20 mm non active side
DE collar NDE
+0,39 NDE
- 0,39 DE
@ zero rotor position
dial gauge setting 5,00
Min clearance according the specification
0,30 mm
4,61 In the non active side i have to consider
0,30-0,18=0,12 mm to remove

New shims:
(6,45+0,39)mm = 6,84 mm active side
(4,20-0,39-0,12)mm = 3,69 mm non active side

180 /
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Exercise 4– thrust bearing thickness
calculation

Actual Thrust
bearing
clearance=0,20mm
Old shims:
Non active Active side
4,10 mm active side
side 6,72 mm non active side
DE collar NDE

Min clearance according the specification

@ zero rotor position
dial gauge setting 5,00
0,35 mm

New shims:
4,15

181 /
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Exercise 4 sol. – thrust bearing thickness
calculation

Actual Thrust
bearing
clearance=0,20mm
Old shims:
Non active Active side
4,10 mm active side
side 6,72 mm non active side
DE collar NDE
+0,85 NDE
- 0,85 DE
@ zero rotor position
dial gauge setting 5,00
Min clearance according the specification
0,35 mm
4,15 In the non active side i have to consider
0,35-0,20=0,15 mm to remove

New shims:
(4,10+0,85)mm = 4,95 mm active side
(6,72-0,85-0,15)mm = 5,72 mm non active side

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