WRVT 510

$ffiMVEGH

MANUAL

GAS

&

_{REFRIGERATION COMPRESSOR}

1

?

G

COI.IPRESSOR SERYICE HAHUAL

INDEX TO SECTIOH Foretrord Description

2.1

Compressor

2.2

Compression Cycle

2.3

Gas System

?.4 0il

System

2.5

0ils

Instal I

ation

3.1

Ai ignment

of

Compressor Coupl ings

3.2

Alignment Tolerance

3.3

Dowe11 _ing

3.4

Piping

3.5

External

Arrangement Draw'ings

First

Start

Up

4.1 First

Start

4.2

Use

of

Compressor as

a

vacuum pump

Hormal 0peration

5.1

Normal

Start

5.2

Normal Stop

Precautions During Shut Dmrn

6.1

Procedure on Shut Down

6.2

Inhibiting

0i1s

i{ai ntenance

7

.l

General Comments

7

.Z

Preparation

for

Annual Inspection

7.3

Djsmantl

ing

Procedure

for

Annual Inspection 7

.4

Check i ng C1 earances

7.5

Re-Assembly

after

Annual Inspection 0verhaul

8.1

General Comments

B.?

Dismantl

ing

Compressor

for

l'lajor

0verhauls

8.3

Re-Assembly Compressor

after

0verhaul

8.4

Compressor General Arrangements

Special Instructions

9

.1

Torque Spec i

fi

cati ons

9

.2

P rocedure f

or

F i

tt'i

ng Lockrvashers

9.3

Special

Tool

Li

st

9.4

Component l,Jei ghts

Spares

10.1

Compressor Recommended Spares Li

st

Page Ho. 2 Section Section

Section

3 Section 4 Section 6

Section

7 Section B Section 9 c^^+:^- ln JtJl.-LIUII IU a J 3

4q

,t-4 _r5 6 7

I

o B g _{,10 ,11}

I

$ L?_12,13

Section

5 L/ Page 1 -@l=--rr-ffi:ffi 14 T4 15 15 B $ 16 i6 16 L7 1B 19 19,20 20,21 ?2,?3 Lq 25 26

s

-0

a

+

COMPRESSOR SERVICE MANUAL

SECTION

1-

FOREWORD

READ

CAREFULLY BEFOtrE INSTALLING

AND

STARTING YOUR COMPRESSOR

These instructions have been prepared to ensure that your compresSor gives lorrg and satisfactory service.

The entire manual should be read before reverlrng to any one section for specilrc

inf ormation

One copy should be given to the personnel responsible for installing and operating the compressor.

All requests for information. services or spares should be directed

to:-HOWDEN

CCM PRESSORS

LIM

ITED

SERVICE DEPARTMENT,

133

BARFILLAN

DRIVE,

G

LASGOW

G52

1 BE

Telephone

Number.

041 -BBZ

3346

Telex

Number'.778711

-

ROCOMP

Ail

enquiries should

be

accompanied

by

the Howden Contract

Number and the Compressor Serial

Number,

taken from

the

nameplate

on

the side

of

the compressor

body.

ts

s

B

a

SECTION

2

-

DESCRIPTION

?.1

cot-tPREss0Rs

The Howden

0il

injected

Screw Compressor

is

a

positive

disp'lacement,

capacity conirolled,

oil

flooded

rotary

machine.

Compression

is

achieved by

the

meshing

of

two

hel'ical rotors

on para'I1e1

shafts

housed

in

a

casing.

The

accurately

mach'ined

helical

rotors

are

called

Male and

Female.

The

male

(driving)

rotor

has

four

lobes which mesh

with six flutes

in

the female

(driven)

rotor,

both

rotors

having

the

same

outside

djameter.

Each

rotoris

supported by two

plain

white

metal

thjck

walled

journal

bearings

fitted

adjacent

to

the

compression chamber.

As

the lubricating

or'l

is

at

discharge pressure

plus

30

p.s.i

_Q

xg/cnZ)

the

bearinEs

act

as

shaft

seals

within

the

compressor.

Rotor end

thrust

is

accomodated

by a

balance

piston

on

the

male

rotor

and

tilting

pad

thrust

bearings on both male and female

rotors.One side

of

the

bal ance pi

ston

'is

subject

to

o'i'l

pressure (gas _outl

_et

pressure pl us 30

p.s.i),

the other

side

is at

suction

pressure and

therefore

the

balance

piston

opposes

the

normal

rotor

end

thrust

and

assists the thrust

bearing

loading

on

the

male

rotor.

The male

rotor

has

lobes

of

approximate'ly

circular

arc

sections

formed

helically

along

the

rotor

length

and these

mesh

with

corresponding

flutes

on

the

female

rotor.

When

the

interlobe

space

aiong

the rotor iength

is

fi11ed, the

rotation

of

the rotors

moves

the

end

of

the

I obes

past

the

'i _nl

et port,

_{so seal} 'i _ng

_the

_{i nterl obe space.}

As

the rotors

continue

to

rotate the

intermeshing

of

the

lobes on the

discharge

side

of

the

compressor

progressively

reduces

the

space occupied

by

the

gas causing compress'ion. Compression continues

until

the

interlobe

becomes exposed

to

the

outlet

port

in

the

casing and gas

is

discharged. See Secti on 2.?

-Capac'ity

controi

is

achieved by means

of

a

slide

valve

in

the

casing operated by

a piston

in

a hydraulic

cyf inder mounted on

the

compressor.

The

Piston

is

actuated

by

lubricating

oi1,

fed

from

the

compressor

lubricating

oi1

manifold,

to

one

or

other

side

of

the ptston,

moving the

slide

valve

and

altering

the

point

jn

the

rotor

length

at

which compression

begins.

Th'is

allows

internal

gas

recirculation,

thus controlf ing

the

capacity

from 100% down

to

10%

with

approximately

proportjonate

saving in

p owe

r.

Various methods

of

hydraulic

cy1

inder

control are available

and the

appropriate

literature

provided by

the

compressor

set supplier,

should be

studied before

carry'ing

out

any work on

this

equipment.

I

-$

B

B

2.2

COI{PRESSIOH CYCLE

Fig

1.

Gas

js

drawn

in

to

fill

the

interlobe

space between adiacent

I obes

Fig

2.

As

the rotors

rotate

the

interlobe

space moves Past

the

inlet

port

so

sealing

the

j _{n ter'l obe space.}

.^

\

uur1r _^LJJUn JLKI ILE- ru\KUf\L

SECTION

Z

_-

DESCRIPTIOI{

_t&

I

&

Fig

3.

Continued

rotation

progressively

reduces

the

space

occupied

by the

gas causing compression

If

necessary

a

second

non-return

val

tank

to

prevent the

entry

of

gas or

Primary separation

of

the

oil

mjxed

secondary separation

takes place

in

positioned

close

to

the

tank

outlet

In

some

separator

designs

the

wire

cartridge.

Fig

4.

l.{hen

the interl

obe

space becomes exposed

to

the

outlet

port

the

gas

is

di scharqed

ve

is

positioned

at

the

outlet

of

the

1 i

quid

refri

gerant.

with

the

gas

_is

achieved

in

the

tank,

a

wi

re

mesh el ement separator

mesh

is

repl aced by

a

separator

A

further

secondary separator

separation

efficiency

i s

ined

into

the

compressor through

a protective

filter

and an

2.3

DESCRIPTION OF GAS SYSTEI'{ FOR A STAI{DARD

REFRIGERATI0?{ C0MPRESS0R SET(Fig

5)

.

Gas

is

drawn

into

the

compressor throuqh

a

non-return valve

and then a

strainer

fitted

directly

on

the

inlet

flange

and discharged

into

an

oil

tank/separator.

The

non-return

valve

is

necessary

to

prevent the

compressor be'i

ng

'motoreC'

'in the

_reverse

d'i

rect'ion

when i

t

'is

stopped wi th

h'igh gas pressure

at

the

outl

et.

&

s

The separated

oil

drains'into

the

oil

tank.

vessel

may

also

be

fitted

where

a very

high requi

red.

The

oil

separated i

s

usual 1y dra

a

small

bore

pipe

which can be

fitted

with

i sol

ati

ng va1 ve.

0i1

at

outlet

pressure

is

drawn

from

the through

a

cooler

and

micronic

filters

to

the

bearings,

balance

piston, shaft

seal, actuator.

2.4

DESCRIPTIOH OF OIL SYSTEI'{ FOR A STAHDARD

REFRIGERATI0N C0MPRESS0R SET

(Fig

5)

tank by

the oi1

pump, passed

the

manifold where

it is

fed

to compression chamber and hydraul IC

1.{hen

liquid

refrigerant iniection

is

used

there

is

no

oil

cooler.

A

differential

pressure

relief

valve

in

the

system

before

the

filters,

majntains

a

manifold

pressure

in

the

range

of

30

p.s.i

(2

Xg7crTl1. !{hen

the

compressor operates on

a continous

duty,

duplex

micronic

filters

may be

fitted,

allowing

one f

ilter

e1ement

to

be changed

while

the other

is

in

n^^-:+i^-vPcr

qLruil-B

Approved I ubrj cati ng oi I

s

for

refri

gerati on compressors

are

I i sted under

Section

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Ftr-ll-

.-Ei=r:-:,=:, Page 5

-G

2.5

BECOMMENDED LUBRICATING OILS.

Details of recommended oils are given in (Fig.6) and (Fig. 7). dependanl on application APPROVED LUBRICANTS

_-

REFRIGERATION COMPRESSORS

Fis

6

AMMONIA AND R22

B

$

MATiUIAC IURER | {7E

vrsco srTY s PE CtFrC GRAVIT Y ( l 5"Cl s P€crFrc HEAT (1 _5"Cl (caUKg o _C POUR POINT rLASH POINT cLos € o FLASH PO IIJT rso GRADE'

CENTISTOKES R€OWO()o No.l

40"c 100"c ro00c 200" F

B.P

€ri E RC OL

IPT 68 68 67 t.3 310 48.5 o.901 o.437 - 34 -42 183

S H€LI CLAVUS 68 68 68 7.3 Jr5 4 8.5 o.895 o.4 39 -30 24 111 rE XACO/C A LT E X CAPELI.A wF68 68 6? 6.3 285 o.902 0.440 -60 204 ES SO Z ERIC E 68 68 65 7.4 300 4 8.6 o.89s o.4 39 34 207 MOBIL ARCTIC 300 63 250 45 o.895 o.438 -34 -44 r90 CASTROL ICEMATIC 299 56 5.9 245 0.9?0 o 433 -36 -54 183 SUN s uNls{-) 4GS 59 5.8 268 4 3.8 o.925 0.450 -40 48 168 CULF ESKTTO 6B 68 5 5.5 300 .18 5 o a9B o 438 33 212 cH EVRON 6ALF 6g 68 6.7 305 o c31 o 430 -48 200

ll ' The vrscosriy ol lhese olls,s between ISO 46 g'trCe and ISO 6B qrarle

2) 1 Kcal,'tg'C.1 Bru/lb"F.1 I9K,/trg"C

3) The exisleoce ol lhis l;st does not erclude the use ol olher o,ls. bul arO.oval lo( o,ls not included above musl be oblained [.om Howden Compressors Lld . before use

APPROVED LUBRICANTS

_-

REFRIGERATION COMPRESSORS R12 PROPANE AND PROPYLENE

Fig 7 (\/here discharge pressure exceeds 1OO psia _- (7.O31 Kg/cm^) See Note 1 Belor^r

MANUFACTURER TYPE VISCOSiTY s P ECTFTC GRAVITY (15.C1 {1 50CI S P€CIFIC H EAT Kcal/(g'C POUR POIN T oc closEo FLASH POINT rso C RAD€

CENIISTOKES REDWOOO NO.1

40. c lo0'c l oo'c 200"F BP EN€RCOL GCS 1 508 150 144 21 630 126 l 060 o.44 39 235 SilELL C ORE NA I 150 148 650 r26 1.060 o44 40 259 IEXACO SYMLUsE

sA€ 1 40 180 7AO 155 1054 o.4 6 30 2e0

ESSO rG 150 150 158 690 i o.1 1.0a9 o.+4 - 33 240

r,10BlL GLYCOYLE 22 r50 161 ?2 695 106 1.012 048 29 CASIROL ALPHA sN6 150 150 23 670 104 1 008 0.44 40 255 CULT TS 695 150 26 610 1 067 ?2 230 $ B rr, r6s

il !r'releds.hareep,eseere,slesrthan lOOFSIA{7Oll (g/cm') amneral o,l {forn F,g6mayLeuse'J

2) ihese tubrlcanl, afe polyqtycol llu,ds aod must 6or be m,rec *,1h no.mal m,riefal o,1s ln meTi,slaGe planl5 !11 slaget musl lhe'elore u5e a CoiYgltcol liurd

J) V,sccs,ty o{ und,luted lubrrcanl !; e on rn,riat s1a.ti is 5i9^,l,cantly h,ghe, lhao lha! ol .acommeoded m ner.l orlt lo' R22 and NH) ..,.tia--.lece la. !h,s rrcrg3rec v!9ac't\,r: neaalsJ,i *he^ des,g.,ng lrrb:rc;rrcn syster-s a g oil tur.p molor, , lier otessute dloi at 't 1 .,: ,.1,'a- - ] rJ lL'a .. ,i l! I:,::"4

A 5l ' Ihe v,scos,tv ol lh,5 orl rs bel*e4n ISO 150 gr3'Je 3'd ISO 22O g'ade B

-te

*e

A

.$'

COMPRESSOR

SERVICE

_MANUAL

SECTION

3

-

INSTALLATION

3.1

ALIGNMENT OF COMPRESSOR COUPLINGS

The _{couplings supplied vrith this compressor must be aligned using the method described} below as

follows:-lf a compressor only is supplied the coupling _{alignments tolerance ligures can be seen under} Section 3.2.

lf a compressor set is supplied, the _{coupling alignment tolerances and any special instructions}

regarding allowances for expansion or movement during running will be sio*n _{on the General}

Arrangement Drawing and must be adhered to.

During aliinment _{checks both half couplings should be rotaied together from}

0o to 900, lg0o,

27oo aad 3600 and readings of radial and facial alignment recorded. Turning both half couplings together ensures that readings are recorded at the same point on each hJlf coupling, thus _{eliminating the effect of any irregularities on the outside diameters. or faces of}

the half coupling.

Commence alignment by setting the faces of the coupling halves _{parallel in the vertical} plane.

The units will nov; be parallel in the horizontal ptane a"no further adjustment to obtain the

correct centre heights, will require equal si-rinrrning under each foot of tie unit being adlusted. The units are _{now positioned vertically and horizontally.}

Further adjustment to obtain the correct coupting _{gap, radial and facial alignment, will only} require movement of one unit on the existing shim slze.

Coupling gap dimensions should be set with _{the couplings held in a} repeatable position, i.e

hard together or hard apart. _{This ensures that each coupli"ng half is removed to the same axial}

position as each check is made.

The _{actual coupling gap should be correct when} condition lf the combined float of the driving and tolerance, the value and direction of float to? Ootn

the shafts are in their normal running driven shaft exceeds the coupling gap

shafts will be shown on the General

e q

Arrangement Drawing

When setting the gap the axial f Ioat of each

or "hard apart" dimension calculated shaft shoutd be determined and the,.hard toEether,, Example:- _{Compressor directly driven by a turbine}

Compressor Shaft Ftoat 0.002" (0.05mm)

Turbine Shaft Float 0.010" (0.250mm)

Normal running posrtion of compressor shaf i is towards the turbine

runs thrusting tovrards the compressor. and the turbine normally Bequired Gap 0.125" (3.175mm)

if the gap is checked with the couplings "hard apart" it should be 0.i25,,(3.175mm) + 0.010

(0.250mm) for Turbine shaft Float and + 0.002'; (0.05mm) for Compressor Shaft Float i e.

0 137" (3.475mm).

lf the gap is checked rvith the _{couplings "hard together" it should be 0.125"'(3.175mm).}

NOTE:

lf a "limited f Ioat" coupling is _{used w'ith an electric motor whose shaft has no thrust bearing}

the

gap _{must be correct rvith the rnotor shaft on its magnetic centre ln this instance}

the faclal

alignment _{check should be mace rotating the,ii-lverihaif coupiing oniy, as ihe orive (motor)}

hrlf e clrplin3 i: ncl lccatecj :xialiy oi _{pi-ufcri.Li';, Ly a "cioublc cioox'nretirocj which}

avorc.Js tire

problem of repeated axial position"

rl t I {6 p

3.2

ALIGNMENTTOLERANCE Flg 8

The maximum _{acceptable lrne-up tolerance for couplings on compressor installations}

is as follows:_ Radial Tolerance Eccentncity ₌ !/. _{T l.R. on circumference} A) A) B)

I

s RADIAL TOLERANCE Applicaticn

Motor to Gearbox or Compressor, i.e.

couplings operating up to 3,6O0 r.p m.

Gearbox to Compressor, i.e. couplings operating above 3,600 r.p.m.

----'

Radial Toierance 0.15 mm (0.00,6")T l R B) 0.10 mm (0.0O4")T.t R _B) Face Tolerance T.l.R. 0.005 mm/cm dia. of coupling. T.l.R. 0.0005"/inch dia. of coupling.

-B

T.l.R. denotes Total lndicator Reading oblained by clockgauqe.

3.3 DOV/ELLING

Only one unit of _{any assembly vrill be dowelled before despatch. Dowels should be fitted}

to

ease _{re-alignment when components are removed for overhaul.}

3.4 PIPING

Before _{installing the piping, the compressor inlet and outlet ports should be}

inspected to e nsure no did _{is present.}

AII plping should be supported so _{lhai no strain is transmitted to the compressor casings.}

The piping should be inspected for _{cleanliness before installation. As each pipe is connected to}

the cornpressor, the coupling alignment should be checked to _{ensure that no alteration has} taken place.

lf _{alignment has altered, the compressor is being strained and the piping supports must} be

a dju sted.

It is not sufficient merely to re-align the drive unit as this will not correct the strain being

imposed on the compressor.

oii

injected i'efrigeration compi'essors _{inusi have a suction} sirainer lternianrntlr,, f lttcC direcil.,,cr-- iitc ccirpre _{ssoi- iriiei.}

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1-PA6t 1i

I

COI'IPRESSOR SERYICE I{AHUAL

SECTIOH

4

-

FIRST START UP

4.1

FIRST START

Installation

of

the

compressor

w'ill

have been

_{carried out}

_in

accordance

with

Section

3

of

this

manual however

the

commissioning engineer should

ascertajn

that

the correct

_{procedures have been fol'tow6O,}

_in

_particular

_the

cgupling

ai ignment must be checked, then proceed

_as

fol lows:-'

1)

Disconnect

the

coupling between

the

dri've

anC

the

compressor and check

that

the direction

of

rotation

is

correct

to

drive

thf

compressor

in

a

clockwise

direction

looking

on

to

the

compressor

input

snait.

2)

Fill

the

oil

tank

with

lubiicating

oil of

the correct

grade

_to

the

required

level

as

indicated

on

the

tank

level

sight

_91iss.

3)

Ensure

that

the

manifold and

oil

pipes

to

the

compressor

are

clean then

start

the

lubricating oi1

pump motor

to

_circulate

_the

_ojl

_and

_clean

_the

system.

4)

The

lubricating oi1

pressure

_{differential relief}

_valve

_{should be}

_set

_to

give

a

30

p.s.i

_Q

Kg/cnz)

_oil

manifold

differential

pressure _at

.

correct

operating temperature,

with

clean

oil filter

elements

fitted.

5)

Check

the

operation

of

the safety

trips

by

running

the

drive

unit

dis-connected from

the

compressor and mechanicaliy operating

the

trips,

check

that

the actual settings are

in

accordance

with

the contract

specification.

The

lubrica!ing

oil differential

pressure

trip

can be

set

at

12

p.s.i

(0.85

Kg/cn?)

5y

partiatiy-ctosing

rhe

oit fitter

outlet

isolation

valve

and thereby reducinq

the

differential

oi'l

pressure.

As

the

filters

become

dirty

the

differential

ojl

pressure

yjll

drop

to

these

figures

which

are

the

minimum accepted vaiue.

6)

Check

that

the

compreisor

turns

freely

and reconnect the coupling between

the drive

unit

and

the

compressor.

7)

Check

that

the

cooling water

is

turned on

to

the lubricating oi1

coo'ler,

r'f

f i

tted.

B)

check

that

ali

gas

inlet

and

ouilet

isolating

valves are open.

9)

Start

the Iubricating

oii

pump motor.

N0TE:

The _{conipressor should be unrcaded}

prior

_{to start}

_{up. If}

_the compressor

is

started

without

first

being unloaded

a

higher

starting

torque wi .l

'l

be requi red.

i0)

Start

the

drive

unit

and check

that al1

gauges

_{are indicating correctly.}

11) Run

the

compressor

for

30 minutes

at

minimum gas

flows

and check

that

all

readings

are

normal, then operate

the

capacity

contro'l

valve

to

the

required

positjon,

this

position

_will

_{be indicated}

_on

_the

_dial

_mounted

on

the

hydraulic

cylinder. if

possible

check

the slide

valve control

over

the

full

ranqe

of

capacity.

4.2

USING THE COI"IPRESSOR AS A YACUUII AIR PU}IP IH A REFRIGERATION SYSTEFI

Jf

n9 vacuurTl pump

is

available

to

evacuate

the plant

prior

to

charging with

Ref

rigerant,

the

_{compressor may be used}

for

_{th.i_s purpose.}

Close an

isolating

valve

downstream

of

the

compressor

ojl

tank and arranse

a vent

at

the

hiqhest

point available, situated

between the

oj'l

tank and i sol ati ng va1 ve.

l.It'th

the

suctjon

isolating

valve

open,

start

the

compress0r,

air will

be

drawn from

the plant

and djscharged through

the vent

thus evacuating the

p1ant.

Under these condit'ions some

oil

vapour

carry

over may be seen in

the

discharged

a'ir. Initialiy

_the

_{compressor discharge presiure}

_wili

_be

f ai

r'ly

hl gh

but

thi

s

wi I

I

drop

as

the

pl

ant

i

s

evacuated. ,6 -f-I

c

e €

s

q Page l2

l

i0

_{COI'IPRESSOR SERYICE}

I.IAHUAL

SECTION

4

-

FIRST START UP

When

the plant

is

evacuated

close the

suction valve

and

stop the

compressor

inrnediately

the valve

_is

_closed.

_The

_{vent valve}

_.un

_{no*-ue-cioseo.}

The

plant

is

now evacuated

_{but the}

_compressor

jtself

_contains

_air

_at

atmospheric

pressure.

This

can be removed as

follows:-0pen

the

val ve on

the vent

'l i ne

-through which a j

r

was di

scharged.

Af

ter

the plant

has been charged

with

Refrigerant

open

the

suction

isolat.ing

valve

a

small

amount

allowing

Refrigeiant

_into

_the

_.o*p..rro.

_,ut

displac_ing

the

remaining

air.

When-Refrigerant

_starts

_to

_{pass through the}

vent,

close

the

vent

line valve.

The comfressor

_set'is

now charged with

Refrigerant

with

the

minimum

quantity

of

_irapped

_air.

HOTE

0

6

If

_this

a

suction

_switch

_to

low pressure

_allow

_the

_{compressor suction}

trjp is fitted it

e

6

may be necessary

_to

disconnect pressure

_to

_{fal I} .

&

-re

I

;-6

€

_s

\l t t \

COMPRESSOR SERVICE MANUAL

SECTION 5

_-

NORMAL OPERATION

5.1

NORIITAL START

1)

Check _{the level of the oil in the} tank.

2)

check that ari necessary gas, oir and water varves are open.

3)

Start the _{lubricating oil pump motor.}

4)

Ensure the capacity contror varve _{is in the fuily unroaded position.}

5)

Start the drive unit and check that all gauges ire indicating normal readings.

5.2

NORMAL STOP

1)

Stop the drive unit.

2)

After the _{compressor stops, the control system should be operated to}

move the slide

valve into the off load position unless _{the control system does this automatically.}

3)

_{After the compressor stops rotating, stop the lubriiating oir pump motoi.}

-!)

Close all gas _{and water isolating valves.} The compressor is _{then ready for start up sequence.} NOTE

A log should be kept of the instrument readings so _{that deviations from correct running}

conditions can be readily observecJ by the *nglnee, in charge ot the installation.

ii

COIIPRESSOR SERVICE I,IAI{UAL

SECTION

6

_

PRECAUTIONS DURIXG SHUTDOI.{N PROCEDURES ON SHUT DOI{I{

The Howden

0il

Iniected

Screw Compressor cperates on an

oil/gas

mixture

and

short

periods

of

shut

down

will

not

adversely

affect

the compressor.

if

the

compressor

is

shut

down

for

an extended

period

the lubricating

oi1

pump

shoul

d

be operated

for

approximately

ten

mi nutes week'ly,

to

di

strr'bute

oi I

throughout

the

set.

1f

the shut

down

period

is

three

months

or

more

the

above procedure can be

repeated

at

weekly

intervals,

but the

compressor

set

should

also

run

for

one hour each

three

months,

a'lternatively the

normal

lubricating

oil

can be

drained

off,

replaced

with

inhibiting oi1,

and

the set

run

for

one hour.

If

the

compressor has been

run

on

inhibiting oi1

thjs

should be repeated

at

three month'ly

intervals

during

the

shut

down

period.

Approved

oils

are

shown

in

Section 6.2. HOTE

1)

Before

putting the

compressor

set into

normal

operation,

the inhibiting

oil

must be removed and

the

system

filled

wjth

normal

oil.

?)

During

shut

down

period'in cold

_conditions

_{any water cooled items}

_of

plant

should be

drained,

or

the

cooling water

flow

majntained to

prevent damage due

to

freezing.

6

.2

_{IHHIBITI}IG OiLS} APPROYED FOR USE h{iTH HOHDEH SCREH COI,{PRESSORS

The

following

is

a

list of

approved

inhib'iting

oils

suitable

for

use on the

Howden Screw Compressor

pricr to

a

lengthly

period

of

shut

down.

Shell

Ensis 10

Esso

lL

1175

ttobil

-

Armo 524

Caltex Preservation

0il

10H

6.1 0 6 e q &

I

E 9

€

7.1

COI'IPRESSOR SERYICE I{ANUAL

SECTIOH

7

-

I,{AI}TTENANCE

GE}IERAL COI'I'IE}ITS

The component

parts

of

this

compressor

are

large

and heavy and considerable

dif

f icul

ty

w'i11 be encountered

'if

maintenance/overhaul

is

attempted w'ithout

the

use

of

a

manipulator frame

The compressor

is

designed

to

give

long

periods

of

trouble-free

operation

with the

minimum

of

maintenance, however, an annual inspect'ion

js

reconmended

to

check

if

there

is

any

significant

wear on

thrust

bearings,

slide valve

guide

block

or

PTFE

seals.

Should wear be found these

components must be rePi aced.

Refer

to

the sectional

arrangement drawings

supplied.

All

fasteners should be torqued

to

the

specified value as stated

in

Sect'ion

9.1

using

appropriate

torque

wrenches.

All

lockwashers, tabwashers,

0

R'ings and PTFE

seals must be renewed on assemblY.

Sectjon

9.2

describes I ockwasher assembly

procedure.

Special tool

s

to faci I'i

tate

di smantl i ng and assembly can be provi

ded.

These

are

I i sted under Section

9.3.

Detai.l

s

can be provided on request.

Sectjon 10

detajls part

numbers

of

normal'ly replaceable components.

7.2

PREPARATION FOR AHNUAL INSPECTIOH

Before doing any work on

the

compressor

the following

precautions should be

taken.

.

Isolate

the

drive

unit.

DepressLtrise and purge

the

system.

.

Djsconnect

the drive

couPl ing.

.

Pl ace

a

receptacl

e

under

the

outl

et

end

of

the

compressor

to

catch any

o'il

which may

drip

when

the hydraulic cylinder

or

the

outlet

end cover

are

removed.

(A

dra'in

pluq

is fjtted

on

the

underside

of

the

inlet

and

outlet

casing

to

facjl

itate oil

drainage).

4.

Insure

all

I

ifting

tackle

in

good condition.

7

.3

DISI'TANTLITIG PROCEDURE FOR ANNUAL IHSPECTION

Commence

at

djscharge end

wjth hydraulic

actuator.

Extract

the

4

off

cap

screws

holdjng

the

a'luminium cover

to

the

cylinder

Cover and remove"

Extract the

15

off

cap screws securing

the cylinder

cover

to

the

hydraul

ic

cylinder

and remove

the

cover complete

with

limit

switches and the

i"ndicator

spindle

which

are

attached

to

it.

The

cylinder

c0ver weighs

I 20K9.

I'lo te : - The

indicator

spindle

has

to

clear a

guide

block

whjch moves along

a

spiral

groove

in

the

spindle.

care must be taken

to

avo'id

damage

to

either

spindle

or

gu'ide

curing

either

removal 0r

assembly.

Mark

the

spi nd1

e

to

ensure

correct

assembly -1

? 3

COI"TPRESSOR SERYICE I,{AI{UAL

SECTION

7

_ I'TAINTENANCE

Remove

the

actuator

stop

sleeve,'if

fjtted,

from

the cylinder

bore.

iii tfr.

piston

withdrawal gear

listed

under Section

9.3

and pu11

the

sl ide

valve

assembly

until

the piston

locknut

js

clear

of

the

cyljnder.

Untoct

the

pi!ton

lockwasher and

locknut

and

remove.

i.lithdraw

the

piston from

the

cyf

inder.

The

piston

weighs 50 Kg'

push

_{the piston}

rod and

slide

valve

towards

the

inlet to

the

limit of its

travel .

Support

the

weight

of

the

actuator

cylinder.

The

actuator

cyf inder weighs S0b' f

g

so

a

crane

or

chai

n

bl ock wi I

I

be requi red _'

Extract the

16 bol

ts

and spri ng washers securi ng

the

cy'l 'inder and usi ng the

jacking

holes provided

in

the flange, iack out

the cylinder.

REITOYIHG THE OUTLET EHD COYER

Extract

most

of

the

set

pins

securing

the

outlet

end cover.

Fit

a

shackle

to

the

liftjng

eye on

the

top

of

the

cover and support cover

with a

sI

ing.

The

outlet

end cover weighs 900 Kg'

ng

the

cover

to

the

outlet

end casing, and remove

the

cover.

Take care

not

to

l,l.ith

the out'let

cover removed

the

sl

ide

valve can be drawn

to

a

pos'ition where i

t

j

s

sti

l'l

supported by

the

val

ve

gu'ide,

to

a1l ow sl i ngi ng

'

The

slide

valve

and

piston

rod

weigh 400

Kg.

Support

the

valve

by means

of

a

sf

ing

and

puiI

clear.

The compressor has now been dismantled enough

to

allow

inspection'

By

shin.ing

a torch

from

the

valve bore,

a visuai

inspection

of

the

rotors

can

be ach'ieved.

New

0

Rings and PTFE

seals

shou'ld be

fjtted

prior

to

re-assembly on the

piston

and

piston

rod

guide

in

the cylinders'

7.4

CHECKIHG CLEARAHCES

Knock

out the

dowel

_Pins

locati

extract the

rema'ini ng

set

Pi ns

damage

the piston

rod.

REI.iOVI}IG THE SLIDE YALYE

GUlDT BLOCK

The gui de bl ock 'l ocates

wi

dth

of

the

gu'ide bl ock

Should

the

dimension

fal

the sl'irle

val ve and shoul

d

be checked

for

wear'

The

shou'ld be

within

the

I

jmits

49.991/49.965 mm'

I

outside

these I imj

ts

i

t

must be repl aced.

THRUST BEARiNG FLOAT

I\,1ount

a

dia'l

test

indicator

to

a su'itable

point

on

the

casing

with

the

ipi.afe

touch'ing

the

end

of

the

male

rotor.

Using

a

suitab'le eyebolt

(t'124)

in

tne

tapped h6le

of

the

inlet

shaft

pull

the

rotor

hard

to

inlet.

Th'is

will ..qrire

some form

of

tackle

since the

male

rotor

weighs 1200

Kg"

Set

the

dial

test

jndicator

to

zero and puslr

the

rotor

hard

to

outlet

and

l.ecorri Liie r.ead

rrig.

Tir

is

rcriii

iirg

i

s iltc

rtal

c

l"otci'

fl

cat

arC shoul

d

be

w1thin

the

range

0.450/0-35mm

_page

,

-e

COHPRESSOR SERYICE }'IA}IUAL

SECTION

7

_

T.IAIHTEHAI{CE

Repeat

this

procedure

for

the

female

rotor.

To do

thjs

the

female

rotor

cover,

R51132, weighing 55 Kg

will

have

to

be removed.

Should

the

rotor

float

be

greater

than 0.450 nm

the thrust

assemb'ly should be dismantled and

the

other

bearjngs checked

for

wear.

In

this

case

proceed as

for

maior

overhaul,

see Sectjon 8.

7

.5

REASSEI'{BLY AFTER AHHUAL I}.ISPECTIOH

Ensure

the

gu'ide

block

is in

posit'ion

on

the

slide

valve

bore. Lift

the

slide

valve

into

position

and push

it all

the

way

home.

Take

care

to

support

the

slide

valve

unt'il

a'll its

weight

is

taken by

the

guide.

Lift

the outlet

end

cover,

with a

new

0

Ring,

into

position

and

locate

with

dowel

pins.

Take

care

not

to

damage

piston

rod.

Secure

with set

pins.

Fit

a

new

0 ring

and PTFE sleeve

in

the piston

rod

guide on

the

actuator

cylinder. Fit

two new

0

rings'into

their

recesses on

the

cylinder

body.

rlt

two lengths

of

screwed

rod

(M24)

into

opposite holes

in

the

outlet

end

cover.

The rods must be

at

least

350 mm

1ong.

Lift

the

cyl"inder over

these rods and

locate

in

pos'ition.

The rods

w'ill

act

as gu'ides.

I'lB:

0n no account al I ow

the

screwed rods

to

support

the

wei

ght

of

the

cy1 i nder.

Fit

suitable

washers and

nuts

to

the

rods and pu11

the

cyf

inder

home,

securj ng wi

th

set

pi ns.

pull

_the

piston rod

out

until

ihe

end

is

clear

of

the

cylinder.

Re-fit

the

piston

to

the

piston

rod

and secure

with

new

locknut

and lockwasher.

Re-fit

the

actuator

stoP.

Careful1y f

ift

the

cy1inder c0ver

into

position

conrplete

with

actuator

spindle

making sure

the

guide

fits

jnto

the

correct spira'l

gro0ve whjch has

been marked

pieviously.

Secure

with

cap screws and

re-fit

cover assemb'ly"

$ s

I

CCfiPRESSOR SERYICE Ii{ANUAL

SECTION B

_

OYERHAUL

--*

8.1

GE}IERAL COI''T{EHTS

Although a

yearly

inspection

is

reconrmended

it is

essential

that

a

major

overhau'l is-

carried

out

when approxjmately 4

years

operation has been reached.

Should bearing wear be excessive before

this

then

a

major overhaul

will

be

iequired

earlier.

To

carry out

a

major overhaul

the

compressor

will

have

to

be removed from

the

bed

to

a

cl ean workpl ace and mounted on a

manipul

ator

frame.

8.2

DISI'{ANTLIHG PROCEDURE

The compressor

is first

to

be dismantled as

for

annual

inspection

under sections

7.2

and 7.3.

REI'IOYIHG THE IHPUT SHAFT SEAL

After

the

driven

half

coupling

and key have been removed,

extract

the

cap

screws from

the shaft

end'cover and using

the

iacking

holes provided and

ihe "T" bar iacking tools

remove

the shaft cover.

(80 Kg)

Follow

th'is

by

removjng

the

seal

jng

washer and

the statjonary

seat-

Aga'in

,;i;;

tt e

;t""

iacking

iool s

withdriw the

seal

housing.

Pul'I._out

the

shaft

ieal

-tak'ing

caie

not

to

damage

the

carbon

face-

Usjng

the "l':

_^iacking.

tools

withdraw

the

balance

piston

and balance

p'iston

sleeve

(if

fitted)

from

the

inlet

end

casing.

(Ba1ance

piston

20 Kg) INSPECTION OF THRUST BEARI}IG ASSEI{BLY

Release

the

locking

plates

on

the

rotor

shaft

end

p1ate,

remove

the

three

bolts

and

the shafi

end

plate.

Remove

the

B hex screws from

the

reverse

thrust p'late

and remove comp'l

ete

w j

th

f I oati ng

seal

and

seal

retai ni ng

p1ate.

Remove

the

adiust'ing

packers. Extract the

reverse

thrust

bearings'

itn. tf,.rst

bearr'ngs wei gh 50 Kg) _'

Draw

the

thrust

collar

from

the shaft

and remove

the

key.

Remove

the

8

hex

screws and

lift

out

the

thrust

hous'ing

with the

main

thrust

bearing.

(The irous'ing and bearing compl

ete

we j ghs 200 Kg) _'

Visually

inspect

the thrust

pads

for

damage

or

wear,

if

they

are

not

being

,.un.*edthey

should be

cleaned'in solvent,

then dipped

in

clean

oil

and wrapped

in

greaseproof paper

or

clean

cloth

until

re-assembly takes place.

RET,IOYII{G IHLET END CASING

Fit

a

shackle

at

the

top

of

the

inlet

casing"

Knock

out

the

dowel pins

locatjng the

casing

to

the

main

casing.

Support

the

weight

w]th

the

crane'

Remove

the

44 set

Iins

from

the

inlet

casing and

careful'ly

slide

the

casing

over

the

extended

shaft

of

the

male

rotor

taking the 0

ring

seal w'ith

it"

The

jnlet

casr'ng weighs 1053 Kg.

A ?

I

D:ao I O

+-LUTTITKL))UK )LKI ILL TU\NUAL

SECTIOH

8

-

OVERHAUL

RE}TOVAL OF ROTORS

l.li

th

the

'inl

et

casing and

thrust

assembl

ies

removed and

the

compressor

securely fastened

to

the

manipulator frame

rotate the

compressor

tjll

the

.inlet

_ena

_is

_{uppermost. Screw an eyebo'lt}

_into

_the

_end

_of

the male

rotor

and

lift

clear'of

the

casing slow'ly

turning

it

clockwise

to

ease

the

rotor

form

past the female.

The

rotors

weigh

1

tonne each.

Repeat

for

the

female

rotor.

rotors

by

the.ir iournals

on

soft

(preferably

wooden) vee

allow

rotors

to

rest

on

their tip

seals-outlet

end

journal

bearings

are

held

in

position

by set

these removed

the

bearjngs can be pressed

out

using the

I

isted

in

Section 9.3. Always support bl ock

s.

Never The i nl

et

and

screws.

Hi th spec i a1 tool s

Turn

the

compressor back

hcrjzontal

and, having smeared

the

bearing bores w.ith

oi'l

carbf ul 1y f i

t

the

i nl

et

casi ng wi

th

a

new

0

ri

ng over

the

rotors .

Locate

the

inlet

iasing

in

position

with

dowel

pins,

fit

the

bolts

and

secure

them.

(see torque

specjfication

in

Section

9).

ASSEMBLY OF THRUST BEARIHGS

T

_Fi

_t

_thrust

housi ng wr'th adjusti ng washers

to

the

outl

et

end casi

ng.

Fl't

;

main

thrust beariig,

thrusi

collar

w"ith key and

rotor

end

piate.

Torque

thrust

housing

bolts

to

required

setting'

Check

the

journal

bearing clearances

are

within

the

tolerances 0.28/0.34mm.

if

outw'ith

th'is

speciticitton

fit

new bearings

in

preparation

for

re-assembly.

The

_iournal

bearings weigh 100 Kg each'

8.3

RE-ASSE}'{BLY AFTER OVERHAUL

Smear

the

outlet

end bearing bores

w'ith

lubricat'ing

oil

and

turn

the

compressor body

vertical

w'ith

the

j nl

et

end upperrnost.

Carefully

lift in

the

female

rotor.

Carefully

lift in

the

male turning

anti-clolt*ise

to

allow

the rotors

to

mesh.

Ensure

the rotor

lobes mesh at

the

seri

a'l

numbers.

push

_the

_rotor

hard

to

outl

et

and mount

a

di

al

i ndi cator'

at

a

conven'ient place

with the

spindle

horizontal

and

the

dial

set

to

zero.

push

_the

_rotor

hard

to

inlet until

the

thrust

collar

comes up hard against

the

pads and note

the

reading.

Thjs

reading

is

the

0UTLET END, HARD T0

INLEi CLEARANCT and should be 0.650/0.600

mm.

To

obtain

the

correct

clearance shims should be added

or

packers ground

as

required.

Final readjnqs must be taken

with

housing

bolts

and

rotor

plate bolts

torqued

io

the

requj

red

setti

ngs.

Fit

the

reverse

thrust

bearing and p'1ate

with

adiusting

washers.

Leave the

bolts

slackened back. Push

the

rotor

hard

to outlet

and

set

the

dial

to

i..o.

Torque

the

bo:lts

to

the

required valug

_9ld

check

the

reading'

Thjs

rearti ncr i

s

ihe

0uTl,tT Ef,JD

,

HARD T0 0uTi

tT

cLtARAl'lCt and shoul

d

be

0.250/A.200 mm.

COI.IPRESSOR SERVICE I{AHUAL

r

SECTI0NB-oYERHAUL

Again

the

correct

clearance should be obtained by adding sh'ims

or

grinding

packers as requj red.

Repeat

this

procedure

wjth

the

other

rotor.

The

origina'l

readings, taken on assembly

in

the factory,

will

be shown under

contract

detajls-Renew

the

floating

seals and

rotor

end

piate locking

plates.

Ensure

all

bolts

are

correctiy

torqued and

fitted

with

loctjte

275 which should also

be used

to

I ocate

the

thrust

col I

ar

to

the

shaft.

RE-ASSEI-{BLY OF OUTLET EHD COYER AilD HYDRAULIC CYLINDER

Proceed as described

in

Section 7.

RE-ASSET'{BLY OF INPUT SHAFT SEAL

1. Fit

balance

piston

sleeve

(if

required)

and balance

piston

making sure

i

t

fi

ts

over

the

dowel .

2.

Locate

seal driv'ing

pjn

into

hole

in

balance

piston'

3.

Lubricate

shaft

seal

and assemble

to

rotor

shaft.

Ensure

I't fl'ts

over drj vi ng pi n.

4.

Carefully

fit

stationary

seat

into

shaft

cover

locatjng

it

on dowel.

5. Fit

shaft

cover

in

position

and secure

with

cap screws.

i

t

9; rE :,9 i

;

? \? rEl >E5

t:i

lx{ '11 tr'x o23 5-i t : !1: I >; IE iv o: >: Yg =J -;r: , ;i: --

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/'- t-\<= \9/ re ?; fl t. !,ol

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;

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fJ/

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--{':

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P; :! tq I YY_., ?= :d =I > i i:

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a: .J _{-rct._o}

,-{ 9;tulrf

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i;=i3ei:

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Pnee 23

': _

Y

COI'IPRESSOR SERYICE I{ANUAL

SECTIOH

9

-

SPECIAL I}ISTRUCTIO}IS

I

I

9.i

ToRQUE SPECIFICATI0T{S

Torque

specifications

are

as

PART NO. G16032 G24102 G24103 G2501 1 G250 37 G26002 G26006 G26030 G26037 G26038 G260 39 G27002 G27012 GZ70l3 G270 1 5 G270i6 G?7017 G27018 G2800 I G2800 2 FrG 104 T0RqUE DESCRIPTlON

detai 1 ed

per

Tabl

e

Fi

g.

104.

SPECIFICATIOHS FOR FASTEHERS OH

HRVT51O COI.PRESSOR

Slotted

Cheese Head Screw 68A x

1 1/4"

1G

Hex Nut M30

Hex Nut M24

Hex Socket Head Cap Screw N0.10

UNC

x

5/8"

LG.

Hex Socket Head Cap Screw l{o.10

UNC

x

3/8"

LG.

Hex Socket Set Screw (Grub Screw)

with

Cup Pojnt

Steel

Hammer

Drive

Screw No.6 x

1/4"

LG

Hex Socket Head Cap Screw MB

x

20

Hex Socket Head Cap Screw M24 x

45 LG

Hex Socket Head Cap Screw M24 70 LG

Hex Socket Head Cap Screw l'116 45 LG

Hex Head Screw Ml6

x

50 LG

Hex Head Screw M30

x

120 LG

Hex Head Screw ll24

x

B0 LG

Hex Head Screw M10

x

30 LG

Hex Head Screw 1124

x

60 LG

Hex Head Screw M24

x

70 LG

liex l{ead Screvr 1"120

x

50 tG

Stud 1430

to

Drawi ng LCV332l/A

Stud t'124

to

Drawi ng LCV332l/B r c )1 ? LU LL J

583

BO IORQUE

Lbs.FT

Kg.l'1 4

liBB

164

583

BO

41

583 t71 777 liBB 4i 30J 1/ n 1 IBB 583 t+ ?4 tb4 BO 6 BO BO 47 154 BO BO ry B

?

P age 24

COI{PRESSOR SERYICE HANUAL

!-

sEcTI0N

9

-

SPECIAL IHSTRUCTIoHS

9.?

PROCEDURE FOR FITTII{G LOCKI{ASHERS

This

instruction

applies

to

all

lockwashers used on Howden Compressors

for

the

purpose

of

reta'ining'in

pos'ition

the

locknuts

locating

the

bearings,

thrust

collars,

pistons

etc.

A

typical

example

of

the

items concerned

is

shown below

(rtg.

105).

Fi 9.105

Assemt-rly Method:

-In

all

cases where

this

type

of

lockwasher

is

used

the

components must be

assembled

without the

lockwasher and torqued

to

the

prescribed

value.

The

locknut must

then

be removed,

the

lockwasher d'ipped

in

oil

and placed on

the shaft, the locknut

replaced and aga'in torqued

to

the

pr^escribed value.

This

assembly process

limjts

the

amount

of

relative

movement between the

locknut

and

the

lockwasher under

torque,

and avoids

the

possibility

of

the

inner

tang being damaged.

9.3

SPECIAL TOOLS FOR THE COI'{PRESSOR

Tools can be provjded as deta'i1ed

per

(fig.106)

for

ease

of

dismantling/assembiy however,

they

are not

a

mandatory requirement.

v

**11

il II U Fis lO5 t Fig.106

'ilRVT510 LIST OF SPECIAL TOOLS

i oescnrPlroN

I

ennr

No

I

I

socrEr sPANNER

-

Bo HH LocKlluT

I

stooieJ

I

I

socrrr

saANNER

-

100 MM

LocKNUT

I

s10015J

I

sEr on

ltrrntc

socrrrs

coupntsiNe

to

ttt'i,

to

MM

I

I

I

zo

ulr,

z+ NN

:o

ltu

socrErs

plus

nnrcHrr

I

I

I

ExtrNsioN enRs

to"

a

s"

I

I

I

srr

or

RLLnN

rrvs

compRrstNe

-

o

Ftlt, B

tltt,

to

ttM

I

I

I

rz

rru, zq

H[1

I

I

3

-

B

COI'IPRESSOR SERYICE I'IAHUAL

SECTIO}I

9

-

SPECIAL IHSTRUCTIONS

9.4

COMPOHEIT I{EIGHTS FOR I{RYTs1O COI.IPRESSOR

l,leights

detailed

below

to

allow

correct

lifting facilities

to

be used"

I

coueourur

I

wrrcHT-(Kg) '

RoToR

I

-2652-l .our-2652-lrr

cASING

I

zw

t

I

rNlrr

cASTNG 1053 OUTLET COYER

I

Nnr-r RoToR 1 tB6 FEMALE ROTOR

t

t

t

I

r'rarr RoToR covER

BALANCE PISTON

l-

sucr roN -BRG '(

2

of f )'

I

rrmnlr

RoroR

covER

_I DISCHARGE-BRG _I2.OFF) -THRUST HSG

(2

OFF)

I

nrv 'niRUSr'PLATE

(z

orr) -

_]

Inolusrrrucnnic(zorr)

-'

- j -- -g,e

I

I

rHnusr sPACTR

(z orr)

I

4:B

I

I

rHnusr colLAR

(2

oFF)

1 'zs

I

I

runusr Pi-ATE "('2 oFF)

' '6.2

I

I

ersroru noo

1i0

-

'

q

9

I

ncrunroR sToP I

PrsToN

l

CYLINDIR END COVER

I

-

iie

I

i

cvt- t runrn 516

I

slroe

vALYE )II

"'

257

I

sL

rrr

vALVr sToP ccJJ

I

srr

scRrils 200

I

rHnusr eacs

ct

\ -# Hage r0