Murray K Series Condensing Turbine

This Project is a Remedial (3yr) Internal NDE Inspection of a 6-stage Murray K Series Condensing Turbine being performed by S.E. Peter Recchia, S.E. Andres Cortes and Service Mechanic Joe Cracchiolo. The project consisted of, in part, upper and lower diaphragm inspections, rotor removal, followed by concentricity and dimensional checks, fits and clearance inspection and NDE evaluation of component condition. All bearing and bearing case components appeared well within tolerance with only light to moderate journal and thrust wear. Stationary and rotating components, however indicate reasonable degenerative wear, likely associated with erosion.

Plans will be made to remove and perform Magnetic Particle inspections of all components including governor valve and valve seats, all stationary segments and nozzle block followed by same to 6 stage rotor assembly.

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York OM238, Multistage Turbomaster, Seal Renewal

Senior Service Engineer Michael Santonocito and Service Engineer Robert Kane performing a seal renewal for Seagrams Building Chief Engineer Mr. Ron Hughes. The OM series compressors are similar to many seals that are sensitive to the seal “bore crush” on the mating assembly which require a field configurable gasket shim fit. You will see S.E Michael Santonocito and S.E Robert Kane clearly measuring bore depths to insure ideal shim selection and ultimate seal performance is obtained.

1800 HP 6-Stage K Turbine Restoration and Reassembly
 
As discussed in the preceding disassembly photos and text, this turbine suffered a major failure associated with each stationary and rotating segment, including nozzle block fractures. ICACS proposed a plan that would reduce lead times by 8 months and save an estimated $100,000.00. This plan included renewal of an entire 6-stage OEM Rotor, new 6-segment Curtis Stage Reversing Segments, all new Bearing Case components and remanufacturing of all Diaphragm Stations.
 
The Turbine was fundamentally "stripped" internally to insure the casing, lube and steam chest were free of any and all foreign particulates. At this point failed and non-failed components were thoroughly cleaned and filmed with joint compounds for reassembly. All stationeries were secured with strung bold heads and recessed cap screws peened over. The turbine fits, clearances, dimensions and concentricities were inspected by Sr. S.E. DiDonna, DiGuiseppe and Recchia, and were at spec on initially install. Final Assembly is being performed by S.E. Recchia, Whitehead and Cracchiolo

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Trane CVHA Sidewinder Series 5 Year Overhaul

This is a long standing client of ICACS. This CVHA series Sidewinder is undergoing a routine NDE inspection, bearing replacement and regasketing. The last NDE inspection was performed in 1995 by ICACS and has been operating flawlessly over the prior 10 plus years. Other then being overdue for inspection, the driveline internals were found with little or no wear and only the buffer seal was replaced due to mild peening of labyrinth faces. Many more useful years of performance from this hermetic chiller can survey be expected.

OM238 CFC-12 Engineered Retrofit to HFC134a, Phase I Murray K Turbine Rotor Replacement, Phase II Retubing

This project is phase I and II of an Engineered HFC134a retrofit to an OMS Chiller. This project includes, in part, renewal of condenser tubes to high efficiency - enhanced tubes, replacement of new High Performance Turbine, OM238 Compressor Restage Pak and ISN Turbine Modulator Controller.
Phase I and II have been completed and awaiting CFC mineral oil flush to the chiller vessels. Essentially all of our service engineers participated in Phase I and II of this project. Please look forward to future sectors schedule into early 2007.

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Murray K Series 4500HP Multistage Turbine, Rotor Shaft Replacement

One of the ongoing revitilation plans and projects for the Turbine chiller plant has been restoring the #2 Turbine into service. This included, removal of the Turbine rotor assembly, NDE test of all stationary and rotating segments to insure candidacy for repair, and replacing a damaged rotor shaft that had significant exhaust bearing journal damage.
The NDE revealed disc damaged at several diaphragms segments. The plant’s management approved repairs of all disc and diaphragm services. Senior Service Engineers John DiGuseppe and Dominic DiDonna with the assistance of Service Mechanic Joe Cracchiolo expeditiously assembled all renewed components and re-tapped damaged split line screws during the heat wave of August 2006. The turbine was connected to the load less than four days after field service commenced!
The flawless performance and assembly was well received by the engineering plant under Project Manager James Zeiner and Director of Engineering Mr. Paul Meirderck. This machine is in use and will remain a prime chiller at ambient OA temperature in excess of 40° F.

Parallel Reciprocating Ice Rink, Oil Management System Retrofit.

ICACS was contacted by a prominent Long Island Ice Rink plant that expressed a long term and consistent problem associated with oil logging to the flooded cooler. Estimates suggested near 350lbs of excess oil per year was often required to maintain operation. We immediately recognized deficiencies in the oil separation system as well as oil management system.
Plans and drawing’s were submitted and shortly there after approval for a fully Electronic Oil Management System. The system consists of a Duplex Optical Level Control to pulse oil request from a pair of High-Low Separators that were dedicated for separation of oil and reserving of oil. The separators utilized optical sensors to manage the oil from the high to the low side with the use of hold back valves for surety of oil into sumps of the “requesting” compressor. Oil scavenging was performed by an “active eductor jet” as apposed to the existing passive gravity drain. Oil removal at start up post retrofit approached nearly 1000lbs!!
Post start up, the compressor pull down was unprecedented as HBR resides were hot distilled during the recharge of the HFC-22 charge. The oil management system has performed as expected and “additions” of oil requirements has all but ceased.

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Click on Picture to see more photos

York LKC-73 Single Stage TurboMaster Overhaul

Service Engineer Robert Kane and S.E. Mike Santonocito were responsible for a 10 yr plus inspection on a single stage York 1200 ton compressor. The compressor was found with severe bearing wear, primarily on thrust collars and thrust faces, some exiting blade wear from liquid carryover found on the H.S. SS Impeller with associatted balance seal and nose seal journal wear. An NDE inspection noted spline cracks at the bull gears helical crown teeth, and to a lesser extent at the pinion.

The impellar is being HS balanced and has had the wearing nose seal areas sprayed and faired to dimensional clearances. The gears are being renewed with an OEM UL gear- set.

1800 HP Muray K Turbine Restoration

This turbine suffered a major failure at the initial blade staging due to the 2nd curtis stationary segment reversing blade loss. A stationary segment apparently loosened on a stand-off resulting in sequential segment failures and ultimate rotor blade damage to a catastrophic degree. Plans were approved to authorized ICACS to restore this, in entirety, including new reversing segments, remanufacture and repair of all diaphragm segments followed by reassembly and ancillary component upgrades and repairs. Look forward to our progress and accompanying photos.

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Ellis Island – 3rd of Three, CVHE070 Bearing Inspection and Gasket Renewal, 2006

The last of the (3) Trane Multistage CTV Chillers undergoes a 5-year internal component inspection, bearing replacment and gasket renewal. In addition, all (3) impellers are planned for LPI/NDE testing, balancing check and final dynamic balancing. The project work leaders are Senior Service Engineer Mike Santonocito and Service Engineer Robert Kane. This project is being performed for C&S Building Services Mr. John Caulkin.

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Trane 1550 Nominal Ton CenTraVac 5 Year Overhaul

This Project was performed byService Engineer Mike Santonocito and apprentice Joe Carachiolo manned the entire CVHB compressor overhaul with on again -off again support from S.E. Peter Recchia,and Sr S.E. DiDonna, especially during the large Volute to Motor o-ring renewals. The Overhaul was a planned service for the purpose of a 5yr bearing inspection and renewal of all o rings and gasketing which had experienced some recent compromise. Looking closely at the "tight-end" or "thrust side" motor bearing assembly you can notice the heat and carbon found as a result of poor axial thrust clearance on the slinger collar to thrust bearing. This clearance was found at .002", about .004" too tight. The condition was corrected, and motor/chiller assembly reassembled with new bearings, collars, slingers and labyrinths. Evacuations were ideal at nearly 300 microns and the chiller's charge was hot vapor distilled.

The machine was operating for the late July, early August '06 heat wave for the buildings convenience.

Elliot DYR

When ownership required a 45-day emergency turnaround overhaul on his Elliot 4EO-1 Multistage Turbine, he contacted Industrial Cooling Air Conditioning Service Agency. The scope initially included extensive rotor service, diaphragm inspection, bearing inspection, compressor side work, chiller side work and tube cleaning.

ICACS Service Engineers Peter Recchia, Robert Kane and Walter Cortes were responsible for the expeditious disassembly and inspection of all driveline components as well as routine chiller side service.

Upon final inspection, the turbine was found with significant FOD damage to blade shrouding, damaged and cracked diaphragm partitions, bearing liners wiped and thrust rings scarred and washed of babbit material, in addition, interstage and package gland carbons were so worn they were "ovalled".

The responsibility then passed on to all our vendors, including Dresser-Rand, General Electric and Unique Systems for rotor rework, diaphragm repair and new bearing thrust assembly reverse engineering to maintain an already tight schedule.

Senior Service Engineer Dominic DiDonna and Peter Recchia returned shortly with re-worked assemblies and dressed the rotor with all new components and bearings as well as refitting of repaired diaphragms - These services were performed well in advance of our pre-determined period, even in view of the unforeseen repair obstacles.

Some notes of interest include the dual stage, 4 blade Curtis assembly with only one sequential final stage. Looking closely at the diaphragm segments and reversing blades you can notice the condition of the renewed segments. Also you will find Senior Service Engineer Dominic DiDonna installing bearings with his indicator at his side insuring concentric runouts. Also Mr. Recchia's apparent "excitement" to get the cap off that turbine.

Click on Picture to see more photos

Click on Picture to see more photos

Trane 4500 Nom Ton LOCV Chillers and Murray K Series Multistage Turbine's Revitalization

Senior Service Engineer Dominic DiDonna and Service Engineer Michael Santonocito performing a 6 month ongoing drive line inspection and component overhaul of (4) Trane Large Open CenTraVac (LOCV) Chillers as well as (4) Murray K Series Multistage Condensing Turbines. These compressors were a "limited build" production compressor that utilize open type low speed Multistage rotor assemblies. The customer was interested in the overall condition and candidacy of the drivelines for both near-term and long-term plant line use. We proposed an initial inspection that was approached from a position of the lubrication, refrigerant, driveline, rotor, compressor and control systems evaluation and inspection.

Each "system" was inspected to drawing dimensions and/or specifications and presented for repair, component replacement and/or upgrade. The process of "revitalizing" these chiller for long term viability was decided upon and is well underway including, in part, turbine rotor re-work, seal renewal, bearing inspection, refrigerant side enhancements and testing of all components.

In addition, a plan for routine maintenance and upgrade retrofits will be presented to achieve both efficiency and reliability at a fraction of the cost to replace even one driveline.

Ellis Island

The (3) Trane Centravac Chillers at Ellis Island's Liberty State Park underwent major overhaul and modification. One chiller was converted from CFC-11 to HCFC-123 with an OEM Trane Engineered Conversion and controlled with a York OPTIview graphics display panel. The other chillers underwent a 5-year bearing replacement and major overhaul.
Service Engineers, Andres Cortes and Walter Cortes, performed the overhaul services, while Mike Santonocito and Dominic DiDonna performed New York's first OPTIview Panel installation, specifically designed, by York for the (3) stage Trane CVHE chiller. As you can see, the Engineering Staff seem quite pleased!

Bloomingdales -
Hackensack, New Jersey

Here we were asked to perform an emergency overhaul of a leaking Trane CVHE Chiller - just prior to the Cooling Season! The owner had concern over the time their current contractor expressed to perform this project. We assured them an expeditious and proficient turnaround with an almost immediate start date. Service Engineers, Andres Cortes and Mike Santonocito, delivered the overhauled chiller, from downtime to 42 degrees leaving fluid, in 8 working days, without any expenses for O.T.!!! The customer expressed his gratitude and claimed the machine "has not ever operated so well".