Emerson VSG Theory of Operation, Gas Flow, Oil Life and Oil Flow, 1. Gas Compressor Unit P&ID

Page 19
Section 2 • Theory of Operation

Section 2 • Theory of Operation

1

2

3

4

5

 

 

 

 

SUCTION GAS

 

 

 

 

 

6

 

 

 

TE

 

 

 

CHECK DISCHARGE

 

 

 

 

 

 

VALVE

STOP VALVE

 

1/4” OIL CHARGING

 

 

 

 

 

 

 

 

COMPRESSOR

 

 

TE

 

 

BLEED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTOR

 

 

 

 

1/4”

 

 

 

 

 

 

 

 

 

 

 

 

14

13

 

 

 

 

BLEED

 

 

 

 

15

 

 

 

 

 

OIL SEPARATOR

 

 

 

 

 

 

 

 

 

 

TE

 

12

 

 

 

 

 

 

 

 

 

 

FILTER

 

 

 

 

11

 

 

 

 

STANDARD SINGLE

TE

 

 

BLEED

DRAIN

 

 

OIL FILTER

 

100#

 

 

DRAIN

 

 

MOTOR

7

 

 

 

 

 

 

 

 

 

BLEED

 

 

M

 

 

 

 

 

 

 

FG

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

PUMP

 

FILTER

DRAIN

 

 

 

 

 

 

 

 

 

 

 

8

 

 

 

FILTER

 

 

 

 

OPTIONAL DUAL OIL FILTERS

DRAIN

 

 

 

 

 

 

 

 

 

 

 

 

 

10

9

OPTIONAL REMOTE AIR COOLED OIL COOLER

 

VENT

 

OIL COOLER

OIL

DRAIN

DRAIN

 

STANDARD WATER COOLED OIL COOLER

Figure 2-1. Gas Compressor Unit P&ID

The gas and oil systems work in unison, but each one will be explained separately. Reference Figure 3 - Gas Compressor Unit P&ID for gas and oil flow descriptions.

Gas Flow

The gas compression process begins as processed gas enters the suction inlet (1). The processed gas flows through a stop valve (2), check valve (3) then through a suction line strainer (4) to the compressor (14). The processed gas is then pressurized through the compres- sor and discharged as high pressure gas vapor into the oil separator (13). In the oil separator, the oil is then separated from the discharged gas vapor by impinge- ment separation. The high pressure gas flows out to

the aftercooler and scrubber for cooling while the oil is pumped or syphoned back to the compressor.

Moreover, check valves (3) and (6) are provided between the oil separator to prevent gas vapor or liquid from flow- ing back to the compressor during shutdown periods.

An equalizing line is also installed between the high pressure side (oil separator) and low pressure side (suc-

tion) to allow .

Oil Life and Oil Flow

The life of the oil is directly affected by the quality of the gas. Proper separation of any liquids must be accom- plished to prevent droplets of liquid at the compressor

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

2 – 1

Page 18 Page 20
Image 19
Page 18 Page 20
Contents VSG/VSSG compressor unit Installation, operation & maintenance manualPage VSG/VSSG Standard Vilter Warranty Statement READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR Important MessageVilter Manufacturing LLC Section 1 General Information Table of ContentsSection 3 Installation Section TitleSection 4 Operation Section 5 Maintenance/ServiceSection 6 Troubleshooting Section NumberTable/Figure Section 7 Warranty and PartsList of Tables and Figures AppendicesFigure 3-12. Installation of Coolers - Next to Buildling Section 1 General Information How To Use This Manual Figure 1-1. Gas Compressor Unit Model Designation Section 1 General Information Gas Compressor Unit Model DesignationsSection 1 General Information System Unit Identification Compressor Unit Component Identification Section 1 General InformationFigure 1-2. Gas Compressor Unit Components 1 of Figure 1-2. Gas Compressor Unit Components 2 of Figure 1-2. Gas Compressor Unit Components 3 of Section 1 General Information Component Identification ContinuedSection 1 General Information Piping & Identification Component Tags Position Transmitter Symbols and Identifications3-Way Thermostatic Valve High Side Float Valve Steady-Mount Bulb & Capillary 1 - 10 / Blank Figure 2-1. Gas Compressor Unit P&ID Section 2 Theory of OperationGas Flow Oil Life and Oil FlowControl System RTDs and Pressure TransducersThis is a continuous cycle Figure 3-1. Rigging and Lifting Points Section 3 InstallationDelivery Inspection Rigging and Lifting of Compressor UnitThe following are recommendations regarding long term storage Long Term Storage RecommendationsRecommended Onsite Tools Compressor Unit Inspections Prior to Storage or InstallationAIR COOLED OIL COOLERS Compressor has been placed in operation as of LONG TERM STORAGE LOGBuilding the Foundation FoundationFoundation Materials Considerations Prior to Startingof both Check the ability of the soil to carry the load Compressor Unit Installationrecommendations for setting, precautions, mixing, and Leveling and GroutingAdditional Information Codes and Standards COMPRESSOR UNIT HOUSEKEEPING PADS Figure 3-6. Housekeeping Pad Dimension Detail - Top View2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT LEVEL010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 PipingFy lbf Table 3-2. Maximum Allowable Flange LoadsNozzle Dia. in Fz lbfONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION Figure 3-13. Discharge Elevation of Coolers Figure 3-14. Cooler Placement and SpacingPREFERRED Do not hydro test compressur unit. Failure to comply Pressure TestingInitial Oil Charging Using Non -Vilter Oils Unit Oil Charging and PrimingMinimum Operating Level Normal Operating Level Maximum NON-Operating LevelBypass Valve OIL MIXING CLOSESUCTION INLET VALVE OPENREMOTE Section 3 InstallationInitial Oil Charging Priming Remote Oil Cooler and PipingOIL FILTER OPEN SUCTION INLETMOTOR Pre Start-Up Checklist Section 3 Installation Pre Start-Up15. Verify that all valves are in the open position Section 3 Installation Start-Up Dual Oil Filters Section 4 OperationOperation Oil InspectionCalibrate Slide Valve Actuators Control System CalibrationStopping/Restarting Starting, Stopping and Restarting the Compressor StartingFigure 4-2. Actuator Assembly Section 4 Operation Figure 4-5. Photo-chopper Figure 4-4. Slide Valve Calibration Screen Compact Logix PLCAngle/Slide Travel Table 4-1. Command Shaft Rotation SpecificationsCapacity 18. Press the “Set Max” button Oil Temperature Control Valve Oil Mixing Valve OperationFail Position Purging with Dry Nitrogen 10. Close discharge bleed valve while still purging Pressure Indicator Purging with Dry GasOIL SEPARATOR Section 4 Operation Figure 4-13. Suction Oil Charging Valve Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction OilCoalescing Oil Return Line Setup Control Table 5-1. Maintenance/Service ScheduleOil Circuit UnitCompressor Unit Isolation for Section 5 Maintenance/ServiceMaintenance/Service Maintaining Proper OperationCompressor Unit Leak Check Send samples immediately to the oil analysis lab after Oil System Components Oil SamplingUse Vilter Oil Analysis Kit VPN 3097A to collect an oil sample for analysis. For an example, see Figure 5-2. FillOil Charging Oil Draining Oil Filter ReplacementSingle Oil Filter Assembly Dual Oil Filter AssemblyVent Valve Drain Valve Inlet Shut-Off Valves Coalescing Filter Coalescing Filter ReplacementCentering Strap View From Back of Oil Pump Strainer Oil Pump StrainerTable 5-3. Shaft and Hub Distances Drive Coupling Form-Flex BPU Hub InstallationSize 17. Install set screw in hub cap to secure key in keyway of shaft Drive Center Member Installation and AlignmentTable 5-4. Hub Clamp Bolt and Set Screw Torque Specifications Table 5-5. Disc Pack Installation Torque SpecificationsAngular Alignment Drive Coupling Form-Flex BPU Center Member and Hub Removal Drive Coupling Type C Sure-Flex ReplacementTable 5-6. Clamping Bolts and Set Screw Torque Specifications Compressor ReplacementLock Washer Figure 5-11. Bearing Axial Float Inspection Compressor Shaft Bearing Float InspectionsFigure 5-13. Gate Rotor Float Gate Rotor Float and Gate Rotor Bearing Float InspectionTable 5-7. Maximum Bearing Float Figure 5-12. Bearing Radial Float InspectionGate rotor bearing float being measured Table 5-8. Gate Rotor FloatFigure 5-14. Gate Rotor Bearing Float Applied Force Rigidly attach dial indicator Use bolt for fulcurmFigure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Section 5 Maintenance/Service Gate Rotor and Support ClearanceStraight Edge Straight Edge Straight Edge Figure 5-16. Gate Rotor and Support Clearance - MeasuringGate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor Gate Rotor Support Gate RotorVSG 301-701 Compressors Gate Rotor Assembly Replacement All VSG & VSSG Compressors ExceptTable 5-9. Gate Rotor Tool Sets Figure 5-18. Gate Rotor Assembly Removal Figure 5-17. Gate Rotor Assembly Removal and ToolsFigure 5-20. Gate Rotor and Shelf Clearance Figure 5-19. Gate Rotor Assembly and ToolsFigure 5-21. Gate Rotor Assembly Breakdown Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLYFigure 5-22. Gate Rotor Thrust Bearing Figure 5-23. Gate Rotor and Shelf ClearanceFigure 5-25. Gate Rotor Blade Installation Gate Rotor DisassemblyFigure 5-24. Gate Rotor Blade Assembly Figure 5-26. Gate Rotor Thrust Bearing Figure 5-27. Thrust Bearing InstallationFigure 5-28. Roller Bearing Assembly Slide Valve Actuator Assembly ReplacementCommand Shaft Seal Replacement Command Shaft Assembly ReplacementFigure 5-29. Command Shaft Seal Figure 5-30. Command Shaft Seal Installation Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of Section 6 TroubleshootingProblem SolutionTable 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Meaning Flash PatternTable 6-2. Slide Valve Actuator LED Blink Codes* 1 of not the loss of 24V power during calibration, possible causes are er before the calibration procedure was completed. The actuatorwill not move while this error code is displayed. To clear the error calibrate the actuator. If this error has occurred and the cause wasTable 6-3. Troubleshooting Guide - General Problems & Solutions 1 of Table 6-3. Troubleshooting Guide - General Problems & Solutions 2 of Table 6-3. Troubleshooting Guide - General Problems & Solutions 3 of 6 - 8 / Blank Warranty does not cover labor and extraneous expenses Section 7 Warranty and PartsWarranty Claim Processing On Site Service SupportRequest a “VSG Single Screw Compressor Rebuild Form” Remanufactured Gas Bare Shaft Compressor ProcessTorque Specifications ft-lbs Appendix A Torque SpecificationsTorque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix B Motor Compressor - General Storage Instructions No Action Required Appendix C Oil Analysis ReportEvaluation PRODUCT ANALYSIS REPORTAppendix D Recommended Header Piping OUTLET ON TOP Appendix E Recommended Remote Air Cooled Oil Cooler PipingINLET ON BOTTOM Blank
Top Page Image Contents