Emerson VSG, VSSG manual Installation, Delivery Inspection, Rigging and Lifting of Compressor Unit

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Section 3 • Installation

Section 3 • Installation

Delivery Inspection

All equipment supplied by Vilter are thoroughly inspect- ed at the factory. However, damage can occur in ship- ment. For this reason, the units should be thoroughly inspected upon arrival, prior to off-loading. Any dam- age noted should be photographed and reported im- mediately to the transportation company. This way, an authorized agent can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays. At the same time, the local Vilter representative or the home ofﬁce should be notiﬁed of any claims made within ten (10) days after its discovery. Refer to long term storage for additional recommendations.

Rigging and Lifting of Compressor

Unit

WARNING

Whenriggingandliftingacompressorunit,useproper lifting device capable of lifting and maneuvering the weight and size of the compressor unit. Use only qualiﬁed personnel and additional personnel and lifting equipment (i.e. spreader bar) as required. Failure to comply may result in death, serious injury

and/or damage to equipment.

Only qualiﬁed personnel shall operate rigging and lift- ing equipment. Ensure that the lifting device is capable of lifting the weight of the compressor unit, refer to the supplied Vilter General Assembly (GA) drawing.

To lift the compressor unit, use lifting points on com- pressor unit frame to attach the lifting device, see Figure 3-1. There are a few points to consider prior to moving the unit:

•Ensure that the weight is evenly distributed amongst the lifting device (i.e. lifting chains and spreader bar) prior to lifting.

•Ensure that the lifting device is not obstructed by any parts of the compressor unit to prevent damage to components.

•Use additional personnel as needed to spot and aid in maneuvering the compressor unit.

•Ensure there is plenty of space to maneuver the com- pressor unit and a clear path to its location.

Lifting Point

Use lifting chains/straps and spreader bar. Evenly distribute weight. Keep lifting chains and spreader bar clear of components to prevent damage.

Figure 3-1. Rigging and Lifting Points

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

3 – 1

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Contents VSG/VSSG compressor unit Installation, operation & maintenance manualPage VSG/VSSG Standard Vilter Warranty Statement Important Message READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSORVilter Manufacturing LLC Section 3 Installation Table of ContentsSection Title Section 1 General InformationSection 6 Troubleshooting Section 5 Maintenance/ServiceSection Number Section 4 OperationList of Tables and Figures Section 7 Warranty and PartsAppendices Table/FigureFigure 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 Section 1 General Information Compressor Unit Component IdentiﬁcationFigure 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 Symbols and Identiﬁcations Position Transmitter3-Way Thermostatic Valve High Side Float Valve Steady-Mount Bulb & Capillary 1 - 10 / Blank Gas Flow Section 2 Theory of OperationOil Life and Oil Flow Figure 2-1. Gas Compressor Unit P&IDRTDs and Pressure Transducers Control SystemThis is a continuous cycle Delivery Inspection Section 3 InstallationRigging and Lifting of Compressor Unit Figure 3-1. Rigging and Lifting PointsThe following are recommendations regarding long term storage Long Term Storage RecommendationsCompressor Unit Inspections Prior to Storage or Installation Recommended Onsite ToolsAIR COOLED OIL COOLERS Compressor has been placed in operation as of LONG TERM STORAGE LOGFoundation Materials FoundationConsiderations Prior to Starting Building the Foundationof 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 2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT Figure 3-6. Housekeeping Pad Dimension Detail - Top ViewLEVEL COMPRESSOR UNIT HOUSEKEEPING PADS010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 PipingNozzle Dia. in Table 3-2. Maximum Allowable Flange LoadsFz lbf Fy lbfONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION Figure 3-14. Cooler Placement and Spacing Figure 3-13. Discharge Elevation of CoolersPREFERRED Initial Oil Charging Using Non -Vilter Oils Pressure TestingUnit Oil Charging and Priming Do not hydro test compressur unit. Failure to complyNormal Operating Level Maximum NON-Operating Level Minimum Operating LevelBypass Valve CLOSE OIL MIXINGSUCTION INLET VALVE OPENInitial Oil Charging Section 3 InstallationPriming Remote Oil Cooler and Piping REMOTESUCTION INLET OIL FILTER OPENMOTOR Pre Start-Up Checklist Section 3 Installation Pre Start-Up15. Verify that all valves are in the open position Section 3 Installation Start-Up Operation Section 4 OperationOil Inspection Dual Oil FiltersStopping/Restarting Control System CalibrationStarting, Stopping and Restarting the Compressor Starting Calibrate Slide Valve ActuatorsFigure 4-2. Actuator Assembly Section 4 Operation Figure 4-5. Photo-chopper Figure 4-4. Slide Valve Calibration Screen Compact Logix PLCTable 4-1. Command Shaft Rotation Speciﬁcations Angle/Slide TravelCapacity 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 Purging with Dry Gas Pressure IndicatorOIL 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 Oil Circuit Table 5-1. Maintenance/Service ScheduleUnit ControlMaintenance/Service Section 5 Maintenance/ServiceMaintaining Proper Operation Compressor Unit Isolation forCompressor Unit Leak Check Use Vilter Oil Analysis Kit VPN 3097A to collect an oil Oil System Components Oil Samplingsample for analysis. For an example, see Figure 5-2. Fill Send samples immediately to the oil analysis lab afterOil Charging Single Oil Filter Assembly Oil Filter ReplacementDual Oil Filter Assembly Oil DrainingVent Valve Drain Valve Inlet Shut-Off Valves Coalescing Filter Replacement Coalescing FilterCentering Strap View From Back of Oil Pump Strainer Oil Pump StrainerDrive Coupling Form-Flex BPU Hub Installation Table 5-3. Shaft and Hub DistancesSize 17. Install set screw in hub cap to secure key in keyway of shaft Drive Center Member Installation and AlignmentTable 5-5. Disc Pack Installation Torque Speciﬁcations Table 5-4. Hub Clamp Bolt and Set Screw 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 InspectionsTable 5-7. Maximum Bearing Float Gate Rotor Float and Gate Rotor Bearing Float InspectionFigure 5-12. Bearing Radial Float Inspection Figure 5-13. Gate Rotor FloatFigure 5-14. Gate Rotor Bearing Float Table 5-8. Gate Rotor FloatApplied Force Rigidly attach dial indicator Use bolt for fulcurm Gate rotor bearing float being measuredFigure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Section 5 Maintenance/Service Gate Rotor and Support ClearanceGate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor Figure 5-16. Gate Rotor and Support Clearance - MeasuringGate Rotor Support Gate Rotor Straight Edge Straight Edge Straight EdgeGate Rotor Assembly Replacement All VSG & VSSG Compressors Except VSG 301-701 CompressorsTable 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 ClearanceGate Rotor Disassembly Figure 5-25. Gate Rotor Blade InstallationFigure 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 Assembly Replacement Command Shaft Seal ReplacementFigure 5-29. Command Shaft Seal Figure 5-30. Command Shaft Seal Installation Problem Section 6 TroubleshootingSolution Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 ofTable 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Flash Pattern MeaningTable 6-2. Slide Valve Actuator LED Blink Codes* 1 of will not move while this error code is displayed. To clear the error er before the calibration procedure was completed. The actuatorcalibrate the actuator. If this error has occurred and the cause was not the loss of 24V power during calibration, possible causes areTable 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 Claim Processing Section 7 Warranty and PartsOn Site Service Support Warranty does not cover labor and extraneous expensesRequest a “VSG Single Screw Compressor Rebuild Form” Remanufactured Gas Bare Shaft Compressor ProcessAppendix A Torque Specifications Torque Specifications ft-lbsTorque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix B Motor Compressor - General Storage Instructions Evaluation Appendix C Oil Analysis ReportPRODUCT ANALYSIS REPORT No Action RequiredAppendix D Recommended Header Piping Appendix E Recommended Remote Air Cooled Oil Cooler Piping OUTLET ON TOPINLET ON BOTTOM Blank