Emerson VSSG, VSG Pressure Testing, Initial Oil Charging Using Non -Vilter Oils, Installation

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Pressure Testing

Section 3 • Installation

Pressure Testing

NOTICE

CAUTION

Do not hydro test compressur unit. Failure to comply

may result in damage to equipment.

CAUTION

The compressor unit along with other system units contain many components with various pressure ratings. Pressure relief protection provided considers the design pressure of a system components. Before replacing a pressure relief valve with a relief valve having a higher presure setting, all system

components must be evaluated for acceptability.

Pressure test in compliance with Chapter VI of the ASME B31.3 Process Piping Code.

Initial Oil Charging

Using Non -Vilter Oils

CAUTION

Do not mix oils. Failure to comply may result in

damage to equipment.

NOTICE

Vilter does not approve non-Vilter oils for use with Vilter compressors. Use of oils not specified or supplied by Vilter will void the compressor warranty.

Due to the need for adequate lubrication, Vilter recom- mends only the use of Vilter lubricants, designed spe- cifically for Vilter compressors. With extensive research that has been performed, we are able to offer gas com- pression lubricating oils. Use of oil not specified or sup- plied by Vilter will void the compressor warranty.

Please contact your local Vilter representative or the Home Office for further information.

Unit Oil Charging and Priming

WARNING

Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply may result in serious injury or death.

Failure to follow these instructions will result in bearing damage and compressor seizing and will void any and all warranties that may apply.

Typically, the compressor unit is shipped from Vilter with no oil charge. The normal operating level is between the two sight glasses on the oil separator, see Figure 3-15. Refer to supplied GA drawing for unit specific oil charge requirement.

For regular oil charging and draining procedures, see Section 5.

Tool Required:

•Oil Pump, Maximum 2-3 GPM with Motor approved for Division 1 or Division 2 and with ability to over- come suction pressure.

(Reference Figure 3-17)

1.At initial start up, compressor unit must be off and depressurized prior to initial oil charging.

2.Using a properly selected oil pump, connect oil pump to oil separator drain valve (4). For oil separa- tor drain valve location, see Figure 3-16.

3.Open oil separator drain valve (4) and fill oil separa- tor (3) to Maximum NON-Operating Level.

4.Once Maximum NON-Operating Level has been reached, shut off oil pump, close oil separator drain valve (4) and remove oil pump.

5.If equipped with remote oil cooler, refer to Priming Remote Oil Cooler and Piping procedure.

PRIMING OIL COOLER (SHELL AND TUBE) AND PIPING

If equipped with a shell and tube oil cooler, continue with the following steps:

6.Close shut-off valve (8) at oil filter inlet. Do the same for second oil filter, if equipped with dual oil filters. For shut-off valve location, see Figure 3-16.

7.Open oil bypass shut-off valve (5). For oil cooler by- pass valve location, see Figure 3-16.

8.Energize compressor unit.

9.Close oil mixing valve (oil temp. control valve) (7) via control panel. In Manual Mode, change “Manually Open (%)” value to “0”.

NOTE

The oil cooler is considered primed when the oil

level in the separator is constant.

10.Run the oil pump (6) twice for 1-2 minutes. Repeat this step until the oil level (9) is constant.

3 – 16

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

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Contents Installation, operation & maintenance manual VSG/VSSG compressor unitPage VSG/VSSG Standard Vilter Warranty Statement Important Message READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSORVilter Manufacturing LLC Table of Contents Section 3 InstallationSection Title Section 1 General InformationSection 5 Maintenance/Service Section 6 TroubleshootingSection Number Section 4 OperationSection 7 Warranty and Parts List of Tables and FiguresAppendices Table/FigureFigure 3-12. Installation of Coolers - Next to Buildling Section 1 General Information How To Use This Manual Section 1 General Information Gas Compressor Unit Model Designations Figure 1-1. Gas Compressor Unit Model DesignationSection 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 Section 1 General Information Component Identification Continued Figure 1-2. Gas Compressor Unit Components 3 ofSection 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 Section 2 Theory of Operation Gas FlowOil Life and Oil Flow Figure 2-1. Gas Compressor Unit P&IDRTDs and Pressure Transducers Control SystemThis is a continuous cycle Section 3 Installation Delivery InspectionRigging and Lifting of Compressor Unit Figure 3-1. Rigging and Lifting PointsLong Term Storage Recommendations The following are recommendations regarding long term storageCompressor Unit Inspections Prior to Storage or Installation Recommended Onsite ToolsAIR COOLED OIL COOLERS LONG TERM STORAGE LOG Compressor has been placed in operation as ofFoundation Foundation MaterialsConsiderations Prior to Starting Building the FoundationCompressor Unit Installation of both Check the ability of the soil to carry the loadLeveling and Grouting recommendations for setting, precautions, mixing, andAdditional Information Codes and Standards Figure 3-6. Housekeeping Pad Dimension Detail - Top View 2 - # CLOSED TIES CENTER LINE 5 - # 6 VERTLEVEL COMPRESSOR UNIT HOUSEKEEPING PADSPiping 010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5Table 3-2. Maximum Allowable Flange Loads Nozzle Dia. inFz lbf Fy lbfONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION Figure 3-14. Cooler Placement and Spacing Figure 3-13. Discharge Elevation of CoolersPREFERRED Pressure Testing Initial Oil Charging Using Non -Vilter OilsUnit 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 OPEN VALVESection 3 Installation Initial Oil ChargingPriming Remote Oil Cooler and Piping REMOTESUCTION INLET OIL FILTER OPENMOTOR Section 3 Installation Pre Start-Up Pre Start-Up Checklist15. Verify that all valves are in the open position Section 3 Installation Start-Up Section 4 Operation OperationOil Inspection Dual Oil FiltersControl System Calibration Stopping/RestartingStarting, Stopping and Restarting the Compressor Starting Calibrate Slide Valve ActuatorsFigure 4-2. Actuator Assembly Section 4 Operation Figure 4-4. Slide Valve Calibration Screen Compact Logix PLC Figure 4-5. Photo-chopperTable 4-1. Command Shaft Rotation Specifications Angle/Slide TravelCapacity Oil Temperature Control Valve Oil Mixing Valve Operation 18. Press the “Set Max” buttonFail Position Purging with Dry Nitrogen 10. Close discharge bleed valve while still purging Purging with Dry Gas Pressure IndicatorOIL SEPARATOR Section 4 Operation Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction Oil Figure 4-13. Suction Oil Charging ValveCoalescing Oil Return Line Setup Table 5-1. Maintenance/Service Schedule Oil CircuitUnit ControlSection 5 Maintenance/Service Maintenance/ServiceMaintaining Proper Operation Compressor Unit Isolation forCompressor Unit Leak Check Oil System Components Oil Sampling Use Vilter Oil Analysis Kit VPN 3097A to collect an oilsample for analysis. For an example, see Figure 5-2. Fill Send samples immediately to the oil analysis lab afterOil Charging Oil Filter Replacement Single Oil Filter AssemblyDual Oil Filter Assembly Oil DrainingVent Valve Drain Valve Inlet Shut-Off Valves Coalescing Filter Replacement Coalescing FilterCentering Strap Oil Pump Strainer View From Back of Oil Pump StrainerDrive Coupling Form-Flex BPU Hub Installation Table 5-3. Shaft and Hub DistancesSize Drive Center Member Installation and Alignment 17. Install set screw in hub cap to secure key in keyway of shaftTable 5-5. Disc Pack Installation Torque Specifications Table 5-4. Hub Clamp Bolt and Set Screw Torque SpecificationsAngular Alignment Drive Coupling Type C Sure-Flex Replacement Drive Coupling Form-Flex BPU Center Member and Hub RemovalCompressor Replacement Table 5-6. Clamping Bolts and Set Screw Torque SpecificationsLock Washer Compressor Shaft Bearing Float Inspections Figure 5-11. Bearing Axial Float InspectionGate Rotor Float and Gate Rotor Bearing Float Inspection Table 5-7. Maximum Bearing FloatFigure 5-12. Bearing Radial Float Inspection Figure 5-13. Gate Rotor FloatTable 5-8. Gate Rotor Float Figure 5-14. Gate Rotor Bearing FloatApplied Force Rigidly attach dial indicator Use bolt for fulcurm Gate rotor bearing float being measuredSection 5 Maintenance/Service Gate Rotor and Support Clearance Figure 5-15. Gate Rotor and Support Clearance - Minimum ClearancesFigure 5-16. Gate Rotor and Support Clearance - Measuring Gate Rotor Support Gate Rotor Gate Rotor Support Gate RotorGate 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 5-17. Gate Rotor Assembly Removal and Tools Figure 5-18. Gate Rotor Assembly RemovalFigure 5-19. Gate Rotor Assembly and Tools Figure 5-20. Gate Rotor and Shelf ClearanceGate Rotor Assembly Replacement VSG 301-701 Compressors ONLY Figure 5-21. Gate Rotor Assembly BreakdownFigure 5-23. Gate Rotor and Shelf Clearance Figure 5-22. Gate Rotor Thrust BearingGate Rotor Disassembly Figure 5-25. Gate Rotor Blade InstallationFigure 5-24. Gate Rotor Blade Assembly Figure 5-27. Thrust Bearing Installation Figure 5-26. Gate Rotor Thrust BearingSlide Valve Actuator Assembly Replacement Figure 5-28. Roller Bearing AssemblyCommand Shaft Assembly Replacement Command Shaft Seal ReplacementFigure 5-29. Command Shaft Seal Figure 5-30. Command Shaft Seal Installation Section 6 Troubleshooting ProblemSolution 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 er before the calibration procedure was completed. The actuator will not move while this error code is displayed. To clear the errorcalibrate 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 Section 7 Warranty and Parts Warranty Claim ProcessingOn Site Service Support Warranty does not cover labor and extraneous expensesRemanufactured Gas Bare Shaft Compressor Process Request a “VSG Single Screw Compressor Rebuild Form”Appendix A Torque Specifications Torque Specifications ft-lbsTorque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix B Motor Compressor - General Storage Instructions Appendix C Oil Analysis Report EvaluationPRODUCT ANALYSIS REPORT No Action RequiredAppendix D Recommended Header Piping Appendix E Recommended Remote Air Cooled Oil Cooler Piping OUTLET ON TOPINLET ON BOTTOM Blank
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