Emerson VSG Installation, Suction Inlet, Remote, Oil Separator, Oil Filter Open, Close, Valve

Page 41

SUCTION INLET

DISCHARGE OUTLET

Section 3 • Installation

PRIMING COMPRESSOR AND OIL FILTERS NOTE

Running the compressor oil pump at this point will help lubricate the compressor bearings and shaft seal surfaces.

(Reference Figure 3-20)

8.Open shut-off valve(s) (7) at oil ﬁlter inlet(s).

9.Close oil bypass shut-off valve (4).

10.Open oil mixing valve (6) via control panel. In Manual Mode, change “Manually Open (%)” value to “100”.

11.Run oil pump (5) for approximately 20 seconds only.

12.Stop oil pump and wait for a minimum of 30 min- utes. This will allow oil in the compressor (2) to drain and oil level (8) in separator (3) to settle.

NOTE

Oil mixing valve can remain in Manual Mode since the setpoint will change it to Auto mode. For further details, see PLC Compact Logix manual.

13.Refer to Pre Start-Up Checklist and ensure all items are ready prior to starting the compressor.

14.When ready, run compressor unit and allow it to reach normal operating temperature.

15.Using a properly selected oil pump, connect oil pump to suction oil charging valve (1). For suction oil charging valve location, see Figure 3-16.

16.Open suction oil charging valve (1) and ﬁll oil separa- tor (3) to Normal Operating Level.

17.Once the Normal Operating level has been reached, shut off the oil pump and close the suction oil charg- ing valve (1). Disconnect and remove oil pump.

NOTE

Oil separator does not need to be ﬁlled again until oil

level reaches Minimum Operating Level.

Every size of compressor will hold different amounts of oil, so amount of oil draining back into oil separator will vary.

18. More accurate ﬁll levels can be accomplished by marking the level on the oil separator (2) after cor- rect levels have been achieved during the unit oper- ation and when the compressor unit has been down for 1 hour.

SUCTION INLET

OIL RETURN LINE

PRESSURE EQUALIZING LINE

COALESCING

FG

001

	1	OIL CHARGE
PT	1	TE

001

001

BLEED

MOTOR

8

LG 001

OIL

1000W

TE	QE
005	101

			TE
			002
004			REMOTE
TE
			OIL COOLER
		COMPRESSOR	007
			TE
		2	VENT
		2
PT
002			QE
			QE
			007
BLEED		3
		3	TE
OIL SEPARATOR			DRAIN 003
			DRAIN 003
LG
002
1000W	QE	1000W
QE	QE	DRAIN
102	103	DRAIN
102	103

OIL FILTER	OPEN
7

OIL FILTER OPEN 7

		4	CLOSE
			CLOSE
	OPEN		MOTOR
	OIL MIXING	5	MOTOR
	OIL MIXING	5
	VALVE		OIL PUMP
	6
	PT		DRAIN
	004

BLEED

Figure 3-20. Priming Compressor and Oil Filters

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

3 – 21

Image 41

Contents VSG/VSSG compressor unit Installation, operation & maintenance manualPage VSG/VSSG Standard Vilter Warranty Statement Vilter Manufacturing LLC Important MessageREAD CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR 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 Figure 1-2. Gas Compressor Unit Components 1 of Section 1 General InformationCompressor Unit Component Identiﬁcation 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 3-Way Thermostatic Valve Symbols and IdentiﬁcationsPosition Transmitter 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&IDThis is a continuous cycle RTDs and Pressure TransducersControl System 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 RecommendationsAIR COOLED OIL COOLERS Compressor Unit Inspections Prior to Storage or InstallationRecommended Onsite Tools 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 PREFERRED Figure 3-14. Cooler Placement and SpacingFigure 3-13. Discharge Elevation of Coolers Initial Oil Charging Using Non -Vilter Oils Pressure TestingUnit Oil Charging and Priming Do not hydro test compressur unit. Failure to complyBypass Valve Normal Operating Level Maximum NON-Operating LevelMinimum Operating Level SUCTION INLET CLOSEOIL MIXING VALVE OPENInitial Oil Charging Section 3 InstallationPriming Remote Oil Cooler and Piping REMOTEMOTOR SUCTION INLETOIL FILTER OPEN 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 PLCCapacity Table 4-1. Command Shaft Rotation SpeciﬁcationsAngle/Slide Travel 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 OIL SEPARATOR Purging with Dry GasPressure Indicator 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 Centering Strap Coalescing Filter ReplacementCoalescing Filter View From Back of Oil Pump Strainer Oil Pump StrainerSize Drive Coupling Form-Flex BPU Hub InstallationTable 5-3. Shaft and Hub Distances 17. Install set screw in hub cap to secure key in keyway of shaft Drive Center Member Installation and AlignmentAngular Alignment Table 5-5. Disc Pack Installation Torque SpeciﬁcationsTable 5-4. Hub Clamp Bolt and Set Screw Torque Speciﬁcations 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 EdgeTable 5-9. Gate Rotor Tool Sets Gate Rotor Assembly Replacement All VSG & VSSG Compressors ExceptVSG 301-701 Compressors 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 5-24. Gate Rotor Blade Assembly Gate Rotor DisassemblyFigure 5-25. Gate Rotor Blade Installation Figure 5-26. Gate Rotor Thrust Bearing Figure 5-27. Thrust Bearing InstallationFigure 5-28. Roller Bearing Assembly Slide Valve Actuator Assembly ReplacementFigure 5-29. Command Shaft Seal Command Shaft Assembly ReplacementCommand Shaft Seal Replacement 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 Table 6-2. Slide Valve Actuator LED Blink Codes* 1 of Flash PatternMeaning 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 ProcessTorque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix A Torque SpecificationsTorque Specifications ft-lbs Appendix B Motor Compressor - General Storage Instructions Evaluation Appendix C Oil Analysis ReportPRODUCT ANALYSIS REPORT No Action RequiredAppendix D Recommended Header Piping INLET ON BOTTOM Appendix E Recommended Remote Air Cooled Oil Cooler PipingOUTLET ON TOP Blank