Emerson VSG, VSSG manual Table of Contents, Section Title, General Information, Theory of Operation

Page 5
Table of Contents

Table of Contents

Section Title

Section Number

VSG/VSSG Standard Vilter Warranty Statement

i

Important Message

ii

Section 1 • General Information

 

How To Use This Manual

1-1

Gas Compressor Unit Model Designations

1-2

System Unit Identification

1-3

Compressor Unit Component Identification

1-4

Piping & Identification Component Tags

1-7

Symbols and Identification

1-8

Section 2 • Theory of Operation

 

Gas Flow

2-1

Oil Life and Oil Flow

2-1

Oil Pressure Regulating

2-2

Control System

2-2

RTDs and Pressure Transducers

2-2

Section 3 • Installation

 

Delivery Inspection

3-1

Rigging and Lifting

3-1

Short Term Storage Recommendations

3-2

Long Term Storage Recommendations

3-2

Compressor Motor

3-2

Air Cooled Oil Coolers

3-3

Compressor Unit Inspections Prior to Stoarge or Installation

3-3

Recommended Onsite Tools

3-3

Long Term Storage Log

3-4

Foundation

3-5

Piping

3-10

Header Piping and Drains

3-10

Remote Air Cooled Oil Cooler Piping

3-10

General Installation Guideline for Multiple Air Coolers Installed in a Common Area

3-12

Free Flow

3-12

One Fan Diameter

3-12

Intake Velocity

3-12

Hot Air Recirculation

3-14

Pressure Testing

3-16

Initial Oil Charging

3-16

Using Non-Vilter Oils

3-16

Unit Oil Charging and Priming

3-16

Priming Oil Cooler (Shell and Tube)and Piping

3-16

Priming Compressor and Oil Filters

3-18

Priming Remote Oil Cooler and Piping (Initial Oil Charging)

3-20

Priming Compressor and Oil Filters

3-21

Pre Start-Up

3-22

Start-Up

3-24

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

TOC - 1

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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
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