Emerson VSG, VSSG manual Purging with Dry Gas, Operation, Pressure Indicator, Oil Separator

Page 55
Purging with Dry Gas

Section 4 • Operation

Purging with Dry Gas

NOTICE

Purging is recommended if the compressor will be inactive for 12 hours or more. For additional long term storage information, refer to Long Term Storage Recommendations in Section 3.

PREPARATION

WARNING

When working with LFG, NG or other dangerous or flammable gases, ensure there are adequate ventilation and vapor detectors. Refer to national fire and building codes. Failure to comply may result in serious injury or death.

WARNING

When working pressured systems, always wear safety glasses and/or face shield. Failure to comply may result in serious injury.

To purge the compressor unit using a dry gas (i.e. methane), a purge line must be installed. If there is not enough purge pressure, connect purge line to a lower pressure line or to atmosphere. The purge line, associated valves and gauges are not provided from the

factory and must be installed by the customer.

1.Refer to Figure 4-10 for recommended purge line design.

2.Press “Stop” button to stop compressor unit, see Figure 4-11.

3.If equipped with equalizing solenoid, allow pres- sure in compressor unit to equalize to suction pres- sure, see Figure 4-12.

4.If equipped with manual suction bypass valve and it is not open, open suction bypass valve. Allow pressure in compressor unit to equalize to suction pressure.

5.Close suction and discharge shut-off valves to isolate the compressor unit from house system. Lockout/tagout valves.

To Lower Pressure Line or

PI

Pressure Indicator

Atmosphere. See NOTICE.

002

Shut-off Valve

 

Check Valve

 

Shut-off Valve

 

 

 

 

 

 

Drain Valve

 

 

 

 

PI

 

 

002

 

PURGE LINE

SUCTION INLET

 

DRAIN

 

 

 

 

PRESSURE EQUALIZING LINE

 

OIL RETURN LINE

 

 

COALESCING

FG

 

 

001

 

 

 

 

 

 

DISCHARGE OUTLET

 

 

 

 

 

TE

 

 

 

 

 

 

 

002

 

 

OIL CHARGE

 

 

 

 

REMOTE

 

PT

001

004

 

 

 

 

001

TE

TE

 

 

 

 

 

 

 

 

 

 

 

BLEED

 

 

 

 

OIL COOLER

 

MOTOR

 

 

 

COMPRESSOR

TE

 

 

 

 

 

 

007

VENT

 

 

 

PT

 

 

 

 

 

 

 

002

 

 

QE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

007

 

 

 

 

BLEED

 

 

 

 

 

 

 

OIL SEPARATOR

 

 

TE

 

 

 

DRAIN

003

 

LG

 

 

 

 

 

 

 

001

 

 

 

 

 

 

 

 

LG

 

 

 

 

 

 

 

002

 

 

 

 

 

TE

1000W

1000W

QE

1000W

 

 

 

QE

QE

 

 

 

 

005

101

102

103

DRAIN

 

 

 

 

 

 

 

 

 

 

Figure 4-10. Customer Purge Line

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

4 – 11

Image 55
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