Emerson VSG, VSSG manual Oil Charging, Maintenance/Service

Page 63
Oil Charging

Section 5 • Maintenance/Service

Oil Charging

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.

1.Using a properly selected oil pump, connect oil pump to suction oil charging valve, see Figure 5-3.

2.Open suction oil charging valve and fill oil separator to Normal Operating Level.

3.Once the Normal Operating Level has been reached, shut off the oil pump and close the valve. Disconnect and remove oil pump.

CAUTION

Do not add oil to the coalescent side of the oil separator. Failure to comply may result in damage to equipment.

Normal oil level operating range must be maintained for optimum performance and to prevent damage to equip- ment. See Figure 4-1. for normal operating levels. There are a couple of ways to maintain oil, while the compres- sor unit is in operation and during shutdown.

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.

Charging During Operation:

During operation, if the oil level is low, add oil to the operating compressor through the suction oil charging valve, see Figure 5-3. Pump oil into the compressor until the oil level reaches the normal operating level. Watch this level carefully to maintain proper operation. Never allow the oil to reach a level higher than the Maximum Operating Level, since this may impair the operation and efficiency.

Charging During Shutdown:

During shutdown, if oil is to be added, charging can be performed through the drain valve located underneath the oil separator, see Figure 5-3. During shutdown, oil can be added to the Maximum Non-Operating Level. For shutdown procedure, see Compressor Unit Isolation procedure.

1.Using a properly selected oil pump, connect oil pump to oil separator drain valve.

2.Open oil separator drain valve and fill oil separator to Maximum NON-Operating Level.

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

View Rotate 180°

Suction Oil

Oil Drain Valve

Charging Valve

(Oil Separator)

Oil Drain Valve

(Oil Cooler)

Oil Filter Shut-Off Valves

View From Back - View Rotate 180°

Figure 5-3. Suction Oil Charging Valve, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves

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

5 – 5

Page 62 Page 64
Image 63
Page 62 Page 64
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 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 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 Figure 2-1. Gas Compressor Unit P&ID Section 2 Theory of OperationGas Flow Oil Life and Oil FlowRTDs and Pressure Transducers Control SystemThis 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 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 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 3-14. Cooler Placement and Spacing Figure 3-13. Discharge Elevation of CoolersPREFERRED Do not hydro test compressur unit. Failure to comply Pressure TestingInitial Oil Charging Using Non -Vilter Oils Unit Oil Charging and PrimingNormal Operating Level Maximum NON-Operating Level Minimum Operating LevelBypass Valve CLOSE OIL MIXINGSUCTION INLET VALVE OPENREMOTE Section 3 InstallationInitial Oil Charging Priming Remote Oil Cooler and PipingSUCTION 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 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 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 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 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 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 RotorGate 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 Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of Section 6 TroubleshootingProblem SolutionTable 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Flash Pattern MeaningTable 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 ProcessAppendix A Torque Specifications Torque Specifications ft-lbsTorque 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 Appendix E Recommended Remote Air Cooled Oil Cooler Piping OUTLET ON TOPINLET ON BOTTOM Blank
Top Page Image Contents