Emerson VSSG, VSG manual Remanufactured Gas Bare Shaft Compressor Process, Warranty and Parts

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Remanufactured Gas Bare Shaft Compressor Process

Section 7 • Warranty and Parts

Remanufactured Gas Bare Shaft Compressor Process

These instructions are an overview of how the process works when a bare shaft compressor is in need of being remanufactured. This is to help clear any questions that may arise prior to contacting customer service.

The process begins by contacting Vilter’s Customer Service Department. Vilter contact information can be found on page ii.

•Request a “VSG Single Screw Compressor Rebuild Form”.

•Submit the Rebuild Form and a Purchase Order (PO) for the inspection. A fee is required for the ini- tial inspection and teardown report; contact Vilter Customer Service representative for the latest fee.

•A Return Material Authorization (RMA) number will be provided.

•Send the compressor to Vilter in the condition as stated on the Rebuild Form (i.e. no oil in the compres- sor). Charges may apply if conditions are not met.

•A report will be sent to you after the inspection has been completed explaining what level of rebuild is necessary along with the cost.

NOTE

Level 3 - Current Reman Compressor requires complete rebuilding and re-conditioning to “as-new” condition. All the components listed in Level 2 are replaced plus all hardware, slide assemblies, pistons, and a main rotor (if damaged) and/or gate rotor supports.

NOTE

A Level 1 and Level 2 rebuild will include washing the housing and repainting over the current paint. A Level 3 rebuild will include blasting all the current paint off before repainting.

BARE SHAFT COMPRESSOR DESCRIPTION

Single Screw Bare Shaft Compressor features include:

•Cast grey iron frame with cast ductile iron discharge manifold and gate rotor covers with discharge con- nection horizontal.

•Standard drive shaft is tapered.

•Standard slide assembly.

•Viton shaft seal O-rings.

•Crating with Purge & Gauge.

•Does not include handwheels or slide valve motors.

Inspection and rebuild times will vary, contact Vilter Customer Service representative for further details.

•Submit a new PO for the amount that will be needed for the rebuild. The inspection cost will be waived upon receipt of the new PO. Make sure to provide your “Ship to Address” and “Billing Address”.

EXPLANATION OF REBUILD LEVELS

Level 1

Compressor is in good condition. Replace bearings, gas- kets, shaft seal and o-rings. All hardware is intended to be re-used (when possible). Parts are organized in part kit form.

Level 2

Compressor is in good condition, but requires new gate rotor blades. Replace all items in Level 1 plus new gate rotor blades and bushings.

7 – 2

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

Page 97 Page 99
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Page 97 Page 99
Contents Installation, operation & maintenance manual VSG/VSSG compressor unitPage VSG/VSSG Standard Vilter Warranty Statement Vilter Manufacturing LLC Important MessageREAD CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR Section Title Table of ContentsSection 3 Installation Section 1 General InformationSection Number Section 5 Maintenance/ServiceSection 6 Troubleshooting Section 4 OperationAppendices Section 7 Warranty and PartsList of Tables and Figures 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 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 Section 1 General Information Component Identification Continued Figure 1-2. Gas Compressor Unit Components 3 ofSection 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 Oil Life and Oil Flow Section 2 Theory of OperationGas Flow Figure 2-1. Gas Compressor Unit P&IDThis is a continuous cycle RTDs and Pressure TransducersControl System Rigging and Lifting of Compressor Unit Section 3 InstallationDelivery Inspection Figure 3-1. Rigging and Lifting PointsLong Term Storage Recommendations The following are recommendations regarding long term storageAIR COOLED OIL COOLERS Compressor Unit Inspections Prior to Storage or InstallationRecommended Onsite Tools LONG TERM STORAGE LOG Compressor has been placed in operation as ofConsiderations Prior to Starting FoundationFoundation Materials 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 LEVEL Figure 3-6. Housekeeping Pad Dimension Detail - Top View2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT COMPRESSOR UNIT HOUSEKEEPING PADSPiping 010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5Fz lbf Table 3-2. Maximum Allowable Flange LoadsNozzle Dia. in Fy lbfONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION PREFERRED Figure 3-14. Cooler Placement and SpacingFigure 3-13. Discharge Elevation of Coolers Unit Oil Charging and Priming Pressure TestingInitial Oil Charging Using Non -Vilter Oils Do not hydro test compressur unit. Failure to complyBypass Valve Normal Operating Level Maximum NON-Operating LevelMinimum Operating Level SUCTION INLET CLOSEOIL MIXING OPEN VALVEPriming Remote Oil Cooler and Piping Section 3 InstallationInitial Oil Charging REMOTEMOTOR SUCTION INLETOIL FILTER OPEN Section 3 Installation Pre Start-Up Pre Start-Up Checklist15. Verify that all valves are in the open position Section 3 Installation Start-Up Oil Inspection Section 4 OperationOperation Dual Oil FiltersStarting, Stopping and Restarting the Compressor Starting Control System CalibrationStopping/Restarting 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-chopperCapacity Table 4-1. Command Shaft Rotation SpecificationsAngle/Slide Travel 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 OIL SEPARATOR Purging with Dry GasPressure Indicator 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 Unit Table 5-1. Maintenance/Service ScheduleOil Circuit ControlMaintaining Proper Operation Section 5 Maintenance/ServiceMaintenance/Service Compressor Unit Isolation forCompressor Unit Leak Check sample for analysis. For an example, see Figure 5-2. Fill Oil System Components Oil SamplingUse Vilter Oil Analysis Kit VPN 3097A to collect an oil Send samples immediately to the oil analysis lab afterOil Charging Dual Oil Filter Assembly Oil Filter ReplacementSingle Oil Filter Assembly Oil DrainingVent Valve Drain Valve Inlet Shut-Off Valves Centering Strap Coalescing Filter ReplacementCoalescing Filter Oil Pump Strainer View From Back of Oil Pump StrainerSize Drive Coupling Form-Flex BPU Hub InstallationTable 5-3. Shaft and Hub Distances Drive Center Member Installation and Alignment 17. Install set screw in hub cap to secure key in keyway of shaftAngular Alignment Table 5-5. Disc Pack Installation Torque SpecificationsTable 5-4. Hub Clamp Bolt and Set Screw Torque Specifications 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 InspectionFigure 5-12. Bearing Radial Float Inspection Gate Rotor Float and Gate Rotor Bearing Float InspectionTable 5-7. Maximum Bearing Float Figure 5-13. Gate Rotor FloatApplied Force Rigidly attach dial indicator Use bolt for fulcurm Table 5-8. Gate Rotor FloatFigure 5-14. Gate Rotor Bearing Float Gate rotor bearing float being measuredSection 5 Maintenance/Service Gate Rotor and Support Clearance Figure 5-15. Gate Rotor and Support Clearance - Minimum ClearancesGate Rotor Support Gate Rotor Figure 5-16. Gate Rotor and Support Clearance - MeasuringGate Rotor Support Gate Rotor Gate 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 5-17. 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 BearingFigure 5-24. Gate Rotor Blade Assembly Gate Rotor DisassemblyFigure 5-25. Gate Rotor Blade Installation Figure 5-27. Thrust Bearing Installation Figure 5-26. Gate Rotor Thrust BearingSlide Valve Actuator Assembly Replacement Figure 5-28. Roller Bearing AssemblyFigure 5-29. Command Shaft Seal Command Shaft Assembly ReplacementCommand Shaft Seal Replacement Figure 5-30. Command Shaft Seal Installation Solution Section 6 TroubleshootingProblem 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 calibrate the actuator. If this error has occurred and the cause was er before the calibration procedure was completed. The actuatorwill not move while this error code is displayed. To clear the error 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 On Site Service Support Section 7 Warranty and PartsWarranty Claim Processing Warranty does not cover labor and extraneous expensesRemanufactured Gas Bare Shaft Compressor Process Request a “VSG Single Screw Compressor Rebuild Form”Torque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix A Torque SpecificationsTorque Specifications ft-lbs Appendix B Motor Compressor - General Storage Instructions PRODUCT ANALYSIS REPORT Appendix C Oil Analysis ReportEvaluation 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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