Theory of Operation, Gas Flow, Oil Life and Oil Flow | Emerson VSG

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Emerson VSG, VSSG manual Theory of Operation, Gas Flow, Oil Life and Oil Flow, 1. Gas Compressor Unit P&ID

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 Title Section 4 Operation Section 5 Maintenance/ServiceSection 6 Troubleshooting Section Number Table/Figure Section 7 Warranty and PartsList of Tables and Figures Appendices Figure 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 Designations Section 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 Continued Section 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 Flow Control 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 Unit The following are recommendations regarding long term storage Long Term Storage Recommendations Recommended Onsite Tools Compressor Unit Inspections Prior to Storage or InstallationAIR COOLED OIL COOLERS Compressor has been placed in operation as of LONG TERM STORAGE LOG Building the Foundation FoundationFoundation Materials Considerations Prior to Starting of both Check the ability of the soil to carry the load Compressor Unit Installation recommendations for setting, precautions, mixing, and Leveling and Grouting Additional Information Codes and Standards COMPRESSOR UNIT HOUSEKEEPING PADS Figure 3-6. Housekeeping Pad Dimension Detail - Top View2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT LEVEL 010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 Piping Fy lbf Table 3-2. Maximum Allowable Flange LoadsNozzle Dia. in Fz lbf ONE 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 Priming Minimum Operating Level Normal Operating Level Maximum NON-Operating LevelBypass Valve OIL MIXING CLOSESUCTION INLET VALVE OPEN REMOTE Section 3 InstallationInitial Oil Charging Priming Remote Oil Cooler and Piping OIL FILTER OPEN SUCTION INLETMOTOR Pre Start-Up Checklist Section 3 Installation Pre Start-Up 15. Verify that all valves are in the open position Section 3 Installation Start-Up Dual Oil Filters Section 4 OperationOperation Oil Inspection Calibrate Slide Valve Actuators Control System CalibrationStopping/Restarting Starting, Stopping and Restarting the Compressor Starting Figure 4-2. Actuator Assembly Section 4 Operation Figure 4-5. Photo-chopper Figure 4-4. Slide Valve Calibration Screen Compact Logix PLC Angle/Slide Travel Table 4-1. Command Shaft Rotation SpeciﬁcationsCapacity 18. Press the “Set Max” button Oil Temperature Control Valve Oil Mixing Valve Operation Fail 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 Oil Coalescing Oil Return Line Setup Control Table 5-1. Maintenance/Service ScheduleOil Circuit Unit Compressor Unit Isolation for Section 5 Maintenance/ServiceMaintenance/Service Maintaining Proper Operation Compressor 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. Fill Oil Charging Oil Draining Oil Filter ReplacementSingle Oil Filter Assembly Dual Oil Filter Assembly Vent Valve Drain Valve Inlet Shut-Off Valves Coalescing Filter Coalescing Filter ReplacementCentering Strap View From Back of Oil Pump Strainer Oil Pump Strainer Table 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 Alignment Table 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 Replacement Table 5-6. Clamping Bolts and Set Screw Torque Speciﬁcations Compressor Replacement Lock Washer Figure 5-11. Bearing Axial Float Inspection Compressor Shaft Bearing Float Inspections Figure 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 Inspection Gate 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 fulcurm Figure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Section 5 Maintenance/Service Gate Rotor and Support Clearance Straight 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 Rotor VSG 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 Tools Figure 5-20. Gate Rotor and Shelf Clearance Figure 5-19. Gate Rotor Assembly and Tools Figure 5-21. Gate Rotor Assembly Breakdown Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLY Figure 5-22. Gate Rotor Thrust Bearing Figure 5-23. Gate Rotor and Shelf Clearance Figure 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 Installation Figure 5-28. Roller Bearing Assembly Slide Valve Actuator Assembly Replacement Command 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 Solution Table 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 was Table 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 Support Request a “VSG Single Screw Compressor Rebuild Form” Remanufactured Gas Bare Shaft Compressor Process Torque 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 REPORT Appendix D Recommended Header Piping OUTLET ON TOP Appendix E Recommended Remote Air Cooled Oil Cooler PipingINLET ON BOTTOM Blank