1. Maintenance/Service Schedule, Oil Circuit, Unit | Emerson VSG

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Emerson VSG, VSSG manual 1. Maintenance/Service Schedule, Oil Circuit, Unit, Control, Calibration

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 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 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 Continued Section 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 Figure 2-1. Gas Compressor Unit P&ID Section 2 Theory of OperationGas Flow Oil Life and Oil Flow This is a continuous cycle RTDs and Pressure TransducersControl System 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 AIR COOLED OIL COOLERS Compressor Unit Inspections Prior to Storage or InstallationRecommended Onsite Tools 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 PREFERRED Figure 3-14. Cooler Placement and SpacingFigure 3-13. Discharge Elevation of Coolers Do not hydro test compressur unit. Failure to comply Pressure TestingInitial Oil Charging Using Non -Vilter Oils Unit Oil Charging and Priming Bypass Valve Normal Operating Level Maximum NON-Operating LevelMinimum Operating Level SUCTION INLET CLOSEOIL MIXING VALVE OPEN REMOTE Section 3 InstallationInitial Oil Charging Priming Remote Oil Cooler and Piping MOTOR SUCTION INLETOIL FILTER OPEN 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 Capacity Table 4-1. Command Shaft Rotation SpeciﬁcationsAngle/Slide Travel 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 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 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 Centering Strap Coalescing Filter ReplacementCoalescing Filter View From Back of Oil Pump Strainer Oil Pump Strainer Size 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 Alignment Angular 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 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 Table 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 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 5-24. 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 Installation Figure 5-28. Roller Bearing Assembly Slide Valve Actuator Assembly Replacement Figure 5-29. Command Shaft Seal Command Shaft Assembly ReplacementCommand Shaft Seal Replacement 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 Table 6-2. Slide Valve Actuator LED Blink Codes* 1 of Flash PatternMeaning 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 for 17-4 Stainless Steel Fasteners ft-lbs Appendix A Torque SpecificationsTorque Specifications 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 INLET ON BOTTOM Appendix E Recommended Remote Air Cooled Oil Cooler PipingOUTLET ON TOP Blank