Maintenance/Service, Maintaining Proper Operation | Emerson VSSG

Section 5 • Maintenance/Service

Section 5 • Maintenance/Service

Maintaining Proper Operation	Compressor Unit Isolation for
To ensure proper operation, the following items should	Maintenance/Service
To ensure proper operation, the following items should
be checked:	WARNING
	WARNING

•Calibrate all transducer and RTDs.

•Check capacity and volume actuator calibration.

•Check fuses in the PLC panel.

•Check for loose wiring connections in the PLC panel.

•Check relay and contact operation for relays in the PLC panel.

•Verify the operation of the suction and discharge check valves.

•Check for correct rotation of all motors on the pack- age (compressor, oil pump, and fan motors).

•Check that the piping to the oil cooler is correct.

•Check setup of soft starts and VFDs.

•Verify set points in the PLC.

•Check oil heater operation.

•Verify oil line check valve is installed for correct ﬂow .

•Check for loose bolts on the compressor unit. Tighten any loose bolts.

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

Avoid skin contact with any condensate or oil. Wear rubber gloves and a face shield when working with condensate or oil. Failure to comply may result in serious injury or death.

WARNING

At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to equipment.

WARNING

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or damage to equipment.

NOTICE

Recover or transfer all gas vapor in accordance with local ordinances before opening compressor unit to atmosphere.

The compressor unit must be isolated and depressurized to atmosphere prior to servicing.

1.Shut down the compressor unit, refer to Stopping/ Restarting procedure in Section 4.

Suction By-Pass Valve

Figure 5-1. Suction By-Pass Valve Location (Manual) (1 of 2)

5 – 2

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

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Emerson VSSG, VSG manual Maintenance/Service, Maintaining Proper Operation, Compressor Unit Isolation for

Contents

Installation, operation & maintenance manual VSG/VSSG compressor unitPage VSG/VSSG Standard Vilter Warranty Statement Important Message READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSORVilter Manufacturing LLC Table of Contents Section 3 InstallationSection Title Section 1 General Information Section 5 Maintenance/Service Section 6 TroubleshootingSection Number Section 4 Operation Section 7 Warranty and Parts List of Tables and FiguresAppendices Table/Figure Figure 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 Designation Section 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 Section 1 General Information Component Identiﬁcation Continued Figure 1-2. Gas Compressor Unit Components 3 of Section 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 Section 2 Theory of Operation Gas FlowOil Life and Oil Flow Figure 2-1. Gas Compressor Unit P&ID RTDs and Pressure Transducers Control SystemThis is a continuous cycle Section 3 Installation Delivery InspectionRigging and Lifting of Compressor Unit Figure 3-1. Rigging and Lifting Points Long Term Storage Recommendations The following are recommendations regarding long term storage Compressor Unit Inspections Prior to Storage or Installation Recommended Onsite ToolsAIR COOLED OIL COOLERS LONG TERM STORAGE LOG Compressor has been placed in operation as of Foundation Foundation MaterialsConsiderations Prior to Starting Building the Foundation Compressor Unit Installation of both Check the ability of the soil to carry the load Leveling and Grouting recommendations for setting, precautions, mixing, and Additional Information Codes and Standards Figure 3-6. Housekeeping Pad Dimension Detail - Top View 2 - # CLOSED TIES CENTER LINE 5 - # 6 VERTLEVEL COMPRESSOR UNIT HOUSEKEEPING PADS Piping 010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 Table 3-2. Maximum Allowable Flange Loads Nozzle Dia. inFz lbf Fy lbf ONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION Figure 3-14. Cooler Placement and Spacing Figure 3-13. Discharge Elevation of CoolersPREFERRED Pressure Testing Initial Oil Charging Using Non -Vilter OilsUnit Oil Charging and Priming Do not hydro test compressur unit. Failure to comply Normal Operating Level Maximum NON-Operating Level Minimum Operating LevelBypass Valve CLOSE OIL MIXINGSUCTION INLET OPEN VALVE Section 3 Installation Initial Oil ChargingPriming Remote Oil Cooler and Piping REMOTE SUCTION INLET OIL FILTER OPENMOTOR Section 3 Installation Pre Start-Up Pre Start-Up Checklist 15. Verify that all valves are in the open position Section 3 Installation Start-Up Section 4 Operation OperationOil Inspection Dual Oil Filters Control System Calibration Stopping/RestartingStarting, Stopping and Restarting the Compressor Starting Calibrate Slide Valve Actuators Figure 4-2. Actuator Assembly Section 4 Operation Figure 4-4. Slide Valve Calibration Screen Compact Logix PLC Figure 4-5. Photo-chopper Table 4-1. Command Shaft Rotation Speciﬁcations Angle/Slide TravelCapacity Oil Temperature Control Valve Oil Mixing Valve Operation 18. Press the “Set Max” button Fail Position Purging with Dry Nitrogen 10. Close discharge bleed valve while still purging Purging with Dry Gas Pressure IndicatorOIL SEPARATOR Section 4 Operation Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction Oil Figure 4-13. Suction Oil Charging Valve Coalescing Oil Return Line Setup Table 5-1. Maintenance/Service Schedule Oil CircuitUnit Control Section 5 Maintenance/Service Maintenance/ServiceMaintaining Proper Operation Compressor Unit Isolation for Compressor Unit Leak Check Oil System Components Oil Sampling Use Vilter Oil Analysis Kit VPN 3097A to collect an oilsample for analysis. For an example, see Figure 5-2. Fill Send samples immediately to the oil analysis lab after Oil Charging Oil Filter Replacement Single Oil Filter AssemblyDual Oil Filter Assembly Oil Draining Vent Valve Drain Valve Inlet Shut-Off Valves Coalescing Filter Replacement Coalescing FilterCentering Strap Oil Pump Strainer View From Back of Oil Pump Strainer Drive Coupling Form-Flex BPU Hub Installation Table 5-3. Shaft and Hub DistancesSize Drive Center Member Installation and Alignment 17. Install set screw in hub cap to secure key in keyway of shaft Table 5-5. Disc Pack Installation Torque Speciﬁcations Table 5-4. Hub Clamp Bolt and Set Screw Torque SpeciﬁcationsAngular Alignment Drive Coupling Type C Sure-Flex Replacement Drive Coupling Form-Flex BPU Center Member and Hub Removal Compressor Replacement Table 5-6. Clamping Bolts and Set Screw Torque Speciﬁcations Lock Washer Compressor Shaft Bearing Float Inspections Figure 5-11. Bearing Axial Float Inspection Gate Rotor Float and Gate Rotor Bearing Float Inspection Table 5-7. Maximum Bearing FloatFigure 5-12. Bearing Radial Float Inspection Figure 5-13. Gate Rotor Float Table 5-8. Gate Rotor Float Figure 5-14. Gate Rotor Bearing FloatApplied Force Rigidly attach dial indicator Use bolt for fulcurm Gate rotor bearing float being measured Section 5 Maintenance/Service Gate Rotor and Support Clearance Figure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Figure 5-16. Gate Rotor and Support Clearance - Measuring Gate Rotor Support Gate Rotor Gate Rotor Support Gate RotorGate Rotor Support Gate Rotor Straight Edge Straight Edge Straight Edge Gate Rotor Assembly Replacement All VSG & VSSG Compressors Except VSG 301-701 CompressorsTable 5-9. Gate Rotor Tool Sets Figure 5-17. Gate Rotor Assembly Removal and Tools Figure 5-18. Gate Rotor Assembly Removal Figure 5-19. Gate Rotor Assembly and Tools Figure 5-20. Gate Rotor and Shelf Clearance Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLY Figure 5-21. Gate Rotor Assembly Breakdown Figure 5-23. Gate Rotor and Shelf Clearance Figure 5-22. Gate Rotor Thrust Bearing Gate Rotor Disassembly Figure 5-25. Gate Rotor Blade InstallationFigure 5-24. Gate Rotor Blade Assembly Figure 5-27. Thrust Bearing Installation Figure 5-26. Gate Rotor Thrust Bearing Slide Valve Actuator Assembly Replacement Figure 5-28. Roller Bearing Assembly Command Shaft Assembly Replacement Command Shaft Seal ReplacementFigure 5-29. Command Shaft Seal Figure 5-30. Command Shaft Seal Installation Section 6 Troubleshooting ProblemSolution Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of Table 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Flash Pattern MeaningTable 6-2. Slide Valve Actuator LED Blink Codes* 1 of er before the calibration procedure was completed. The actuator will not move while this error code is displayed. To clear the errorcalibrate the actuator. If this error has occurred and the cause was not the loss of 24V power during calibration, possible causes are 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 Section 7 Warranty and Parts Warranty Claim ProcessingOn Site Service Support Warranty does not cover labor and extraneous expenses Remanufactured Gas Bare Shaft Compressor Process Request a “VSG Single Screw Compressor Rebuild Form” Appendix A Torque Specifications Torque Specifications ft-lbsTorque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix B Motor Compressor - General Storage Instructions Appendix C Oil Analysis Report EvaluationPRODUCT ANALYSIS REPORT No Action Required Appendix D Recommended Header Piping Appendix E Recommended Remote Air Cooled Oil Cooler Piping OUTLET ON TOPINLET ON BOTTOM Blank