Compressor Unit Leak Check, Maintenance/Service | Emerson VSG, VSSG

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Emerson VSG, VSSG manual Compressor Unit Leak Check, Maintenance/Service

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 3 Installation Table of ContentsSection Title Section 1 General Information Section 6 Troubleshooting Section 5 Maintenance/ServiceSection Number Section 4 Operation List of Tables and Figures Section 7 Warranty and PartsAppendices Table/Figure 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 Gas Flow Section 2 Theory of OperationOil Life and Oil Flow Figure 2-1. Gas Compressor Unit P&ID Control System RTDs and Pressure TransducersThis is a continuous cycle Delivery Inspection Section 3 InstallationRigging and Lifting of Compressor Unit Figure 3-1. Rigging and Lifting Points 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 Foundation Materials FoundationConsiderations Prior to Starting Building the Foundation 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 2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT Figure 3-6. Housekeeping Pad Dimension Detail - Top ViewLEVEL COMPRESSOR UNIT HOUSEKEEPING PADS 010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 Piping Nozzle Dia. in Table 3-2. Maximum Allowable Flange LoadsFz lbf Fy lbf ONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION Figure 3-13. Discharge Elevation of Coolers Figure 3-14. Cooler Placement and SpacingPREFERRED Initial Oil Charging Using Non -Vilter Oils Pressure TestingUnit Oil Charging and Priming Do not hydro test compressur unit. Failure to comply Minimum Operating Level Normal Operating Level Maximum NON-Operating LevelBypass Valve OIL MIXING CLOSESUCTION INLET VALVE OPEN Initial Oil Charging Section 3 InstallationPriming Remote Oil Cooler and Piping REMOTE 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 Operation Section 4 OperationOil Inspection Dual Oil Filters Stopping/Restarting Control System CalibrationStarting, Stopping and Restarting the Compressor Starting Calibrate Slide Valve Actuators 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 Oil Circuit Table 5-1. Maintenance/Service ScheduleUnit Control Maintenance/Service Section 5 Maintenance/ServiceMaintaining Proper Operation Compressor Unit Isolation for Compressor Unit Leak Check Use Vilter Oil Analysis Kit VPN 3097A to collect an oil Oil System Components Oil Samplingsample for analysis. For an example, see Figure 5-2. Fill Send samples immediately to the oil analysis lab after Oil Charging Single Oil Filter Assembly Oil Filter ReplacementDual Oil Filter Assembly Oil Draining 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 Table 5-7. Maximum Bearing Float Gate Rotor Float and Gate Rotor Bearing Float InspectionFigure 5-12. Bearing Radial Float Inspection Figure 5-13. Gate Rotor Float Figure 5-14. Gate Rotor Bearing Float Table 5-8. Gate Rotor FloatApplied Force Rigidly attach dial indicator Use bolt for fulcurm Gate rotor bearing float being measured Figure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Section 5 Maintenance/Service Gate Rotor and Support Clearance Gate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor Figure 5-16. Gate Rotor and Support Clearance - MeasuringGate Rotor Support Gate Rotor Straight Edge Straight Edge Straight Edge 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 Problem Section 6 TroubleshootingSolution Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of Table 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Meaning Flash PatternTable 6-2. Slide Valve Actuator LED Blink Codes* 1 of will not move while this error code is displayed. To clear the error er before the calibration procedure was completed. The actuatorcalibrate 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 Warranty Claim Processing Section 7 Warranty and PartsOn Site Service Support Warranty does not cover labor and extraneous expenses 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 Evaluation Appendix C Oil Analysis ReportPRODUCT ANALYSIS REPORT No Action Required Appendix D Recommended Header Piping OUTLET ON TOP Appendix E Recommended Remote Air Cooled Oil Cooler PipingINLET ON BOTTOM Blank