General Information How To Use This Manual | Emerson VSG, VSSG

Section 1 • General Information

Section 1 • General Information

How To Use This Manual

This manual contains instructions for gas compressor units. It has been divided into eight sections:

Section 1: General Information

Section 2: Theory of Operation

Section 3: Installation

Section 4: Operation

Section 5: Maintenance & Service

Section 6: Troubleshooting

Section 7: Warranty and Parts

Appendices

It is highly recommended that the manual be reviewed prior to servicing system parts.

Figures and tables are included to illustrate key concepts.

Safety precautions are shown throughout the manual. They are deﬁned as the following:

NOTICE - Notice statements are shown when there are important information that shall be followed. Not fol- lowing such notices may result in void of warranty, seri- ous ﬁnes, serious injury and/or death.

WARNING - Warning statements are shown when there are hazardous situations, if not avoided, will result in se- rious injury and/or death.

CAUTION - Caution statements are shown when there are potentially hazardous situations, if not avoided, will result in damage to equipment.

NOTE - Notes are shown when there are addtional infor- mation pertaining to the instructions explained.

Additional installation, operation and maintenance in- structions can be found in the associated software man- ual and bareshaft compressor manual.

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

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Emerson VSG, VSSG manual General Information How To Use This Manual

Contents

VSG/VSSG compressor unit Installation, operation & maintenance manualPage VSG/VSSG Standard Vilter Warranty Statement Important Message READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSORVilter 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 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 Figure 1-2. Gas Compressor Unit Components 3 of Section 1 General Information Component Identiﬁcation Continued 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 Gas Flow Section 2 Theory of OperationOil Life and Oil Flow Figure 2-1. Gas Compressor Unit P&ID RTDs and Pressure Transducers Control SystemThis 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 Compressor Unit Inspections Prior to Storage or Installation Recommended Onsite ToolsAIR 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 3-14. Cooler Placement and Spacing Figure 3-13. Discharge Elevation of CoolersPREFERRED Initial Oil Charging Using Non -Vilter Oils Pressure TestingUnit 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 VALVE OPEN Initial Oil Charging Section 3 InstallationPriming Remote Oil Cooler and Piping REMOTE SUCTION INLET OIL FILTER OPENMOTOR 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 Table 4-1. Command Shaft Rotation Speciﬁcations Angle/Slide TravelCapacity 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 Purging with Dry Gas Pressure IndicatorOIL 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 Replacement Coalescing FilterCentering Strap View From Back of Oil Pump Strainer Oil Pump Strainer Drive Coupling Form-Flex BPU Hub Installation Table 5-3. Shaft and Hub DistancesSize 17. Install set screw in hub cap to secure key in keyway of shaft Drive Center Member Installation and Alignment Table 5-5. Disc Pack Installation Torque Speciﬁcations Table 5-4. Hub Clamp Bolt and Set Screw 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 Gate Rotor Assembly Replacement All VSG & VSSG Compressors Except VSG 301-701 CompressorsTable 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 Gate Rotor Disassembly Figure 5-25. Gate Rotor Blade InstallationFigure 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 Assembly Replacement Command Shaft Seal 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 Flash Pattern MeaningTable 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 Appendix A Torque Specifications Torque Specifications ft-lbsTorque 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 Appendix E Recommended Remote Air Cooled Oil Cooler Piping OUTLET ON TOPINLET ON BOTTOM Blank