Remanufactured Gas Bare Shaft Compressor Process | Emerson VSSG

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Emerson VSSG, VSG manual Remanufactured Gas Bare Shaft Compressor Process, Warranty and Parts

Contents

Installation, operation & maintenance manual VSG/VSSG compressor unitPage VSG/VSSG Standard Vilter Warranty Statement Vilter Manufacturing LLC Important MessageREAD CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR Section Title Table of ContentsSection 3 Installation Section 1 General Information Section Number Section 5 Maintenance/ServiceSection 6 Troubleshooting Section 4 Operation Appendices Section 7 Warranty and PartsList of Tables and Figures 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 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 Section 1 General Information Component Identiﬁcation Continued Figure 1-2. Gas Compressor Unit Components 3 of 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 Oil Life and Oil Flow Section 2 Theory of OperationGas Flow Figure 2-1. Gas Compressor Unit P&ID This is a continuous cycle RTDs and Pressure TransducersControl System Rigging and Lifting of Compressor Unit Section 3 InstallationDelivery Inspection Figure 3-1. Rigging and Lifting Points Long Term Storage Recommendations The following are recommendations regarding long term storage AIR COOLED OIL COOLERS Compressor Unit Inspections Prior to Storage or InstallationRecommended Onsite Tools LONG TERM STORAGE LOG Compressor has been placed in operation as of Considerations Prior to Starting FoundationFoundation Materials 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 LEVEL Figure 3-6. Housekeeping Pad Dimension Detail - Top View2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT COMPRESSOR UNIT HOUSEKEEPING PADS Piping 010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 Fz lbf Table 3-2. Maximum Allowable Flange LoadsNozzle Dia. in Fy lbf ONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION PREFERRED Figure 3-14. Cooler Placement and SpacingFigure 3-13. Discharge Elevation of Coolers Unit Oil Charging and Priming Pressure TestingInitial Oil Charging Using Non -Vilter Oils Do not hydro test compressur unit. Failure to comply Bypass Valve Normal Operating Level Maximum NON-Operating LevelMinimum Operating Level SUCTION INLET CLOSEOIL MIXING OPEN VALVE Priming Remote Oil Cooler and Piping Section 3 InstallationInitial Oil Charging REMOTE MOTOR SUCTION INLETOIL FILTER OPEN 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 Oil Inspection Section 4 OperationOperation Dual Oil Filters Starting, Stopping and Restarting the Compressor Starting Control System CalibrationStopping/Restarting 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 Capacity Table 4-1. Command Shaft Rotation SpeciﬁcationsAngle/Slide Travel 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 OIL SEPARATOR Purging with Dry GasPressure Indicator 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 Unit Table 5-1. Maintenance/Service ScheduleOil Circuit Control Maintaining Proper Operation Section 5 Maintenance/ServiceMaintenance/Service Compressor Unit Isolation for Compressor Unit Leak Check sample for analysis. For an example, see Figure 5-2. Fill Oil System Components Oil SamplingUse Vilter Oil Analysis Kit VPN 3097A to collect an oil Send samples immediately to the oil analysis lab after Oil Charging Dual Oil Filter Assembly Oil Filter ReplacementSingle Oil Filter Assembly Oil Draining Vent Valve Drain Valve Inlet Shut-Off Valves Centering Strap Coalescing Filter ReplacementCoalescing Filter Oil Pump Strainer View From Back of Oil Pump Strainer Size Drive Coupling Form-Flex BPU Hub InstallationTable 5-3. Shaft and Hub Distances Drive Center Member Installation and Alignment 17. Install set screw in hub cap to secure key in keyway of shaft Angular Alignment Table 5-5. Disc Pack Installation Torque SpeciﬁcationsTable 5-4. Hub Clamp Bolt and Set Screw Torque Speciﬁcations 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 Figure 5-12. Bearing Radial Float Inspection Gate Rotor Float and Gate Rotor Bearing Float InspectionTable 5-7. Maximum Bearing Float Figure 5-13. Gate Rotor Float Applied Force Rigidly attach dial indicator Use bolt for fulcurm Table 5-8. Gate Rotor FloatFigure 5-14. Gate Rotor Bearing Float 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 Gate Rotor Support Gate Rotor Figure 5-16. Gate Rotor and Support Clearance - MeasuringGate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor Straight Edge Straight Edge Straight Edge Table 5-9. Gate Rotor Tool Sets Gate Rotor Assembly Replacement All VSG & VSSG Compressors ExceptVSG 301-701 Compressors 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 Figure 5-24. Gate Rotor Blade Assembly Gate Rotor DisassemblyFigure 5-25. Gate Rotor Blade Installation Figure 5-27. Thrust Bearing Installation Figure 5-26. Gate Rotor Thrust Bearing Slide Valve Actuator Assembly Replacement Figure 5-28. Roller Bearing Assembly Figure 5-29. Command Shaft Seal Command Shaft Assembly ReplacementCommand Shaft Seal Replacement Figure 5-30. Command Shaft Seal Installation Solution Section 6 TroubleshootingProblem Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of Table 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Table 6-2. Slide Valve Actuator LED Blink Codes* 1 of Flash PatternMeaning calibrate the actuator. If this error has occurred and the cause was er before the calibration procedure was completed. The actuatorwill not move while this error code is displayed. To clear the error 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 On Site Service Support Section 7 Warranty and PartsWarranty Claim Processing Warranty does not cover labor and extraneous expenses Remanufactured Gas Bare Shaft Compressor Process Request a “VSG Single Screw Compressor Rebuild Form” Torque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix A Torque SpecificationsTorque Specifications ft-lbs Appendix B Motor Compressor - General Storage Instructions PRODUCT ANALYSIS REPORT Appendix C Oil Analysis ReportEvaluation No Action Required Appendix D Recommended Header Piping INLET ON BOTTOM Appendix E Recommended Remote Air Cooled Oil Cooler PipingOUTLET ON TOP Blank