Maint.man - Compressors

MAINTENANCE MANUAL FOR THE ATTAHADDY GAS PLANT

SIRTE OIL COMPANY ATTAHADDY GAS FIELD DEVELOPMENT PROJECT 0 REV

FOR REVIEW DATE

DESCRIPTION

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Maintenance Manual Rev 0 , Compressors

APP

SOC

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MTC

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0001

Rev.

0

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Page

Rev

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No. 0001

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Page 1 of 35

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Page

All

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01

2002-11-5

For Review

Rev

Date

Issue

Maintenance Manual Rev. 0 , Compressors

By

M.LESANU

D.W.PARK

Checked

Approved

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4.2 MAINTENANCE MANUAL FOR COMPRESSORS 4.2.1 MAINTENANCE MANUAL FOR PROPANE COMPRESSORS 4.2.1.1 Inspection and Maintenance List

Period Part(s) Inspected

0

1

2

3

4

Yearly than More

Yearly

Every 6 months

Downtime During

Operation During

Interval

5

Purpose of Inspection

6

A. Centrifugal compressor A.1 Journal and thrust bearings

X

Check for wear and over-heating Check rotor axial displacement.

A.2 Rotor

X

After three years check for deposits, erosion and corrosion.

A.3 Diaphragms

X

After three years check for deposits, erosion and corrosion. Check condition of gas labyrinth. Replace gaskets.

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A.4 Casings-Head flanges

X

A.5 Alignment

No. 0001

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After three years check for deposits erosion and corrosion. Check condition of gas labyrinth. Replace gaskets. Clean passages in head flange.

X

Check

B.1 Journal and thrust bearings

X

Check for wear and over-heating

B.2 Gears

X

Check for wear. Check tooth-to-tooth contact. Check tooth clearance.

B. Gearbox

0

1

2

3

4

5

6

C. Compressor couplings Tooth couplings C.1 Teeth

X

Check for centrifugal deposits. Check tooth-to-tooth contact and wear.

C.2 Sleeve

X

Check axial displacement.

C.3 Oil nozzles

X

Check that oil is injected in the right direction.

Flexible diaphragm couplings C.4 Bolts C.5 Flex unit center (spacer)

Maintenance Manual Rev. 0 , Compressors

X X

Check for loose bolts and nuts. Check to see if diaphragms are rusted or corroded.

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D. Lubrication Oil System D.1 Oil properties

X

Check physical and chemical properties.

D.2 Main oil reservoir

X

Check conditions of painting on walls. Check cleanliness of reservoir bottom whenever reservoir is drained.

X

D.3 Pumps

X X

Check coupling. Check cleanliness of suction filter. Check pump capacity. Check pump internals after three years

X X

0

1

D4. Filter

2

3

4

X

X X

Maintenance Manual Rev. 0 , Compressors

X

5

6 Replace filter cartridges when the pressure drop across the filter exceeds set value Replace the cartridge once year regardless of pressure drop. Check for smooth easy operation of the change over valves.

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D5. Water cooler

X

X

D7. Control valves

X

X

X

X

X

X

X

X

Page 5 of 35

Check proper functioning of ventilation. Set actuator to check fan pitch angle. Check finned tubes for deposits and corrosion. Check functioning. Check accessories. After three years check inner parts for wear.

X D8. Safety valves

Rev. 0

Check for smooth, easy operation of the change over valves. Check water side for deposits and corrosion.

X D6. Air cooler

No. 0001

X

Check settings

E. Gas system E1. Water coolers E2. Air coolers

E3. Control valves

X

Check water side for deposits and corrosion

X

X

X

X

X

X

Check proper functioning of ventilation Set actuator to check fan pitch angle. Check finned tubes for deposits and corrosion.

X

X X

E4. Safety valves

Maintenance Manual Rev. 0 , Compressors

X

Check functioning. Check accessories. After three years check inner parts for wear. Check settings.

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5

6

F. Gas seal system F1. Gas filters

X

X

Replace filter cartridges when The pressure drop across the filter exceeds set value. Check functioning of the change over valves. Replace the cartridges once year regardless of pressure drop.

X X

F2. Control valves

X

X X

F3. Safety valves

Check functioning. Check accessories. After three years check inner parts for wear

X

Check settings.

X

Calibrate if necessary.

X

Calibrate if necessary

X X

G. Instrumentation G1. Gauges for pressure & temperature

X

G2. Transmitters, regulator G3. Pressure switches, temperature switches, level switches

X X

G4. Shutdown buttons

Maintenance Manual Rev. 0 , Compressors

X

X

Check alarms. Check auxiliary machinery automatic start-up. Check shut-down system

X

X

Check operation

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TROUBLE

POSSIBLE CAUSE

REMEDY

0

1

2

Vibrations or abnormal compressor

Misalignment

noise

Rev. 0

Carry out a vibration frequency analysis. To check alignment refer to proper section of this instruction manual

Coupling failure

Check condition of coupling

Compressor rotor unbalance

Check to see if particle adherence is the cause, and if necessary, rebalance.

Bearings worn out from dirt in

Check bearings and replace clean oil.

the oil. Stresses transmitted by to

Gas pipes should be properly

casing resulting in misalignment anchored down to prevent excessive stresses on compressor casing and posses sufficient elasticity to allow for heat expansion. Unbalanced coupling

Disassemble coupling and check for unbalance.

Surge

See that compressor operating conditions are kept far from surge point

Machines working in the

Isolate their foundations and increase

vicinity of compressor

elasticity of any connecting pipes.

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Journal bearing failure

Improper lubrication

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Make sure recommended oil is used. Periodically check that no water or dirt has contaminated the oil.

Bearing clearance incorrect

Check clearance and, if necessary, replace.

Compressor or coupling

Refer to sections “Vibrations”

unbalance Thrust bearing failure

Excessive axial thrust

Make sure coupling is clean and assembled so that excessive thrust is not transmitted from the coupled driver to compressor.

Improper lubrication

Refer to section ”Journal Bearing Failure”

Mechanical gas seal failure

Vibrations

Refer to sections “Vibrations”

Dirty gas

Check filter condition and replace dirty cartridges. Check piping cleanliness.

Presence of liquid in the gas

Check gas piping and piping/compressor

system

drains.

0 Mechanical gas seal failure

1 Insufficient buffer gas pressure

2 Check that differential [pressure does not drop below minimum

Insufficient buffer gas pressure

Check that pressure does not below minimum

Presence of oil in the seals

Check the drains of chambers between external rings of gas seals and bearings.

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Insufficient differential pressure

Check values in differential pressure

at primary vents

gauges and adjust orifices to obtain 0.2 to 0.3 Bar g (20 to 30 kPag) at primary vents.

Assembling

Check shaft rotation manually. Check static pressurization of compressor.

Counterrotation (for seals with

Check possible abnormal operating

unidirectional operation )

conditions.

LUBRICATION The oil selected for covering the requirements for the compressor and its auxiliaries shall be a high

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quality oil. The oil, manufactured from refined paraffinic base oils, shall be rust, oxidation and foam inhibited and have good demulsibility for rapid separation of water. The responsibility of supplying the proper oil for the lubricating system rests with the oil vendor and the machine operator. The responsibility includes specifications for flushing, purifying, inspection and treatment of the oil to ensure satisfactory performance of the equipment in service. Oil physical characteristics It is recommended an oil having a ISO viscosity class VG 46 whose characteristics when new are summarized below : : 41.4-50.6 cSt  Cinematic viscosity at 40º C ASTM D445 : equal to or greater than 0.875 kg/dm³  Specific gravity at 15 C ASTM D1298 : equal to or greater than 220 ºC  Flash point in open cup ASTM D92 : equal to or less than –12 ºC  Pour point ASTM D97  Viscosity index ASTM D2270………………….: equal to or greater than 100  Rust test ( NOM-M-63-ASTM D 665-IP 135) : pass  Oxidation test at A.N. 2.0 mg KOH/g ( NOM-M-62-ASTM D 943-IP 157)……………: greater than 3000 hours : equal to or less than 0.08 mg KOH/g  Acid number (A.N.) ASTM D D974 : 40 ml - 40 ml - 0 ml (15 min )  Water separability ASTM D1401 : 450/0- 50/0- 450/0  Foaming characteristics ml, I-II-III : 3 minutes  Air release at 50 C DIN 51381 When gear box is present in the machine train, the oil shall also have the following characteristic : - Load stage : 4-5 Checks of physical oil characteristics During operation oil is subject to contamination by quantities of foreign matters as water, air, iron oxide or other impurities, which alter its original characteristics. It is therefore necessary that the product is periodically checked to ascertain the variation of its physical/chemical characteristics by taking a sample from the oil system when the machine is operating. It is a joint responsibility of the user and the producer of the oil to establish a routine sampling schedule and criteria for determining the limiting property values for the oil in service.

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The following is a guide to be used in setting the time intervals at which oil samples are to be taken for analysis. 1. After the first 100 running hours 2. Every three months thereafter ( approx. 2000 ) The checks to be carried out on the oil samples are : a ) Viscosity ( cSt at 40 ºC ) ASTM D 445 b ) Neutralization number ASTM D 974 c ) Flash point ASTM D 92 d ) Water content (% by weight ) e ) Contaminants content The results of tests shall be constructed and recorded so that the course of oil conditions can be observed and occurrence of abnormal operating conditions prevented. a ) Viscosity ( cST at 40 C ) Generally oil viscosity during operation does not change much when oil refillings are made correctly and the contaminants do not fluidity or thicken the oil. A 10 to 15 per cent viscosity variation compared with the initial value is usually allowed without jeopardizing correct lubrication of the machine. The oil shall be changed when this variation is exceeded. b ) The neutralization number (NN) The neutralization number (NN ) represents the total acidity, organic acidity, + inorganic acidity, of an oil and is expressed by the milligrams of potassium hydroxide (KOH) required to neutralize the acidic constituents in a gram of sample. Lubricating oils never have inorganic acidity so that the neutralization number usually represents the organic acidity. Oxidation of oil causes formation of acid compounds whose presence can be noted during the normal analytical checks ( the neutralization number is established during these checks). This alternation and the consequent increase of organic acidity generally takes place very slowly. As long as the increase is gradual and acidity value is not too high there is no reason for alarm. However, a rapid increase of organic acidity is a sign that a strong oxidation process is occurring and this might lead to formation of undesirable deposits. This phenomenon is influenced by many factors among which is the presence of highly acid contaminants.

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Very high acidity values can cause sludges and oil can become potentially corrosive towards other materials; emulsion might form if water contamination occurs. Usually the oil must be changed when the neutralization number exceeds 0,5 mg KOH/g. Oil producer shall be consulted however when acidity exceeds 0,3 mg KOH/g. c ) Flash point The characteristics does not change during normal operation of the machine. The oil must be changed if it is contaminated when the flash point in open cup falls below 200 ºC. d ) Water Presence of water in the oil can be caused by condensation of the atmospheric humidity, which can enter into the oil system. Water can form emulsion with oil thus causing troubles to the parts to be lubricated and/or be responsible for serious corrosion. It must therefore be removed from oil : 1. Through the case discharge 2. By means of a centrifugal separator The quantity of water in the oil shall never exceed 0.05 % by weight, it is however desirable to keep this value below 200 p.p.m. e ) Impurities The foreign matters, which enter into the oil system, can contribute to oil alteration and must therefore be removed. Removal of solid impurities and of water from oil is usually performed by centrifugal separators which can be operated, at alternate intervals, as clarifier for separation of solids and as purifier for separation of water and for the simultaneous removal of existing solids. 3. Change of oil The amount of oil lost to vaporization is negligible when compared with the oil quantity in the system. Usually, the first oil change shall be carried out after two years of operation. Subsequently, it can proceed according to the results of the above-mentioned analysis. The system is to be drained when oil is still warm in order to avoid separation of impurities and deposits. Any surface, contacting the lube oil after draining, must be thoroughly cleaned. Lubricant List

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EQUIPMENT : CENTRIFUGAL COMPRESSOR FORCED FEED LUBE OIL SYSTEM MANUFACTURER : FLENCO LUBRICATED

LUBRICANT

PART

TYPE

Q.TY

Estimated

OF 1-st

Consumption

FILLING

Frequency

Sample

of

(L/day)

change

(L) - 2 BCL406 (centr.compressor)

LUBE OIL

2240 (2)

See

On the

See SOS

bearings

ISO VG 46

SOS 03158/4

basis of

- Speed gear

As per NP Spec.

T.point no.2

oil analysis

- Electric motor bearings (Driven)

SOS 02111/4

results (see SOS

-Main lube pump P- 4102 A(1)

02111/4 )

- Auxiliary lube pump P- 4102 B(1) (1)- Electric motor driven

02111/4

(2) Quantity for one compressor train

EQUIPMENT : MAIN & AUXILIARY LUBE OIL PUMPS ELECTRIC MOTOR MANUFACTURER : FLENCO LUBRICATED

LUBRICANT

Q.TY

Estimated

PART

TYPE

OF 1-st

Consumption

FILLING

(L/day)

Frequency

Sample

of change

(L) - Electric motor bearings ( PM- 4102 A)

n.a.

Bearings Type

n.a.

GREASED

SKF

FOR

6309/C3

LIFE

- Electric motor bearings ( PM- 4102 B)

n.a.

(1) Electric motor driven

EQUIPMENT : AIRCOOLER FANS ELECTRIC MOTOR MANUFACTURER : NUOVO PIGNONE VIBO LUBRICATED

LUBRICANT

Q.TY

Estimated

PART

TYPE

OF 1-st

Consumption

Maintenance Manual Rev. 0 , Compressors

Frequency of

Sample

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FILLING

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(L/day)

change

(L) - Electric motor bearings ( PM- 4102 A)

Bearings Type

n.a.

n.a.

GREASED

- Electric motor bearings ( PM- 4102 B)

SKF

FOR

- Electric motor bearings ( PM- 4102 C)

6309/C3

LIFE

n.a.

(1) Electric motor driven

OIL PIPING Erection - Flushing 1. Erection All components of the oil system which are fabricated and assembled in Nuovo Pignone’s workshop are cleaned and protected from rust and contaminants before transportation to site. It is recommended that the components be inspected after receipt to determine their condition and integrity of protection. If any contamination is disclosed the components should be cleaned and reprotected. Components of the system which are fabricated at erection site should be cleaned and protected from rust and contamination before erection. 2. Flushing Even if the best care has been taken in fabricating and erecting the oil system to maintain the cleanliness, some contamination will unavoidably be introduced into the oil system, therefore an oil flush must be performed before start up to keep the contamination to an absolute minimum. Prior to charging the system with flushing oil it is recommended to check the state of cleanliness of the oil inspecting all accessible areas. If rust and dirt is found it should be manually removed. To flush it should use a hot oil and make pipe jumper to by pass the machine bearings, seals, couplings and other accessory devices. It is not practical to flush the feed lines on the site, they are to be removed from place, thoroughly cleaned, sealed and stored for all the flushing period. Temporary stainless steel screens of 100 mesh or finer, backed up by perforated steel plates, should be installed to the downstream side of the jumpers for collecting dirt that will be freed

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during the flushing. The amount of dirt, plotted against flushing time will give an indication of the state of the cleanliness of the system. Gate shut off valves may be installed at outlet from jumpers so ensuring a higher flushing velocity by sequential isolation of each line. The charge of the oil for flushing the system, normally selected to be of the same type and characteristics as that prescribed for normal operation, should be enough to maintain lube oil pumps submerged during operation. The success of the operation depends mainly on the capability of the oil pumps to provide a flow rate larger than normal and thus a high velocity within the lines. Throughout the flushing, the oil in the system should be heated and run at a temperature of approx. 75 ºC (165 ºF). A thermal shock of the system, obtained allowing the oil temperature to drop temporarily to approx. 50 ºC (120 ºF), may be found effective for loosening adherent particles which are not readily removed by a continuous flow of hot oil. The dislodgment of particles that may have adhered to the piping surfaces should be accelerated by vibrating or hammering the oil lines. Cleaning of the system should be assisted keeping in operation the oil separator. Throughout the flushing the oil separator, filter elements and screens should be serviced as needed. Flushing should be continued until inspection discloses a definitive reduction in size and number of particles collected in the separators, filter elements and screens. When flushing is completed, heating of the oil should be discontinued and circulation continued until the temperature drops to approx. 50 ºC (120 ºF) at cooler outlet. Then the oil pump and separator are to be stopped and flushing oil removed from the system opening the lines lowest points. Reservoir and filter body should be inspected and all traces of residual contamination removed. Temporary screens, jumpers and blanks are then to be removed from the system, new filter elements installed and pipe spools reinstated. Finally the reservoir is to be topped up to maximum operating level with a new charge of system operating oil to be introduced through screen filter or oil purifier. GENERAL RECOMMENDATIONS  Suitable marked containers should be placed in the machine area for the storage of dismantled parts to avoid mechanical damage or loss. Maintenance Manual Rev. 0 , Compressors

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 

All special tools shall be checked and made available, prior to starting. All possible replacement parts shall be made available and checked, dimensionally and for damage.  All energy sources for equipment to be inspected shall be locked off.  All piping and equipment openings should be covered during maintenance period.  During assembly, carefully follow the assembly drawings and reference numbers stamped on the parts that must be coupled. WARNING : Before initiating maintenance procedures, disconnect all power sources to the machine or accessories. WARNING : During disassembly and assembly operations of compressor components, heavy parts might need to be removed : employ suitable lifting appliance in order to prevent any risk for the personnel. WARNING : During maintenance operations, products considered flammable and have a relatively low order of toxicity, they should be used only in a well-ventilated area that is free from open flames. Avoid prolonged exposure to their vapors. PROCEDURE FOR STUD BOLTS TIGHTENING OF CASING VERTICALLY SPLIT CASINGS ( BCL – 2BCL – DBCL – PCL ) Tightening Smear the stud bolts threads and the mating nuts faces with Molikote. Tighten beginning with four nuts diametrically opposed one another and proceed, subsequently to tighten the remaining ones in the similar way. TORQUES TABLE Stud bolts Nominal Diameter mm

Torques kgm

Nm

M 24

20

200

M 30

40

400

M 36 x 3

80

800

M 42 x 3

130

1300

185

1800

M 48 x 3 – 2BCL 406

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M 56 x 4

305

3000

M 64 x 4

510

5000

M 72 x 4

765

7500

M 80 x 4

1225

12000

M 90 x 4

1530

15000

M 100 x 4

2240

22000

INSTRUCTIONS FOR USE OF THE HYDRAULIC EQUIPMENT FOR TIGHTENING CASE NUTS AND BOLTS ‘ENERPAC’ OLEODYNAMIC LEVER WRENCHES DRIVEN BY PUMP (PNEUMOHYDRAULIC) 1. Preliminary Checks Check the level of the oil in the pump tank. Apply the ring wrench chosen according to the ‘S ’ Hexagon opening of the nut to be tightened. Connect the flexible tube to the oleodynamic wrench chosen according to the torque wrench setting. WARNING : Ensure that the quick connections are well engaged and screwed tight 2. Operation With the hydraulic pressure exerted by the operation of the pump, a thrust is created in the cylinder which is transmitted to the ring wrench by means of a system of levers, after securing the adjustable torque arm at a fixed point. The ring wrench turns a 30º angle around the lever axis and thus transmits torque moment to the nut. Within the 30 ºC of rotation torque wrench settings according to the tolerances indicated at point 5 are obtained. The further rotation after 30º of rotation torque wrench settins according to the tolerances indicated at point 5 are obtained. The further rotation after 30º may be useful to accelerate the loosening or the first stages of tightening. Once the rotating movement ‘CYCLE’ is terminated, stop the pump, leave the control pedal and

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move it to the RELEASE (discharge) position, the wrench cylinder will automatically return to the base position. The tool is removed from the nut and re-applied for a further movement until the required tightness is obtained. Subsequent ‘CYCLE’ are carried out the predetermined PRESSURE/TORQUE is reached. Always perform a final ‘CYCLE’. WARNING : Always ensure the perfect anchoring of the adjustable torque arm of the oleodynamic wrench before using the latter. 3. Use of the equipment 3.1 Torque wrench setting Without engaging the oleodynamic wrench on the nuts. With the system completely connected and the right power supply, find the required PRESSURE/TORQUE on the conversion table (diagram) of the oleodynamic wrench. When regulating the torque, it is essential to ensure that the maximum value does not exceed that of the oleodynamic wrench. Once the PRESSURE/TORQUE value is set, the wrench may be positioned on the nut. This pressure must be regulated on the pump, press the front end of the pedal (marked ‘PRESSURE’) and keep it pressed. Read crosswise (towards the left) on the pressure gauge up to the corresponding pressure. To regulate the pressure, loosen the lock nut on the pressure regulator valve and turn the handle CLOCKWISE to increase the pressure and ANTICLOCKWISE to decrease it (see figure ). NOTE : In decreasing the pressure, the handle must be turned to a lower pressure setting value than the one required and then gradually increased to the desired level. Once the required pressure is stabilized, re-tighten the lock nut. Before starting tightening press the pump control pedal again and check that the correct pressure has been set. The handle of the control valve may be removed to prevent tampering of the regulated pressure. 3.2 Application of the oleodynamic tightening wrench Position the ring wrench on the nut and chose an angular position between the 30º and 70º of the working angle of the rotating torque arm. WARNING : Ensure that the adjustable torque arm is perfectly anchored against a fixed object (nut or casing). Temporarily apply pressure to the system to guarantee the correct operation. Maintenance Manual Rev. 0 , Compressors

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3.3 Working of the oleodynamic tightening wrench Press on the pneumatic pump control pedal in order to produce a pressure (read on the pressure gauge) corresponding to the torque required. The check on the torque wrench setting will be obtained by examining the correspondence table (diagram) between bar and kgm (bar and Nm) on the basis of the specification of the oleodynamic wrench used. 4. LOOSENING PROCEDURE Position the ring wrench on the nut and set the adjustable torque arm in the loosening position. Press the pneumatic pump pedal (already previously set at 700 bar) and keep it pressed (there will be pressure), as soon as the nut turns the cylinder will extend; once the rotating movement is terminated, stop the pump (see point 2). Repeat the operation until is possible to remove the nut by hand.

5. ACCURACY OF THE TORQUE WRENCH SETTING MODEL

CODE

TORQUE Nm

WEIGHT ACCURACY

kg

YWM 767.45

RCO 11547

640 – 4500

±4%

7

YWM 767.100

RCO 11539

1785 – 10100

YWM 767.150

RCO 11537

2100 – 14200

YWM 767.200

RCO 11608

2860 - 20000

9 ±4%

15 18,5

NOTE : For the torque wrench setting reffered to the diameter of the stud bolt to be tightened see the paragraph ‘Procedure for stud bolts tightening of casing’. 6. POWER TRANSFORMER UNIT The pneumatic pump can operate with air from 2,8 to 10,3 bar (700 bar with 5,5 bar of air). 6.1 Preliminary checks Check the oil level, the pressure and the inlet air flow rate to the unit. The unit must always be used with the FILTER/LUBRICATOR MODEL

CODE

Maintenance Manual Rev. 0 , Compressors

INLET

WEIGHT kg

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AIR 2,8-10,3 bar

7,5

7. CHECKS AND POSSIBLE PROBLEMS It is advisable to carefully read the instructions and the safety regulations before using the equipment. It is preferable that just one user operates both the oleodynamic wrench and the pump. When tightening the bolts, keep away from the vertical axis; if the bolt breaks, both the wrench and the bolt are shot along this axis. Before using the wrench with the nuts, carry out some cycles and check the efficiency; in this way, in addition, the air will be vented from the tube.. When positioning the oleodynamic wrench, arrange the tube so that it is not subject to deformation or stretching. Ensure that the quick joints are assembled correctly.

SYMPTOM Lack of pressure

Cylinder that sticks

No pressure in the wrench

PROBABLE CAUSE

REMEDY

1 – Oil level too low

1- Fill the tank

2 - Faulty pressure gauge

2- Replace

3 - Quick joints not tightened

3 –Tighten the quick joints

Air in the circuit

Vent the air in the circuit

1 – Incorrect pressure of control valve

1- Increase pressure

2 – Faulty pressure control valve/torque

2 – Replace the valve

3 – Inlet air rate too low or air tube too small

3 – Check pressure and inside diameter of tube

4 – Air filter clogged

4 - Check and clean

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8. LIST OF RING WRENCHES OLEODYNAMIC WRENCH CODE

TORQUE WRENCH SETTING Max.Nm

0

1

RCO 11547

0

4500

RING WRANCHES HEXAGON “S” CODE

SQUARE CODE

2 24

RCO 11598

27

RCO 11549

30

RCO 11550

32

RCO 11546

36

RCO 11545

41

RCO 11551

46

RCO 11544

55

RCO 11543

65

RCO 11542

70

RCO 83403

75

RCO 11552

85

RCO 83431

2,3/16”

RCO 83416

1

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SOS 63263

2 36

RCO 11631

41

RCO 11632

46

RCO 11633

50

RCO 11616

55

RCO 11590

3

½”

RCO 11584

¾”

RCO 11585

3 1” - RCO 11592 1 ½” - RCO 11547

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RCO 11539

RCO 11537

RCO 11608

10100

14200

20000

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60

RCO 11600

65

RCO 11583

70

RCO 11541

75

RCO 11591

80

RCO 11540

85

RCO 11553

90

RCO 11626

95

RCO 11554

100

RCO 11599

105

RCO 83414

75

RCO 11577

80

RCO 11578

95

RCO 11582

100

RCO 11538

105

RCO 11579

50

RCO 11579

60

RCO 11579

65

RCO 11579

70

RCO 11579

80

RCO 11579

95

RCO 11579

100

RCO 11579

105

RCO 11579

120

RCO 11579

FORK WRENCH 30 - RCO 11592 50 - RCO 11593 60 - RCO 11594

1 ½” - RCO 11588

1 ½” - RCO 11597

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- The items followed by the letter “C” refer to the Part List : “Hydraulic device H.P.” included in Volume II, Section 3 “Drawing” of this manual. -The item followed by the letter “S” refers to the Parts List : “Tools for assembling/disassembling centrifugal compressor supplied with this Job” included in section “Assembly/Disassembly Tools” of this volume: Maintenance Manual Rev. 0 , Compressors

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7C – THERMOPLASTIC TUBE 1S – “S” RING WRENCH

PROCEDURE FOR TIGHTENING BOLTS AND NUTS FOR ALL THE CENTRIFUGAL COMPRESSORS TORQUE TABLE Stud Bolt Nominal Diameter mm

Torque kgm

Nm

M6

0,5

4

M8

1

10

M 10

2

20

M 12

3,5

35

M 14

5,5

55

M 16

9

90

M 18

12

120

M 20

16

160

M 20 x 1,5

17

170

M 22

18

180

M 24

20

200

M 24 X 2

23

230

M 27 X 2

33

330

M 30

40

400

M 30 X 2

45

450

M 36

81

800

M 36 X 3

81

800

M 42

117

1150

M 42 X 3

122

1200

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PROCEDURE FOR TIGHTENING TIE RODS AND NUTS JOURNAL BEARINGS AXIALLY ASSEMBLED SCREWS TORQUES TABLE Bearing Nominal Diameter mm

Torque kgm

Nm

50 to 90

10

100

110 to 120

18

180

130

31

310

150 to 180

63

620

200

110

1080

JOURNAL BEARING ON END OPPOSITE TO THRUST BEARING (Coupled end ) Disassembly NOTE :

A ) To make easier the disassembly and the assembly of the bearing use a proper tools as shown on the Section “Assembling – Disassembling tools” B ) If it is necessary to remove the coupling remove the coupling spacer and with-draw the hub assembled on the end of the shaft. 1. Remove the equipment and instruments installed in the housing cover or in the bearing. WARNING : Be very careful not to damage cables, probes etc. 2. Remove the top half of the coupling guard and the top half of the end cover (or support) 3. Remove the locking screws of the bearing, or of the locking ring of the bearing, to the casing head. 4. Remove the bolts holding the two halves of the bearing and lift the top half. 5. Support the rotor and remove the bottom half of the bearing by rotating it through 180º

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round the shaft. 6. Disassemble the various parts of the bearing and accurately inspect the internal surfaces, make sure that there are no splits, scratches, or other damage. Carefully clean pieces individually. Blow through the entrance conduits and the oil drain conduits and clean them.

Assembly To reassemble the bearing reverse the procedure outlined for removal. WARNING : Make sure that the coupling surfaces have been correctly cleaned before proceeding To assembly the various parts. WARNING : The pads of the bearing must be assembled with the beveled portion in the opposite direction to that of the rotation of the rotor. JOURNAL BEARING AND THRUST BEARING ( Compressor no coupled to the thrust bearing end Disassembly NOTE : To make easier the disassembly and the assembly of the bearings, use proper tools as shown on the Section “Assembling-Disassembling Tools”. 1. Remove the equipment and instruments installed in the housing cover or in the bearings WARNING : Be very careful not to damage cables, probes etc. 2. Remove the closing flange and the top half of the cover. 3. Remove the housing holding the outer parts of the thrust bearing and withdraw axially it with the proper bearing elements. 4. Remove the thrust collar. 5. Remove the housing holding the inner parts of the thrust bearing and withdraw axially it with proper bearing elements. 6. Remove the bolts locking the bearing to the casing head and withdraw axially it from proper seat. 7. Disassemble the various parts of the bearings. Accurately inspect the internal surfaces make sure that there are no splits, scratches or other damage. Carefully clean pieces individually. Blow through the entrance and oil drains conduits, and clean them. JOURNAL BEARING AND THRUST BEARING Maintenance Manual Rev. 0 , Compressors

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Assembly To reassembled the bearings reverse the procedure outlined for removal. WARNING : Make sure that the coupling surfaces have been correctly cleaned before proceeding to assembly the various parts. WARNING : The pads of the journal bearing must be assembled with the beveled portion in the opposite direction to that of the shaft rotation. CHECK OF TILTING PAD BEARING CLEARANCE ( Bearing shell in one piece) 1.1 Disassemble, clean and carefully inspect all parts of the bearings for wear and other damages. 1.2 Clean and check shaft journal for wear and other damages. 1.3 Measure journal diameter with a four points check taken in the vertical and horizontal planes as both the forward and aft edge of the journal. 1.4 Measure bore of the bearing shell at four positions. 1.5 Measure each individual pad thickness at the pivot point and ensure that thickness is uniform. 1.6 Determine the clearance which exists in the bearing assembly subtracting the dimension resulting from the sum of the shaft journal diameter and the thickness of two pads from the bore of the bearing shell. As an alternative to that indicated at the position 1.4, 1.5, 1.6, bearing clearance may be measured as follows : 1.7 Manufacture a stepped mandrel whose smaller diameter is journal diameter plus minimum desired clearance and the larger diameter is journal diameter plus maximum desired clearance. 1.8 Slip the bearing over the smaller diameter of the mandrel. Ensure that the bearing rotates. 1.9 Try to slide the bearing over the larger diameter of the mandrel. 1.10 Determine if clearance is within tolerance by the resistance offered by the bearing to rotation. CHECK OF TILTING PAD BEARING CLEARANCE ( Bearing shell in two piece) 1.1 Disassemble, clean and carefully inspect all parts of the bearings for wear and other damages. 1.2 Clean and check shaft journal for wear and other damages. 1.3 Measure journal diameter with a four points check taken in the vertical and horizontal planes as both the forward and aft edge of the journal. 1.4 Measure bore of the bearing shell at four positions. 1.5 Measure each individual pad thickness at the pivot point and ensure that thickness is uniform. Maintenance Manual Rev. 0 , Compressors

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1.6 Determine the clearance which exists in the bearing assembly subtracting the dimension resulting from the sum of the shaft journal diameter and the thickness of two pads from the bore of the bearing shell. As an alternative to that indicated at the position 1.4, 1.5, 1.6, bearing clearance may be measured as follows : 1.7 Manufacture a stepped mandrel whose smaller diameter is journal diameter plus minimum desired clearance and the larger diameter is journal diameter plus maximum desired clearance. 1.8 Clamp the two shell halves of each bearing with the joint faces together. 1.9 Slip the bearing over the smaller diameter of the mandrel. Ensure that the bearing rotates. 1.10 Try to slide the bearing over the larger diameter of the mandrel. 1.11 Determine if clearance is within tolerance by the resistance offered by the bearing to rotation. CHECK OF THRUST BEARING AXIAL CLEARANCE The thrust bearing clearance is the actual distance that the rotor will travel between shoes in axial direction. The check is to be carried out as follows : a ) Attach a dial indicator to compressor casing, preferably at the thrust bearing end of the compressor, with the plunger depressed one-half, contacting the end of the rotor. b ) Apply force enough to the opposite end of the shaft to move it to the end of its travel. c ) Set dial indicator to read zero. d ) Move the rotor as far as possible towards the other end. e ) The amount read on the dial indicator is the thrust bearing clearance. CHECK OF ROTOR AXIAL DISPLACEMENT WHEN THRUST BEARING IS REMOVED a ) Remove the inboard and outboard shoe assembly b ) Attach a dial indicator to compressor casing, preferably at the thrust bearing end of the compressor, with the plunger, depressed one-half, containing the end of the rotor. c ) Move the rotor axially in one direction until it contacts the stationary parts of the casing (or diaphragms). d ) Set the dial indicator to read zero. e ) Move the rotor in the opposite direction to the end of its travel. f ) The amount read on the dial indicator is the rotor total displacement. g ) Install the inboard shoe assembly and move the rotor until the thrust collar is hard up against the shoe. Maintenance Manual Rev. 0 , Compressors

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h ) Set the dial indicator to read zero. i ) Move the rotor in the opposite direction until it stops. l ) The amount read on the dial indicator is the rotor axial displacement in one direction. m ) The rotor axial displacement is to be recorded and compared with values indicated in the machine assembly drawing.

POSITIONING OF AXIAL POSITION PROBE The axial position probe shall be set so that, when the rotor is in the center of its thrust float, zero reading is obtained on the monitor. After the check of the thrust bearing clearance force the rotor against the inboard shoes assembly, zero the dial indicator and adjust the probe gap until an indication of one half thrust bearing clearance is obtained on the axial position monitor in (-) direction. The adjustment of the probe gap shall be done in accordance with the instruction of the monitoring system manufacturer . Move the rotor as far as possible towards the other end. A rotor pump check should indicate a travel, corresponding to the thrust bearing clearance, on the dial indicator and the axial position monitor. The dial indicator should read the thrust bearing clearance. The axial position monitor should read one half of the thrust bearing clearance in (+) direction. MECHANICAL SEALS The mechanical gas seals with the proper tertiary seals are supplied by JOHN CRANE UK Ltd. NOTE : Before beginning the mechanical gas seals disassembly it is necessary to remove the journal bearings and the thrust bearing with its collar in accordance with the instructions given in the coupling spacer and disassemble the coupling hub installed on the shaft end(s). ROTOR, LABYRINTH SEALS AND DIAPHRAGMS 1. Disassembly In order to check the compressor internal components, the rotor/diaphragm bundle should be extracted from the casing. For this purpose remove first the compressor head flange on thrust bearing side, and then the rotor/diaphragm bundle. If the unit consists of two or more compressor mounted in tandem, the compressor coupled on both ends should be removed from their base. Maintenance Manual Rev. 0 , Compressors

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Use the following procedure : 1.1 Remove all piping which may cause trouble during disassembling of the casing head flange (thrust bearing side). If interstage drains or gas connections are used remove the sleeves screwed in the diaphragms.

This is important to clear the bundle disassembly/assembly. 1.2 Remove the coupling guard and coupling spacer WARNING : The coupling flange bolts are gauged and therefore they can be found with difficulty. Therefore pay attention they do not fall in the lube oil drain header. To this purpose, put temporarily a rag or plate on the oil drain hole of coupling. 1.3 Remove both end covers. 1.4 Remove the coupling hub(s) from the coupling(s) end of the shaft 1.5 Remove the thrust bearing and the journal bearings, complying with the foregoing chapters. 1.6 Remove the oil seals or the mechanical gas seals following the instructions described in ……..chapter 1.7 Remove the nuts from the reference studs of the casing head flange, thrust bearing side, and screw on them the guide pins, supplied with the standard assembling tools. 1.8 Remove all stud bolts nuts. Install jack screw in head flange and tighten evenly to force head flange out of casing. 1.9 Adjust hoisting equipment, draw out the head flange and lower it carefully to floor resting it on wooden blocks. 1.10 Remove rotor/diaphragm bundle positioning key. 1.11 Withdraw rotor/diaphragm bundle assembly as indicated in the dwg.”Ass/disass. rotor/diaphragm bundle” 1.12 Lower bundle to floor resting it on wooden blocks. Remove union bolts and dowels from bundle split line. Adjust hoisting equipment and carefully raise upper half and lower it do suitable supports 1.13 Prepare two hardwood supports having the same height and a wide enough base. Make two “V” notches where the rotor will rest for the installation in the journal bearing zone. Protect these two “V” notches with lead or other soft material. Maintenance Manual Rev. 0 , Compressors

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1.14 Wrap rope slings or plastic covered wire slings around shaft at each end. Carefully lift the rotor in good balance., guiding it by hand, to avoid damaging the labyrinths. Lower the rotor carefully to the hardwood supports.

LIFTING THE ROTOR

NOTE : Keep the rotor in good balance, guiding it by hand, to avoid damaging labyrinths, at lifting or lowering it. Be careful that slings do not bear any loads against impellers 2. Rotor and diaphragms cleaning and inspection All internal parts of the centrifugal compressor can be cleaned and inspected as follows : Maintenance Manual Rev. 0 , Compressors

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- Dirt tenaciously adheres to the impellers and diaphragms.. Treat these parts first with proper thinner such as naphtha, trichloroethylene etc., then remove it by wire brushes of different size so as to clean internal parts such as the channels of impellers and diffusers. Owing to the toxicity and flammability of some thinners, it is advisable to perform these operations outdoors or in sufficiently ventilated places.

- Rusty parts, if any, of the rotor shall be treated with deoxidizers, such as “FOSFORUST” : when wide areas are involved, the parts shall be immersed in a bath, in the other cases the deoxidizer shall be applied by brush or sprayed. - After the cleaning, cover the parts with protective oil. Should the parts have to be left outdoors, even if under roof, cover them with waterproof cloth against sand, rain, humidity. - It is a good practice not to remove the diaphragms unless are damaged. WARNING : The rotor shall be considered as a single piece and no part shall be removed except for the thrust collar should any rotor part be damaged owing to cracks, splits or material removal, the rotor completely assembled should be shipped to Nuovo Pignone for necessary repairs and balancing. -Verify the impeller condition, particularly the internal channels and check if there are corrosion signs. -Check that the thrust bearing and the rotor zones where the bearings and the seals work have no scoring. Eliminate the scoring only by means of an abrasive, very fine grain stone 3. Check of labyrinth seal clearances 3.1 Preparation a ) Place lower half diaphragm assembly horizontally on a saddle-shaped support. b ) Level lower half assembly with a precision level and lock it to the support with brackets. c ) Assemble the two half rings for rotor centering on diaphragms bundle, supplied by assembling tools for this job, in place of labyrinths at both ends of the half bundle. Position the rotor on half bundle and let the rotor supported by the two half rings d ) Position axially the rotor making the impeller outlet channel center coincide with the nozzle inlet channel center. 3.2 Side clearances a ) Gauge, by means of feeler gauges. The labyrinth seal side clearances. b ) Two values (one for each side) are taken for each labyrinth and added to each other. Maintenance Manual Rev. 0 , Compressors

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The results is then compared with the relevant value on the diametral clearance table. WARNING : Clearances shown on the table are diemetral that is total.

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