V-02260-1510-k-151-0053 Iom

RAPID PROJECT PACKAGE 3

EQUIPMENT:   1510‐K‐151  TR PROJECT NO. 02260 

 

PURCHASE ORDER NUMBER : 0226005040  REVIEW RESPONSE BY PURCHASER: 

Purchaser review and comments do not indicate either responsibility or liability for accuracy and completeness of this document or alter any  contractual terms and conditions:  Rejected 

Comment As Noted 

Reviewed With Comments 

Reviewed Without Comments

Reviewed As built 

VOID 

For Information 

DATE:     

DOCUMENT DATA VENDOR IDENTIFICATION: BURCKHARDT COMPRESSION AG 

DOCUMENT TITLE: Installation, Operation and Maintenance Manual 

VENDOR DOCUMENT NO.: IM200322_2001754 

REV: 0 

CODE:  MAN‐0001 

PURCHASER DOCUMENT NO.: V‐02260‐1510‐K‐151‐0XXX  V-02260-1510-K-151-0053

REV: A 

CLASS: O 

OWNER DOCUMENT NO.:  RAPID‐P0003‐3004‐MEC‐MAN‐1510‐0XXX  RAPID-P0003-3004-MEC-MAN-1510-0481

REV: A 

DOCUMENT NUMBER V‐02260‐1510‐K‐151‐0XXX ‐A V-02260-1510-K-151-0053-A Project  Package  Originator Discipline Doc. Type 3004  MEC  MAN  RAPID  P0003 

Rev  Unit nº 1510 

Serial nº  0XXX  0481

Page   638 

A 

PETRONAS  RAPID  PROJECT  (PACKAGE  3) 

   

         

Installation, Operation and Maintenance  Manual  1510‐K‐151                        OWNER approval:  Name:  Date   

Signature: 

  Document Class: O 

X

 

 

Pages modified under this revision:   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A 

18‐MAY‐16 

IFA ‐ Issued for REVIEW 

REV. 

DATE  DD‐MMM‐YY 

STATUS‐REVISION MEMO 

 

kalajdzisa_a 

  MUELLER_A 

WRITTEN BY 

CHECKED BY 

(name & signature) 

(name & signature) 

Sections changed in last revision are identified by a vertical line in the right margin.   

Electronic  Filename:  RAPID‐P0003‐3004‐MEC‐MAN‐1510‐0XXX_A.pdf 

  FEUSI_M  APPROVED BY (name & signature)

Burckhardt Compression AG Im Link 5 P.O. Box 65 CH-8404 Winterthur Switzerland Tel. +41 (0) 52 262 55 00 Fax +41 (0) 52 262 00 53 www.burckhardtcompression.com

Instruction Manual IM 200322en

Compressor Type 2B1XC2.64_1 Serial No. 200322

for Process Gas Compressor

Process Gas Nitrogene (N2) Project No. 2001754 Key Word PRPC PENGERANG-09 Purchaser Técnicas Reunidas S.A., MADRID, SPAIN Order No. 0226005040 Operating Company PRPC Refinery and Cracker Sdn. Bhd., PENGERANG, MALAYSIA Item No. 1510-K-151

Original instructions

Table of Contents

Table of Contents 1

Definitions for this Document

2

Elementary Safety Advice

3

Plant Configuration and Function

4

General Design and Function of Compressors

5

Transport, Installation and Pre-Commissioning

6

Operation

7

Trouble Shooting

8

Preventive Maintenance

9

Dismantle and Assemble Compressor Components

10 Clean and Degrease Plant and Compressor Components 11 Decommissioning or Dispose Plant 12 Spare Parts 13 Appendix 14 Index

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Table of Contents

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Definitions for this Document

1 Definitions for this Document 1.1 1.2 1.3 1.4

Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Legal Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2 Target Groups and Assumed Knowledge . . . . . . . 1.5 Compressor Designation . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Contact Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Structure and Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.1 Document Structure . . . . . . . . . . . . . . . . . . . . . . . 1.7.2 Visual Elements . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Term Cross Reference to API Standard . . . . . . . . . . . . . . . 1.9 Warnings and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9.1 Level of Hazard Seriousness . . . . . . . . . . . . . . . . 1.9.2 Useful Information . . . . . . . . . . . . . . . . . . . . . . . . 1.9.3 Warning Symbols Used in this Instruction Manual 1.10 Registered Trademarks and Brands . . . . . . . . . . . . . . . . . .

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1-3 1-3 1-3 1-4 1-4 1-4 1-5 1-5 1-6 1-6 1-6 1-6 1-7 1-7 1-7 1-8 1 - 10

1–1

Definitions for this Document

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Definitions for this Document Revisions

1.1 Book revision

Chapter revision

Revisions Page Technical writer

001

Date

ADK

Description First release

If there have been necessary technical modifications, the present Instruction Manual will only be adapted to these or corrected upon request. Please integrate incoming revision sheets in the Instruction Manual immediately. We greatly appreciate new ideas and recommendations for this Instruction Manual.

1.2

Copyright The copyright for this Instruction Manual remains with Burckhardt Compression. Instructions and drawings may be neither

•

partly or completely copied nor

•

duplicated, used or passed on to third parties

without our authorization. Any violation of these terms will be prosecuted.

1.3

Legal Disclaimer Burckhardt Compression warrants that its products are free of defects in design, workmanship and material upon delivery. Excluded from such warranty or any other guarantee and/or liability for defects are all deficiencies which cannot be proven to have their origin in bad material, faulty design or poor workmanship such as, but not limited to, deficiencies resulting from normal wear and tear (e.g. for compressor valve parts, packing rings, oil scraper rings, bearings and mechanical shaft seal rings, gaskets, etc.), or deficiencies resulting from improper maintenance, failure to observe the operating instructions or other reasons beyond Burckhardt Compression's control. Explicitly excluded is any warranty for wrong conservation and protection. Burckhardt Compression will not take over any liability for defects arising out of third parties' modifications or repairs.

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Definitions for this Document Purpose of this Manual

1.4 1.4.1 Reference Documents

Purpose of this Manual Scope This Instruction Manual is part of the Technical Documentation (overall compressor documentation). Some supplier documentation can be found in the appendix of this Instruction Manual. Manufacturer’s instructions for instruments and auxiliary equipment which are delivered by Burckhardt Compression can be found in the Technical Documentation. Therefore the complete Technical Documentation should always be kept near the compressor. Retain this Instruction Manual as long as the compressor is in service and hand it over to successive users.

Applicability

All instructions given in this document are valid only for the compressor(s) with serial number(s) mentioned on the cover page. The contents of this Instruction Manual are subject to technical changes. This Instruction Manual makes special reference to important details for the use of the compressor. Only when the content of this Instruction Manual has been read and understood can trouble-free operation be assured.

The Instruction Manual must be read carefully before commissioning, as Burckhardt Compression does not accept liability for damages and operating troubles resulting from neglecting the instructions here.

1.4.2

Target Groups and Assumed Knowledge These instructions have been written with the intention of being read and understood by all who are responsible for the compressor described. Personnel working at the compressor site must be qualified through training and experience.

Target group

Description

Tasks and responsibilities

Everyone

All personnel working at the compressor site

Taking care with regard to security 1, 2, 3, 4 issues

Operator

Personnel with profound knowledge of process and compressor operation

Starting and stopping the plant

5, 6, 7, 8, 9, 10, 11

Installation

Purchasing

Orders for spare parts and stock maintenance

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Surveillance tasks during compressor operation

Field service engi- Experienced field service neer engineer who has visited a Burckhardt Compression service training or has been authorized by Burckhardt Compression Purchasing/service department personnel

Chapter

Commissioning Maintenance Repair

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Definitions for this Document Compressor Designation

1.5 Name Plate

Compressor Designation Name plates are tagged to the crankgear and to each cylinder. The serial number is located on the name plates.

1

2

Fig. 1-1

1 2

3 4

1.6

3

4

5

6

7

8

PA_XX_0001b_01

The IM number in the footer of the Instruction Manual corresponds with the serial number of the compressor. If an order includes several compressors, the IM number will comply with the lowest serial number.

Example for compressor designation

Number of cranks Compressor type: B = horizontal C = vertical Number of stages Piston stroke [mm:] Q = 125 Y = 160 S = 200 X = 250, 280, 320 A = 250, 280, 320 C = 280, 315, 350 E = 315, 360, 400

5

6 7 8

Cylinder lubrication: – = lubricated C = non-lubricated Number of cylinders of 1st stage Cylinder diameter of 1st stage [cm] Revision index

Contact Address Please contact your local Burckhardt Compression Office or Burckhardt Compression Agent. For details visit our website www.burckhardtcompression.com. In case of an incident, contact our 24-hour emergency service: Tel. +41 52 262 53 53

Contact in Switzerland:

Burckhardt Compression AG Burckhardt Compression Services Sulzer-Allee 25 8404 Winterthur Switzerland Tel. +41 52 262 54 77 Fax +41 52 262 00 53 www.burckhardtcompression.com [email protected]

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Definitions for this Document Structure and Layout

1.7 1.7.1

Structure and Layout Document Structure The first four chapters are designed to familiarize you with the compressor plant. The following chapters describe compressor installation, operation and service. For your convenience, each page provides the chapter and section title in its header to make browsing the document easier.

1.7.2

Visual Elements Italicized letters emphasize the significance of a certain text passage. Bold code numbers on spare parts drawings refer to detail drawings. Illustrations may only be examples. Thus, you must not read out exact dimensions nor detailed visual appearance.

1.8

Term Cross Reference to API Standard The designation of the compressor components of Burckhardt Compression can differ to the designation of the API standard. The following table contains the comparison of the different designations. Depending on the type of the compressor, some terms listed in the table below may not be used in this manual.

1–6

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Designation according to API

Designation according to Burckhardt Compression

Anchor bolts

Foundation bolts

Auxiliary pump

Prelubrication pump

Baseplate

Skid

Crankcase

Crankgear

Crankpin bearing

Connecting rod bearing

Crankpin bushing

Crosshead pin bearing

Crankpin journal

Crankshaft journal

Crankshaft-driven lube-oil pump

Gear oil pump

Cylinder head

Valve head

Cylinder pressure packing

Piston rod packing

Motor end

Drive end

Multi-piece piston

2-piece piston 3-piece piston

Oil pump end

Non drive end

Oil-wiper packing

Oil scraper

Outboard bearing

External bearing

Outboard cylinder head

Cylinder cover

Pulsation suppressor

Pulsation damper

Shaft key

Sunk key

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Definitions for this Document Warnings and Symbols

1.9 1.9.1

Designation according to API

Designation according to Burckhardt Compression

Single-piece piston

Solid piston

Slinger

Oil shield

Slugging wrench

Flogging spanner

Valve cage, valve hold down

Lantern

Wear band, rider ring

Guide ring (rider ring)

Wiper packing rings

Wiper elements

Warnings and Symbols Level of Hazard Seriousness The following signal words are used in this Instruction Manual. Please pay careful attention to these. DANGER Your life or physical wellbeing are in serious danger if such warnings are ignored.  Follow the prevention instructions carefully.

WARNING Severe injuries or damage to the equipment can occur if such warnings are ignored.  Follow the prevention instructions carefully.

CAUTION Damage to the equipment or your tools can be the consequence if such warnings are ignored.  Follow the prevention instructions carefully.

1.9.2

Useful Information Useful information and tips make your life easier. Follow these notes for your convenience.

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Definitions for this Document Warnings and Symbols

1.9.3

Warning Symbols Used in this Instruction Manual The symbols used for safety-related notices have the following significance: Common safety sign. Generally, the triangular warning symbol indicates the possibility of personal injury or loss of life if the instructions are not followed. Whenever possible, the symbol indicates the hazard a person is exposed to more specifically. The symbols used in this Instruction Manual have the following significance:

Automatic start-up possible

Electrical danger or hazard

Machine under maintenance or overhaul

Flammable material or risk of fire

Oxidizing materials

Potentially explosive atmosphere

Hot surface, don’t touch!

Pressurized vessel or pipe – depressurize plant before you start working!

Suspended loads

Slip hazard – watch your step!

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Definitions for this Document Warnings and Symbols

Corrosion hazard, avoid contact with caustic substances!

Toxic hazard

Risk of frost or low temperature

Drawing-in and crush hazard – keep hands clear!

Read instruction for operation and maintenance

Wear hearing protection

Do not remove Instruction Manual from compressor site

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Definitions for this Document Registered Trademarks and Brands

1.10

Registered Trademarks and Brands Burckhardt Plate Valve™ is a trademark of Burckhardt Compression AG, Im Link 5, 8404 Winterthur, Switzerland. Chockfast® is a trademark of ITW Philadelphia Resins, 130 Commerce Drive, Montgomeryville, PA 18936, USA. ERMETO® is a trademark of SENIOR AEROSPACE ERMETO, F-41330 Fosse, 8, rue du Clos Thomas, Cedex, France. Keyphasor® is a trademark of Bently Nevada, Llc, 1631 Bently Parkway South, Minden, NV 89423, USA LOCTITE® is a trademark of Henkel Corporation, Henkel Loctite Deutschland GmbH, Arabellastr. 17, D-81925 München, Germany. MASTERFLOW® is a trademark of BASF, The Chemical Company. MOLYKOTE® is a trademark of Dow Corning Corporation, Corporate Center, P.O. Box 994, MIDLAND MI 48686-0994, USA. NORD-LOCK® is a trademark of Nord-Lock International AB. Nord-Lock® products are supplied by Nord-Lock GmbH, In der Waage 10, D-73463 Westhausen, Germany. PEEK™ is a trademark of Victrex plc, Hillhouse International, Thornton Cleveleys, Lancashire FY5 4QD, United Kingdom. Redura® is a trademark of Burckhardt Compression AG, Im Link 5, 8404 Winterthur, Switzerland. RUD® is a trademark of RUD Ketten, Rieger & Dietz GmbH und Co. KG, Friedensinsel, D-73432 Aalen, Germany. SERTO® is a trademark of SERTO AG, CH-8355, Aadorf, Switzerland. SUPERBOLT® is a trademark of Nord-Lock International AB. The SUPERBOLT® tensioner is supplied by Nord-Lock AG, Rietwiesstrasse 2, 8735 St.Gallenkappel, Switzerland. SWAGELOK® is a trademark of Swagelok Company, Solon Ohio, 44139, USA. Tectyl® is a trademark of Ashland Consumer Markets (Valvoline) in the Europe, Middle East and African (EMEA) region. Ashland Nederland BV, Pesetastraat 5, 2991 XT, Barendrecht, the Nederlands TURCITE® and STEPSEAL® are trademarks of Trelleborg AB (publ), P.O. Box 153, SE-231 22 Trelleborg, Sweden.

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Elementary Safety Advice

2 Elementary Safety Advice 2.1 2.2 2.3 2.4

2.5

2.6 2.7 2.8

2.9

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Avoiding Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Legal Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1 Warning Signs at Compressor Site . . . . . . . . . . . 2.4.2 Preventive Measures . . . . . . . . . . . . . . . . . . . . . . 2.4.3 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4 Mechanical Hazard. . . . . . . . . . . . . . . . . . . . . . . . 2.4.5 Thermal Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.6 Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.7 Protection against Loud Noise . . . . . . . . . . . . . . . 2.4.8 Handling Lubricants . . . . . . . . . . . . . . . . . . . . . . . 2.4.9 Handling Chemicals . . . . . . . . . . . . . . . . . . . . . . . Explosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1 Explosion Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2 Protection Principles. . . . . . . . . . . . . . . . . . . . . . . Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1 Cleaning of Compressor Plant . . . . . . . . . . . . . . . 2.8.2 Compressor Maintenance . . . . . . . . . . . . . . . . . . 2.8.3 Commissioning after Maintenance . . . . . . . . . . . . Process Gas and Purge Gas . . . . . . . . . . . . . . . . . . . . . . . 2.9.1 Gas Specification . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2 Hazard Identification Diamond . . . . . . . . . . . . . . . 2.9.3 N2 Nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Elementary Safety Advice

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Elementary Safety Advice Avoiding Dangers

2.1

Avoiding Dangers Safety means recognizing and avoiding dangers as well as knowing and controlling the process. The compressor is designed and built in accordance with the present stateof-the-art technology and the recognized technical safety regulations. Nevertheless, risks to users, property, and environment can arise when the compressor is operated carelessly or improperly. The compressor may only be operated if the following criteria are taken into consideration:

• •

2.2 CE Conformity

the compressor’s faultless operation, with special regard to safety requirements.

Legal Regulations Please refer to Quality Documentation for the applicable declaration of conformity issued for this project:

• • •

2.3

the compressor’s intended use,

EC Machinery Directive 2006/42/EC Pressure Equipment Directive 97/23/EC Atmospheric Explosion Protection 94/9/EC

Obligations The safety of personnel can only be ensured if these safety instructions and the safety notices in this manual are strictly observed and followed. Therefore, the Instruction Manual must always be available to all people performing the tasks described. Additionally, general national rules of accident prevention and occupational medicine must be observed.

Superior Authority’s Obligations

It is the superior authority’s responsibility to

•

specify who is authorized to install, commission, prepare, operate, maintain and repair the compressor,

• • •

prevent unauthorized persons from tampering with the compressor,

• • •

equip personnel with adequate protective clothing,

check personnel’s security awareness regularly, induce inspection of all control equipment and safety devices on a regular basis, integrate incoming revision sheets into the Instruction Manual, inform personnel about revisions.

The superior authority may only allow personnel to operate the compressor who are

• •

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qualified through practical experience and training on the compressor, familiar with basic work safety and accident prevention regulations.

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Elementary Safety Advice Obligations

Trainees may only operate the compressor under supervision of an experienced person. The compressor must be operated and maintained in such a way that the safety of the operator, maintenance personnel or third party is guaranteed at all times. Personnel’s Obligations

Personnel charged with duties on the compressor plant

•

must check with their supervisor and/or safety officer if a work and entry permit is required,

•

must have read and understood the respective parts of the Instruction Manual,

•

must observe basic work safety and accident preventing regulations before they start working on the compressor,

•

is obliged to report any changes on the compressor which might impair safety, e.g modification of mode of operation or unusual noise,

•

must know the hazards and limitation of compressor operation imposed by the process.

Only operate the compressor when it is in faultless condition. Eliminate faults which could impair safety immediately by professionals according to chapter 7 Trouble Shooting.

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Elementary Safety Advice Safety Measures

2.4 2.4.1

Safety Measures Warning Signs at Compressor Site Corresponding warning signs must be fitted on the installation. Notices at the compressor site must be easily legible, clearly understandable and of durable quality. Never remove warning signs nor safety alerts from the compressor. Replace damaged signs or signs that have come off immediately.

Wear hard hat!

Wear protective goggles!

Wear hearing protection!

Wear protective gloves!

Wear safety shoes in this area!

Slip hazard – watch your step!

Pressurized vessel or pipe – depressurize plant before you start working!

Hot surface, don’t touch!

Corrosion hazard, avoid contact with caustic substances!

2.4.2

Preventive Measures • •

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Provide approved fire-extinguishing equipment. Provide marked escape routes furnished with emergency stop devices.

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Elementary Safety Advice Safety Measures

2.4.3

Safety Devices The safety devices installed on the compressor plant must be neither removed nor disabled during operation. If such devices have been removed, e.g. for maintenance work, resume operation only after you have fully installed and checked all safety devices.

2.4.4

Mechanical Hazard DANGER Rotating components, drawing-in and crush hazard! Exposed rotating components can cause severe injury or death.  Do not operate the compressor with flywheel guard removed!  Follow lockout procedure before maintenance.

2.4.5

Thermal Hazard WARNING Hot or cold surface! Burns, scalds and other injuries may possibly arise through direct contact with plant components of an extreme high or low temperature.  Fit installation with corresponding warning signs.

2.4.6

Electrical Hazard Installation and maintenance of electrical parts must be performed by professionals. All the electrical equipment and the installations must be maintained periodically to prevent danger. Burckhardt Compression strongly recommends that this includes an appropriate visual inspection and testing, where necessary. DANGER Electrical danger or hazard.  Before any inspection or repair on the compressor or any related electrical item, turn high and/or low-voltage main switch off at the switch box and padlock the switch in the off-position.  Always keep control panel and/or local operator panel locked. Only authorized personnel may have access.  Do not allow work on or near exposed live parts of equipment unless it is absolutely unavoidable. Suitable precautions must be taken to prevent injury, both to workers and to anyone else who may be in the area.

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Elementary Safety Advice Safety Measures

2.4.7

Protection against Loud Noise Personnel must be equipped with hearing protection if the continuous sound pressure level meets 85 to 87 dB(A) per day or week. For sound pressure level figures see section “Technical Data” in chapter 13 Appendix.

2.4.8

Handling Lubricants For more detailed information see Material Safety Data Sheet (MSDS) from supplier.

Hazards

Under normal condition of use, lubricants are not considered hazardous according to regulatory guidelines. Nevertheless, the superior authority is obliged to inform the personnel handling lubricants about possible dangers to humans and the environment which are imposed by the particular material. Hazard classification can be made according to:

• • •

flash point, toxicity, MAC-value (Maximum Allowable Concentration for working area).

DANGER Health hazard! Excessive exposure can irritate the eyes, skin or respiratory system. Slip hazard.  Wear oil-resistant gloves and/or other protective clothing when handling lubricants.  If eye contact is likely, wear protective goggles.  If mists are generated, and/or when ventilation is not adequate, wear approved respirator mask.  Do not eat, drink or smoke.

DANGER Fire and explosion hazard!  No open fire.  No smoking.

Storage, Labeling

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• •

Do not store in open or unlabeled containers.

• •

Storage areas must be marked with clearly visible warning signs.

Do not store near heat, sparks, flame or strong oxidants and combustible materials. In storage rooms, good ventilation must be ensured.

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Elementary Safety Advice Safety Measures

• •

Oils must be recycled, return them to the supplier.

•

It is strictly forbidden to dispose of lubricants in toilets, cleaning rooms, water drains or to discharge to the ground or waste containers etc.

Leak Response

•

Adsorb any spillage with appropriate material and remove mechanically into containers.

Fire-Fighting Measures

•

Extinguish fire with carbon dioxide, extinguishing foam or dry chemical. Do not use water.

First Aid

•

Should eyes have been affected, rinse immediately for 15 minutes with large quantity of water (eye wash).

• • •

Remove oil soaked clothing.

Disposal

2.4.9 Hazards

Take care of the environment: dispose of lubricants according to national regulations.

Rinse affected skin with soap and water. If irritation occurs, get medical attention.

Handling Chemicals The superior authority is obliged to inform the personnel handling chemicals about possible dangers to humans and the environment. Hazard classification can be made according to:

• • •

flash point, toxicity, MAC-value (Maximum Allowable Concentration for working area).

DANGER Health hazard and fire hazard! Chemicals can be toxic, caustic, flammable and explosive.  Do not eat, drink or smoke in the proximity of chemicals!  Before handling any chemicals, • pay attention to the warning symbols, peril indications and safety advice on the label of the storage container, • familiarize yourself with procedures in the event of contamination, poisoning, corrosion, spilling, leakage of unknown substance.  Always wear adequate protective clothing when handling chemicals.

Storage, Labeling

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• •

Do not store chemicals in open containers.

• • •

Combustibles must be kept in specially marked containers.

Label chemical containers clearly in accordance with the valid regulations (chemical act). Those who draw off chemicals are responsible for labeling containers. Storage areas must be marked with clearly visible warning signs. Ensure good ventilation in storage rooms.

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Elementary Safety Advice Safety Measures

Handling

Disposal

• •

Don’t spill chemicals.

•

Take care of the environment: dispose of chemicals according to national regulations.

•

It is strictly forbidden to dispose of chemicals in toilets, cleaning rooms, water drains, into the ground or waste containers etc.

Use a funnel, transfer pump and collecting tub for drawing off chemicals.

Acids and Lyes DANGER Health hazard! If water is added to concentrated acids or lyes, it can boil and spit dangerously. Inhalation of vapors or aerosols may lead to severe lung damage. Skin or eye contact leads to chemical burn (danger of blindness).  Avoid any contact with eyes and skin.  Use face shield or heavy protective goggles, suitable protective gloves and apron.  If vapors form, wear approved respirator mask.  If large amounts of vapors occur, leave danger zone immediately.  Dilution: always pour concentrated acids or lyes/caustic soda into water while stirring, never contrariwise.

DANGER Fire hazard! Flammable acids or lyes: danger of fire, vapors form explosive mixtures with air.  No open fire.  No smoking.

Leak Response

•

Adsorb any spillage with appropriate material (e.g. diatomaceous earth, mountain flour).

•

Subsequently clean thoroughly with water.

Fire-Fighting Measures

• •

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If possible, quench small fires by means of a fire blanket. Extinguish fire with carbon dioxide or dry chemical. Do not use water.

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First Aid

•

Should eyes have been affected, rinse immediately for 15 minutes with large quantity of water (eye wash).

• • •

Remove wet clothing at once. Rinse affected skin immediately with large quantity of water. Get immediate medical attention – take Material Safety Data Sheet (MSDS) to physician with victim.

Organic Solvents DANGER Health hazard! Organic solvents can be toxic and narcotic. They degrease the skin.  Avoid all contact with eyes and skin.  Use protective goggles and suitable protective gloves.  If vapors form, wear approved respirator mask.  If large amounts of vapors occur, leave danger zone immediately.

DANGER Fire and explosion hazard! Organic solvents can be flammable. They evaporate quickly and can form explosive mixtures with air or can ignite by contact with hot surfaces.  No open fire.  No smoking.  Avoid escape of vapors.  Eliminate any possible source of ignition including sparks and electrostatic discharge.

Leak Response

•

Adsorb any spillage with appropriate material (e.g. diatomaceous earth, mountain flour) and remove mechanically into tightly closing containers.

•

Make sure that there is sufficient circulation of fresh air. Wear approved respirator mask.

•

Eliminate any possible source of ignition.

Fire-Fighting Measures

• •

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If possible quench small fires by means of a fire blanket. Extinguish fire with carbon dioxide, extinguishing foam or dry chemical. Do not use water.

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Elementary Safety Advice Explosion Protection

First Aid

2.5 2.5.1

•

Should eyes have been affected, rinse immediately for 15 minutes with large quantity of water (eye wash).

• • • •

Remove wet clothing at once. Rinse affected skin immediately with large quantity of water. Give artificial respiration if victim is not breathing. Get medical attention – take Material Safety Data Sheet (MSDS) to physician with victim.

Explosion Protection Explosion Risk An explosive atmosphere normally requires oxygen and flammable substances in a certain ratio to each other. For an explosion to occur, also a corresponding ignition source is required such as open flames, hot surfaces, electrical or mechanical sparks, electrostatic discharge (e.g. even tiny quantities of ignition energy from the clothing worn by workers), short circuits, ultrasonics, electromagnetic radiation, shock waves and adiabatic compression.

2.5.2

2.6 Correct Application

Protection Principles •

Rule out the risk of creating an explosive atmosphere right from the very start. For example, purge the compressor plant with nitrogen to avoid generating explosive mixtures.

•

Avoid the ignition of an explosive atmosphere by using corresponding machines, parts and materials, as well as complying with corresponding instructions and procedures for working in such areas.

•

The last measure is limiting the effects of an explosion to a harmless level (e.g. by means of corresponding constructional measures, or cautious selection of the erection site).

Intended Use This compressor type is exclusively designated for the compression of gas as specified for this application (see section 2.9.1 Gas Specification). Any other use is considered improper and is strictly forbidden. Appropriate utilization includes adherence to instructions for installation, dismantling, assembly, commissioning, operation and maintenance specified by the manufacturer.

Incorrect Application

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Any utilization beyond this specific designation is considered as not to conform to designation. Burckhardt Compression will not be liable for damages resulting from incorrect application. The risk of such non-permissible applications must be borne solely and entirely by the operating company.

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Elementary Safety Advice Compressor Operation

If you want to extend the contractual range of application, please consult Burckhardt Compression Services in Switzerland. Address see section 1.6 Contact Address.

Design Changes of Compressor

Modifications to the compressor plant are only permitted with the written approval of Burckhardt Compression. We will decline any claim resulting from unauthorized modifications.

Software Changes

Do not change the code of software programs under any circumstances!

2.7

Compressor Operation For the operation of the compressor, local, state, federal laws and safety rules must be adhered to (e.g. smoking ban, open flame, placing spectacle flanges or blanks etc.). When operating with process gas, access to the compressor might be hampered for safety reasons. Nevertheless, the safe operation of the plant must be assured.

2.8 2.8.1

•

Prior to starting the compressor, make sure that nobody will be harmed by the starting compressor.

•

Check compressor and plant for visible damages and for faults of safety devices at least once per shift.

•

Check pressure and temperature values periodically.

Safe Maintenance Practices Cleaning of Compressor Plant Keep the compressor and surrounding area clean and tidy. Use appropriate cleansing agents and materials. For safe use of cleansing agents see section 2.4.9 Handling Chemicals. Please take care of the environment! DANGER Fire hazard! Dust accumulation on large, hot surfaces (e.g. compressor or main motor) might cause an ignition source within an explosive atmosphere. In this case operator is obliged to specify a regular cleaning procedure.  Special attention must be assured, to avoid dust accumulation on compressor surface and related auxiliaries.  Follow cleaning instructions given in chapter 10 Clean and Degrease Plant and Compressor Components.

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Elementary Safety Advice Safe Maintenance Practices

2.8.2

Compressor Maintenance Carry out adjustments, preventive and corrective maintenance according to intervals given in the maintenance manuals. Before beginning any inspection or repair

•

protect all plant components such as main motor, oil and cooling system pumps, pneumatic or hydraulic control systems etc. against unintended start-up,

• •

depressurize compressor plant,

•

make sure there is sufficient circulation of fresh air.

in case of flammable or toxic process gas, purge compressor plant with dry nitrogen,

Only use original equipment manufacturer (OEM) spare parts, otherwise the operational safety of the compressor cannot be assured. WARNING Limited operational safety! The specially designed characteristics of the compressor or related plant components and/or their operational safety may be influenced negatively (= increased risk) by improper actions.  Do not modify parts or spare parts.  Use genuine spare parts only.  Do not use unsuitable material.  Do not modify clearances on compressor.  Eliminate troubles immediately.  Replace worn parts.

CAUTION Increased risk! Damage to the equipment or risk of injury can occur.  Only use original (OEM recommended) tools.  Only use special tools delivered with compressor.  Clean tools after use and store them in a closed and corrosion-resistant cabinet nearby the compressor.

2.8.3

Commissioning after Maintenance Before commissioning,

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•

check working order of compressor and motor by turning the flywheel min. 1 rotation in running direction,

•

fit flywheel guard and assure working order.

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Elementary Safety Advice Process Gas and Purge Gas

2.9 2.9.1

Process Gas and Purge Gas Gas Specification Process gas composition

Normal case [mol%]

N2

100.00%

Nitrogen

Purge gas N2

Normal case Nitrogen

100.00%

Buffer gas N2

Normal case Nitrogen

100.00%

Summary information about above mentioned gases or foreign matters in process gas (if applicable) see later in section 2.9.

For in-depth safety information, please consult the respective Material Safety Data Sheets, e.g. on the Internet.

2.9.2

Hazard Identification Diamond The hazard identification symbol is a color-coded array of four numbers or letters arranged in a diamond shape. Example: see Fig. 2-1. Hazard identification diamonds like this are placed on storage tanks, bottles of chemicals and in various other places around the plant. The blue (health hazard), red (flammability) and yellow (reactivity) fields all use numbering scale ranging from 0 to 4, according to National Fire Protection Association (NFPA-Rating). A value of zero means that the material poses essentially no hazard; a rating of four indicates extreme danger. The white field (specific precautions) can have variable content, depending on who prepared the signal.

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Flammability 0 Material will not burn. 1 Material must be pre-heated before ignition can occur. 2 Material must be moderately heated before ignition can occur. 3 Material can be ignited under almost all ambient temperature conditions. 4 Highly flammable at all temperatures. Reactivity Health Hazard

0 Material that in itself is normally stable.

0 No specific danger under fire conditions. 1 Material that on exposure would cause irritation but only minor residual injury. 2 Material that on intense or continued but not chronic exposure could cause temporary incapacitation or possible residual injury.

1 Material can become unstable at elevated temperatures and pressures.

3 4

2 W

3 Material that on short exposure could cause serious temporary or residual injury.

2 Violent chemical change at elevated temperatures and pressures or violent reaction with water (may form explosive mixtures with water). 3 Explosion hazard under impact of heat or shock/bash or explosive reaction with water.

4 Material that on very short exposure could cause death or major residual injury.

4 Material is highly explosive at normal temperatures and pressures.

W

Shows unusual reactivity with water. Don’t use water as an extinguishing agent!

OX

Material possesses oxidizing properties.

Fig. 2-1

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Specific Precautions (National Fire Code)

Hazard identification diamond

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2.9.3

N2 Nitrogen NFPA-rating for nitrogen. Explanation see section 2.9.2 Hazard Identification Diamond.

0 0

0

Health = 0 Fire = 0 Reactivity = 0

For in-depth safety information, please consult the respective Material Safety Data Sheets, e.g. on the Internet.

DANGER Health hazard! Risk of suffocation! Nitrogen gas is an asphyxiant and presents a health hazard by displacing the oxygen in the atmosphere. At high concentrations, unconsciousness or death may occur.  Depressurize the installation before you open the compressor.  When working on the compressor, make sure there is sufficient circulation of fresh air.  Be aware of any signs of dizziness or fatigue. Exposures to fatal concentrations of nitrogen could occur without any significant warning symptoms.  During an emergency situation, before entering the area, check for oxygen-deficient atmospheres.

Fire-Fighting Measures Leak Response

First Aid

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Nitrogen does not burn – however, containers, when involved in fire, may rupture or burst in the heat of the fire.

•

Wear self-contained breathing apparatus to rescue people and to seal leak.

• •

Evacuate the affected area.

• • •

Remove victims to fresh air, as quickly as possible.

Seal leak, when possible without risk.

Give artificial respiration if necessary. Get immediate medical attention – take Material Safety Data Sheet (MSDS) to physician with victim.

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Plant Configuration and Function

3 Plant Configuration and Function 3.1 3.2 3.3

3.4 3.5

3.6

3.7

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Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Pneumatic Barring Device . . . . . . . . . . . . . . . . . . Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.3 Buffer Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.4 Pulsation Damper . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Avoiding Deposits. . . . . . . . . . . . . . . . . . . . . . . . . Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 Oil Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3 Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.4 Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.5 Oil Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . Control and Operating Elements . . . . . . . . . . . . . . . . . . . . 3.6.1 Local Instrument Board (LIB) . . . . . . . . . . . . . . . . 3.6.2 Local Operator Panel (LOP) . . . . . . . . . . . . . . . . . Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.1 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.2 Temperature Monitoring . . . . . . . . . . . . . . . . . . . . 3.7.3 Pressure Monitoring . . . . . . . . . . . . . . . . . . . . . . . 3.7.4 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.5 Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.6 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.7 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.8 Vibration Monitoring . . . . . . . . . . . . . . . . . . . . . . . 3.7.9 Piston Rod Monitoring . . . . . . . . . . . . . . . . . . . . . 3.7.10 Level Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.11 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.12 Flywheel Guard . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.13 Proximity Probe for Barring Device . . . . . . . . . . .

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3-3 3-3 3-4 3-5 3-5 3-6 3-7 3-7 3-8 3-8 3-8 3 - 10 3 - 10 3 - 10 3 - 10 3 - 10 3 - 11 3 - 11 3 - 11 3 - 12 3 - 12 3 - 13 3 - 13 3 - 13 3 - 13 3 - 13 3 - 13 3 - 14 3 - 14 3 - 14 3 - 14 3 - 14

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Plant Configuration and Function

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Plant Configuration and Function Overview

3.1

Overview The term “safe location”, as used in this Instruction Manual, may refer to any location to which the process gas, purge or buffer gas can be taken safely, e.g. flare, atmosphere or any other location. For details about the applied safe location, please refer to section “P & I Diagram” in chapter 13 Appendix.

The process gas is compressed to the required pressure by a process gas compressor with appropriate number of stages. The compression act generates heat, therefore certain compressor components and in most cases the compressed gas must be cooled. The lubricating system assures that bearing and crosshead are sufficiently lubricated.

3.2

Drive System

Fig. 3-1

Process gas compressor with flexible coupling

The compressor is driven by a direct coupled electric motor. For better illustration, Fig. 3-1 shows a typical view without flywheel guard.

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Plant Configuration and Function Drive System

DANGER Rotating components, drawing-in and crush hazard! Exposed rotating components can cause severe injury or death.  Do not operate the compressor with flywheel guard removed!  Follow lockout procedure before maintenance.

For the description of the electric motor refer to the documentation of the motor manufacturer.

3.2.1

Pneumatic Barring Device 1

2

3

PB_L1_0049b_01

4

Fig. 3-2 1 2 3 4

Pneumatic barring device

Flywheel Pawl Proximity probe Barring device

For maintenance purposes a pneumatically operated barring device is fitted. An engaged barring device turns on the flywheel compressor and motor. A proximity probe prevents compressor start-up with engaged barring device. For description of barring device, refer to manufacturer’s documentation.

For detailed description of the pneumatic driven barring device refer to the manufacturer’s documentation (see Customer Documentation or Technical Documentation).

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Plant Configuration and Function Gas System

3.3

Gas System For information about the gas system see section “P & I Diagram” in chapter 13 Appendix.

3.3.1

Suction Strainer To prevent foreign matter from entering the compressor from the suction side, fit a suction strainer of sufficient strength and appropriate mesh size in the suction line to the first stage. Install according to client’s and manufacturer’s instructions. If you have any doubts or questions concerning the appropriate strength or mesh size of the suction strainer, please contact Burckhardt Compression Services, address see section 1.7 Contact Address. CAUTION Heavily contaminated gas or very hard foreign particles can damage the suction strainer.  Observe the specifications concerning the gas composition.

3.3.2

Purge System Dependent on the chemical properties of the process gas, a purge system is required to protect personnel and equipment.

Components of Purge System

For layout of the purge system see section “P & I Diagram” in chapter 13 Appendix.

Purging during Normal Operation

During normal operation of the compressor, the distance piece is continuously purged with nitrogen. This procedure avoids process gas entering the crankgear which may otherwise alter the viscosity of the lubricating oil or could result in a corrosive or explosive atmosphere in the distance piece or crankgear.

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Plant Configuration and Function Gas System

A

1 2

3

5

4 B

C

Fig. 3-3

A) B) C) 1) 2)

Purging prior to Maintenance or Normal Operation

3.3.3

PB_XX_0006c_01

6

Purge system (typical view)

Cylinder Distance piece Crankgear Leak gas from piston rod packing Buffer gas to piston rod packing

3) 4) 5) 6)

Purge gas to distance piece Buffer gas to distance piece packing To flare Via breather to atmosphere

After operation of the compressor with a toxic, explosive or flammable process gas (if applicable), the compressor plant must be purged with dry inert gas like nitrogen prior to performing any maintenance work. The same applies after maintenance, prior to normal operation with an explosive or flammable process gas or if contamination of process gas with air must be prevented.

Buffer Gas Depending on the chemical properties of the process gas, buffer gas is required to protect personnel and equipment. During normal operation of the compressor, the piston rod packing and the distance piece packing is supplied with buffer gas. The excessive buffer gas is led to a process gas dependent safe location (see section “P & I Diagram” in chapter 13 Appendix). This procedure avoids process gas entering the crankgear which may otherwise alter the viscosity of the lubricating oil or could result in a corrosive or explosive atmosphere in the distance piece or crankgear.

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Plant Configuration and Function Cooling System

3.3.4

Pulsation Damper Up- and downstream of the process gas line pulsation dampers are fitted to reduce gas pulsations in the piping. For further reduction of pulsations, orifice plates are fitted on the pulsation damper.

XA_P3_0001b_01

1

Fig. 3-4 1

3.4

Pulsation damper (typical view)

Orifice plate (detail see section “Technical Data” in chapter 13 Appendix)

Cooling System For information about the cooling system see section “P & I Diagram” in chapter 13 Appendix. The compression of the process gas generates heat which is almost completely dissipated by the coolant. A clean, non-corrosive coolant with a sufficient low freezing point must be used. Via a supply manifold, the coolant is led to the individual elements. At commissioning, the various control valves must be adjusted: the coolant flow rates at minimum allowable coolant pressure must still be sufficient – even during the summer months – to prevent the outlet flow temperature of the coolant rising above the max. admitted value. Manually operated control valves are installed in the individual coolant lines allowing to optimize the outlet temperature of the coolant. The drain valves in the cooling system can be used for blowing in air or flushing suspended matters/deposits while the plant is in operation.

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Plant Configuration and Function Lubricating System

CAUTION Risk of frost! If the ambient temperature and/or gas temperatures drop below 0 °C and if cooling water without or inappropriate antifreeze solution is used, the cooling water may freeze.  Use always appropriate antifreeze solution.

3.4.1

Avoiding Deposits A minimal flow of coolant must always be maintained. CAUTION Deposits in piping!  Avoid stationary coolant.

3.5

Lubricating System For information about the lubricating system see section “P & I Diagram” in chapter 13 Appendix.

Technical information of components as well as operating and maintenance instructions of accessories: see Technical Documentation.

The lubricating system guarantees that bearing and crosshead are lubricated. The lubricating oil circulates in a closed system. Prelubrication Pump

The prelubrication pump provides lubricating oil to bearing and crosshead before the compressor is started. Therefore, the prelubrication pump must be started a short time before the compressor is started. The prelubrication pump must also be started at a compressor shutdown or if the compressor has been stopped by one of the safety devices except of low lubricating oil pressure and emergency stop.

Gear Oil Pump

During compressor operation, lubrication is ensured by the gear oil pump, which is driven by the crankshaft. The temperature control valve maintains the defined oil temperature. The temperature control valve makes the lubricating oil bypass the oil cooler if the oil temperature is below the preset value.

3.5.1

Oil Skid This is a general function description. As built illustration see section “General Arrangement” in chapter 13 Appendix.

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Plant Configuration and Function Lubricating System

1 2 4

3

11 10 9 8 PA_XX_0067b_01

7 5

6

Fig. 3-5

1 2 3 4 5 6

Oil skid (typical view)

Oil cooler Temperature indicator Temperature control valve Pressure control valve Shut-off valve Duplex oil filter

7 8 9 10 11

Non-return valve Pressure gauge or transmitter Lubrication pump Oil tank Sight glass

During normal operation, the lubrication pump sucks oil from the oil tank through the oil strainer, forcing it through the oil cooler (1) and the duplex oil filter (6) to the compressor bearing and crosshead. The lubrication pump (9) provides lubricating oil to bearing and crosshead before the compressor is started. The non-return valve in the lubricating system prevents the standby oil pump from turning backwards and lubricating oil from leaking back to the oil tank due to the operating pressure of the lubricating oil. The shut-off valves (5) up- and downstream of the lubrication pump remain normally open. They are closed for maintenance work on the lubrication pump.

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Plant Configuration and Function Control and Operating Elements

Duplex Oil Filter

3.5.2

The duplex oil filter consists of two filter housings and is equipped with a differential pressure indicator or switch. During normal operation, the oil flows through one of the two filter elements. If the degree of contamination exceeds the tolerance threshold (differential pressure between filter inlet and outlet) the operator must switch to the other filter element. The contaminated filter element can be cleaned/replaced whilst the plant continues operating.

Oil Drain The oil drain is installed on the oil tank.

3.5.3

Oil Strainer For each oil pump an oil strainer is installed in the suction line of the oil tank to prevent solid contaminants in the lubricating system.

3.5.4

Oil Level Transmitter A level transmitter is installed in the oil tank to protect the compressor from low lubricating oil level.

3.5.5

Oil Sight Glass A sight glass on the oil tank allows local observation of lubricating oil level. When the compressor is running, 1/2 of the oil sight glass should be covered.

3.6

Control and Operating Elements DANGER Electrical danger or hazard.  Before any inspection or repair on the compressor or any related electrical item, turn high and/or low-voltage main switch off at the switch box and padlock the switch in the off-position.  Always keep control panel and/or local operator panel locked. Only authorized personnel may have access.  Do not allow work on or near exposed live parts of equipment unless it is absolutely unavoidable. Suitable precautions must be taken to prevent injury, both to workers and to anyone else who may be in the area.

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DANGER Automatic start-up possible! Severe injuries caused by unexpected start-up of compressor.  Before any inspection or repair on the compressor turn high and/or lowvoltage main switch off at the switch box and padlock the switch in the off-position.  If this is not possible, make sure there is no way of starting the compressor (disconnect control panel, PLC etc.).

3.6.1

Local Instrument Board (LIB) For detailed description of the local instrument board refer to the documentation of the manufacturer (see Technical Documentation).

Various instruments are installed on the local instrument board. For more information about these instruments see section “Instrumentation” in chapter 13 Appendix.

3.6.2

Local Operator Panel (LOP) For detailed description of the local operator panel refer to the documentation of the manufacturer (see Technical Documentation).

On the local operator panel (LOP) the main motor of the compressor as well as auxiliary equipment can be started and stopped. The local operator panel is either installed on the local instrument board (LIB) or is a stand-alone panel. In any case, the LOP must be installed right beside the compressor unit. For applicable installation see Technical Documentation.

3.7

Safety Devices For detailed description of safety devices refer to the documentation of the manufacturer (see Technical Documentation).

The installation points of safety devices are given on the corresponding “P&I Diagram” in chapter 13 Appendix. For set values of safety devices see section “Instrumentation” in chapter 13 Appendix.

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Plant Configuration and Function Safety Devices

The final settings of the safety devices are determined during pre-commissioning of the compressor plant by our specialists – according to the actual operation values. DANGER Inoperable safety devices! Risk of severe injuries.  To ensure correct operation, the safety devices (setpoints, switching points etc.) must be tested and calibrated periodically.  Safety devices must only be attended to by authorized personnel. Safety devices must not be isolated, bypassed or have their settings changed without authorization.  Defective safety devices must be replaced immediately.

3.7.1

Emergency Stop To permit an immediate shutdown of the compressor in an emergency situation, an emergency stop button must be installed nearby the compressor.

Use this safety device only in emergency situations and not to shut down the compressor under normal conditions.

3.7.2

Temperature Monitoring Temperature safety devices protect the compressor against excessively high or low temperatures. Thermostats which protect the compressor against high temperatures must be adjusted to a value of about 10–15 °C above the maximum operating temperature (considering bypass operation, if applicable). Various temperature indicators allow local observation and remote monitoring of temperature values.

Temperature Monitoring of Piston Rod Packing

The temperatures of the piston rod packings are monitored. The thermocouples are installed in the packing flange. Elevated temperatures are a result of increased gas leakage from the packing rings. If the temperature of a piston rod packing is above the critical value, an alarm is triggered.

Temperature Monitoring of Suction and Discharge Valves

The temperatures of suction and discharge valves are monitored. The thermocouples are installed in the valve cover. Elevated temperatures are a result of defective or contaminated valves etc. If the temperature of a valve is above the critical value, an alarm is triggered.

Temperature Monitoring of Main Bearings

The temperatures of main bearings are monitored. The thermocouples are installed in the bearing cover.

Temperature Monitoring of Oil

The temperature of oil is monitored. The thermocouples are installed on the oil skid.

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Plant Configuration and Function Safety Devices

3.7.3

Pressure Monitoring Pressure safety devices protect the compressor against excessively high or low pressures. Pressure transmitters are used for remote monitoring of pressure values and to control the control valves (if applicable). Pressure gauges allow local observation of pressure values. Protection against excessive pressure shall be implemented by plant owner.

3.7.4

Safety Valve Mechanical safety valves protect the compressor and its auxiliary equipment against excessive pressures. Safety valves are the ultimate protection devices for compressor, vessels and pipes. They must be inspected periodically with regard to plant operating conditions. Each stage is safeguarded by a mechanical safety valve which opens at excessive pressure and exhausts to a process gas dependent safe location as indicated on the corresponding “P&I Diagram” in chapter 13 Appendix. Under operating conditions, due to gas pulsations, the safety valves can blow off at pressures slightly below the set values. Design and installation of safety relief valves is plant owner responsibility.

3.7.5

Relief Valve The lubricating system and the cooling system are equipped with spring loaded relief valves.

3.7.6

Breather The breather are installed on the frame cover to prevent pressure fluctuation (due to pump effect of crosshead) in the crankgear.

3.7.7

Non-Return Valve A non-return valve (in client’s scope) is installed in the discharge line to prevent process gas from flowing back to the compressor system. The non-return valve in the lubricating system prevents the prelubrication pump from turning backwards and lubricating oil from leaking back to the crankgear due to the operating pressure of the lubricating oil.

3.7.8

Vibration Monitoring Vibration monitoring of the piston rod is done by the proximity probe(s) installed in the packing flange.

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Plant Configuration and Function Safety Devices

A vibration sensor protects the compressor from destructive shocks due to excessive vibrations caused by loosening of bolted connections, damaged piston, valves and bearings. If the recorded values exceed a defined limit, the compressor will be shut down.

3.7.9

Piston Rod Monitoring Proximity probes are installed on piston rod packing flanges to monitor the piston rod. The system protects the compressor from excessive rod vibration. The guide ring (rider ring) wear is also evaluated based on the signal of this sensor.

3.7.10 Lubricating System

3.7.11 Lubricating System

3.7.12

Level Monitoring A level transmitter is installed in the oil tank to protect the compressor from low lubricating oil level.

Level Indicator A sight glass on the oil tank allows local observation of lubricating oil level.

Flywheel Guard A proximity switch is installed on the flywheel guard to prevent the compressor from starting with engaged bar or barring device.

3.7.13

Proximity Probe for Barring Device A proximity probe is installed on the pneumatic barring device (see Fig. 3-2) to prevent the compressor from starting with engaged barring device.

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General Design and Function of Compressors

4 General Design and Function of Compressors 4.1 4.2

4.3

4.4

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Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Non-Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.4 Connecting Rod and Crosshead . . . . . . . . . . . . . Distance Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Oil Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Distance Piece Packing . . . . . . . . . . . . . . . . . . . . Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . 4.4.2 Piston Rod and Piston . . . . . . . . . . . . . . . . . . . . . 4.4.3 Piston Rod Runout . . . . . . . . . . . . . . . . . . . . . . . . 4.4.4 Piston Rod Monitoring . . . . . . . . . . . . . . . . . . . . . 4.4.5 Suction Valves and Discharge Valves . . . . . . . . . 4.4.6 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . .

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4-3 4-7 4-9 4 - 11 4 - 13 4 - 15 4 - 17 4 - 19 4 - 20 4 - 21 4 - 23 4 - 26 4 - 29 4 - 30 4 - 31 4 - 35

4–1

General Design and Function of Compressors

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2B1XC2.64_1

Rev. 001/kalajdzisa_a

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General Design and Function of Compressors Overview

4.1

Overview This chapter describes the general design and function of a compressor of type BA or BX.

In this description the function and design of the compressor is simplified. The illustrations may differ from your installation. The exact design with its technical details and technical data is shown in chapter 9 Dismantle and Assemble Compressor Components and chapter 13 Appendix.

Process gas compressors are designed according to API 618. All types of process gas compressors have an non-gastight crankgear. Breathers are fitted to the crankgear to prevent rise of gas pressure inside the crankgear. The linear movement of piston rod and piston is ensured by the crosshead and the guide rings (rider rings) at the pistons. The three main parts of a process gas compressor are crankgear, distance piece and cylinder. Depending on the application, a single-compartment or a two-compartment distance piece is installed. All process gas compressors can be provided with either lubricated or nonlubricated cylinders.

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General Design and Function of Compressors Overview

1

3

4

5

6

7

8

9

17

16

15

Fig. 4-1

1 2 3 4 5 6 7 8 9 10

Crankgear

14

13

12

11

PB_XX_0039b_01

18

2

10

Process gas compressor type BA/BX

Crankgear Non-drive end Crankshaft Connecting rod Crosshead Piston rod Piston rod packing Piston Valves Cylinder

11 12 13 14 15 16 17 18

Two-compartment distance piece Distance piece packing Oil scraper Drive end Single-compartment distance piece Tail rod Step piston Valve head

The crankgear (1) consists of the crankcase and its components. Main components are crankshaft (3), connecting rod (4) and crosshead (5). The crankgear is of non-gastight design. It is equipped with breathers and an oil-tight crankshaft seal. Optionally it can be equipped with an explosion relief valve. During operation, the crankgear is normally filled with air. The crankgear pressure is maximal 0.05 bar g/0.005 MPa g higher than atmosphere pressure. If the pressure unit is kg/cm2, the same values as for bar g apply. For special applications, the crankgear can be purged with nitrogen. The oil reservoir usually is in an external oil tank. For special applications the oil reservoir can also be in the crankgear.

Drive End

At the drive end (14) of the crankgear, normally a flywheel is fitted to the crankshaft. The flywheel compensates uneven load from the compressor to the motor. If only small irregular torques occur, a flywheel is not necessary and the compressor can be directly coupled to the motor. In this case a small flywheel is used as a barring wheel for the barring device. It can be mounted either on the drive end or the non-drive end of the motor.

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General Design and Function of Compressors Overview

Where the crankshaft protrudes from the crankcase at the drive end, the crankshaft seal prevents oil leakage to the environment and contaminants from entering the compressor. Non-Drive End Crankshaft

The non-drive end (2) is closed by a cover, sealed with a flat gasket. The crankshaft (3) normally is coupled via the flywheel to the electric motor on the drive end. In special cases, i.e. if the compressor is driven by a single bearing motor, the crankshaft is coupled directly to the motor shaft. Depending on the number of cranks, the crankshaft is supported by two or more bearings which consist of two bearing shells.The bearing shells are held together by bearing covers. An axial bearing on the drive end limits the axial movement of the crankshaft.

Connecting Rod and Crosshead

The rotation of the crankshaft is transformed via the connecting rod (4) into a reciprocating movement of the crosshead (5). The exact guided crosshead moves the piston rod. During compressor operation the connecting rod bearing, the crosshead pin bearing and the crosshead itself are usually lubricated by an external oil pump.

Distance Piece

Depending on the gas properties, a two-compartment distance piece (11) or a single-compartment distance piece (15) is used. The two-compartment distance piece (11) is designed to contain flammable, hazardous, or toxic gases. For all other gases a single-compartment distance piece can be used.

Oil Scraping

The wiper elements are installed in a housing/plate which is located on the crankgear side of the distance piece.

Distance Piece Packing

The distance piece packing (12) is only used in a two-compartment distance piece. It is installed in the intermediate partition of the distance piece. The distance piece packing provides a distinct separation of the outer and the inner compartment of the distance piece.

Cylinder

In the cylinder (10), the process gas is compressed to the required pressure by a piston with piston rings. Depending on the application, the cylinder is lubricated or non-lubricated. The number of stages depends on the pressure ratio between suction and final discharge pressure. Each cylinder is equipped with a replaceable cylinder liner.

Piston Rod Packing

The piston rod packing (7) seals off the gas compression area. The packing rings are in forced contact with the piston rod. As a standard, the packing is provided with a leakage line which is led to a safe location or the flare.

Piston Rod and Piston

The piston rod (6) is connected to the crosshead by either a SUPERBOLT® nut or a hydraulic nut. The piston is equipped with piston rings and guide rings (rider rings). The piston rings are used for sealing. The guide rings (rider rings) ensure the linear movement of the piston rod together with the crosshead.

Piston Rod Runout and Piston Rod Monitoring

18.05.2016

In order to monitor the rod vibration a proximity sensor is installed in vertical direction on the piston rod packing flange. The same sensor is used to monitor the guide ring (rider ring) wear to prevent any contact between piston and cylinder liner.

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General Design and Function of Compressors Overview

In order to have a reference of the position of the piston, a trigger sensor/ Keyphasor® is installed on the drive end side. The trigger sensor/Keyphasor® is used to detect the rotation angle of the crankshaft via a monitoring system. Valves

The suction and discharge valves (9) ensure the gas delivery to the individual stages. Burckhardt Compression has its own valves: Burckhardt Plate Valve™, Burckhardt Poppet Valve™, and, licensed by Burckhardt Compression, Manley® valves.

Capacity Control

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There are different possibilities of capacity control, e.g. by suction valve actuators, clearance pockets, rotation speed control, and bypass over 1st stage or bypass overall.

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General Design and Function of Compressors Crankgear

4.2

Crankgear 2

3

4

5

6

7

1

PB_M0_0022b_01

8

Fig. 4-2

1 2 3 4

Crankgear

Crankgear (typical view)

Non-drive end Crankcase Center bearing Connecting rod

5 6 7 8

Crosshead Main bearing Crankshaft Drive end

The crankgear consists of the crankcase (2) and its compressor components. Main components are crankshaft (7), main bearings (6), connecting rod (4), crosshead (5) and crankshaft seal at the drive end (8). The crankgear is neither of gastight nor pressure-tight design. In the crankgear the rotating movement of the crankshaft is converted to a reciprocating movement of the crossheads by the connecting rods. During operation, the crankgear is normally filled with air. The crankgear is provided with breathers and, optionally, with explosion relief valves to protect the crankgear against rapid pressure rise. Depending on the number of cranks, one ore more breathers are installed. Crankcase Burckhardt crankcases are designed for atmospheric pressure. All ports are closed by frame covers and sealed with flat gaskets. The crankcase is cast in one piece, the standard material is EN-GJL-250.

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General Design and Function of Compressors Crankgear

Components of Lubricating System

Lubrication The oil reservoir is in an external oil tank. During compressor operation, the lubrication of bearings and crossheads is ensured by an oil pump which is located on the oil skid. In special cases – instead of 2 external oil pumps – there is a crankshaft driven gear oil pump and a prelubrication pump.

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General Design and Function of Compressors Crankgear

4.2.1

Drive End

12

11

1 2 10

3 4

9

8

5

PB_M1_0031b_03

6 7

Fig. 4-3

1 2 3 4 5 6

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Drive end (typical view)

Crankcase Oil trap Main bearing, drive end Seal rings Crankshaft flange Axial bearing

2B1XC2.64_1

7 8 9 10 11 12

Oil pipe Crankshaft Connecting rod bearing Connecting rod Cylindrical pin Trigger sensor/Keyphasor®

IM 200322en

4–9

General Design and Function of Compressors Crankgear

The drive end is of oil tight design. The flywheel which is fitted to the crankshaft flange (5) compensates irregular torque from the compressor to the motor. If only small irregular torques occur, a flywheel is not necessary and the compressor can be directly coupled to the motor. In this case a small flywheel is used as a barring wheel for the barring device. It can be mounted either on the drive end or the non-drive end of the motor. Crankshaft Seal The crankshaft is sealed at the drive end by two lip-seal rings. They are located in the oil trap (2) on the drive end side. The outer lip-seal prevents contaminants from entering the compressor; the inner lip-seal prevents oil loss. Since the diameter of the crankshaft flange is bigger than the diameter of the lip-seals, the two lip-seal rings are sliced to enable an easy replacement if necessary. Trigger Sensor/Keyphasor® The trigger sensor/Keyphasor® (12) reports the top dead center to the monitoring system. In combination with other vibration sensors this allows crank angle referenced vibration analysis. Main Bearing For design and function of the main bearing (3) see section 4.2.3 Crankshaft.

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General Design and Function of Compressors Crankgear

4.2.2

Non-Drive End

1

2

6

3

4

PB_M1_0032b_02

5

Fig. 4-4

1 2 3

Non-drive end (typical view)

Crankcase Crankshaft Connecting rod bearing

4 5 6

Connecting rod Oil pipe Main bearing, non-drive end

As a standard, the non-drive end is closed by a cover sealed with a flat gasket. In special cases a crankshaft driven gear oil pump can be fitted to the non-drive end of the compressor. External Oil Pump During compressor operation, lubrication of bearings and crossheads is ensured by an oil pump on the oil skid. The supply pipe from the oil skid is connected to the oil collector at the non-drive end of the compressor. Gear Oil Pump During compressor operation, lubrication of bearings and crossheads is ensured by the gear oil pump. Lubrication of Bearings and Crosshead An oil collector distributes the oil to the main bearings.

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General Design and Function of Compressors Crankgear

The connecting rod bearings and the crossheads are lubricated via the bores in the crankshaft and in the connecting rod. Main Bearing For design and function of the main bearing (6) see section 4.2.3 Crankshaft.

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General Design and Function of Compressors Crankgear

Crankshaft

1

2

6

5

Fig. 4-5

1 2 3

3

4

PB_M1_0038b_03

4.2.3

Crankshaft (typical view)

Main bearing non-drive end Center bearing Main bearing drive end

4 5 6

Axial bearing Crankshaft Lubricating oil bore

The rotation of the crankshaft (5) is transformed into a reciprocating movement of the crosshead via the connecting rod. Depending on the number of cranks, the crankshaft is supported by two or more bearings (1, 2, 3). All main bearings are identical. The lubricating oil from the main bearing to the connecting rod passes through bores in the crankshaft.

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General Design and Function of Compressors Crankgear

Crankshafts of Burckhardt Compression are always forged. Independent of the number of cranks, no counterweights are used. On the drive end, the crankshaft is coupled to the electric motor. The coupling can be flexible or rigid. Compressors with shaft power < 250 kW may be V-belt driven. Main Bearing and Axial Bearing The compressor is provided with precision shell bearings. The lower bearing shell is supported by the crankcase. The upper bearing shell is fixed by a bearing cover which is fitted on the crankcase. The bearing shells are marked and must not be interchanged. At the drive end there are two axial bearing halves (4) on either side of the main bearing. They take up the axial clearance of the crankshaft. Center Bearing For crankshafts with four or more cranks center bearings are used, the design of the center bearings (2) is identical to the main bearing.

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18.05.2016

General Design and Function of Compressors Crankgear

4.2.4

Connecting Rod and Crosshead 1 2

3

4

5 6

7

8

9

PA_M3_0017b_02

10

11

Fig. 4-6

1 2 3 4 5 6

Connecting Rod

Connecting rod and crosshead (typical view)

Piston rod Adjusting ring Piston rod nut Crosshead Crosshead pin Crosshead pin bearing

7 8 9 10 11

Connecting rod Connecting rod bearing half Crankshaft Connecting rod bolt Connecting rod cover

The connecting rod (7) is the link between crankshaft (9) and crosshead (4). It converts the rotation of the crankshaft into a reciprocating movement of the crosshead. The forged connecting rod and connecting rod cover (11) have been machined together and match-marked as pairs. The connecting rod bearing halves and the connecting rod bolts (10) are also marked. The nuts for the connecting rod bolts are tightened either by a SUPERBOLT® nut or hydraulically.

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General Design and Function of Compressors Crankgear

The connecting rod bolts have rolled threads and are not positive locked (i.e. they need no mechanical locking) due to their high pretension and high elasticity. Connecting Rod Bearing The connecting rod has two bearings. At the big end is the connecting rod bearing (8). It consists of two halves which are identical. They have no shims. Therefore, the bearing clearance cannot be readjusted. The design of the connecting rod bearing is of trimetallic type with a galvanic running layer as a standard. Crosshead Pin Bearing The crosshead pin bearing (6) is at the small end of the connecting rod. It is a part of the connecting rod and designed as a bush. It is typically of a galvanic running layer type. The crosshead pin bearing is lubricated via the bore in the connecting rod. Crosshead

Crossheads can be built as 1-piece crosshead or as 3-piece crosshead. The crossheads are made of cast steel with a white metal layer in the area of sliding. The standard crosshead is a 1-piece crosshead. Optionally, 3-piece crossheads with replaceable crosshead shoes are available. The crosshead is moved back and forth in the crosshead guide by the connecting rod. The crosshead guide is part of the crankcase. The lubrication of the crosshead takes place from the crankshaft bearing via the bore in the connecting rod along the crosshead pin to the crosshead body.

Connection between Crosshead and Piston Rod

The piston rod is connected to the crosshead with a SUPERBOLT® nut or optionally with a hydraulically tightened nut. The cylinder clearance is adjusted by inserting a washer between the adjusting ring (2) and the crosshead (4).

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General Design and Function of Compressors Distance Piece

Distance Piece 1

12

2

11

Fig. 4-7

1 2 3 4 5 6

Distance Piece

10

3

9

8

4

8

7

5

PB_M6_0024b_03

4.3

6

Sectional view of distance piece (typical view)

Crankgear end Breather Buffer or purge gas to the distance piece packing Distance piece cover Cylinder end Outer compartment

7 8 9 10 11 12

Distance piece packing Various connections Inner compartment Oil drain Oil scraping Distance piece

The distance piece is the area between piston rod packing and the oilscraping. It separates the crankgear from the gas cylinder. Depending on the gas properties a two-compartment distance piece or a single-compartment distance piece is used. All ports of the distance piece are closed by distance piece covers (4), sealed with flat gaskets. The distance piece is attached to the crankgear either by SUPERBOLT® connections or by hydraulically tightened nuts. Single-Compartment Distance Piece Type B The Burckhardt Compression single-compartment distance piece is always of type B (long version of distance piece). This allows to fit an oil shield on the piston rod. In combination with the oil scraping (11), the oil shield prevents oil creepage along the piston rod.

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General Design and Function of Compressors Distance Piece

Depending on the gas properties the single-compartment distance piece is purged with nitrogen or equipped with a breather (2). The single-compartment distance piece is provided with an oil drain. Two-Compartment Distance Piece Type C The Burckhardt Compression two-compartment distance pieces are always of type C (type long/long). This allows to fit an oil shield on the piston rod. In combination with the oil scraper, the oil shield prevents oil creepage along the piston rod. It consists of a inner compartment (9) and a outer compartment (6). The outer compartment is designed for an overpressure of

• • •

4 bar g, or 0.4 MPa g, or 4 kg/cm2 g.

The two-compartment distance piece is provided with a distance piece packing (7). The distance piece packing can be fed with buffer gas or purge gas to prevent process gas entering the inner compartment. Additionally the outer compartment can be purged to remove process gas. The inner compartment is provided with an oil drain (10) and with a breather (2).

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General Design and Function of Compressors Distance Piece

4.3.1

Oil Scraper

1 2 3 4

8

7

PB_M5_0009b_03

5

6

Fig. 4-8

1 2 3 4

Oil scraping (typical view)

Oil scraper plate Cover Piston rod Oil shield

5 6 7 8

Wiper element Spring plate Pre oil scraper cover Prewiper element

The oil scraping consists of the oil scraper plate (1), the prewiper element (8) and the wiper elements (5). The oil scraper plate is installed in the distance piece at the crankgear side. The prewiper element removes the largest quantity of oil from the piston rod. The wiper element (5) remove the remaining oil from the piston rod. The wiper elements are kept in place by a spring plate (6) which is fixed to the cover (2). The standard wiper elements are 3-piece plastic wiper elements. As an option, 1-piece metal wiper elements can be implemented. The two types of oil wiper elements can be interchanged. Scraped off oil runs back into the crankgear. In combination with the wiper elements an oil shield (4), installed above the wiper elements prevents oil creepage along the piston rod (3).

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General Design and Function of Compressors Distance Piece

4.3.2

Distance Piece Packing 1

2

PB_M6_0025b_01

3

4

Fig. 4-9

1 2

Distance piece packing (typical view)

Housing Cover

3 4

Seal element Side-loaded pressure ring

The distance piece packing is installed in the intermediate partition of a two-compartment distance piece. It clearly separates the inner compartment from the outer compartment. The distance piece packing is equipped with two sets of seal rings. These sets ensure a sealing effect in both directions. A set consists of a seal element (3) and a side-loaded pressure ring (4). They are fixed against each other by a positioning pin. The distance piece packing rings are of the same type as the rings in piston rod packing flange. Depending on the application buffer gas or purge gas can be supplied to this packing to prevent process gas from entering the inner compartment, respectively the crankgear itself.

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General Design and Function of Compressors Cylinder

4.4

Cylinder 2

3

4

5

6

7

PB_C0_0056b_01

1

Fig. 4-10 Sectional view of cylinder (typical view)

1 2 3 4

Cylinder

Piston rod Piston rod packing Cylinder bottom Cylinder

5 6 7

Piston Valve Cylinder cover

In the cylinder (4), the process gas is compressed to the required pressure by the piston (5). The number of stages depends on the total pressure ratio between suction and final discharge pressure or the specified discharge temperature. Cast cylinders are mainly assembled of three parts, the cylinder bottom, the cylinder and the cylinder cover. Depending on the necessary pressure, the material are grey-, nodular cast iron or cast steel. Cylinders with only two suction and discharge valves are normally made of forged steel. In this configuration the cylinder bottom (3) is integrated in the cylinder and no single part. The cylinder is bolted to the distance piece. Normally pistons are double acting i.e. in the cylinder the gas is compressed on both sides of the piston. Each cylinder is equipped with a cylinder liner which can be replaced in case of wear. Depending on the application, the cylinder liner is made of grey cast iron or nitrited steel. For NACE applications Ni-Resist or nitrited steel is used, depending on the pressure and lubricated/non-lubricated cylinders. For easy replacement, Burckhardt Compression does not shrink in any cylinder liner. Each horizontally arranged cylinder is supported by a cylinder support and accurately aligned. The cylinder, and if necessary the cylinder cover (7), is water cooled.

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General Design and Function of Compressors Cylinder

Spacer Ring The spacer ring is installed between cylinder cover and cylinder. It increases the top cylinder clearance and thereby reduces the volumetric efficiency. Spacer rings are mainly used to adapt capacity to the specified volume flow. Step Piston Cylinder

The step piston cylinder is used to compress the gas in two stages which are arranged in one line (on one crank). Each piston is single acting. Instead of a cylinder cover there is a valve head where the suction and the discharge valves for the upper piston are located. Burckhardt Compression does not use tandem cylinders.

Cylinder with Tail Rod

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To ensure rod reversal for small pistons (and therefore lubrication of the crosshead pin bearing) a tail rod can be installed.

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General Design and Function of Compressors Cylinder

4.4.1

Piston Rod Packing 1

2

3

6

5

PB_C5_0047b_01

7

4

Fig. 4-11 Piston rod packing with longflow cooling (typical view)

1 2 3 4

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Packing flange Seal element (zone C) Packing cup Basic bush

2B1XC2.64_1

5 6 7

Pressure breaker Seal elements (zone B) Cooling water inlet

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General Design and Function of Compressors Cylinder

The piston rod packing is fitted to the bottom side of the cylinder and seals the compression space. The packing is designed as a cartridge for easy maintenance. The packing is configured by Burckhardt Compression for every application, whether high-pressure, lubricated or non-lubricated cylinders, or other special process conditions. Longflow Cooling To suit the various applications the piston rod packings can be built in the following designs:

• • •

purged or sealed (buffered) lubricated or unlubricated cooled or uncooled

PB_C5_0048b_02

1

Fig. 4-12 Lubricating oil flow (typical view) 1

Lubrication

PB_C5_0049b_03

1

2

Fig. 4-13 Leak gas and buffer gas (typical view) 1 2

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Buffer gas Leak gas

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General Design and Function of Compressors Cylinder

Piston Rod Packing Configuration The configuration of the packing rings depends on the application of the compressor. The engineering is done with software Redura® sealing system. In general, a piston rod packing is equipped with a set of seal elements (zone C), a pressure breaker and a variable amount of seal elements (zone B). A seal element consists of a support ring and 1 or 2 of the following ring types:

• • • •

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pressure breaker, seal element with radial cut, seal element with step bridge cut, seal element with tangential cut,

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General Design and Function of Compressors Cylinder

4.4.2

Piston Rod and Piston

2

3

5

11

9

8

PB_C1_0108b_01

10

6

7

Fig. 4-14 Piston details

1 2 3 4 5 6

Piston Rod

– Piston nut SUPERBOLT® Hardened washer – Upper and lower piston crown Piston skirt

7 8 9 10 11

Guide ring (rider ring) Piston ring Center ring Piston rod Groove for oil shield

The piston rod (10) is indirectly connected to the crosshead by the crosshead coupling. The piston rod (10) is connected to the crosshead by either a SUPERBOLT® nut or a hydraulic nut. Where the piston is attached to the piston rod there is a rolled thread at its end. The piston and piston rod guidance is provided by the forced-fed lubricated crosshead, the cylinder liner and the guide rings (rider rings).

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General Design and Function of Compressors Cylinder

The piston rod is divided in two sections by a groove (11). In this groove an oil shield is installed which prevents oil creepage further up along the piston rod. The standard piston rod is made of nitrided steel with a nitrided surface. In accordance with the application, other materials are used. Piston

The standard piston is double acting i.e. it compresses the process gas as well on its upper as on its lower piston side. The pistons are equipped with sealing and guiding elements. The number and type of sealing elements depends on the application. The guide rings (rider rings) ensure the linear movement of the piston rod together with the crosshead. Cylinder Clearance The cylinder clearance is the gap between piston and cylinder cover in the Top Dead Center (TDC) respectively between piston and cylinder bottom in the Bottom Dead Center (BDC). The cylinder clearance is adjusted by inserting a washer between the adjusting ring and the crosshead.

Piston Design

According to the application, different piston design types are used for process gas compressors: 3-Piece Piston The 3-piece piston consists of a upper and a lower piston crown (5) and a piston skirt (6). 2-Piece Piston The 2-piece piston consists of a upper and a lower piston half. It is fixed to the piston rod either by means of a piston nut SUPERBOLT® or a hydraulic piston nut. Solid Piston The solid piston is a one-piece piston. It is fixed to the piston rod either by means of a piston nut SUPERBOLT® or a hydraulic piston nut. Solid Piston with Integrated Piston Rod The solid piston with piston rod consists of one part, that means the piston is not screwed onto the piston rod. This kind of piston is used for small cylinder diameters. Step Piston The step piston is a single acting piston. There are always two pistons installed in one line (on one crank). In this way the step piston is effectively double acting and ensures the rod reversal (and therefore lubrication of the crosshead pin bearing).

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General Design and Function of Compressors Cylinder

Step pistons can either be built as a one-piece piston, or the higher stage piston can be fixed to the lower stage piston. Piston Rings The piston rings are used for sealing. Number, types and design of piston rings are individually configured depending on the application. The engineering is done with software Redura® sealing system. Combinations of lap joint piston rings which are overlapping at the end and/or scarf joint piston rings with bevel cut are used. Connection between Piston Rod and Piston

Piston Nuts The piston is fastened to the piston rod with a piston nut. There are two different types of piston nuts:

• •

piston nut SUPERBOLT® hydraulically tightened piston nut

Piston Nut SUPERBOLT® This tensioning system is based on the principle of breaking down the force for a single large screw connection into several manageable torques, using the pressure screws threaded through the body of the piston nut. The hardened washer underneath the nut provides a flat surface for the pressure screws to push against. In order to avoid contamination/corrosion of pressure screws in connection with certain gases, the piston nut SUPERBOLT® has a groove to accommodate an O-ring. Hydraulically Tightened Piston Nut A piston nut for hydraulic tightening can be used.

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General Design and Function of Compressors Cylinder

4.4.3

Piston Rod Runout Piston rod runout is always an inspection requirement during the shop assembly of a new compressor to verify alignment. On installation of the compressor in the field, the piston rod runout must also be checked. It is also a requirement of the normal compressor maintenance, especially after overhaul and reassembly of the cylinders. Runout must be checked in both horizontal and vertical directions. Check runout at crosshead and cylinder to verify a perfect running of crosshead and piston. Adjustment of Piston Rod Runout The runout can be adjusted by use of the adjusting ring at the crosshead.

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General Design and Function of Compressors Cylinder

4.4.4

Piston Rod Monitoring

2

3

4

5

PB_C1_0109b_01

1

Fig. 4-15 Location of piston rod and trigger sensor/Keyphasor® (schematic view)

1 2 3

Trigger sensor/Keyphasor® Crankshaft Piston rod

4 5

Piston rod proximity probe Piston

Piston Rod Proximity Probe The rod is monitored with one vertical proximity probe (4) on each piston rod. The proximity probe detects excessive rod vibration. The guide ring (rider ring) wear is also evaluated. An alarm is set if the piston rod vibration exceeds a set limit. Additionally the guide ring (rider ring) wear is evaluated based on this sensor signal. An alarm is set to prevent damage due to contact of cylinder liner and piston. Trigger Sensor/Keyphasor® For detailed illustration see section 4.2.1 Drive End. A trigger sensor /Keyphasor®(1) – installed at the drive end – reports the top dead center to the monitoring system. In combination with other vibration sensors this allows crank angle referenced vibration analysis.

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General Design and Function of Compressors Cylinder

4.4.5

Suction Valves and Discharge Valves The suction valves and discharge valves ensure the gas delivery from the suction side to the discharge side of each compressor cylinder. Both valves are self-acting and work as non-return valves. Location and Fixation of Valves

6

5

4

3

PB_CX_0002b_01

2

1

Fig. 4-16 Location and fixation of valves

1 2 3

Cylinder Valve Lantern

4 5 6

Valve cover bolt Pressure screw Valve cover

The valves are fixed in the cylinder cavities by means of lanterns (3), valve covers (6) and pressure screws (5). However, pressure screws are not used if valves are very small or not according to API 618. The lanterns on the suction side are shorter than those on the discharge side. Valve Types

Burckhardt Compression has its own valves: Burckhardt Plate Valve™, Burckhardt Poppet Valve™, and, licensed by Burckhardt Compression, Manley® valves. The most suitable valve type will be selected in accordance with process requirements and the handled gas. The center bolt is screwed into the valve seat of the discharge valves or into the valve guard of the suction valves. This design prevents the center bolt from falling into the cylinder if it becomes loose.

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General Design and Function of Compressors Cylinder

The diameter of the suction valve is larger than the diameter of the discharge valve. This prevents suction valves from being installed in place of discharge valves and vice versa. Both of these design features meet the API 618 requirements. Burckhardt Plate Valve™ 2

10

3

4

9

8

7

6

5

XA_CX_0076b_01

1

Fig. 4-17 Sectional view of Burckhardt Plate Valve™ (typical view of a suction valve)

1 2 3 4 5

Valve seat Nut Center bolt NORD-LOCK® washer pair Valve plate

6 7 8 9 10

Damper plate Valve guard Lift washer Cylindrical pin Valve spring

The Burckhardt Plate Valve™ is of proven design. The sealing element, the valve plate (5), has concentric rings that are joined together by radial connections. The valve plate is loaded by springs (9). The lift of valve plate is adjusted by lift washers (8). The dynamic valve behavior can be influenced by the springs and the lift of valve plate. However, it will be simulated for each valve and process condition to yield optimal behavior and best reliability. The damper plate (6) supports the dynamic valve behavior. The valve plate and the damper plate are made of stainless steel. For special applications there are non-metallic valve plates. If a non-metallic valve plate is used, no damper plate is necessary.

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General Design and Function of Compressors Cylinder

Burckhardt Poppet Valve™

10

2

9

3

8

4

7

6

5

XA_CX_0078b_01

1

Fig. 4-18 Sectional view of a Burckhardt Poppet Valve™ (typical view of a suction valve)

1 2 3 4 5

Valve seat Nut Center bolt NORD-LOCK® washer pair Cylindrical pin

6 7 8 9 10

Spring support Poppet Spring Seat plate Valve guard

The Burckhardt Poppet Valve™ is equipped with many individual poppets (7) that work independently of each other. The poppets are pressed against the seat plate (9) by springs (8) and the differential pressure to reach tightness. To protect the bottom of the spring bore, the spring is supported by a plastic spring support (6). The Burckhardt Poppet Valve™ is designed with a separate replaceable seat plate. However, the seat plate needs no re-machining in case of damage to its sealing face. It can be easily replaced. The rounded form of the poppets and the optimized flow area result in less pressure drop and increase efficiency. They perform excellent in demanding applications with gases containing oil and particles. The poppets are always made of plastic.

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General Design and Function of Compressors Cylinder

Manley® Valve, licensed by Burckhardt Compression 2

8

3

7

4

6

XA_CX_0077b_01

1

5

Fig. 4-19 Sectional view of Manley® Valve (typical view of a suction valve)

1 2 3 4

Valve seat Nut Center bolt NORD-LOCK® washer pair

5 6 7 8

Valve disc Valve guard Spring button Spring

The Manley® Valve is equipped with single non-metallic valve discs (5). They work individually. Each ring is pressed against the sealing face by the springs (8), (i.e. the spring forces) and the differential pressure. The springs press on the valve disc via a spring button (7) made of plastic. The valve disc design results in lower pressure drop and therefore in less power consumption of the compressor. It also provides maximum availability for gases that contain impurities.

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General Design and Function of Compressors Cylinder

4.4.6

Capacity Control 9

1

8

2

3 4 7 5

PB_C3_0010b_01

6

Fig. 4-20 Suction valve actuator and controlled suction valve, actuator piston in full load position by control medium pressure (typical view)

1 2 3 4 5

Spring Actuator piston Pressure pin Nipple Intermediate piece (only for smaller valves)

6 7 8 9

Controlled suction valve Mixture of leaking process gas and control medium Control medium Control medium return pipe

There are different possibilities of capacity control, e.g. by suction valve actuators, clearance pockets, rotation speed control, and bypass over 1st stage or bypass overall.

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General Design and Function of Compressors Cylinder

If capacity is not controlled by controlled suction valves, please proceed directly to paragraphs “Rotation Speed Control” and/or “Bypass Control”.

Suction Valve Actuator and Controlled Suction Valves

The easiest way to adjust capacity is by means of controlled suction valves (6). The valves are equipped with actuators and finger unloaders to operate the compressor at steps of 0 %, 50 % or 100 % load. Depending on the number of 1st stage pistons, smaller steps are possible. This type of capacity control can be applied to all three valve types. The actuators are either operated by spring (1) or medium. Common control mediums are nitrogen, air, process gas or oil. A spring operated actuator keeps the suction valve open at no-load when control medium pressure is off. The medium operated actuator, however, only keeps the suction valve open at no-load if the actuator is pressurized. The flow of the medium for the actuators is controlled by the control unit which has the function of a 3-way valve. The control unit is either hand operated, pneumatically operated or electrically activated. Actuator Options Actuators can be equipped with a visual position indicator. It is located on top of the actuator. The indicator shows the state of the actuator and of the valve (open or closed). To protect actuators from getting clogged by impurities, the actuator is equipped with a scraper ring. It is located in the nipple (4) at the lower end of the actuator. If process gas and control medium of the actuator have to be hermetically separated, the pressure pin is surrounded by a diaphragm sealing.

Clearance Pocket Control

Clearance pocket control is used in connection with controlled suction valves. It is only applied in the cylinder cover and therefore only on the upper piston side. It is used to achieve smaller steps in reducing the capacity of a compressor. The achieved steps depend on the number of 1st stage pistons as well as on the additional clearance. If clearance pocket control is used, capacity can be reduced by opening the clearance pocket in the cylinder cover. Due to the larger cylinder clearance, the volumetric efficiency is reduced.

Rotation Speed Control

Capacity can also be adjusted by speed control of the main motor. This is achieved by a frequency converter that gets its input signal from the monitoring of the suction or discharge pressure. The frequency converter then gives a control signal to the main motor which adjusts its speed accordingly.

Bypass Control

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IM 200322en

A common way of reducing the capacity is either a bypass over the 1st stage or a bypass overall.

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Transport, Installation and Pre-Commissioning

5 Transport, Installation and Pre-Commissioning 5.1

Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Importance of Cleanliness . . . . . . . . . . . . . . . . . . 5.1.3 Mandatory Tightening Torques . . . . . . . . . . . . . . . 5.2 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Safety of Transport . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 Shipping Package. . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3 Shipping Condition . . . . . . . . . . . . . . . . . . . . . . . . 5.2.4 Unload Compressor . . . . . . . . . . . . . . . . . . . . . . . 5.2.5 Check Scope of Supply . . . . . . . . . . . . . . . . . . . . 5.2.6 Store Components prior to Installation . . . . . . . . . 5.3 Dimensions, Weights, Space Requirement. . . . . . . . . . . . . 5.4 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Grouting Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Prepare Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Lifting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.1 Tightening Torques for Attachment Gear . . . . . . . 5.7.2 Lift Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.3 Lift Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.4 Lift Crankgear with Distance Pieces. . . . . . . . . . . 5.7.5 Lift Cylinder with Distance Piece . . . . . . . . . . . . . 5.7.6 Lift Distance Piece . . . . . . . . . . . . . . . . . . . . . . . . 5.7.7 Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.8 Lift Plant Components . . . . . . . . . . . . . . . . . . . . . 5.8 Install Compressor on Foundation . . . . . . . . . . . . . . . . . . . 5.8.1 Place and Level Compressor . . . . . . . . . . . . . . . . 5.8.2 Grout Foundation Bolts. . . . . . . . . . . . . . . . . . . . . 5.8.3 Grout Supporting Surface of Sole Plates . . . . . . . 5.8.4 Tighten the Foundation Bolts . . . . . . . . . . . . . . . . 5.9 Check Crankshaft Deflection . . . . . . . . . . . . . . . . . . . . . . . 5.10 Assemble Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.1 Prepare Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5.10.2 Cylinder Support. . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.3 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.4 Install Pneumatic Barring Device . . . . . . . . . . . . . 5.10.5 Turn Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.6 Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 Install Electric Motor and Coupling . . . . . . . . . . . . . . . . . . . 5.11.1 Place Electric Motor . . . . . . . . . . . . . . . . . . . . . . . 5.11.2 Align Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . 5.11.3 Grout Foundation Bolts. . . . . . . . . . . . . . . . . . . . . 5.11.4 Check Crankshaft Deflection . . . . . . . . . . . . . . . .

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5-3 5-3 5-3 5-3 5-5 5-5 5-5 5-7 5-7 5-8 5-8 5 - 10 5 - 12 5 - 13 5 - 15 5 - 18 5 - 18 5 - 19 5 - 20 5 - 21 5 - 22 5 - 23 5 - 24 5 - 25 5 - 28 5 - 28 5 - 30 5 - 32 5 - 33 5 - 35 5 - 36 5 - 36 5 - 36 5 - 40 5 - 43 5 - 43 5 - 44 5 - 45 5 - 45 5 - 47 5 - 49 5 - 50

5–1

Transport, Installation and Pre-Commissioning

5.11.5 Grout Sole Plates . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 51 5.12 Install Plant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52 5.12.1 Prepare Installation . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52 5.12.2 Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52 5.12.3 Oil Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 56 5.12.4 Local Instrument Board LIB . . . . . . . . . . . . . . . . . . 5 - 56 5.13 Install Pipe Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 58 5.13.1 Prepare Fabrication . . . . . . . . . . . . . . . . . . . . . . . . 5 - 58 5.13.2 Fabricate Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59 5.13.3 Check Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 62 5.13.4 Pickle and Passivate Piping . . . . . . . . . . . . . . . . . 5 - 64 5.13.5 Sandblast Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 68 5.13.6 Recommendation for Pipe Support . . . . . . . . . . . . 5 - 68 5.13.7 Recommendation for Tube Fittings . . . . . . . . . . . . 5 - 71 5.13.8 Final Assembly of Piping . . . . . . . . . . . . . . . . . . . . 5 - 83 5.13.9 Hydrostatic Pressure Test . . . . . . . . . . . . . . . . . . . 5 - 85 5.14 Non-Return Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 85 5.15 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 85 5.15.1 Fit Grounding Wire . . . . . . . . . . . . . . . . . . . . . . . . 5 - 85 5.16 Pre-Commissioning of Compressor Plant . . . . . . . . . . . . . . 5 - 88 5.16.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 88 5.16.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 88 5.16.3 Crankgear Lubricating System . . . . . . . . . . . . . . . 5 - 89 5.16.4 Check Cleanliness of Gas System . . . . . . . . . . . . 5 - 90 5.16.5 Turn Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 90 5.16.6 Mechanical Test Run . . . . . . . . . . . . . . . . . . . . . . . 5 - 91 5.16.7 Blowing out the Gas Piping System . . . . . . . . . . . 5 - 92 5.16.8 Nitrogen Test Run . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 94 5.16.9 Assess Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 94 5.16.10 Frame Vibration Measurement . . . . . . . . . . . . . . . 5 - 97 5.16.11 Inspect Compressor Plant . . . . . . . . . . . . . . . . . . . 5 - 98 5.16.12 Preserve Compressor Plant after Installation . . . . 5 - 98 5.16.13 Maintain Plant during Decommissioning . . . . . . . . 5 - 100 5.16.14 Recommission Plant . . . . . . . . . . . . . . . . . . . . . . . 5 - 100

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Transport, Installation and Pre-Commissioning Important Notes

5.1

Important Notes

5.1.1

Technical Support Service life and lifetime of the compressor greatly depend on the quality of the installation works. An insufficient foundation layout and/or non-appropriate assembly can lead to increased vibrations (see section 5.16.9 Assess Vibrations) and, therefore, to problems and/or service interruptions. Examples of possible consequences are: bursting of pipes, excessive wear of piston rings and guide rings (rider rings).

We strongly recommend to install the compressor under the supervision of a specialist from Burckhardt Compression. For damage caused by nonprofessional installation, Burckhardt Compression will not assume any liability.

If you have any questions concerning transport, installation or pre-commissioning procedures, please consult Burckhardt Compression Services (address see section 1.6 Contact Address).

5.1.2

Importance of Cleanliness Prior to dispatch, all assembled parts of the compressor as well as accessories coming in contact with process gas have been cleaned either in our works or by sub-suppliers. Parts from sub-suppliers have been checked for cleanliness. Care must be taken that all parts and surfaces of the plant components exposed to process gas are compatible with the process gas and free from contaminants. If any cleaning of surfaces is necessary, refer to section 10.1 Cleaning Specification and the cleaning instructions in chapter 10 Clean and Degrease Plant and Compressor Components. CAUTION Contamination of process gas! All components coming in contact with process gas must be checked for cleanliness prior to their installation.  When performing overhauls or exchanging spare parts, make sure that all significant surfaces have been cleaned according to the cleaning specification prior to assembly or installation.  If in doubt about cleanliness, repeat cleaning procedure.

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5.1.3

Mandatory Tightening Torques

Plant

For mandatory tightening torques and tightening method of bolted connections see section 8.5.1 Tightening Torques and Method.

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Transport, Installation and Pre-Commissioning Important Notes

Compressor

For tightening methods of bolted connections see section 8.7.7 Tightening Methods.

For mandatory tightening torques, appropriate tightening methods and applicable lubricants: see section “Compressor” in chapter 13 Appendix.

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18.05.2016

Transport, Installation and Pre-Commissioning Transport

5.2 5.2.1 Recognize and Avoid Possible Danger

Obey Transport Rules

Accident Free Crane Transport

Transport Safety of Transport Load transport may only be carried out by qualified personnel, i.e. must be supervised by responsible, skilled employees.

•

Observe warning symbols and marking of packages.

• • •

Always secure loads.

• • • • • •

Know weight of load.

Always store loads safely. Secure loads against falling.

Pay attention to center of gravity and attachment points. Use proper lifting and transport devices. Use appropriate attachment gear. Attach load securely. Give clear signals.

DANGER Suspended loads! Falling loads can cause serious injury or death.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

WARNING Plant components like coolers, pulsation dampers, separators can fall!  Store them securely.  Keep them from falling.

5.2.2

Shipping Package The packing specifications agreed upon in the contract constitute the basis for preservation, package and transport. The measures taken shall prevent damage to compressor and plant components as far as possible. Nevertheless, they will not protect these goods against the consequences of improper handling.

Package

18.05.2016

The purpose of package is to protect the goods during transport and intermediate storage. In addition, a professional package has to simplify the loading and transport procedures as well as the stacking of the packed goods or units.

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5–5

Transport, Installation and Pre-Commissioning Transport

Three main types of packing are to be distinguished (for applied packing specification please refer to the contract):

•

Land packing (truck, train or airfreight) is used for door-to-door delivery – without intermediate storage.

•

Seaworthy packing is applied to goods with oversea destinations and several handling as well as for shipments in containers from seaport to seaport. This type of packing guarantees a protection of the material for a period of 6 months when stored in a covered and dry place.

•

Long-term packing protects the goods during a longer storage period (> 6 month) and is only applied when specifically requested by the customer. Protection is only guaranteed when suppliers storage instructions are strictly followed.

All items are packed in wooden boxes which provide a long-lasting seal and protect its content against climatic and chemical influences. The package is suitable to withstand high dynamic and static forces. The wooden boxes are marked on the two longitudinal sides with waterproof paint. Packages requiring special handling are additionally marked with the international standardized handling instructions: XA_XX_0087a_02

Marking of Packages

This side up

Fig. 5-1

Fragile goods

Keep dry

Protect from heat

Center of gravity

Use no hooks

Sling here

Package handling instructions

Pay attention to the instructions on the package concerning transport, handling and storage. Guarantee claims are not accepted if the package is untimely opened or damaged as a consequences of improper handling.

Preservation

Depending on the nature of the goods, different kinds of corrosion protection will be applied to compressor, plant components and spare parts susceptible to corrosion due to atmospheric or climatic influences. Compressor To protect the internal parts against corrosion, cylinders are flushed with dry nitrogen prior to dispatch. VCI (Volatile Corrosion Inhibitor) mats are inserted into cylinder and crankgear for protection. Tectyl® is used to protect blank compressor parts. The wax-like coating can be removed without difficulty with any hydrocarbon compound.

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Transport, Installation and Pre-Commissioning Transport

Damper, Gas Cooler To protect the internal parts against corrosion, the vessel is filled with dry nitrogen prior to dispatch. An adhesive label with corresponding warning sign is affixed to the vessel. Coolant Skid, Oil Skid To protect the internal parts against corrosion, the skid is filled with dry nitrogen prior to dispatch. An adhesive label with corresponding warning sign is affixed to the skid. WARNING Pressurized system part! To protect the internal parts against corrosion, some components are filled with dry nitrogen prior to dispatch.  Take notice of the corresponding warning sign.  Depressurize system part before you start installation work.

Components, Spare Parts Material requiring particular corrosion protection is packed in VPI (Vapor Phase Inhibitor) paper and wrapped into polyethylene sheeting or sealed into polyethylene bags.

5.2.3

Shipping Condition The shipping condition depends on transport circumstances, local situation and on the lifting tackle available on site. As a general rule the compressor should be transported as completely assembled as possible. When leaving our works, the compressor is delivered separated into the following component groups:

• • • •

5.2.4

compressor complete, flywheel, coupling flange, individual components palletized.

Unload Compressor Please proceed according to sections 5.2.1 Safety of Transport and 5.7 Lifting Procedure.

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Transport, Installation and Pre-Commissioning Transport

5.2.5

Check Scope of Supply The scope of supply is specified in the sales documents and packing list. If installation takes place right away, check the delivery for completeness immediately after receiving of the goods. Any transport damage and/or missing parts must be reported immediately. For preservation reasons, do not open long-term packages as long as you do not start installation work. As soon as the wooden boxes are opened to check the individual items, compressor components and plant components must be stored in a orderly manner in a dry place, protected from environmental influences (storehouse). CAUTION Corrosion or contamination due to improper storage after opening the consignment.  Do not check delivery in long-term packages beforehand. Wait until the material is used.  For intermediate storage of opened consignment consult Burckhardt Compression Services (address see section 1.6 Contact Address) concerning protective measures to be taken.

5.2.6 Storage Guarantee for Unopened Package

Store Components prior to Installation Our storage guarantee for this contract is limited to a period of 6 months after delivery (ex works), providing the necessary measures have been taken to avoid the entry of moisture and water during transport and storage. Upon expiration of this time limit:

Opened or Damaged Package

•

Open the wooden box and check preservation state of the complete consignment.

•

If necessary, clean or renew the preservation.

Guarantee claims for the preservation are not accepted if the package is opened for custom purposes during transport or at construction site, or if it is damaged due to improper handling. In this case, we are not liable for damaged parts. This also applies to any damage that may occur during the period of guarantee, as a result of such damaged parts. We request customers to check opened and/or damaged consignments as early as possible and to immediately report to us any damage observed. This will enable us to make suggestions to the customer concerning further procedure to be adopted.

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Transport, Installation and Pre-Commissioning Transport

Intermediate Storage

If the compressor plant is not installed immediately after transport, all components must be stored in a dry place, protected from environmental influences (storehouse). If this is not possible, the packed goods must be protected against water, namely by means of storage under a roof.

XA_XX_0008a_02

The wooden boxes must also be protected against the entry of water from below, i.e. by placing them on wooden beams.

Fig. 5-2

Intermediate storage

Components must be stored safely. They must not tip over or topple down when jolted by vehicles or hooked onto by hanging crane cables. CAUTION Corrosion due to improper preservation during long-term storage.  For long-term storage consult Burckhardt Compression Services (address see section 1.6 Contact Address) concerning protective measures to be taken.

After the guarantee period is expired, inspect the stored parts in regular intervals and in accordance with section 5.2.2 Shipping Package. Replace moisture absorbent agent if necessary. To protect the internal parts against corrosion, some components are filled with dry nitrogen prior to dispatch. If these plant components are stored for a longer time, pressure must be controlled and nitrogen filled up if necessary. DANGER Health hazard! Risk of suffocation! Nitrogen can leak from plant components such as coolers, dampers, etc. into the storage rooms and displace the oxygen in the atmosphere. At high concentrations, unconsciousness or death may occur.  Before entering the area, check for oxygen-deficient atmospheres.  Make sure there is sufficient circulation of fresh air.  Be aware of any signs of dizziness or fatigue. Exposures to fatal concentrations of nitrogen could occur without any significant warning symptoms.

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Transport, Installation and Pre-Commissioning Dimensions, Weights, Space Requirement

5.3

Dimensions, Weights, Space Requirement Compressor Dimensions Length

7942 mm

Width

1809 mm

Height

2040 mm

Electric Motor Dimensions Length

5073 mm

Width

2912 mm

Height

3250 mm

Weights (Approximative) Compressor complete (without flywheel)

20340 kg

Electric motor

25425 kg

Flywheel

3350 kg

Crankgear complete

5200 kg

Distance piece

1020 kg

st

Cylinder 1 stage (inclusive covers, valves and piston rod packing) Cylinder cover 1st stage

487 kg

st

Piston with piston rod 1 stage

460 kg

st

Piston rod packing 1 stage

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6550 kg

97 kg

Crosshead

120 kg

Connecting rod

156 kg

Crankshaft

731 kg

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Transport, Installation and Pre-Commissioning Dimensions, Weights, Space Requirement

Space Requirements 1

2

3

W 1

4

PB_XX_0038b_02

D

F

Fig. 5-3 1 2 3 4

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Space requirements

Crankgear Cylinder Piston Flywheel

W For piston removal

9000 mm

F For flywheel removal

1120 mm

D Diameter of flywheel

2040 mm

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Transport, Installation and Pre-Commissioning Foundation

5.4 The Basics about Foundation

Foundation •

The pouring of the foundation must be accomplished according to the foundation plan of Burckhardt Compression.

•

The foundation must be resistant to the lubricating oils, to coolant and to process gases of the compressor.

• •

Prevent surfaces from infiltration by oil or coolant.

•

Compressor and electric motor are to be anchored to the foundation with foundation bolts.

•

The foundation layout must be evaluated and dimensions determined by a civil engineer, who is also responsible for reinforcement. The foundation must have adequate distance from buildings and other foundations.

•

Vibration-isolating procedures may only be carried out after notifying Burckhardt Compression. Also contact us if bad ground conditions exist. Acceptable vibration values are stated on the foundation plan, see section “Foundation” in chapter 13 Appendix.

The foundation must be reinforced and casted in one pouring.

Foundation Block 1

3

30°

Fig. 5-4 1 2 3

30°

XA_XX_0099b_02

2

Distance from foundation block to building (recommended solution)

Detail, correct design Joint, 20 mm Detail, incorrect design

1. Separate the compressor foundation block from all parts of the building by a joint. Seal joints with elastic material. 2. Do not arrange building parts close to the compressor foundation block (see Fig. 5-4, detail 1 for correct design). Non-compliance may result in transfer of vibrations onto the building. Pay attention to building’s natural frequencies. Consider compressor speed. 3. Do not arrange building supports or bases close-by or beneath the compressor foundation block (Fig. 5-4, detail (3) shows the incorrect design).

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Transport, Installation and Pre-Commissioning Grouting Material

Foundation Bolt Holes

We recommend to line foundation bolt holes for compressor and motor exclusively with corrugated pipes as they ensure an optimal, pulling-proof connection of the foundation bolt in the foundation (see Fig. 5-6, version A).  Sufficiently fasten the corrugated pipes before pouring concrete in the appropriate positions.  Make sure that their positions do not change during pouring of concrete.

Prerequisite for Installation

•

The valid reference points/center lines must be marked on the foundation by the construction supervision (customer side).

•

Before installation, check the dimensional accuracy of the foundation according to the foundation plan of Burckhardt Compression.

Grouting Surfaces

5.5 Requirements

•

The surface of the foundation as well as the foundation bolt grout pockets must be roughened up with suitable tools for the best binding effect with the concrete.

•

The surface of the foundation as well as the grout pockets for the foundation bolts must be clean and absolutely free of residual matter like oil, wood, plastics, etc. Any material used for foundation bolt grout pockets must be removed before the concrete has set.

Grouting Material For grouting work, we recommend to use grouting material based on cement or epoxy. The grouting material must fulfill the following requirements:

• • • • •

Product Recommendation

Minimum resistance to pressure = 60 N/mm2. Flow properties: liquid and capable of flowing. Free of shrinkage and swelling. No ferritic additives. The coefficient of expansion must correspond to that one of the concrete and should be preferably low.

The following table of various products represents a recommendation of non-shrinking grouts used by Burckhardt Compression.

Manufacturer

Product

Compressor installation

ITW Philadelphia Resins

Chockfast® Red

On concrete foundation



ITW Philadelphia Resins

Chockfast®

Skid mounted



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Black

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Epoxy based

Cement based

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Transport, Installation and Pre-Commissioning Prepare Installation

Manufacturer

Product

Compressor installation

ITW Philadelphia Resins

Chockfast® Orange

Marine applicationa



On concrete foundation



BASF Construction Chemicals BASF Construction Chemicals

®

b

MASTERFLOW 648

Epoxy based

Cement based

PCI Repaflow EP Plus MASTERFLOW® 928 ®

MASTERFLOW 870

Foundation bolts and accessories



PCI Repaflow Chockfast®

a. Orange is approved or accepted for its intended marine use by American Bureau of Shipping. Lloyd‘s Register, Bureau Veritas, Det Norske Veritas, Germanischer Lloyd and most other major regulatory agencies worldwide. b. MASTERFLOW products may in certain regions be on the market under different product names. Tab. 5-1

Grouting material product information

For grouting of the compressor’s supporting surface, Burckhardt Compression recommends to use one of the in Tab. 5-1 listed epoxy grouting materials.

If another grouting material than listed in Tab. 5-1 will be used, please consult your local civil engineer for support.

Handling of Grouting Material

Consider following points:

• • • • •

encasing method, influences of temperature, mixing process, grouting procedure, setting time.

WARNING Health hazard! Material and environmental damage! Grouting material can be toxic and caustic. Inappropriate use can lead to injury, material and environmental damage.  Strictly follow grout manufacturer’s instructions.

For the protection of the foundation surface against environmental influences and/or infiltration of oil, we recommend the application of an oil-resistant coating.

5.6 Prepare Jackscrews

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Prepare Installation With compressors of type horizontal it is not necessary to remove the jackscrews after grouting.

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Transport, Installation and Pre-Commissioning Prepare Installation

1. To avoid clogging, lubricate the threads of the jackscrews before setting them, using MOLYKOTE® G-N Plus or ballbearing grease. 2. For each foundation bolt, use a jackscrew and adjust to required height. Adjustment range is 12 to 22 mm, depending on jackscrew type.

Fig. 5-5

Jackscrew

3. For additional height adjustment, add shims.

4. Level the jackscrews accurately. It must be ensured, that the jackscrews are kept absolutely horizontal in all directions by using a precision spirit level. 5. Use mortar for temporary fixation of the jackscrews. Prepare Sole Plates (Compressor)

6. Clean the bottom side of sole plates, getting into contact with the grouting material. The supporting surface must be clean and absolutely free of oil, rust, paint and grease. The epoxy grouting material shall stick onto the sole plates. 7. Protect the surface of the crankgear and the sole plates which are not getting in contact with the epoxy grouting material.

Prepare Sole Plates (Motor)

8. Clean the bottom side of sole plates, getting into contact with the grouting material. The supporting surface must be clean and absolutely free of oil, rust, paint and grease. The epoxy grouting material shall stick onto the sole plates. 9. Protect the surface of the motor and the sole plates which are not getting in contact with the epoxy grouting material.

Prepare Foundation Bolts

10. Insulate the foundation bolts at least for 1/3 length from the top with thick tape or using an insulating tube of foam material (free expansion length of foundation bolt). 11. Center the foundation bolts in the through holes of the compressor using cardboard or sealing material. This procedure enables a later readjustment of the compressor.

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Transport, Installation and Pre-Commissioning Prepare Installation

A

B

1

3

1/3

1/3

2

4

2/3

2/3

5

XA_XX_0036b_03

6

Fig. 5-6

A B 1 2

Prepare foundation bolts (typical view)

Version with corrugated pipe (preferred) Standard version Cardboard or sealing material Insulation/tape

3 4 5 6

Grout pocket for foundation bolt Foundation bolt Foundation Corrugated pipe

CAUTION Insufficient alignment of foundation bolts We urgently advise against casting-in foundation bolts before setting of compressor!  Nevertheless, if this procedure is still desired (necessary), make sure that the foundation bolts are fixed by a jig in the correct position.  When pouring the foundation, do not offset the foundation bolts.

Specify Encasing

12. Before placing the compressor on the foundation, specify how to encase the supporting surfaces to be poured. Jackscrews can be cast-in. Specify the encasing accordingly.

Specify Encasing (Motor)

13. Before placing the motor on the foundation, specify how to encase the supporting surfaces to be poured. Jackscrews can be cast-in. CAUTION Stress cracks in the epoxy grouting material due to thermal expansion of the compressor.  Provide expansion joints every 1.5 meter.

Prepare Foundation

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14. Coat the foundation surface with oil protective coating (1).

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2

3

PA_XX_0002b_01

1

Fig. 5-7 1 2 3

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Protective coating (typical view)

Oil protective coating Grout pocket for foundation bolt Foundation

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Transport, Installation and Pre-Commissioning Lifting Procedure

5.7

Lifting Procedure This section describes also the lifting procedure for cylinder and distance piece – despite the fact that the compressor is transported completely assembled – to use for a later dismantling of the compressor e.g. for maintenance reason.

Size of thread

Carrying capacity

Tightening torque

M12

1.0 t

100 Nm

M16

1.5 t

150 Nm

M20

2.5 t

250 Nm

M24

4.0 t

400 Nm

M27

4.0 t

400 Nm

M30

5.0 t

500 Nm

M36

7.0 t

700 Nm

M42

15.0 t

1500 Nm

Tab. 5-2

RUD VLBG

XA_T9_0025c_01

Lifting Rings (RUD®: VLBG)

Tightening Torques for Attachment Gear

RUD VLBG

5.7.1

Lifting rings

The lifting rings remain fitted; do not remove them after use. Please note the transport and lifting specification in the following sections.

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5.7.2

Lift Compressor Take care to avoid any damage; please refer also to section 5.2.1 Safety of Transport. DANGER Suspended loads!

PB_T9_0173b_01

mi

n.

45

°

Falling loads can cause serious injury or death.  Lift compressor only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

Fig. 5-8

Transport and lifting of compressor on transport frame

PB_T9_0051a_01

max. 90°

Fig. 5-9

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Transport and lifting of compressor

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Transport, Installation and Pre-Commissioning Lifting Procedure

5.7.3

Lift Crankgear Take care to avoid any damage; please refer also to section 5.2.1 Safety of Transport. DANGER Suspended loads!

PB_T9_0149a_01

Falling loads can cause serious injury or death.  Lift crankgear only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

Fig. 5-10 Transport and lifting of crankgear

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Transport, Installation and Pre-Commissioning Lifting Procedure

5.7.4

Lift Crankgear with Distance Pieces Take care to avoid any damage; please refer also to section 5.2.1 Safety of Transport. DANGER Suspended loads! Falling loads can cause serious injury or death.  Lift crankgear with distance piece only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the weight of the heaviest individual component.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

PB_T9_0180b_02

min. 45°

Fig. 5-11 Transport and lifting of crankgear with distance pieces

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Transport, Installation and Pre-Commissioning Lifting Procedure

5.7.5

Lift Cylinder with Distance Piece Take care to avoid any damage; please refer also to section 5.2.1 Safety of Transport. DANGER Suspended loads!

PB_T9_0133a_03

Falling loads can cause serious injury or death.  Lift cylinder with distance piece only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the weight of the heaviest individual component.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

Fig. 5-12 Transport and lifting of cylinder with distance piece

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Transport, Installation and Pre-Commissioning Lifting Procedure

5.7.6

Lift Distance Piece This section describes also the lifting procedure for distance piece – despite the fact that the compressor is transported completely assembled or cylinder and distance piece are pre-assembled – to use for a later dismantling of the compressor e.g. for maintenance reasons.

Take care to avoid any damage; please refer also to section 5.2.1 Safety of Transport. DANGER Suspended loads! Falling loads can cause serious injury or death.  Lift distance piece only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

in.

m PB_T9_0005a_01

°

45

Fig. 5-13 Transport and lifting of distance piece

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Transport, Installation and Pre-Commissioning Lifting Procedure

5.7.7

Lift Cylinder This section describes also the lifting procedure for cylinder – despite the fact that the compressor is transported completely assembled or cylinder and distance piece are pre-assembled – to use for a later dismantling of the compressor e.g. for maintenance reasons.

Take care to avoid any damage; please refer also to section 5.2.1 Safety of Transport. DANGER Suspended loads!

PB_T9_0154a_01

Falling loads can cause serious injury or death.  Lift cylinder only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

Fig. 5-14 Transport and lifting of cylinder

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Transport, Installation and Pre-Commissioning Lifting Procedure

5.7.8

Lift Plant Components Take care to avoid any damage; please refer also to section 5.2.1 Safety of Transport. DANGER Suspended loads! Falling loads can cause serious injury or death.  Lift plant components only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the weight of the heaviest individual component.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

Following illustrations exemplify how to transport and lift plant components. Consider them for applicable plant components.

Lift plant components and use carrying ropes according to the relevant directive (angle must be > 45°). Example for Damper (Typical View)

Fig. 5-15 Transport and lifting of a damper (horizontal design)

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Transport, Installation and Pre-Commissioning Lifting Procedure

Example for Auxiliary Skid (Typical View)

Chose suitable lifting method according to design, weight and dimension of auxiliary skid (see Fig. 5-16 and Fig. 5-17).

Fig. 5-16 Transport and lifting of an auxiliary skid, using spreader frame

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Fig. 5-17 Transport and lifting of an auxiliary skid, using spreader beam

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Transport, Installation and Pre-Commissioning Install Compressor on Foundation

5.8

Install Compressor on Foundation The final installation procedure of the compressor on to the foundation is defined at site by our field service engineer according to site conditions. The following general description of the installation of the compressor is only a guide line.

5.8.1 Check Preparation

Place and Level Compressor 1. Check preparations according to section 5.6 Prepare Installation: •

Sufficient distance between jackscrews and foundation bolts.

•

The supporting surface must be clean and absolutely free of oil, rust, paint and grease. The epoxy grouting material shall stick onto the sole plates. 2

3

PA_XX_0002c_01

1

4

Fig. 5-18 Place jackscrews (typical view) 1 2 3 4

Transport and Lifting of Compressor

Oil protective coating Grout pocket for foundation bolt Foundation Jackscrew

For transport and lifting of compressor, take care to avoid any damage; please refer to section 5.2.1 Safety of Transport. 2. Attach carrying ropes to the compressor in the safe manner as illustrated in 5.7.2 Lift Compressor.

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Transport, Installation and Pre-Commissioning Install Compressor on Foundation

DANGER Suspended loads! Falling loads can cause serious injury or death.  Lift compressor only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

Place Compressor

1 2 3 4 5

11

10

9

8

PA_XX_0027c_01

6

7

Fig. 5-19 Placing compressor onto foundation

1 2 3 4 5 6

Crankgear Protective cap SUPERBOLT® tensioner Washer Sole plate Foundation

7 8 9 10 11

Foundation bolt Oil protective coating Grout pocket for foundation bolt Fixation bolt (crankgear–sole plate) Jackscrew

3. Lift the compressor. 4. Fix the sole plates with the fixing screws to the compressor. 5. Fix the foundation bolts with temporary nuts to the compressor. 6. Place the compressor including its sole plates and foundation bolts on the jackscrews, located between the grout pockets for the foundation bolt.

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Transport, Installation and Pre-Commissioning Install Compressor on Foundation

7. Center the foundation bolts in the holes of the sole plates by using a cardboard or sealing material.

 You are able to readjust the sole plates later. Level Compressor

8. The compressor must be leveled out exactly in length, cross and diagonal direction using a precision spirit level. Place the spirit level on top of a machined surface of the crankgear. Do not place the spirit level on top of a cylinder. The display accuracy (scale lines) of the spirit level must show at least 0.2 mm/m. The horizontal misalignment of the compressor must not exceed 0.1mm/m, that means a deflection of half distance between two scale lines on spirit level. 9. Make sure that all jackscrews are evenly loaded. Check this on the basis of the resistance on the spanner and with light hammering directly on the jackscrews. 10. Level the compressor lengthwise, crosswise and in diagonal direction by turning the jackscrews using a spanner. 11. Carefully check the aligned crankgear and foundation bolts.

5.8.2

Grout Foundation Bolts If another grouting material than listed in Tab. 5-1 will be used, please consult your local civil engineer for support.

1. Before grouting the foundation bolts of the compressor, once again check the center line of the electric motor with respect to the foundation bolt grout pockets, to ensure proper motor setting. 2. Make sure that the foundation bolts are fixed in correct position. When pouring, do not offset the foundation bolts.

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Transport, Installation and Pre-Commissioning Install Compressor on Foundation

A

B

1 2

XA_XX_0036c_03

3

Fig. 5-20 Grout foundation bolts (typical view) 1 2 3

Non-shrinking grouting material Foundation bolt Foundation

Proceed with grouting of supporting surface only after the grouting material of the foundation bolts has hardened. Please refer to manufacturer’s instructions.

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Transport, Installation and Pre-Commissioning Install Compressor on Foundation

5.8.3

Grout Supporting Surface of Sole Plates For grouting of the compressor’s supporting surface, Burckhardt Compression recommends to use one of the in Tab. 5-1 listed epoxy grouting materials.

If another grouting material than listed in Tab. 5-1 will be used, please consult your local civil engineer for support.

CAUTION Inappropriate use of grouting material can lead to deformation of crankgear!  Strictly follow grout manufacturer’s instructions (e.g. layer thickness, treatment temperature etc.).  Grouting must be carried out or supervised by an authorized company.

8 1

7

4 5

PB_XX_0101b_01

3 6

Fig. 5-21 Grouting of sole plates (typical view)

1 2 3 4

Crankgear – Open space Non-shrinking or epoxy grouting material

5 6 7 8

Foundation Foundation bolt Epoxy grouting material Sole plate

3. With respect to the grouting manufacturer’s instruction, grout the supporting surface across the entire length.

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CAUTION

1 2

5 3 4

PB_XX_0018b_01

Stress cracks in the epoxy grouting material due to thermal expansion of the compressor.  Provide expansion joints if the entire length exceeds 1.5 meter.

Fig. 5-22 Grouted supporting surface without expansion joint

1 2 3

5.8.4

Crankgear Sole plate Epoxy grouting material

4 5

Foundation Open space

Tighten the Foundation Bolts CAUTION Deformation of crankgear due to premature pressure load of grouting material.  Tighten foundation bolts only after the grouting material has hardened or has at least reached a resistance to pressure of 40 N/mm2. 1. Loosen the SUPERBOLT® tensioner of the foundation bolts. 2. Check the crankgear for perfect seating. 3. Slightly grease the threads of the foundation bolts, pressure screws and seating faces of SUPERBOLT® tensioner by using MOLYKOTE® G-N Plus.

You can use a number of commercially available graphite lubricant compounds for re-lubrication in the field. Nickel pastes are less suitable, copper bearing compounds have not performed well as pressure screw lubricants.

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4. Place dial gauge always next to the foundation bolt which has to be tightened (see Fig. 5-23). 5. Start tightening in the middle of the crankgear and thereafter crosswise. 6. Tighten the SUPERBOLT® tensioners according to section 8.7.8 Tensioner SUPERBOLT®. 7. If the sag of the crankgear exceeds 0.05 mm during tightening, the crankgear must be releveled. 8. Fill half of the SUPERBOLT® protective cap with grease and put it over the SUPERBOLT®. 1 2 3

4 5 6

PB_XX_0003b_01

7

8

Fig. 5-23 Tighten foundation bolt

1 2 3 4

Readjust the Crankgear

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Protective cap Pressure screw SUPERBOLT® tensioner Hardened washer

5 6 7 8

Crankgear Foundation bolt Sole plate Dial gauge

Releveling is only necessary, if the crankgear was stressed during tightening the foundation bolts.

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Transport, Installation and Pre-Commissioning Check Crankshaft Deflection

Proceed as follows to readjust the crankgear: 1. Loosen the SUPERBOLT® tensioners for the foundation bolts according to section 8.7.8 Tensioner SUPERBOLT®. 2. Lift the compressor by using a hydraulic jack or according to section 5.7 Lifting Procedure. 3. Add or remove shims.

4. Lower the compressor. 5. Finally tighten the SUPERBOLT® tensioners with the mandatory tightening torque. 6. Check the leveling again. 7. Repeat this procedure, if necessary.

Check Crankshaft Deflection 2

y

1

XA_M0_0009b_01

5.9

4

3

Fig. 5-24 Measure crankshaft deflection

1 2 3

Prerequisites

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Crank in 12 o’clock position Crankshaft Measuring position of dial indicator

4 y

Dial indicator Measuring distance (y) in mm

•

Set the dial indicator (4) always at the same position (y), at the end of the crank (opposite crankshaft journal).

•

The crankshaft must be properly supported by its bearings (check with a feeler gauge).

• •

Connecting rod on the drive end must be dismounted. Use a dial indicator with an accuracy of 0.01 mm.

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Measuring Procedure

1. Measure the crankshaft deflection on the drive end crank in 4 positions according to Fig. 5-24. Record all measured values as well as the measuring position (y) – i.e. offset from crankshaft journal – of the dial indicator.

 The measured deflection must not exceed 0.01 mm.

5.10 5.10.1 Remove VCI Mats

Assemble Compressor Prepare Assembly To protect the internal parts against corrosion, VCI (Volatile Corrosion Inhibitor) mats are inserted into cylinder and crankgear for protection. 1. Remove all VCI mats from crankgear and cylinder.

5.10.2 Special Tools

Cylinder Support Spirit level, combination spanners

Installation 1

2

3 6

5

4

7

8

PB_C0_0031b_02

4

9

Fig. 5-25 Cylinder support

1 2 3 4 5

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Cylinder Fixation bolt (support–cylinder) Cylinder support Foundation bolt Adjusting screw

2B1XC2.64_1

6 7 8 9

Fixation bolt (support–plate) Shims Plate Grout

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Preliminary Installation 1. Position the foundation bolt (4) and the plate (8) temporary. Alignment of Cylinder 1. Remove cylinder cover. 2. Check the alignment of the cylinder (liner) and the crosshead bore by using a spirit level (see Fig. 5-26).

Fig. 5-26 Check cylinder alignment with a spirit level

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Transport, Installation and Pre-Commissioning Assemble Compressor

PB_C0_0007a_01

Fig. 5-27 Temporary support with wood

Fig. 5-28 Temporary support with pipe and jackscrew

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3. Adjust the cylinder temporarily by fixing an temporary support (see Fig. 5-27 and Fig. 5-28). 4. Arrange the shims (7) on both sides of the foundation bolts. 5. Tighten the fixation bolts (6). Grout Foundation Bolts and Base Plate 6. Grout the foundation bolts according to 5.8.2 Grout Foundation Bolts. A

B

1 2

XA_XX_0036c_03

3

Fig. 5-29 Grout foundation bolts 1 2 3

Non-shrinking or epoxy grouting material Foundation bolt Foundation

7. Prepare encasing. 8. Make sure that the foundation bolts are held in correct position. When grouting, do not offset the foundation bolts.

After grouting the foundation bolts, wait at least one day, then chip away the grout on the top of the foundation bolt grout pockets (approximately 10 mm), as this grout is of bad quality.

9. Grout the base plate according to 5.8.3 Grout Supporting Surface of Sole Plates. 10. Wait until the grouting has hardened. CAUTION Deformation of crankgear due to premature pressure load of grouting material.  Tighten foundation bolts only after the grouting material has hardened or has at least reached a resistance to pressure of 40 N/mm2.

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5.10.3 Special Tools Transport and Lifting of Flywheel

Flywheel none For transport and lifting of flywheel, take care to avoid any damage; please refer to section 5.2.1 Safety of Transport. DANGER Suspended loads!

PA_L1_0002a_01

Falling loads can cause serious injury or death.  Lift flywheel only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand underneath suspended loads.

Fig. 5-30 Transport and lifting of flywheel

Assembly

1. Remove Tectyl® from crankshaft and from flywheel hub. Tectyl® is used to protect blank compressor parts. The wax-like coating can be removed without difficulty with any hydrocarbon. 2. Check contact surfaces on flywheel as well as on crankshaft for possible damage, unevenness or corrosion. Eliminate any unevenness using a smooth file or a scraper. 3. Use a light oil with corrosion inhibitor to slightly lubricate flywheel hub and crankshaft. 4. Attach carrying ropes in the safe manner as illustrated in this section and lift flywheel.

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1

2

3

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Transport, Installation and Pre-Commissioning Assemble Compressor

Fig. 5-31 Flywheel 1 2 3

Allen screw Flywheel Crankshaft flange

5. Carefully slide the flywheel (2) onto the crankshaft flange (3). 6. Slightly tighten the two Allen screws (1). 7. Align the holes for the coupling bolts. 8. Tighten the Allen screws firmly. 9. Tighten the coupling bolts (4) firmly. Required Checks

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10. Check radial and face runout as illustrated in Fig. 5-32.

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2

3

4

PA_L1_0001b_01

1

Fig. 5-32 Radial and face runout 1 2 3 4

Flywheel Crankshaft Dial gauge Measuring head

Tolerance of radial and face runout must not exceed 0.04 mm. When checking the face runout, push the crankshaft to the drive end side up to its stop. The axial clearance of the crankshaft must be eliminated.

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5.10.4

Install Pneumatic Barring Device 1

2

3

PB_L1_0049b_01

4

Fig. 5-33 Pneumatic barring device 1 2 3 4

Install Barring Device

Flywheel Pawl Proximity probe Barring device

1. Install barring device according to manufacturer’s instructions. •

For grouting of foundation bolts see section 5.8.2 Grout Foundation Bolts.

•

For positioning and grouting the supporting surface of barring device, see section “Foundation” in chapter 13 Appendix.

For grouting of the supporting surface, Burckhardt Compression recommends to use one of the epoxy grouting materials listed in Tab. 5-1.

2. Tighten the foundation bolts with the mandatory tightening torque, see section “Compressor” in chapter 13 Appendix.

5.10.5

Turn Flywheel 1. Check compressor assembly by turning the flywheel min. 1 rotation by means of the barring device in running direction. 2. Verify that everything is in proper mechanical condition. 3. While turning the flywheel, lavishly smear the piston rods below the oil scrapers with the operating oil of the compressor.

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5.10.6 Installation Measure Cylinder Clearance

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Cylinder Cover For detailed description see section 9.8 Cylinder Cover. Proceed according to section 8.7.3 Cylinder Clearance Measurement.

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5.11

Install Electric Motor and Coupling Installation of electrical parts must be performed by professionals. Please refer to manufacturer’s instructions.

The electric motor is coupled directly (rigid coupling) with the compressor. The alignment of the electric motor to the compressor must be done carefully and accurately. You have to connect the crank- and motorshaft, so that neither of them is stressed and the axial clearance is distributed. Thus both shafts attain free thermal expansion. The axial float of the motor shaft is measured at a suitable point and the end positions are marked. Thus the clearance distribution may be checked after coupling with the crankshaft.

5.11.1 Check Runout

Place Electric Motor Before the electric motor can be placed, check the runout of motor coupling flange:

When checking the face runout, make sure to push the motor shaft to one side up to its stop. The axial clearance of the motor shaft must be eliminated.  Maximum runout shown on dial gauge should not exceed 0.04 mm.

1. Make sure that the motor is kept absolutely horizontal in all directions by using a precision spirit level. 2. Measure runout at the largest diameter of the coupling flange.

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Transport, Installation and Pre-Commissioning Install Electric Motor and Coupling

2

3

LA_L1_0004b_01

1

Fig. 5-34 Radial- and face runout 1 2 3

Dial gauge Motor shaft Coupling flange

Install Motor on Sole Plates DANGER Falling machine parts! Serious injury or death  The electric motor may only be lifted according to manufacturer’s instructions.  The carrying capacity of the hoist must at least correspond to the heaviest individual component weight.  Do not stand underneath suspended loads.  Protect carrying ropes against sharp edges!

3. To enable vertical realignment of the electric motor (after maintenance/ overhaul), insert thin stainless steel shims between the sole plates and the support surfaces of the electric motor. These shims should have a thickness of about 3 mm in total. 4. Clean the bottom side of sole plates, which comes into contact with the grouting material. The supporting surface must be clean and absolutely free of oil, rust, paint and grease. The epoxy grouting material must stick to the sole plates.

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5. Place the motor onto the sole plates. 6. Fix the sole plates to the motor. Place Electric Motor DANGER Falling machine parts! Serious injury or death  The electric motor may only be lifted according to manufacturer’s instructions.  The carrying capacity of the hoist must at least correspond to the heaviest individual component weight.  Do not stand underneath suspended loads.  Protect carrying ropes against sharp edges!

7. In the same way as for the compressor, place electric motor including sole plates and shims on four jackscrews, located between the foundation bolts. 8. Approximately line up the electric motor.

5.11.2

Align Electric Motor For electric motor installation and operating instructions refer to manufacturer’s instructions. For electric motor drawings see section “Drive System” in chapter 13 Appendix.

Clean Coupling Parts

1. Prior to starting the assembly, the coupling parts must be cleaned thoroughly.

Alignment

The alignment of the electric motor to the compressor must be done carefully and accurately.

In general, the magnetic/mechanical center of the electric motor is marked on the motor shaft in respect to the housing.  The permissible axial displacement of the motor shaft must be taken into account during installation of the electric motor.  For applicable crankshaft clearances: see “Compressor” in chapter 13 Appendix.

1. Measure crankshaft deflection on the crank at the drive end (flywheel in a hanging position) with a dial indicator (see 5.9 Check Crankshaft Deflection.

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2. Adjust the dial indicator for the positions 3 o’clock and 9 o’clock to zero (0). 3. Bring crank into 6 o’clock position by turning the flywheel. The position of the dial indicator is now in 6 o’clock position. 4. In consideration of above taken readings, jack-up flywheel to eliminate its sag.

1

2

3

LA_L1_0027b_01

5. Lift the flywheel, until dial indicator shows zero (0).

4

Fig. 5-35 Jack-up flywheel 1 2 3 4

Crankgear Flywheel Jack Motor

6. Remove the jack. 7. Take a note of sag and angular movement. 8. Check the contact surfaces on the motorshaft (flange) as well as on the flywheel for possible damage or unevenness. 9. Correct any unevenness by using a fine file or a scraper. 10. Check the bores of the coupling bolts for cleanliness and for damages.

 The bores of the coupling bolt are absolutely clean and free of any damages. 11. Position the electric motor together with the sole plates on the leveling spindles, which are located between the foundation bolts. 12. In relation to the flywheel, carefully align the motorshaft, by means of a dial gauge, attached to the flywheel. 13. Rotate the flywheel. 14. Align the motor.

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15. Consider the sag and angular movement and correct it, if necessary. 16. Lift the flywheel according to step 5. 17. Align the bores for the coupling bolts. 18. Remove the shaft-locking device and other devices provided for the transportation safety.

When checking the face runout, make sure to push the motorshaft to one side up to its stop. The axial clearance of the motorshaft must be eliminated.  Maximum runout shown on dial gauge shall not exceed 0.04 mm.

In general, the magnetic/mechanical center of the electric motor is marked on the motor shaft in respect to the housing.  The permissible axial displacement of the motor shaft must be taken into account during installation of the machinery.  For applicable crankshaft clearances: see section “Compressor” in chapter 13 Appendix.

5.11.3

Grout Foundation Bolts The top 1/3 of the foundation bolts should be wrapped with tape to prevent binding of the grout with the foundation bolts. Proceed as specified in section 5.8.2 Grout Foundation Bolts. Make quite sure that no air bubbles are trapped within the poured-in concrete. To permit a possible realignment of the electric motor at a later date, the foundation bolts must have equal clearance around them where they pass through the motor frame during pouring of the concrete. After you will have tightened the foundation bolts, check the crankshaft deflection once more and, if necessary, realign the electric motor with the sole plates.

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Check Crankshaft Deflection 2

y

1

XA_M0_0009b_01

5.11.4

4

3

Fig. 5-36 Measure crankshaft deflection

1 2 3

Prerequisites

Measuring Procedure

Crank in 12 o’clock position Crankshaft Measuring position of dial indicator

4 y

Dial indicator Measuring distance (y) in mm

•

Set the dial indicator (4) always at the same position (y), at the end of the crank (opposite crankshaft journal).

•

The crankshaft must be properly supported by its bearings (check with a feeler gauge).

• •

Connecting rod on the drive end must be dismounted. Use a dial indicator with an accuracy of 0.01 mm.

1. Measure the crankshaft deflection on the drive end crank in 4 positions according to Fig. 5-24. Record all measured values as well as the measuring position (y) – i.e. offset from crankshaft journal – of the dial indicator.

 For maximum permissible deflection on the dial indicator for a complete turn of crankshaft see Fig. 5-37.

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CD/mm 0.07 0.06 0.05 0.04

0.02 0.01 y/mm 0

100

200

300

400

PA_M0_0001b_1

0.03

Fig. 5-37 Maximum permissible crankshaft deflection CD Crankshaft deflection in mm y Measuring distance (y) in mm

2. If the deflection exceeds this limit, consult Burckhardt Compression Services; address see section 1.6 Contact Address.

5.11.5

Grout Sole Plates In general, proceed according to section , as for the compressor. Burckhardt Compression recommends to use an epoxy resin to grout the compressor supporting surface (see Tab. 5-1). CAUTION Observe the corresponding product information (e.g. layer thickness, treatment temperature etc.) or hire a specialized company.

Those surfaces of the sole plates which are getting into contact with the sealing compound must be clean and absolutely free of oil, rust, paint and grease. The epoxy resin sealing compound shall stick onto the sole plates. With respect to manufacturer’s instruction, grout the supporting surface across the entire length. CAUTION Tension cracks in the epoxy grout! Thermal expansion of the sole plates may lead to tension cracks in the epoxy grout.  Provide expansion joints if the entire length exceeds 1.5 meter.

Thus avoiding that tension cracks in the epoxy grout develop due to thermal expansion of the sole plates.

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One week after grouting, nuts of the foundation bolts should be loosened. Check the motor for perfect seating and finally retighten nuts of foundation bolts. The thread of the foundation bolts and the seating faces of the nuts must be slightly greased. After tightening the foundation bolts, check the crankshaft deflection once more and, if necessary, realign the electric motor.

5.12 5.12.1

Install Plant Components Prepare Installation Plant accessories (e.g. gas coolers and pulsation dampers) are normally assembled after the compressor has been installed. Finally, the piping is fitted. Inaccurate installation of gas coolers and pulsation dampers must be corrected by weld seams with length additions. This is often necessary when the piping has not been made according to our isometries. CAUTION Bearings in the crankgear can be damaged by welding current!  Never run welding current (grounding) through compressor parts.  Attach the power clamp of the welding equipment to the piping/flanges as close to the weld seams as possible.  Carry out welding work according to national or international standards.

5.12.2

Damper Before dispatch, the dampers have been blasted or sand-blasted, degreased and passivated on their inside by the manufacturer. The vessels are filled with dry nitrogen with a slight overpressure of 0.30 bar g/0.03 MPa g/0.30 kg/cm2 g before dispatch. WARNING Pressurized system part! To protect the internal parts against corrosion, some components are filled with dry nitrogen prior to dispatch.  Take notice of the corresponding warning sign.  Depressurize system part before you start installation work.

Check dampers before installation to make sure that they have not been contaminated with oil or grease during handling. If there are any doubts about cleanliness degrease dampers, separators and gas coolers again!

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WARNING Plant components like coolers, pulsation dampers, separators can fall!  Store them securely.  Keep them from falling.

Install pulsation dampers according to the foundation drawings and general arrangement drawings. Align dampers carefully. Check if inlet/outlet nozzles have been positioned correctly.

1

2

XA_XX_0050b_01

Distinguish between “firm” and “sliding” fixations, to allow free expansion of coolers/dampers. Slotted holes in the feet of dampers and coolers are provided for such purpose.

Fig. 5-38 Firm fixation (typical view) 1 2

Foot of damper Support

2 3 4 5 6 7

XA_XX_0051b_01

1

Fig. 5-39 Sliding fixation (typical view) 1 2 3 4 5 6 7

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Stud bolts with 2 nuts Sleeve/jacket Belleville spring Washer Slotted hole Foot of damper Support

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Supports

The supports will be installed on the foundation as follows, see Fig. 5-40:

1 9

2 3 4 8 7 5

XA_XX_0121b_01

6

Fig. 5-40 Installation of support

1 2 3 4 5

Support HILTI® adhesive anchor Nut and washer (above base plate) Base plate of support Nut and washer (below base plate)

6 7 8 9

Foundation Grouting material Washer Leveling bolt

1. Mark the bores for the support (1) exactly, use the base plate of the support (4) or an appropriated jig as template. 2. Drill the bores for the HILTI® adhesive anchors (2) true to dimension (preferably with a core drill). 3. Insert HILTI® adhesive anchors according to section 5.12.1 Prepare Installation, observe the curing time. 4. Fit nuts and washers (5) onto the HILTI® adhesive anchors, pre-adjust nuts to the required level. 5. Clean and degrease the lower side of the base plate of the support. 6. Place the support on the pre-adjusted nuts with washers. 7. Adjust the support to the final level. 8. Fit washers and nuts (3) and tighten the nuts. 9. Fit leveling bolts (9) into the base plate of the support and set washers (8) below them on the foundation. Adjust the leveling bolts to the required level and apply a separating layer (adhesive tape or grease) to the thread section below the base plate.

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10. Turn the nuts (5) with washers down to the foundation (6) and tighten nuts. 11. Grout the support in accordance with section 5.11.5 Grout Sole Plates. 12. After the grouting material (7) has cured completely, tighten the nuts (3) with the mandatory tightening torque (see section “Compressor” in chapter 13 Appendix). 13. To avoid vibration transfer between foundation and support, turn back (loosen) the leveling bolts (9) some turns or remove the leveling bolts completely and close the bores, e.g. with grouting material. Dampers

Dampers are shipped separately, i.e. they are not mounted on the cylinders or compressor. Prerequisites

•

Compressor and main motor have been grouted in the foundation and have been aligned to each other.

• • •

Cylinders are mounted on the frame/crankgear. Damper supports have been previously installed (not grouted). Auxiliary piping has been fitted to the compressor (tested, cleaned, painted etc.).

Procedure Handle gaskets and orifice plates with care. Do not align dampers with the support, rather align supports with the dampers.

Respect sliding points. Make sure that there is sufficient space between the bolt and the equipment. The bolt should be located in the middle of the slotted/big hole (Fig. 5-39).

1. Install discharge dampers attached to the foundation. 2. Attach and grout the supports. 3. Starting from the compressor, fit the process gas piping between cylinder and discharge damper (including orifice plates). 4. Starting from the compressor, fit the process gas piping between cylinder and suction damper (including orifice plates). 5. Attach and grout the supports.

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5.12.3

Oil Skid DANGER Falling machine parts! Serious injury or death  The skid may only be lifted according to manufacturer’s instructions.  The carrying capacity of the hoist must at least correspond to the heaviest individual component weight.  Do not stand underneath suspended loads.  Protect carrying ropes against sharp edges!

For details see section “Foundation” in chapter 13 Appendix.

The attachment of the oil skid on the foundation is in client's scope.

5.12.4

Local Instrument Board LIB DANGER Electrical danger! Serious injury or death may occur.  All individual units must be grounded according to local standards and to IEC regulations.

DANGER Falling machine parts! Serious injury or death  The local Instrument board (LIB) may only be lifted according to manufacturer’s instructions.  The carrying capacity of the hoist must at least correspond to the heaviest individual component weight.  Do not stand underneath suspended loads.  Protect carrying ropes against sharp edges!

For details see section “Foundation” in chapter 13 Appendix.

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1 2 3 4 5 6 7

XA_XX_0109b_01

8

Fig. 5-41 Installation of local instrument board (typical view)

1 2 3 4

Local instrument board (typical view) HILTI® adhesive anchor Nut and washer Support

5 6 7 8

Nut and washer Grouting material Foundation Bore

1. Check the foundation (7), mark the bores (8) exactly, use the support (4) as a template. 2. Drill the bores (8) true to dimension (preferably with a core drill). 3. Insert HILTI® adhesive anchors (2) according to section 5.12.1 Prepare Installation, observe the curing time. 4. Fit nuts and washers (5) onto the HILTI® adhesive anchors, adjust nuts to the required level. 5. Clean and degrease the lower side of the support. 6. Place the local instrument board (1) onto the HILTI® adhesive anchors, realignment can be done with the nuts. 7. Fit washers and nuts (3) onto the HILTI® adhesive anchors, tighten nuts. 8. Grout the local instrument board in accordance with section 5.8.3 Grout Supporting Surface of Sole Plates.

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5.13

Install Pipe Work

5.13.1

Prepare Fabrication CAUTION Bearings in the crankgear can be damaged by welding current!  Never run welding current (grounding) through compressor parts.  Attach the power clamp of the welding equipment to the piping/flanges as close to the weld seams as possible.  Carry out welding work according to national or international standards.

Carefully clean and degrease all material fitted in the gas circuit after welding and before final fitting in place. CAUTION Wrongly applied solvents!  Observe the manufacturer’s instructions about the use of solvents!

The contractor shall ensure that the piping associated with the compressor and accessories complies with the manufacturer’s and client’s requirements/specifications.

The following instructions describe adjustment, welding, fastening and cleaning of piping at the installation site. They are of a general, non-binding character and in no way influence the agreements made with the customer in the main contract.

•

To prevent ingress of dirt and foreign matter, all openings of compressor and plant components must be covered and sealed. Dust blinds shall remain installed until final alignment.

•

Piping for gas and water are usually pre-manufactured and delivered with additions for assembly welding. Coolant pipes with diameters less than 50 mm are delivered in separate pieces and must be adjusted and welded on site. Piping delivered in separate pieces means additional expenditures at the installation site and additional personnel.

•

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Ensure stress-free installation of piping between compressor, plant components and other piping. Otherwise, stress will build up leading to vibration problems and pipe cracking. The lifetime of installed elements such as control valves, safety relief valves, temperature and pressure

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transmitters and other instruments will be affected, too. Excessive wear of parts may occur and satisfactory operation/running cannot be guaranteed.

5.13.2

18.05.2016

•

Piping must be welded by skilled personnel with suitable equipment. Personnel must adhere to normal guarantees concerning material quality and standard of work.

• •

Welding must be carried out according to local welding specifications.

•

Paint and other protective coatings on the pipes, flanges, pipe bends, preformed components, reducers etc. are to be removed before further processing. A method suitable for the removal of the particular protective coating is to be used for cleaning, e.g. sandblasting, mechanical action, burning off, acid pickling or solvent.

•

Weld seams which cannot be ground internally have to be welded on the root side using inert gas.

•

Take care that sufficient flange pairs per piping run are provided. This ensures that all piping pieces can be dismantled after fitting for acid treatment and cleaning.

•

Gas piping fitted to the compressor must be installed allowing for axial removal. This is required to be able to clear the piping from the studs on the cylinder block (i.e. by means of a spool piece or 90°-flanged connection).

•

Arrange the piping system in such a way that no liquid accumulation in the gas pipes is possible even with closed isolating suction valve.

Pipes marked and provided with material certificates may only be separated, cut, re-welded and re-stamped according to local regulations in the presence of quality control personnel.

Fabricate Piping •

Lube oil pipes, with the exception of stainless steel pipes welded with inert gas, must be cleaned with acid according to the following section after completion.

•

Dismantle and clean piping by sandblasting, with acid or mechanically after it has been fitted.

•

Some main pipe supports may be installed first to install the piping in the right position.

•

Weld ends of pipe sections must be parallel and fit together without any misalignment. For a correct full penetration welding, the required size of the root face must be fixed or tack-welded.

•

As a rule, tack-welding is carried out in the same welding procedure as for the root layer. If so stipulated, the same pre-heating temperatures for welding also apply to tack-welding. Uneven and/or faulty tack-weldings must be removed prior to welding of the root layer. Welded-on fixations to pipe ends are not permitted.

•

If welded connections are locally heat-treated (if applicable) make sure that – at least for the length of the weld seam – the parameters for heat treatment are observed on both sides of the weld seam and at the complete circumference of the seam.

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Flange Face Alignment

The following instruction only describes flange face alignment when flat gaskets are used. Two types of alignment are recognized:

•

Lateral alignment, that is the offset of the aligned flange center lines, applicable for the complete flange set as well as the relevant position of bolt holes (Fig. 5-43).

•

Parallelism, of the aligned flange faces, sometimes referred as angular alignment (Fig. 5-42).

XA_XX_0103a_03

X1

Fig. 5-42 Parallelism of aligned faces X1 Deviation X1

XA_XX_0073a_02

X2

X2

Fig. 5-43 Lateral alignment X2 Deviation X2

Set-Up prior to Measurement

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•

The flanges shall be lined up so that the bolts can be inserted without force.

•

A gasket and 25 percent of the bolts, at least four, shall be inserted. The bolts shall be uniformly fastened using manual spanners to take out the free slack, to ensure the real misalignment will be measured.

•

The fitting of the pipes to the connections on the compressor (stub ends) has to be carried out very carefully. Special attention is required so that no distortion of the stub ends takes place due to welding, i.e. due to thermal stress.

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Particularly for stainless stub ends: In order to minimize thermal stress, screw two stub ends of the same size together during welding (see fig. below).

1

4

3

XA_XX_0368b_01

2

Fig. 5-44 Stub-end welding 1 2 3

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Pipe Weld Stup end

•

Should, however, the sealing surfaces of the weld-on pieces be distorted due to welding in spite of this measure, these surfaces are to be faced up square and checked by means of a surface plate.

•

Spare gaskets should be built in for pipe adjustments. Consider the settlement of final gaskets when using spare gaskets for pipe adjustments.

•

Consult pipe layout and dimension of piping. Stress-relieved with regard to operating temperature, also consider the temperature during assembly, i.e. install piping having been negatively or positively prestressed in order to compensate for large temperature differences.

• •

Reference value, e.g. for carbon steel: t = 100 °C = 1 mm/m.

•

While installing pipe sections, e.g. welding of T-pieces, special care must be taken that no impurities (burnt out material, etc.) remain within the bore of the pipe after treatment. Hence the line has to be cleaned thoroughly before installing and welding in the next pipe. The same applies for the fitting of connections for thermometers, pressure gauges, etc.

The flange connections of the pipes, especially those on the gas cooler and pulsation damper, have to be symmetrical and either square or accurately aligned to the design angle with regard to each other. If this is not done, high stresses occur which can lead to material fractures in lines and vessels.

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5.13.3

Check Fabrication Acceptance Criteria for Misalignment

Stub End Flange Connections to Compressor Cylinder

The stub end flange alignment at the cylinder side can not be checked easily because of a recess. Procedure:

•

Install the piping to the cylinder with the other end free but aligned to damper, etc.

• • • •

Do not remove the studs from cylinder.

•

Consider the heat expansion of gas discharge pipes.

Snug tighten the nuts. Check the gap between the flange and cylinder. Check the opposite flange for parallelism and make sure the bolts are inserted loosely.

Flange faces shall be aligned parallel within 0.05 degrees in all directions. Maximum deviation (X1) from parallel across flange diameter, see Tab. 5-3. The measured lateral misalignment (X2) shall not exceed the values given in Tab. 5-4. Flange diameter [mm]

Deviation X1

<300

0.2mm

300 to 600

0.3mm

600

0.5mm

Tab. 5-3

Deviation X1

Flange diameter [mm]

Deviation X2

100

2mm

>100

3mm

Tab. 5-4

Deviation X2

Flange connections to compressor requires an even surface. Recheck after welding of stub ends. The maximum flatness tolerance is 0.2 mm.

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Standard Flange Connections

3

XA_XX_0074a_02

X

Fig. 5-45 Maximum deviation X3 Deviation X3

•

Lateral Alignment For standard flanges, the free insertion of the bolts is generally sufficient to demonstrate acceptable alignment. Lateral alignment may also be checked by laying a straight edge along the outside diameter of the flange. Measurements should be taken at locations 90 degrees apart around the flange circumference. The measured lateral misalignment (X2) shall not exceed the values given in table Tab. 5-4. Bolt holes shall straddle the natural center line unless specified otherwise. The maximum deviation from the required theoretical bolt hole position (X3), as measured along the bolt circle, shall be 1.5 mm (Fig. 5-45).

•

Parallelism Flange face alignment shall be checked by measuring the distance between the mating flanges of the pre-assembled joint. Measurements shall be taken around the circumference at equal distances from the center line (the outside rim of the flange will normally be the most convenient position). The difference between the measurements shall not exceed the following values: ASME B 16.5 flanges, all sizes, all ratings: 2.5 mm/m.

Flanged Accessories

Accessories are flanged items which are rigid in themselves (e.g. valves, strainers etc.). The individual flange face misalignment from the design plane shall not exceed 2.5 mm/m. Also, the misalignment of the two flange faces shall not exceed 2.5 mm/m.

Gap between Flanges

Gasket type, material and size shall be checked. The gap between the flanges shall be just sufficient to slide in the gasket without damaging the gasket or the flange faces.

Decrease of Pipe Wall Thickness and Pipe Bend Flattening

The maximum allowable decrease of wall thickness shall not exceed 10 % of nominal wall thickness.

Cleaning

18.05.2016

Pipe wall thickness shall be in accordance with ANSI B 31.3. After the pipes have been fitted, they are to be dismantled and cleaned, e.g. by sandblasting, acid treatment (see section 5.13.4 Pickle and Passivate Piping) or mechanical action.

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CAUTION Contamination of process gas! All components coming in contact with process gas must be checked for cleanliness prior to their installation.  Degrease and clean the process gas pipes with an oil and grease removing solvent to required level of cleanliness.

CAUTION Wrongly applied solvents!  Observe the manufacturer’s instructions about the use of solvents!

Tests

Radiographic and/or pressure tests are to be carried out according to local regulations. After assembly of the complete gas piping system incl. dampers, coolers and all fittings, the system may be submitted to a leak test according to local regulations and project procedures.

Final Checks

After the compressor has been successfully test run, all flange connections and pipe fastenings are to be thoroughly tightened up again. Should pipe vibrations occur, please see section 5.16.9 Assess Vibrations.

5.13.4

Pickle and Passivate Piping Not applicable for stainless steel pipes welded with inert gas.

Since oil and grease generally cannot be removed by acids, these contaminants – if present – must be removed with an organic solvent or alkaline solution prior to acid pickling.

The following instructions describe acid pickling of pipings at the assembly site. They are of a general, non-binding character and in no way affect the agreements made with the customer and forming part of the main contract.

•

Fabrication of the pipings and preparations. Please see section 5.13.2 Fabricate Piping.

•

The final cleaning of the pipings takes place before final assembly, i.e. after completion of any radiographic and pressure tests which may be specified or after formal release of the pipes for the said final assembly.

A clear distinction is to be drawn between the matching/fitting of pipe components which have undergone preliminary cleaning and those which have not.

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Procedure for pipe components which have undergone preliminary cleaning: Pickling of the pipings can be dispensed with in cases where:

•

the pipes were cleaned before welding together, i.e. the surfaces have good metallic lustre and appear clean and

•

the assembly welds were carried out under inert gas and/or ground internally.

Such pipings are to be hammered out, washed out with solvent and subsequently blown out with oil free air or oil free nitrogen. DANGER Where chlorinated hydrocarbons are used as cleaning agent, the safety precautions given in section 10.3 Select Cleansing Agent are to be complied with.

Procedure for pipe components which have not undergone preliminary cleaning: Where the pipings have not been fabricated from preliminary cleaned pipe components, dismantling and acid pickling as described below are required. Acid Pickling Where possible, specialist firms are to be employed to pickle the pipings. DANGER Corrosion and toxic hazard!  All safety precautions are to be strictly complied with when dealing with acids and lyes.  The instructions given in section 2.4.9 Handling Chemicals are to be followed.

Since gases are formed during acid pickling, the pipings must be arranged in such a way that there is no place where gas bubbles can collect, see Fig. 5-46. The pipes can be pickled either by filling the piping completely or, if a suitable pump is available, by circulation of the acid.

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3

XA_XX_0049b_01

2

1

Fig. 5-46 Pipe arrangement for pickling 1 2 3

Liquid Gas Emptying

Acid Mixtures The following dilute acids can be used to pickle pipes made from carbon steel, stainless steel or copper: Acid mixture

Concentration

Temperature

Orthophosphoric-acid (H3PO4)

8–20%

20–60°C

Amino-sulphonic-acid (NH2SO3H) 5–15%

20–40°C

Sulphuric acid (H2SO4)

10–20%

20–60°C

*Hydrochloric acid (HCl)

5–20 %

20–60°C

* Do not use hydrochloric acid for the cleaning of pipe assemblies made of carbon and stainless steels. A corrosion inhibitor must be added to the pickling solution to protect the base material. To orthophosphoric and sulphuric Mulgoten 3482 acids:

0.4%

To hydrochloric acid:

Rodine 213

0.3–0.4%

Propargylalcohol

0.4%

The time required for acid pickling depends on the solution temperature: the higher the temperature of the acid solution the quicker the cleaning. Depending on the temperature and the concentration of the solution, acid pickling requires two to twelve hours.

It is recommended that the required pickling time be determined by using specimen pipes.

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Passivation After acid treatment, neutralise immediately the pickling. Rinse with water and passivate the pipings. For this purpose use the following solutions:

• • •

5 % sodium carbonate (soda) solution (Na2CO3) 5 % sodium hydroxide solution (NaOH) 5 % trisodium phosphate solution (Na3PO4)

Heat the solutions up to 60/70 °C. Passivation requires about one hour. The arrangement of the pipings is the same as for acid pickling (Fig. 5-47).

3

XA_XX_0049b_01

2

1

Fig. 5-47 Pipe arrangement for passivation 1 2 3

Liquid Gas Emptying

After passivation, heat the pipings up with steam and subsequently blow them dry using oil-free air or oil-free nitrogen. Wherever possible, the cleaned pipings should be immediately assembled in place and kept under a nitrogen blanket. Should the assembly of the pipings be delayed, the ends of the pipes must be sealed off with plastic in order to prevent the entry of atmospheric air. CAUTION Observe section 2.8 Safe Maintenance Practices.

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5.13.5

Sandblast Piping Sandblasting is the preferred method to achieve grey, metallic surfaces for carbon steel items such as gas piping. Except for thoroughly removing particles by blowing out, wiping or vacuum cleaning, no further cleaning is required. The term sandblasting includes shot, bead, and grit blasting. WARNING Sand deposits in gas pipes or vessels! Risk of damage to piston and cylinder.  After sandblasting, thoroughly clean gas pipes and vessels by wiping or vacuum cleaning.

WARNING Sand deposits within bearings! Risk of bearing damage.  Oil piping shall not be cleaned by sandblasting.

Oil piping, with the exception of stainless steel pipes welded with inert gas, must be cleaned with acid according to section 5.13.4 Pickle and Passivate Piping.

5.13.6

Recommendation for Pipe Support Please refer to corresponding General Arrangement in section “General Arrangement”, chapter 13 Appendix.

Pipe Support (Fixed Point) for Oil and Coolant Piping

Burckhardt Compression recommends to use a pipe support of this type (fixed point) for oil and coolant piping to max. DN150/6". 1

XA_XX_0075b_01

2

Fig. 5-48 Pipe support with u-bolt 1 2

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U-bolt Support beam

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Pipe Support (Gliding Point) for Gas Piping

For gas piping from DN50/ 2" to DN600/ 24", Burckhardt Compression recommends to use a pipe support of this type (gliding point), consisting of 2 pipe clamps. This type of pipe support with gliding points is used for pipes that are exposed to strong thermal expansion.

1 2 Z1

XA_XX_0076b_01

3

4

5

Fig. 5-49 Pipe support (gliding point) 1 2 3 4 5

Pipe clamp Shim Plate Support beam Shim (non-metallic)

During installation, the gap Z1 (theoretically 5–6 mm) must be bridged with 2 shims (2). The pipe must remain movable in longitudinal direction. After the fastening bolts have been tightened, the supporting surfaces of the pipe clamps must be parallel to the support beam. The fastening bolts must be tightened with two nuts. A 3 mm plate (3) must be installed between pipe/pipe clamp and support beam. A non-metallic shim (5) must be installed between the pipe and the 3 mm plate in order to absorb vibrations.

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Pipe Support (Fixed Point) for Gas Piping

For gas piping from DN50/2" to DN600/ 24", Burckhardt Compression recommends to use a pipe support of this type (fixed point), consisting of 2 pipe clamps.

1

2

XA_XX_0077b_01

Z1

3

4

Fig. 5-50 Pipe support (fixed point) 1 2 3 4

Pipe clamp Plate Support beam Shim (non-metallic)

During installation, the fastening bolts must be tightened to such extent that the pipe is tightly in the piping support and cannot be moved in longitudinal direction. The theoretical gap Z1 (5–6 mm) must remain open. After the fastening bolts have been tightened, the supporting surfaces of the pipe clamps must be parallel to the support beam. The fastening bolts must be tightened with two nuts. A 3 mm plate (2) must be installed between pipe/pipe clamp and support beam. A non-metallic shim (4) must be installed between the pipe and the 3 mm plate in order to absorb vibrations.

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Pipe Support (Fixed Point) for Gas system

For gas piping from DN15/ ½" to DN40/ 1½", Burckhardt Compression recommends to use a pipe support of this type (fixed point).

1

2 Z1

XA_XX_0078b_01

3

Fig. 5-51 Pipe support (fixed point) 1 2 3

Pipe clamp Plate Support beam

During installation, the fastening bolts must be tightened to such extent that the pipe is tightly in the piping support and cannot be moved in longitudinal direction. The theoretical gap Z1 (1–2 mm) must remain open. After the fastening bolts have been tightened, the supporting surfaces of the pipe clamps must be parallel to the support beam. The fastening bolts must be tightened with two nuts. A 3 mm plate (2) must be installed between pipe/pipe clamp and support beam.

5.13.7 SERTO® Compression Ferrule Unions

Recommendation for Tube Fittings Design and Principle The compression ferrule is deformed as the nut is tightened, necking the tube slightly without notching it. The deformation forces generate high specific contact pressure in the neck zone and the butt joint “compression ferrule/basic component”, ensuring a secure hold of the tubes, and a perfect metal to metal sealing. Thanks to the elasticity of the compression ferrule system, SERTO® unions are extremely resistant to vibrations and pressure shocks, insensitive to temperature change, and best suited to repeated dismantling and reassembly. An effective and safe connection is only guaranteed by using exclusively SERTO® original component parts, assembled in accordance with the installation instructions.

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XA_XX_0052a_01

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Fig. 5-52 SERTO® principle, radial dismantling

WARNING An improper installation (loose or excessively tightened threaded connection) as well as leakage of fluid, may cause minor body injuries, injury to eyes or environmental damages.  Strictly follow installation instruction!  Visually and periodically check pipes for leakage or for damages!

Installation Instructions The SERTO® union is supplied assembled.

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1 2 3

d s

XA_XX_0053b_01

4

Fig. 5-53 SERTO® union 1 2 3 4 d s

Basic component Compression ferrule Nut Stiffener sleeve Tube outside diameter Wall thickness

Procedure:

XA_XX_0054a_01

1. Preparation

Fig. 5-54 SERTO® preparation

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•

Cut tube in a right angle to length and deburr it.

•

The end of the tube must be straight for an approximate length of 1.5 d and the surface free of damages.

•

The union is prelubricated. The use of Burckhardt Lubrication Grease BLG05, lube oil, MOLYKOTE® G-N Plus, Teflon® etc. facilitates the reassembly and assembly of bigger sized unions (thread, compression ferrule).

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XA_XX-0055a_01

2. Reinforce Tube and Insert

Fig. 5-55 SERTO® reinforcement

•

Stiffener sleeves are required to reinforce plastic tubes and thin walled tubes.

Copper tubes

Stainless steel tubes

from d 10 mm

s < 1.0 mm

from d 12 mm

s < 1.5 mm

from d 6 mm

s < 0.5 mm

from d 10 mm

s < 1.5 mm

•

Align tube and union.

•

Insert tube up to the stop.

XA_XX_0056a_01

3. Tightening, Stress Relieving, Checking

Fig. 5-56 SERTO® tightening

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•

Tighten the nut with an open end spanner until an increased resistance is felt.

•

Slightly loosen nut in order to relieve possible stresses. Finally tighten union against positive resistance.

•

Check if nut is covering the connecting stem thread, then tube and compression ferrule are properly deformed.

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4. Tubes Use tubes with a clean smooth external surface and with an outside diameter having tolerance of ± 0.1 mm. 5. Turnable Ferrule There is no influence on the efficiency of the connection if, after assembly, the ferrule can be turned on the tube or the tube in the union nut. Description and Function

XA_XX_0057a_01

Progressive Ring Fitting ERMETO® (EO)

Fig. 5-57 Before tightening the nut A B C D

Front cutting edge Second cutting edge Stop cutting edge Collar end

The basic feature of the EO progressive ring is that the precisely designed geometry permits the limited, progressive penetration of the ring into the tube. The front cutting edge (A) has already begun to cut into the tube before the second cutting edge (B) contacts the tube. When the optimum prescribed depth for both cutting edges has been reached, the stop edge (C) prevents further penetration.

XA_XX_0058a_01

Because of the stop edge and the shape of the two cutting edges, the forces arising are distributed along the entire taper length, thus increasing joint strength. This distribution of the forces and the specially designed internal contour at the collar end (D) of the ring guarantee increased reliability for flexure loading. Vibrations are thereby dampened at the entry into the ring.

Fig. 5-58 After tightening the nut E

Collar end

During assembly, the stop edge causes the tightening forces to be increased up to a clearly perceptible fixed point (assembly fixed point). After assembly is completed, the visible thrown-up collar (E) must completely fill out the space in front of the first cutting edge.

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Using original components (EO™), precise knowledge of their function and the following of these instructions exactly guarantee the utmost reliability even under heavy duty applications. WARNING An improper installation (loose or excessively tightened threaded connection) as well as leakage fluid, may result in minor body injuries, injury of eyes or environmental damages.  Strictly follow absolutely installation instruction!  Visually and periodically check pipes for leakage or for damages!

Assembly Instructions Preparation of tubes: Cut off tube square; lightly deburr at the internal and external edges (do not bevel edge tube).

XA_XX_0059a_01

•

Fig. 5-59 Preparation of tube

If a pipe cutter is used (not recommended), be sure to deburr both tube ends at the inside and outside. Also file the tube face flat to ensure complete contact of the tube end face with the stop shoulder inside the taper of the fitting. XA_XX_0060a_01

•

XA_XX_0061a_01

Fig. 5-60 Tube cut using pipe cutter: considerable burr formation/tube not cut off square

Fig. 5-61 Sawn off tube: hardly any burr formation

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Preparation of Fitting Components: Oil thread and taper of fitting as well as EO progressive ring and thread of nut.

XA_XX_0062a_01

•

Fig. 5-62 EO parts

Slide nut and progressive ring onto end of tube.

XA_XX_0063a_01

•

Fig. 5-63 EO ring on tube

•

Do not slide on progressive ring backwards!

XA_XX_0064a_02

1

2

Fig. 5-64 Correct/incorrect assembly 1 2

Correct assembly Incorrect assembly

Direct Assembly in Fitting Body:

•

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Tighten nut by hand up to hand tight. Always press tube against stop in inner cone of fitting body.

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Fig. 5-65 Tighten nut by hand

Mark a line on nut and tube in order to observe the required number of turns.

XA_XX_0066a_01

•

Fig. 5-66 EO parts

•

Tighten nut by approximately 1 1/2 turns (tube is not allowed to turn with nut).

XA_XX_0067a_01

Stop edge limits tightening by increasing force required.

Fig. 5-67 Tighten nut by spanner

Inspection of Assembly:

•

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Loosen nut; check to make sure that a visible collar fills out the space in front of the 1st cutting edge (it does not matter if ring can be rotated on top of tube end).

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Transport, Installation and Pre-Commissioning Install Pipe Work

Fig. 5-68 Loosen nut

Reassembly: After every reassembly, retighten nut without applying more force than for the first assembly. Firmly hold fitting body during the assembly.

XA_XX_0069a_01

•

Fig. 5-69 Reassemble

Tube Fittings SWAGELOK®

Description and Function SWAGELOK® Tube Fittings provide a leak-proof, torque-free seal at all tubing connections and eliminate costly, hazardous leaks in instrumentation and process tubing. All the action in the fitting moves along the tube axially instead of with a rotary motion. Since no torque is transmitted from the fitting to the tubing, there is no initial strain which might weaken the tubing.

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XA_XX_0048a_01

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Fig. 5-70 SWAGELOK® union

Fig. 5-71 SWAGELOK® parts

CAUTION Leaking pipes Damages or injuries may result from interchanging or mixing parts of tube fittings made by other manufacturers.  Do not mix or interchange parts of tube fittings made by other manufacturers with SWAGELOK® Tube Fitting parts.  An improper installation (loose or excessively tightened threaded connection) as well as leakage of fluid, may cause in minor body injuries, injury to eyes or the environmental damages.  Follow absolutely the installation instruction!  Visually and periodically check pipes for leakage or for damages!

Assembly Instructions SWAGELOK® Tube Fittings are delivered completely assembled fingertight and ready for immediate use. Disassembly before use is not necessary and can result in dirt or foreign material getting into fitting and causing leaks. SWAGELOK® Tube Fittings are installed in three easy steps:

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1. Simply insert the tubing into the SWAGELOK® Tube Fitting. Make sure that the tubing rests firmly on the shoulder of the fitting and that the nut is finger-tight.

Fig. 5-72 SWAGELOK® step 1

XA_XX_0046a_01

2. Before tightening of SWAGELOK® nut, mark nut at the 6 o’clock position.

Fig. 5-73 SWAGELOK® step 2

XA_XX_0045a_01

3. Now, while holding the fitting body steady with a backup spanner, tighten the nut 1-1/4 turns. Watch the marking, make one complete turn, and continue to the 9 o’clock position.

Fig. 5-74 SWAGELOK® step 3

By marking nut at the 6 o’clock position as it appears to you, there will be no doubt as to the starting position. When the nut is tightened 1-1/4 turns to the 9 o’clock position, you can easily see that the fitting has been properly installed. Check Gauge Check gauges ensures added safety and reliability. It is an exclusive SWAGELOK® Tube Fitting feature which allows easy inspection for sufficient pull-up, before a system is pressurized.

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Fig. 5-75 Check gauge

XA_XX_0043a_01

The SWAGELOK® check gauge is placed between the nut and body hex or shoulder of a tube fitting after pull-up. If the check gauge does not fit between nut and body hex, the fitting nut is sufficiently tightened.

Fig. 5-76 Check gauge

If the check gauge fits between nut and body hex, additional tightening is required! Retightening Instructions Connections can be disconnected and retightened many times. The same reliable, leak-proof seal can be obtained every time the connection is remade.

XA_XX_0042a_01

1. Fitting shown in disconnected position.

Fig. 5-77 Disconnected fitting

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2. Insert tube with ferrule into fitting until it stops.

Fig. 5-78 Insert tube

XA_XX_0040a_01

3. Tighten nut by hand. Rotate nut to the original position using a spanner. An increase in resistance will be encountered at the original position. Then slightly tighten with spanner. Smaller tube sizes will take less tightening to reach the original position, while larger tube sizes will require more tightening. The wall thickness will also have an effect on tightening.

Fig. 5-79 Tighten nut

5.13.8

Final Assembly of Piping Flange Connections 1. Clean nuts and bolt threads. 2. Grease stainless steel bolts with MOLYKOTE® G-N Plus. 3. Remove spare gaskets that were used for piping adjustments (as recommended in section 5.13.2 Fabricate Piping). Install final, undamaged gaskets for final assembly of pipe work. 4. Tighten nuts manually, do not use spanner. Make sure that the flanges remain parallel. 5. In a first operation, tighten nuts to 1/5 of the mandatory tightening torque according to Fig. 5-80. 6. Check the parallelism of the flanges. 7. If the flanges are not parallel to one another, start the second operation at the position where the flanges are the furthest apart (see allowable clearance).

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8. In the second operation, the nuts are tightened to 1/3 of the mandatory tightening torque. 9. Check the parallelism of the flanges. 10. In a third operation, tighten nuts to 2/3 and then in a fourth operation to the full amount of the mandatory tightening torque. Re-check the parallelism of the flanges after the third operation.

1

9

15

5 13

12

3

4

11 14

7 6

16 10

2

XA_XX_0083a_02

8

Fig. 5-80 Tightening sequence of nuts according to this figure

Gas pipes must be installed stress-free (see section 5.13.6 Recommendation for Pipe Support). Do not apply force to the flange bolts in order to pull the pipes in their correct position. For admissible clearances: refer to “Flange Face Alignment” in section 5.13.2 Fabricate Piping and “Acceptance Criteria for Misalignment” in section 5.13.3 Check Fabrication. Do not use more than one gasket between the flange contact faces. Coolant Lines When the coolant lines are fitted, make sure that the supply and discharge lines to the cooling chambers are connected properly to the main coolant supply (coolant inlet below), otherwise the respective spaces will not be properly filled with water (no back pressure). Ensure sufficient ventilation for the highest spots of closed cooling systems.

Arrange coolant piping in such a way that the system can quickly be drained and easily ventilated.

Particular attention should be given to the internal coolant connections when testing for tightness.

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5.13.9

Hydrostatic Pressure Test Hydrostatic pressure tests of the pipe system must be carried out by trained specialists only. Parts to be pressure tested must be air vented. Please ask for our technical assistance (address see section 1.6 Contact Address) for permitted design pressure on the gas side. Use approved pressure gauges only. For the gas and oil pipes only treated water must be used. WARNING Pressurized plant components. Incorrect pressure testing may result in bursting plant components!  Do not exceed the maximum permitted pressure!  Observe the correct measuring unit on the pressure gauge.

5.14 Installation

Non-Return Valve Install the non-return valve (in client’s scope) according to manufacturer’s instructions.

•

Verify that arrow on housing of non-return valve corresponds to the flow direction of the process gas.

•

Verify that correct gaskets are used.

Only use original spare parts.

5.15

Electrical Installation DANGER Electrical danger! Serious injury or death may occur.  All electrical installation and operations must be carried out by professional personnel only!

5.15.1

Fit Grounding Wire Grounding connections are provided on the crankgear, cylinders, motor, pipes, junction boxes in stainless steel and local instrument boards. Other plant components such as skids (e.g. lubricating system) and vessels are also provided with dual connecting points.

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1

2

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3

Fig. 5-81 Grounding connection (typical view) 1 2 3

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Washer Spring washer Grounding wire

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3 4

PB_M0_0006b_02

2

Fig. 5-82 Grounding connection on crankgear 1 2 3 4

Crankgear Grounding connection Spring washer Washer

Facing the flywheel, the grounding connection (Fig. 5-82) is located on the drive end on the right hand side of the crankshaft. 1. Connect compressor and its auxiliaries to ground. Assure full compliance with national standards. •

Required wire cross-section of copper wire is 50 mm2 (minimum 16 mm2).

•

Fit the grounding wire between the two washers and use a spring washer as a nut-locking device. Do not paint bolt, nuts and washers!

2. Prior to operation:

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Check all grounding connections.

•

Check wiring connections of main motor as well as general condition of insulation and perform an insulation resistance check.

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The insulation resistance check gives information about the condition of windings. In case the minimum value is not obtained, dry and/or clean the main motor and then repeat the insulation resistance check. Consult corresponding manufacturer’s instruction manual (see Technical Documentation). •

Check insulation resistance of other electrical machines/equipment.

Prior to operation, check all grounding connections. The local electrician is in charge of checking the ground wiring systems.

5.16 5.16.1 Emergency Stop during Pre-Commissioning

Pre-Commissioning of Compressor Plant Prerequisite To permit an immediate emergency shutdown of the compressor during pre-commissioning, the electrician must install a temporary emergency stop push button with a sufficiently long cable around the compressor. WARNING An emergency situation may occur.  Before pre-commissioning, check the emergency stop push button for proper functioning.

Instruction of Operating Personnel

Our field service engineer (FSE) will instruct your personnel which is in charge of the monitoring of operation. The chronological order of commissioning depends on site conditions and must be discussed with our specialist. Usually, the pre-commissioning of oil skids will be done first.

5.16.2

Cooling System Check that all pipe screw connections are firmly tightened. Fill the cooling system with coolant and make sure that the cooling system is vented. Let the coolant circulate and visually check the tightness of the system. Do not operate any equipment at conditions which exceed those specified on the name plate(s).

Consider manufacturer’s instruction first.

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General Advice

In all installations, take care to eliminate or minimize transmission of pulsations and mechanical vibrations to the coolers. Avoid thermal shocks

• •

Open all vent valves. Open cold medium first.

In order to guarantee the formation of a perfect protective coating, the cooling water shall circulate continuously (even if the compressor is not running). Bolted Joints

All external bolted joints may require re-tightening after installation and, if necessary, after the cooler has reached operating temperature.

Performance

When performance does not meet specified requirements, investigate the following:

5.16.3

• • • •

Fouled tube surfaces resulting from sludge or scale.

•

Bypassing or short circuiting of either medium, check pass partition gaskets, seal strips and baffle clearance.

Trapped air due to improper venting or lack of vents. Piping connections incorrect. Operating at conditions other than design, check performance data sheet.

Crankgear Lubricating System 1. Clean the crankgear and the lubricating oil tank with a new, unused sponge (do not use any fibrous, fuzzy cloth). 2. Fill the lubricating oil tank with oil till the oil strainer is covered by about 30 mm.

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Oil quality and viscosity must conform to the specifications as mentioned in section “Lubricating System” in chapter 13 Appendix.

3. Open the crankgear covers to check tightness of all oil piping connections. 4. Switch on the prelubrication pump and immediately check rotation and that the oil system is tight. 5. Purge piping, especially the oil cooler by shortly switching on of lubrication pump until clean oil escapes. 6. Turn the flywheel min. 1 rotation by means of the barring device in running direction. 7. Check that lubricating oil is being distributed to all the bearing points of the crankshaft and the crossheads. 8. Operate prelubrication pump for two hours and check oil temperature and pressures. 9. Check tightness of oil system. If the oil system is tight, fill oil to about 3/4 of the sight glass. 10. Check that all instruments and safety devices are properly connected and functioning.

5.16.4

Check Cleanliness of Gas System Before pre-commissioning of the compressor, make absolutely sure that the suction and discharge lines are properly cleaned (see section 5.13.4 Pickle and Passivate Piping). Small foreign bodies on the intake side (welding beads etc.) may cause damage to valves and pistons.

If the pipe fitting has not been supervised by one of our specialists, the cleanliness and quality of the pipe assembly will be sample checked before compressor start-up.

5.16.5

Turn Flywheel WARNING Unlubricated crankgear parts. Damage of bearings and guide bearings.  Never turn compressor by electric motor. Just use barring device or bar to turn flywheel!

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Before switching on compressor for the first time, turn the flywheel min. 1 rotation by means of the barring device in running direction. Verify that everything is in proper mechanical condition.

1

2

3

PB_L1_0049b_01

4

Fig. 5-83 Pneumatic barring device 1 2 3 4

Flywheel Pawl Proximity probe Barring device

DANGER Rotating components, drawing in and crush hazard! Exposed rotating components can cause severe injury or death.  Check the correct position of barring device! Prevent the catch being engaged into toothing of flywheel.  Do not operate the compressor with flywheel guard removed.  Follow lockout procedure before maintenance.

5.16.6

Mechanical Test Run Before initial operation of the compressor a mechanical test run must be carried out.

Also applicable after maintenance or repair works (as repairs on cylinders or crankgear where inner parts have been dismantled, reconditioned or replaced).

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First Start without Load

1. Prepare the cylinders of all stages. Remove the valve covers, lanterns and suction valves as necessary to prevent compression. 2. Remove inspection hole covers of the dampers. 3. Switch on the prelubrication pump. 4. Switch on the electric motor (= compressor start). Check immediately the rotational direction of the electric motor. Stop the motor immediately, if it turns in the wrong direction. 5. Check the following: •

Listen at short intervals for abnormal sounds at the crankgear.

•

Lubricating oil and cooling system for leakage, flow, temperature, pressure.

•

Instrumentation and safety devices for indicating values, switching points.

6. Duration of test runs is as follows: •

1 minute for the first run

•

5 minutes for the second run

•

10 minutes for the third run

•

15 minutes for the fourth run

CAUTION Wear of compressor parts Long duration of test run may lead to wear of compressor parts.  Each test run may last for max. 15 min.

7. After each run, open crankgear covers and check bearing temperatures.

5.16.7

Blowing out the Gas Piping System Blow out the suction line – and its accessories – upstream of the 1st stage with air/nitrogen.

The blowing-out method is defined on site. The chosen method depends on the pipe system installed at the plant. The following “general procedure of blowing-out” is a good guideline.

1. Blow out the suction line before the first stage: •

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Insert blind flanges (5) with mounted distance pieces (4) on the suction side of the first stage. The distance piece must guarantee that the distance between cylinder and the valve covers is 5–8 mm.

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•

Install the valve covers on the suction side of the first stage. The threaded bolts (2) of the valve covers must be tightened.

5

4

3

LA_CX_0005b_01

1

2

Fig. 5-84 Blind flange with distance piece (typical view) 1 2 3 4 5

Valve cover Threaded bolt Valve chamber Distance piece (to be manufactured on site) Blind flange (to be manufactured on site)

•

Blow out the suction line before the first stage and the valve chambers (3) of the first stage with nitrogen (if there is enough available). You can also use air for blowing-out the suction line.

•

Remove all valve covers and all blind flanges (with mounted distance pieces) from the suction side of the first stage.

•

Install suction valves, lanterns and valve covers of the first stage.

2. Blow out the discharge line:

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•

Provide an opening in the suction line before the first stage. Fit a fine stainless steel wire screen of 0.3 mm mesh size between the opening and the first stage.

•

Run the coolant to the compressor and coolers.

•

Turn the flywheel min. 1 rotation in running direction.

•

Switch on the lubrication pump and check the lubricating oil pressure.

•

After the prelubrication time has elapsed, switch on the electric motor (= compressor start). Check immediately the rotational direction of the electric motor. Stop the motor immediately, if it turns in the wrong direction.

•

Use a heavy wooden hammer or vibrator to create maximum shocks on gas piping to break loose any scales.

•

Listen carefully to the crankgear.

•

Repeat bearing temperature check after 5, 10, 25 and finally after 40 minutes of compressor running. The maximum bearing temperature is approximately 60 °C.

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•

Increase pressure to max. permitted value, after 10 minutes drop pressure to min. permitted value.

•

Run the compressor with low and high pressure until the blown out air is clean.

•

Shut down and check all bearing temperatures. The maximum bearing temperature is approximately 60 °C.

3. Remove the steel wire screen from the suction line. 4. Adjust the safety instruments in accordance with section “Instrumentation” in chapter 13 Appendix and check their proper functioning. 5. The piston rod nut, the connection of crosshead with piston rod and the connecting rod bolts must be checked for proper tightening. Check tightening torque of piston rod nut in accordance with section “Compressor” in chapter 13 Appendix. 6. Dry out all condensate in the valve chambers and gas pipes. All flanged connections and pipe fastenings must be re-tightened. Due to pulsating delivery of the gas through pipes, powerful forces and hence pronounced vibrations may set up, especially on long gas lines with several bends. Apart from damaging the weld seams, this may also lead to the smooth running of the compressor being impaired. If necessary, additional pipe supports must be fitted prior to start up of the plant. 7. Install the suction strainer.

5.16.8

Nitrogen Test Run For the N2 test of the compressor and the system blowing out, follow the instructions of Burckhardt Compression’s supervisor, and refer to section “Control Description” in chapter 13 Appendix.

5.16.9 Term Explanation

Assess Vibrations A distinction is to be drawn between the piping with and without stress raisers according to the following explanations. Pipes with Possible Stress Raisers

•

Pipe junctions from a small pipe into a larger pipe (large diametrical difference),

• •

valves with heavy driving elements, safety valves or relief valves set on pipes etc.

Examples of pipes with stress raisers (Fig. 5-85):

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Fig. 5-85 Pipes with stress raisers

Pipes without Stress Raisers

•

Long pipes without junctions with other pipes of large diametrical differences or

•

pipes which have no heavy additional devices (safety valves, relief valves, instrument etc.).

XA_XX_0071a_01

Examples of pipes without stress raisers (Fig. 5-86):

Fig. 5-86 Pipes without stress raisers

Accessories (e.g. Damper) Although the diametrical differences between the accessories and the connecting pipe are usually large and would therefore represent a “pipe with stress raisers”, high vibration velocity is permitted because the connections are reinforced for elevated stress.

Maximal Vibration Velocity acceptable for the Compressor according to ISO 10816-6.

Maximal values for process gas compressors are indicated on the foundation drawing. These values represent the basis for the final determination of the foundation by the civil engineer. The compressor is considered to be a rigid body. Under these considerations the given values of amplitudes apply to measurements made on the cylinder block and are below the values in ISO 10816-6.

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Effective Vibrations on the Installation

The maximum specified acceptable vibration velocity values are not exceeded under normal circumstances, see Tab. 5-5. Burckhardt Compression guarantees the given values taking in consideration an internal pulsation and vibration study for the installation. However, it may occur that excessive vibration velocities are measured during or after commissioning. Depending on the cause, gas pulsations or mechanical excitation, corresponding countermeasures must be undertaken, i.e. additional orifices or pipe supports fitted (examples of pipe supports, see section 5.13.6 Recommendation for Pipe Support). Vibrations on Reciprocating Compressors For the valuation of reciprocating compressors, an own VDI Standard was created. The VDI Standard 3838 replaces the old VDI Standard 2063 and is an addendum to DIN ISO 10816-6 that regulates the allowable vibration at compressors on a rigid foundation. The vibration velocities of the objects to be supplied have to be defined locally. According to DIN ISO 10816-6 class 3 the limit for vibration velocity at the crankgear is 8 mm/s (root mean square, RMS). Since there are only regulations for the crankcase in the existing standards, Burckhardt Compression has defined additional limits for the cylinder 13 mm/s (RMS) and for the components as follows: allowable vibration velocity of 30 mm/s (RMS) and maximum displacement of 1mm peak to peak. These values have been checked and are based on long experience with components on reciprocating compressors which have been exposed to such vibrations without any damage occurring. The components used by Burckhardt Compression are chosen in such a way that these guarantee a faultless operation under constantly occurring vibrations in the range of the given limit values, without taking any damage. The limit values for the individual parts are based on a limiting curve at the foundation (machine fixation level). Should there be lower values registered at the foundation, then the other limiting values can be reduced accordingly. Part

Vibration velocity mm/s RMS

Foundation

3

Frame (top)

8

Cylinder

13

Components

30

Tab. 5-5

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5.16.10

Frame Vibration Measurement Compressors can be equipped with different kinds of measuring instruments for measuring frame vibrations. If there is no description available of the setting procedure for the built-in vibration sensors in chapter 13 Appendix, and the vibration sensor is not connected to a Prognost monitoring system, proceed as follows: 1. Whether acceleration sensors or velocity sensors are installed, the sensors have to be set according to the RMS values. 2. For setting the predefined preliminary alarm values H and HH see section “Instrumentation” in chapter 13 Appendix.

We strongly recommend to perform commissioning under the supervision of a specialist from Burckhardt Compression. The experience of our supervisor allows him to judge the proper running of the compressor. For damage caused by non-professional commissioning, Burckhardt Compression will not assume any liability.

3. During commissioning special attention must be paid to vibration and unusual noise. Use hand held vibration equipment for more detailed vibration information. 4. During the first period of operation (max. 2 months) check all relevant operation modes. A detailed monitoring should show the different levels of vibration reached for each operation mode. Pay special attention to values received during the transition phase between the different modes. Record all measured values. Under normal circumstances the recorded maximum values are much, much lower than the predefined alarm values H and HH. 5. Send the recorded values to Burckhardt Compression. Based on this information Burckhardt Compression defines the specific alarm values H and HH for the given compressor installation. 6. Adjust settings according to these final alarm values. This procedure leads to an optimized vibration protection safety.

Never change these specific set values; except when the compressor has to undergo a general overhaul. In this case, repeat the whole procedure above starting at step 1.

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5.16.11

Inspect Compressor Plant •

After assembly of the complete gas piping system incl. dampers, coolers and all fittings, perform a system leak test according to local regulations and project procedures.

•

All safety and monitoring instruments must be connected. Their functionality must be tested and ensured.

•

Following the successful compressor test run, thoroughly retighten all flange connections and pipe fixations applying applicable tightening torque see “Compressor” in chapter 13 Appendix.

•

Should pipe vibrations occur, please refer to section 5.16.9 Assess Vibrations.

Furthermore, it is advisable to check the following points:

• • • •

5.16.12 Period of Standstill Exceeds 2 Months

Suction strainer, separator or alternative means in the gas lines Some of the suction and discharge valves Visual check of the pistons Visual check of crankgear

Preserve Compressor Plant after Installation If a compressor plant cannot be put into operation for more than 2 months after installation, the compressor and its auxiliary equipment should be protected against possible standstill damage by taking appropriate measures for the respective period of time. CAUTION Standstill damage possible! Due to the numerous possibilities of installation and employment of our compressors, instructions on preservation depend on application.  Please contact Burckhardt Compression Services, address see section 1.6 Contact Address.

General Procedure

The following procedure is intended to provide general advice. Depending on your application, our instructions on preservation are liable to amendment or supplement at any time. 1. Drain the cooling chambers of the compressor and the coolers. Leave the drain valve open. 2. Fill crankgear with lubricating oil. A special corrosion protecting oil from a reputable supplier may be used during the standstill period. 3. Oil the piston rods well by hand up to the oil shield. Turn the flywheel a number of times.

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Generally, the gas conducting compressor and plant components should not be protected by oil or grease (leave surfaces dry and untreated). 4. Fill the compressor or the entire compressor system with dry, oil-free nitrogen. During the whole standstill period, the plant/compressor should be flushed continuously through with nitrogen, or kept under a slight overpressure of 0.05 bar g/0.005 MPa g/0.05 kg/cm2. DANGER Pressurized vessel or pipe! Plant/compressor under nitrogen pressure.  Fit a corresponding warning sign on the installation.  Depressurize plant before you start working.

Under all circumstances, prevent moist air from entering the compressor/ system. DANGER Health hazard! Risk of suffocation! Nitrogen gas is an asphyxiant and presents a health hazard by displacing the oxygen in the atmosphere. At high concentrations, unconsciousness or death may occur.  Depressurize the installation before you open the compressor.  When working on the compressor, make sure there is sufficient circulation of fresh air.  Be aware of any signs of dizziness or fatigue. Exposures to fatal concentrations of nitrogen could occur without any significant warning symptoms.  During an emergency situation, before entering the area, check for oxygen-deficient atmospheres.

5. Alternative solution: To prevent corrosion in the vicinity of the cylinder, insert moisture absorbent agent – e.g. VCI mats (Volatile Corrosion Inhibitor) – in the cylinder, valve spaces and distance piece. Experience has shown that in the area of the lubricated crankgear, absorbent agents are not necessary. CAUTION Forgotten absorbent agent mats can damage the compressor!  Record number and location of absorbent agent packs/mats in the compressor.  Make sure the flywheel can still be turned manually.

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5.16.13

Maintain Plant during Decommissioning 1. Check condition of moisture absorbent agent every six months and replace if necessary. 2. To protect the bearings and to check that everything is in proper working condition, switch on the prelubrication pump for about 5 to 10 minutes every week and, at the same time, turn the flywheel (min. 1 rotation). Be careful of absorbent agent packs in the cylinders! 3. Large differences between day and night temperatures can lead to condensation in the electric motor. Due attention should be given to this occurrence during the standstill period and before putting into operation again (dry out, heat, ventilate, check insulation resistance, etc.).

For the description of the electric motor refer to the documentation of the motor manufacturer.

4. Annually conduct a condition check of the complete compressor system.

5.16.14

Recommission Plant Carefully check the complete compressor system before recommissioning.

•

In particular, the functionality and operation of the mechanical and electrical safety devices.

•

Perform a hydrostatic pressure test of all the cooling chambers, using the specified pressure test data.

We advise customers to arrange for one of our specialists to be present when this work is carried out.  Please contact Burckhardt Compression Services, address see section 1.6 Contact Address.

For the description of the electric motor refer to the documentation of the motor manufacturer.

Commission compressor/plant according to instructions in section 6.2 Commissioning.

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Operation

6 Operation 6.1 6.2 6.3

6.4

6.5

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Design Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 Prepare Operation . . . . . . . . . . . . . . . . . . . . . . . . Operation with Process Gas . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Safety of Operation. . . . . . . . . . . . . . . . . . . . . . . . 6.3.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.3 Buffer Gas to Piston Rod Packing and Distance Piece Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.4 Monitor Operation. . . . . . . . . . . . . . . . . . . . . . . . . Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 Control Unit with Solenoid Valve . . . . . . . . . . . . . 6.4.2 Controlled Suction Valve and Actuator . . . . . . . . . Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2B1XC2.64_1

IM 200322en

6-3 6-4 6-4 6-5 6-5 6-6 6-6 6-8 6 - 11 6 - 11 6 - 12 6 - 13

6–1

Operation

6–2

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Operation Design Data

6.1

Design Data Specification

Value

Key word

PENGERANG-09

Compressor type

2B1XC2.64_1

Serial no.

200322

Weight of compressor (without flywheel) 20340 kg

18.05.2016

Year of manufacture

2016

Process gas

Nitrogene (N2)

Mass flow

48503 kg/h

Standard volume

39691 Nm3/h

Suction volume

5948 m3/h

Suction temperature

50 °C

Suction pressure

8.0 bar a/0.8 MPa a/8.0 kg/cm2 a

Discharge pressure

15.0 bar a/1.5 MPa a/15.0 kg/ cm2 a

Shaft power (coupling)

1102 kW

Electric motor rating

1300 kW

Rotation speed

370 rpm

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

6–3

Operation Commissioning

6.2

Commissioning For detailed instruction about commissioning please refer to section “Control Description” in chapter 13 Appendix.

6.2.1

Prepare Operation Carry out the following tasks before starting the compressor

• • •

after pre-commissioning after maintenance when recommissioning

1. Make sure that all instruments are calibrated. 2. Check that all safety devices are fitted and operational. 3. Check all control loops for continuity. 4. Open all valves to safety instruments. 5. Open supply valves (from pneumatic medium) to all pneumatically controlled valves. 6. Check dampers for liquid by briefly opening drain valves. 7. Open required coolant valves to the oil coolers. 8. Check that spectacle flanges (if applicable) have been set to position for normal operation (gas flow open). 9. Check oil level in oil tank (must be roughly at 3/4 of oil sight glass(es)). 10. Check lubrication for motor bearings according to manufacturer’s recommendation. After maintenance work or after long standstill periods: DANGER Unintended start-up of compressor is possible!  Turn off the power at the switch box and padlock the switch in the OFF position.

11. Turn flywheel of compressor min. 1 rotation by means of barring device in running direction and verify that everything is in proper mechanical condition.

6–4

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Operation Operation with Process Gas

DANGER Rotating components, drawing in and crush hazard! Exposed rotating components can cause severe injury or death.  Check the correct position of barring device! Prevent the catch being engaged into toothing of flywheel.  Do not operate the compressor with flywheel guard removed.  Follow lockout procedure before maintenance.

12. Open discharge line valve. 13. Check hook-up of suction valve actuators and verify that they are working properly.

6.3 6.3.1 Safety Precaution

Operation with Process Gas Safety of Operation Process gas may be dangerous. Read the detailed gas description and warnings in section 2.9 Process Gas and Purge Gas. WARNING Limited operational safety! The specially designed characteristics of the compressor or related plant components and/or their operational safety may be influenced negatively (= increased risk) by improper actions.  Eliminate troubles immediately.

WARNING Hot surface – burn hazard! Gas discharge pipes may have surface temperatures above 70 °C.  Do not touch.  To avoid possible skin burns, allow surface to cool down before maintenance.

CAUTION High sound level!  Be aware that communication in the plant may be impaired due to noise.  Wear hearing protection.

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Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

6–5

Operation Operation with Process Gas

WARNING Slip hazard!  Watch your step.

6.3.2

Handling Detailed information about starting and stopping of the compressor, see section “Control Description” in chapter 13 Appendix. WARNING An emergency situation may occur.  Before switching on the motor (= compressor start), check the emergency stop push button for proper functioning.

Continuous Operation

The compressor must be supervised by well-trained operators. To facilitate checking, the readings of pressures, temperatures, etc. and inspections listed below must be recorded in a log sheet (see example in section 6.3.4 Monitor Operation). Have a hour meter installed or record operating hours in the log sheet. This guarantees better and more reliable care and maintenance of the compressor. Check periodically:

•

Suction, (intermediate, if applicable) and final pressure. The hands of the pressure gauges must continuously oscillate slightly.

•

Lubricating oil pressure.

•

Gas temperatures at suction and discharge side of the compressor.

Process gas temperature can be affected by a change of operating or atmospheric conditions (e.g. warm cooling water, high ambient temperature) or due to a technical defect.

•

6.3.3 Components of Purge System

Ampere reading of electric motor.

Buffer Gas to Piston Rod Packing and Distance Piece Packing For layout of the purge and buffer gas system see section “P & I Diagram” in chapter 13 Appendix.

The purge and buffer gas system (e.g. orifice plates) and the purging procedure must be fine tuned during commissioning.

6–6

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Operation Operation with Process Gas

Purging during Normal Operation

18.05.2016

Buffer gas (N2) is supplied to the piston rod packing and distance piece packing. The buffer/leak gas outlet (with traces of process gas) is connected to the flare. To set the pressure of the buffer gas, a control valve with a pressure indicator is installed. Additionally, there is a pressure transmitter for pressure indication in DCS and an alarm in case of low pressure in the buffer gas line.

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

6–7

Operation Operation with Process Gas

6.3.4

Monitor Operation Example of a Log Sheet:

Log Sheet

TDO_2005678_E01_01.docx

Compressor S/N:

Compressor Type:

Order / Job No.:

Speed min-1:

Gas:

Operating hours:

Date Time / Start Suction pressure Discharge 1. Stage Discharge 2. Stage Discharge 3. Stage Discharge 4. Stage Discharge 5. Stage Discharge 6. Stage

barg / psig

Purge gas Packing Inlet Distance piece pressure Crankcase pressure

barg / psig

Suction Temp. 1. Stage Disch. Temp. 1. Stage Suction Temp. 2. Stage Disch. Temp. 2. Stage Suction Temp. 3. Stage Disch. Temp. 3. Stage Suction Temp. 4. Stage Disch. Temp. 4. Stage Suction Temp. 5. Stage Disch. Temp. 5. Stage Suction Temp. 6. Stage Disch. Temp. 6. Stage

°C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F

Packing Temp. 1. Stage Packing Temp. 2. Stage Packing Temp. 3. Stage Packing Temp. 4. Stage Packing Temp. 5. Stage Packing Temp. 6. Stage

°C / °F °C / °F °C / °F °C / °F °C / °F °C / °F

Capacity mode By-pass 1st Stage open (open=100%) By-pass over all open (open=100%)

%

Template : TDO 2005678 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev.

barg / psig barg / psig barg / psig barg / psig barg / psig barg / psig

barg / psig barg / psig

% %

B

Fig. 6-1

6–8

IM 200322en

Dat.

Sig.

01.04.2015

KAUFMANN_W

07.04.2015

WEISS_M

07.04.2015

KAUFMANN_W

Ersatz für Replacement for Revision vom / date

Seite 1 von 3 Page 1 of 3 gedruckt / printed: 07.04.2015

XA_XX_0039a_0

G A S

Example of a log sheet (first page)

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Operation Operation with Process Gas

Log Sheet

W A T E R

C R A N K G E A R

barg / psig barg / psig barg / psig barg / psig

p to bearing p filter Temp. before cooler Temp. after cooler

barg / psig

Inlet pressure Inlet temperature Cylinder 1. Stage Cylinder 2. Stage Cylinder 3. Stage Cylinder 4. Stage Cylinder 5. Stage Cylinder 6. Stage

barg / psig

Packing 1. Stage Packing 2. Stage Packing 3. Stage Packing 4. Stage Packing 5. Stage Packing 6. Stage

°C / °F °C / °F °C / °F °C / °F °C / °F °C / °F

Guide bearing Crosshead Oil cooler Inter cooler 1. Stage Inter cooler 2. Stage Inter cooler 3. Stage Inter cooler 4. Stage Inter cooler 5. Stage Inter cooler 6. Stage

°C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F

Main Bearing No. 1 Main Bearing No. 2 Main Bearing No. 3 Main Bearing No. 4 Main Bearing No. 5 Main Bearing No. 6 Main Bearing No. 7 Main Bearing No. 8

°C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F

Conn. Rod Bearing V1 Conn. Rod Bearing V2 Conn. Rod Bearing V3 Conn. Rod Bearing V4 Conn. Rod Bearing V5 Conn. Rod Bearing V6 Conn. Rod Bearing V7 Conn. Rod Bearing V8

°C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F

barg / psig

°C / °F °C / °F

°C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F

Template : TDO 2005678 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev. B

Fig. 6-2

18.05.2016

Rev. 001/kalajdzisa_a

Dat.

Sig.

01.04.2015

KAUFMANN_W

07.04.2015

WEISS_M

07.04.2015

KAUFMANN_W

Ersatz für Replacement for Revision vom / date

Seite 2 von 3 Page 2 of 3 gedruckt / printed: 07.04.2015

XA_XX_0120a_03

O I L

Date Time / Start Crankcase pressure Pump suction pressure Pump disch. pressure Pressure to bearing

TDO_2005678_E01_01.docx

Example of a log sheet (second page)

2B1XC2.64_1

IM 200322en

6–9

Operation Operation with Process Gas

Log Sheet

M O T O R

°C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F °C / °F

Voltage Current

kV A

Cos Bearing temp. DE Bearing temp. NDE Winding U Winding V Winding W

°C / °F °C / °F °C / °F °C / °F °C / °F

Signature / Name, BC: Signature / Name, Customer:

Place: Date:

Template : TDO 2005678 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev. B

Fig. 6-3

6 – 10

IM 200322en

Dat.

Sig.

01.04.2015

KAUFMANN_W

07.04.2015

WEISS_M

07.04.2015

KAUFMANN_W

Ersatz für Replacement for Revision vom / date

Seite 3 von 3 Page 3 of 3 gedruckt / printed: 07.04.2015

XA_XX_0D_0 1

C R A N K G E A R

Date Time / Start Crosshead V1 Crosshead V2 Crosshead V3 Crosshead V4 Crosshead V5 Crosshead V6 Crosshead V7 Crosshead V8

TDO_2005678_E01_01.docx

Example of a log sheet (third page)

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Operation Capacity Control

6.4

Capacity Control For information about capacity control see “P & I Diagram” and “Control Description” in chapter 13 Appendix.

Components for Capacity Control

6.4.1

The controlled suction valves are equipped with actuators. The actuators are controlled by the control unit.

Control Unit with Solenoid Valve The electrical control unit is installed on the Local Instrument Board (LIB). The capacity is altered by means of controlled suction valves. The necessary gas to control the actuators of the controlled suction valves is led from the control unit to the actuators.

Control Unit

The control unit has the function of a 3-way valve. It is electrically activated.

Fig. 6-4

Control unit with solenoid valve (typical view)

CAUTION Excessive wear of pistons!  Limit the operation time on 0 % load to maximum 5 minutes.

18.05.2016

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

6 – 11

Operation Capacity Control

6.4.2 Functional Principle

Controlled Suction Valve and Actuator The controlled suction valves are equipped with actuators to operate the compressor at 0 %, 50 %, 75 % or 100 % load. 1

2

3

4

5

6

7

XA_C3_0003b_01

P

Fig. 6-5

P 1 2 3

Controlled suction valve with actuator operated by medium

Control pressure Controlled suction valve Finger unloader Pressure sleeve

4 5 6 7

Pressure pin Spring F Actuator piston Actuator

With spring configuration F, the valve opens and closes normally if control pressure P = 0. In the no-load position of the suction valve, the control pressure (P) is pressing the pressure pin (4) through pressure sleeve (3) and finger unloader (2) towards the valve plate, which is pushed to the valve guard. Thus, the process gas can flow back to the suction side. Control Medium

The actuators (7) are operated with nitrogen. The required pressure for the control medium is 3.5 bar/0.35 MPa/ 3.5 kg/cm2. CAUTION Too low control pressure leads to malfunction of the capacity control system, thus results in damage on valves and pistons!  Maintain control pressure at required value.

6 – 12

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Operation Standstill

6.5 Period of Standstill 24 h to 2 Months

Standstill During the whole standstill period, the plant/compressor should be kept under a slight overpressure of 0.05 bar g/0.005 MPa g/0.05 kg/cm2 g. If no process gas is available, nitrogen shall be used. In this case, full isolation from gas system may be required. DANGER Pressurized vessel or pipe! Plant/compressor under process gas/nitrogen pressure.  Fit a corresponding warning sign on the installation.  Depressurize plant before you start working.

Under all circumstances, prevent moist air from entering the compressor/ system. CAUTION Deposits in piping!  Avoid stationary coolant.

A minimal flow of coolant must always be maintained. During longer standstill periods (exceeding a month): 1. Drain the cooling chambers of the compressor and the coolers. Leave the drain valve open.

If an antifreeze solution is used, drainage is not necessary under certain circumstances.

2. To protect the bearings and to check that everything is in proper working condition, switch on the prelubrication pump for about 5 to 10 minutes every week and, at the same time, turn the flywheel (min. 1 rotation). Be careful of absorbent agent packs in the cylinders! Large difference between day and night temperatures can lead to condensation in the electric motor. Due attention should be given to this occurrence during the standstill period and before putting into operation again (dry out, heat, ventilate, check insulation resistance, etc.). Period of Standstill Exceeds 2 Months

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If the standstill period of the compressor exceeds 2 months, refer to section 11.1 Preserve Compressor Plant or consult Burckhardt Compression Services (address see section 1.6 Contact Address).

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

6 – 13

Operation Standstill

6 – 14

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Trouble Shooting

7 Trouble Shooting 7.1 7.2

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Rev. 001/kalajdzisa_a

Prerequisites before Handling Troubles . . . . . . . . . . . . . . . Trouble Shooting List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.1 Process Gas System . . . . . . . . . . . . . . . . . . . . . . 7.2.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.3 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . 7.2.4 Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 7.2.5 Compressor Vibrations . . . . . . . . . . . . . . . . . . . . . 7.2.6 Piston Rod Monitoring . . . . . . . . . . . . . . . . . . . . . 7.2.7 Compressor Shutdown . . . . . . . . . . . . . . . . . . . . . 7.2.8 Compressor Start-Up Interlock . . . . . . . . . . . . . . .

2B1XC2.64_1

IM 200322en

7-3 7-3 7-4 7-7 7 - 10 7 - 15 7 - 19 7 - 20 7 - 21 7 - 23

7–1

Trouble Shooting

7–2

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Trouble Shooting Prerequisites before Handling Troubles

7.1

Prerequisites before Handling Troubles DANGER Personal injury or loss of life!  Follow the prevention instructions carefully.

The compressor must be maintained in such a way that the safety of the operator, maintenance personnel or third party is guaranteed at all times. See chapter 2 Elementary Safety Advice. Before you start any trouble shooting activity take all safety measures according to section 8.2 Prerequisites for Maintenance.

7.2

Trouble Shooting List Use this trouble shooting list as soon as any faults or troubles have been observed. The first column from the left with the pictogram follows up the display and/ or control elements on the compressor. The changes of operating conditions can be identified in the “Location” column. In the “Cause” column, the most common reasons for the origin of the trouble are listed. The “Trouble Elimination” column gives keywords for the settling of the trouble, the column “See Section” refers to the respective detailed instructions. If no Instruction Manual section is mentioned in this column, the documentation as listed in these footnotes must be consulted: BCS1) Please contact Burckhardt Compression Services, address see section 1.6 Contact Address. CD2) See “Control Description” in chapter 13 Appendix. If CD is not part of this appendix, please refer to customer’s/operator’s approved operating instructions. TD3) For detailed description see documentation of the manufacturer in Technical Documentation.

18.05.2016

4)

For tightening torques see “Compressor” in chapter 13 Appendix.

5)

For orifice plates see “Technical Data” in chapter 13 Appendix.

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

7–3

Process Gas System

Location

Cause

IM 200322en

Suction side of a stage (within Wear of piston rings about 2 months) Wear of cylinder liner Malfunction/wear of suction valve

P

Trouble Elimination

See Section

• • • •

Check piston rings

8.9.3 Piston

Replace piston rings

8.9.4 Piston Nut SUPERBOLT®

Replace cylinder liner Check/replace suction valve

8.10.2 Valve Failures (Malfunction) 9.11 Piston and Piston Rod 9.15 Cylinder BCS1)

2B1XC2.64_1

Discharge side of a stage

Piston rod packing st

Discharge pressure 1 stage too high

Increased suction pressure

•

Reduce suction pressure/flow CD2) rate

Suction temperature lower than designed

•

Adjust gas cooler

BCS1)

Wear of piston rod packing rings

•

Replace piston rod packing rings

8.9.2 Piston Rod Packing

Excessive suction pressure

•

9.13 Piston Rod Packing

Reduce suction pressure/flow CD2) rate

Trouble Shooting Trouble Shooting List

7–4 Pressure Rise

7.2.1

Rev. 001/kalajdzisa_a 18.05.2016

18.05.2016

Pressure Drop

Location

Cause

Trouble Elimination

See Section

Piping

Fracture

•

5.13 Install Pipe Work

Repair/replace piping

9.14 External Gas Pipes P Rev. 001/kalajdzisa_a

Flange connection

Suction side 1st stage 2B1XC2.64_1

Defective gasket

•

Replace gasket

8.6.3 Flange Connections and Pipe Fastenings

Loose connection

•

Tighten flange connection

8.6.3 Flange Connections and Pipe Fastenings

Insufficient elongation length through thermal stress

•

Rework piping

5.13.3 Check Fabrication

Defective pressure gauge

•

Repair/replace pressure gauge

CD2)

Clogged suction strainer

•

Clean/repair suction strainer

5.16.11 Inspect Compressor Plant

Wrong position of shut-off valve in suction pipe 1st stage

• • • • •

Adjust valve position

TD3)

Repair/replace PSV

TD3)

•

Replace piston rod packing rings

8.9.2 Piston Rod Packing

Wrong position of vent valve Leaking of pressure safety valve (PSV) IM 200322en

Piston rod packing

Wear of piston rod packing rings

Check/repair control system Adjust valve position

TD3)

Check/repair control system

9.13 Piston Rod Packing

Trouble Shooting Trouble Shooting List

7–5

Location

Cause

Trouble Elimination

See Section

Suction side (general)

Defective suction valve

•

8.10.2 Valve Failures (Malfunction)

Repair/replace valve

8.10.3 Maintenance of Controlled Suction Valves

T IM 200322en

9.7 Suction Valves and Discharge Valves Suction side 1st stage

Too hot process gas before 1st • stage Insufficient cooling of bypass cooler (if present)

Discharge side (general)

•

Defective suction or discharge • valve on corresponding stage

Check function of previous gas cooler (if applicable)

8.6.4 Cooling System

Clean/repair cooler

8.6.4 Cooling System

Repair/replace valve

8.10.2 Valve Failures (Malfunction)

2B1XC2.64_1

8.10.3 Maintenance of Controlled Suction Valves 9.7 Suction Valves and Discharge Valves Wear of piston rings on corresponding stage

•

Insufficient coolant flow through cylinder

•

Replace piston rings

9.11 Piston and Piston Rod 9.15 Cylinder

Rev. 001/kalajdzisa_a

Fouled cooling chamber of cyl- • inder

Adjust setting

CD2)

Clean cooling chamber

8.6.4 Cooling System

Cylinder

defective parts inside cylinder (pitting, crack)

•

Repair cylinder

9.15 Cylinder

Piston rod packing

Wear of piston rod packing rings

•

Replace piston rod packing rings

8.9.2 Piston Rod Packing 9.13 Piston Rod Packing

Trouble Shooting Trouble Shooting List

7–6

Temperature Rise

18.05.2016

18.05.2016

7.2.2 Pressure Rise

Cooling System

Location

Cause

Rev. 001/kalajdzisa_a

Pressure difference, from sup- Restricted cross-section due ply to return to fouling

Trouble Elimination

•

See Section

Clean cooling system (interior) 8.6.4 Cooling System

P

Process gas cooler bundle de- • fect, gas leakage into coolant Pressure Drop

2B1XC2.64_1

P

Repair/replace cooler bundle

8.6.4 Cooling System

Location

Cause

Trouble Elimination

Coolant return

Restricted cross-section due to fouling

•

Clean cooling system (interior) 8.6.4 Cooling System

Leakage

•

Repair/replace defect compo- 8.6.4 Cooling System nents 8.6.3 Flange Connections and Pipe Fastenings

IM 200322en

Process gas cooler bundle de- • fect, coolant leakage into gas system (if coolant pressure higher than gas pressure)

Repair/replace cooler bundle

See Section

8.6.4 Cooling System

Trouble Shooting Trouble Shooting List

7–7

Location

Cause

Trouble Elimination

See Section

Coolant supply

Incorrectly maintained and/or adjusted cooling system

• •

Service cooling system

8.6.4 Cooling System

Adjust setting

CD2)

Not correct working valves

•

Replace valves

8.6.4 Cooling System

T IM 200322en

TD3)

2B1XC2.64_1

Too high ambient temperature • (summer)

Adjust setting

CD2)

Temperature difference from Insufficient flow in the respecinlet to outlet of a cooling sec- tive cooling section tion

•

Adjust setting

CD2)

Insufficient coolant differential pressure

•

Adjust setting

CD2)

Restricted cross-section due to fouling

•

Clean cooling surfaces

8.6.4 Cooling System

Piston rod packing

Rev. 001/kalajdzisa_a

Temperature Drop

Deposits in cooling chambers • and/or cooling channels of piston rod packing

Clean cooling chambers and/ 8.6.4 Cooling System or channels 8.9.2 Piston Rod Packing 9.13 Piston Rod Packing

18.05.2016

Location

Cause

Trouble Elimination

See Section

Coolant supply

Incorrectly maintained and/or adjusted cooling system

• •

Service cooling system

8.6.4 Cooling System

Adjust setting

CD2)

Too low ambient temperature (winter)

•

Adjust setting

CD2)

Fouling in cooling chambers: deposits of mud, sand, algae, calcium etc.

•

Clean cooling system (interior) 8.6.4 Cooling System

T

Coolant return

Trouble Shooting Trouble Shooting List

7–8

Temperature Rise

18.05.2016

Temperature Drop

Location

Rev. 001/kalajdzisa_a

Cause

Trouble Elimination

See Section

Poor coolant quality (no or wrong coolant treatment)

• • • •

Change coolant

8.6.4 Cooling System

Excessive coolant flow in respective section

•

Adjust setting

Location

Cause

Trouble Elimination

See Section

Cooling system

Leak in cooling system

•

8.6.3 Flange Connections and Pipe Fastenings

Temperature difference from No coolant flow/too low flow inlet to outlet of a cooling sec- rate in respective section tion through fouling

Liquid Level Drop

Correct coolant quality Clean cooling system (interior) 8.6.4 Cooling System Adjust setting

Repair cooling system

CD2)

8.6.4 Cooling System 2B1XC2.64_1 IM 200322en

Trouble Shooting Trouble Shooting List

7–9

Pressure Rise

Lubricating System

IM 200322en

Location

Cause

Trouble Elimination

See Section

External oil tank

Too low ambient temperature (oil too thick)

•

Change oil viscosity

8.6.6 Oil Change

Unsuitable oil used

•

Change oil

8.6.6 Oil Change

P

8.6.7 Lubricating Oil Specifications

2B1XC2.64_1

Pressure Drop

•

Pressure difference from inlet to outlet of duplex oil filter

Clogged filter

Pressure control valve

Wrong adjusted control valve

Relief valve

Wrong adjusted relief valve

• •

Location

Cause

Trouble Elimination

External oil tank

Clogged oil strainer in external • oil tank

Switch to the other filter element, clean/replace clogged filter element

8.6.5 Lubricating System

Adjust setting

TD3)

Adjust setting

TD3)

TD3)

See Section

Rev. 001/kalajdzisa_a

Clean oil strainer

TD3)

Refill oil

8.6.6 Oil Change

P

Too low oil level

•

8.6.7 Lubricating Oil Specifications Blocked lubrication pump

18.05.2016

• •

Remove foreign object

•

Replace defect components

Check lubrication pump components for damages

TD3)

Trouble Shooting Trouble Shooting List

7 – 10

7.2.3

18.05.2016

Pressure Drop

Location

Cause

Trouble Elimination

See Section

Excessive oil loss at the crank- • shaft bearing through excessive bearing clearance

Replace main bearing

9.26 Bearings

•

Replace bearing shell

9.19 Connecting Rod Bearing

Excessive oil loss at the cross- • head pin bearing through worn bearing

Replace bearing bush

9.21 Crosshead Pin Bearing

Replace pressure gauge

TD3)

Change oil

8.6.6 Oil Change

Rev. 001/kalajdzisa_a

Excessive oil loss at the connecting rod bearing through excessive bearing clearance

Defective oil pressure gauge Too low oil viscosity

• •

8.6.7 Lubricating Oil Specifications 2B1XC2.64_1

Too high oil temperature due to insufficient coolant flow through oil cooler

•

Adjust setting of cooling system

CD2)

Broken drive of gear oil pump

• • • • •

Repair pump drive

9.22 Gear Oil Pump

Adjust setting

TD3)

Adjust setting

TD3)

Repair/replace relief valve

TD3)

Pressure control valve

Wrong adjusted control valve

Relief valve

Wrong adjusted relief valve Defective relief valve

IM 200322en

Lubrication pump and prelubri- Too long suction piping cation pump

Rework piping/suction system 5.13.3 Check Fabrication BCS1)

Too small piping cross-section •

Rework piping

• •

Repair leak on piping

Leaking or defective non-return valve

•

Repair/replace valve

8.6.3 Flange Connections and Fill piping with oil (use lubrica- Pipe Fastenings tion pump) 8.6.3 Flange Connections and Pipe Fastenings TD3)

7 – 11

Wrong adjusted relief valves

•

Adjust setting

8.6.8 Safety Devices

Trouble Shooting Trouble Shooting List

Air in the suction piping

5.13.3 Check Fabrication

Location

Cause

Trouble Elimination

• After repair: wrong direction of •

Defective relief valves

See Section

Repair/replace valve

8.6.8 Safety Devices

Correct electrical connection

TD3)

Repair power supply

TD3)

Remove foreign object

TD3)

rotation Power failure IM 200322en

Blocked lubrication pump

Cooler Duplex oil filter

2B1XC2.64_1

Temperature Rise

• • •

Check oil pump components for damages

• Fouled oil cooler (coolant side) • Clogged duplex oil filter •

Replace defect components Clean oil cooler (interior)

8.6.4 Cooling System

Switch to the other filter element, clean/replace clogged filter element

8.6.5 Lubricating System

Change running direction of compressor

6.2 Commissioning

Rev. 001/kalajdzisa_a

Drive system

Wrong running direction of compressor

•

Location

Cause

Trouble Elimination

See Section

Crankgear

Bearing defective

•

Replace bearing

9.26 Bearings

Lubricating oil too hot

•

Adjust water supply to oil cooler

TD3)

Insufficient coolant flow through oil cooler

•

Adjust setting of cooling system

CD2)

Clean oil cooler (interior)

8.2.2 Clean Compressor Plant

T

Oil cooler

Fouled oil cooler (coolant side) •

Trouble Shooting Trouble Shooting List

7 – 12

Pressure Drop

18.05.2016

18.05.2016

Temperature Drop

Location

Cause

Trouble Elimination

See Section

Oil temperature indicator

Excessive cooling

•

CD2)

Location

Cause

Trouble Elimination

See Section

Crankgear

Leaking oil scraper (into the distance piece)

•

Replace wiper elements

9.18 Oil Scraping

Leaking oil piping

•

Repair/replace piping

8.6.3 Flange Connections and Pipe Fastenings

Leaking oil cooler

•

Repair/replace cooler

8.6.3 Flange Connections and Pipe Fastenings

Adjust setting of cooling system

T Rev. 001/kalajdzisa_a

Level Drop

2B1XC2.64_1

TD3) Leaking flat gasket on bearing • bracket drive end or non-drive end

Replace flat gasket

9.25 Crankshaft Seal

IM 200322en

Crankshaft seal

Cured/brittle shaft sealing rings

•

Replace sealing rings

9.25 Crankshaft Seal

Oil scrapers (leaking into the distance piece)

Too low oil viscosity

•

Change oil

8.6.6 Oil Change 8.6.7 Lubricating Oil Specifications

Wear of spring plate

• •

Replace wiper elements

9.18 Oil Scraping

Replace spring plate

9.18 Oil Scraping

7 – 13

Trouble Shooting Trouble Shooting List

Wear of wiper elements

Location

IM 200322en

Cause

Trouble Elimination

See Section

Insufficient tension force of garter springs

•

Replace garter springs

9.18 Oil Scraping

Damaged piston rod surface (rough, scratched)

•

Repair/replace piston rod sur- 9.11 Piston and Piston Rod face 9.18 Oil Scraping Check wiper elements BCS1)

• • Incorrectly installed wiper ele- • ments: rings tilted on piston rod, no offset of inclined cuts between the rings or contact surface to piston rod too narrow

Replace wiper elements Replace wiper elements

9.18 Oil Scraping

Trouble Shooting Trouble Shooting List

7 – 14

Level Drop

2B1XC2.64_1 Rev. 001/kalajdzisa_a 18.05.2016

18.05.2016

7.2.4 Regular Dull Knocking

Compressor Noise

Rev. 001/kalajdzisa_a 2B1XC2.64_1

Location

Cause

Trouble Elimination

See Section

Connecting rod

Loose connecting rod bolts

•

Tighten bolts

9.19 Connecting Rod Bearing

Excessive clearance of connecting rod bearing

•

Replace bearing shell

9.19 Connecting Rod Bearing

Excessive clearance of cross- • head pin bearing

Replace bearing bush

9.21 Crosshead Pin Bearing

Rework crosshead

9.20 Crosshead and Connecting Rod

Crosshead

Insufficient crosshead clearance

•

BCS1) Crankshaft Piston rod

• Loose connection piston rod to •

Crankshaft bearing defective

Replace crankshaft bearing

9.27 Crankshaft Bearing

Tighten connection

9.11 Piston and Piston Rod

crosshead IM 200322en

Piston

Cylinder clearance

•

Adjust top/bottom cylinder clearance

9.11.9 Measure the Cylinder Clearance

Loose piston nut

•

Tighten piston nut

8.9.4 Piston Nut SUPERBOLT®

Drive system

Misalignment of compressor and motor

•

Realign compressor and motor

5.11 Install Electric Motor and Coupling

7 – 15

Trouble Shooting Trouble Shooting List

9.11 Piston and Piston Rod

IM 200322en

Location

Cause

Trouble Elimination

Piston rod

Loose connection piston rod to • crosshead

Connecting rod

Loose connecting rod bolts

Piston

Loose piston nut

See Section

Tighten connection

9.11 Piston and Piston Rod

•

Tighten bolts

9.19 Connecting Rod Bearing

•

Tighten nut

8.9.4 Piston Nut SUPERBOLT® 9.11 Piston and Piston Rod

Excessive pretension of piston •

Adjust pretension

8.9.4 Piston Nut SUPERBOLT®

2B1XC2.64_1

9.11 Piston and Piston Rod Liquid knock

• • •

Check piston or piston compo- 8.9.3 Piston nents for cracks 8.9.4 Piston Nut SUPERCheck piston rod to crosshead BOLT® connection for tightness 9.11 Piston and Piston Rod Check connection rod bearing 9.19 Connecting Rod Bearing for tightness

Trouble Shooting Trouble Shooting List

7 – 16

Irregular Dull Knocking

Rev. 001/kalajdzisa_a 18.05.2016

18.05.2016

Irregular Dull Knocking

Location

Cause

Trouble Elimination

Cylinder

Damaged suction or discharge • valve

Replace/repair valve

See Section 8.10.2 Valve Failures (Malfunction) 8.10.3 Maintenance of Controlled Suction Valves

Rev. 001/kalajdzisa_a

9.7 Suction Valves and Discharge Valves

•

Tighten lantern

9.7 Suction Valves and Discharge Valves

Foreign object in the cylinder

• • •

Remove foreign object

8.9.3 Piston

• •

Check cylinder

9.15 Cylinder

Repair/replace cylinder

BCS1)

2B1XC2.64_1

Loose valve lantern

Regular Metallic Knocking

Check piston

8.9.4 Piston Nut SUPERReplace piston or piston com- BOLT® ponent 9.11 Piston and Piston Rod

IM 200322en

Cause

Trouble Elimination

See Section

Connecting rod

Loose connecting rod bolts

•

Tighten bolts

9.19 Connecting Rod Bearing

Piston rod

Loose connection piston rod to • crosshead

Tighten connection

9.11 Piston and Piston Rod

Piston

Insufficient pretension of the piston crowns

Adjust pretension

8.9.4 Piston Nut SUPERBOLT®

•

9.11 Piston and Piston Rod

7 – 17

Trouble Shooting Trouble Shooting List

Location

Location

Cause

Trouble Elimination

See Section

Loose piston skirt

•

8.9.4 Piston Nut SUPERBOLT®

Adjust pretension

9.11 Piston and Piston Rod IM 200322en

Cylinder

Loose valve lanterns

Too small cylinder clearance

• • • •

Inspect lantern Repair/replace lantern

9.7 Suction Valves and Discharge Valves

Tighten lantern Adjust piston position

8.9.4 Piston Nut SUPERBOLT® 9.11 Piston and Piston Rod

2B1XC2.64_1

Regular High Pitched Ringing

Rev. 001/kalajdzisa_a

Location

Cause

Trouble Elimination

See Section

Connecting rod

Loose connecting rod bolts

•

Tighten bolts

9.19 Connecting Rod Bearing

Piston rod

Loose connection piston rod to • crosshead

Tighten connection

9.11 Piston and Piston Rod

Cylinder

Axial lantern clearance

Inspect lantern

9.7 Suction Valves and Discharge Valves

• • •

Repair/replace lantern Tighten lantern

Trouble Shooting Trouble Shooting List

7 – 18

Regular Metallic Knocking

18.05.2016

18.05.2016

7.2.5 Vibrations

Compressor Vibrations

Location

Cause

Trouble Elimination

Process gas piping

Inadmissible pulsations

•

Rev. 001/kalajdzisa_a

•

See Section

Installation/replacement of ori- 5.13.3 Check Fabrication fice plates 5.16.9 Assess Vibrations Elimination of stress raisers BCS1) 5)

Chafed areas on:– piping– supports– accessories

Loose mounting parts

• •

Repair/replace defective parts 8.6.3 Flange Connections and Check chafed parts for func- Pipe Fastenings tion

2B1XC2.64_1

Cracks in:– piping, pipe junctions– supports– accessories

Loose mounting parts

• • •

Tighten loose parts

8.5.1 Tightening Torques and Method

Repair/replace defective parts 8.6.3 Flange Connections and Pipe Fastenings Tighten loose parts 8.5.1 Tightening Torques and Method

Insufficient elongation length through thermal stress

•

Rework piping/supports

5.13.3 Check Fabrication BCS1)

IM 200322en

Trouble Shooting Trouble Shooting List

7 – 19

High Guide Ring (Rider Ring) Wear

Piston Rod Monitoring

IM 200322en 2B1XC2.64_1 Rev. 001/kalajdzisa_a

Location

Cause

Trouble Elimination

See Section

Piston

Guide rings (rider rings) are worn out

•

Assess condition of guide rings (rider rings)

9.11 Piston and Piston Rod

•

Replace guide rings (rider rings) and piston rings, if necessary

Wrong adjustment of proximity sensor

•

Check adjustment of proximity 9.11 Piston and Piston Rod sensor (if value of proximity sensor was not recorded, only installation of new piston rings can solve the problem)

Cause

Trouble Elimination

Loose parts

•

High Peak to Peak Location Values on Piston Rod Position Measurement (Vibration) Piston rod

• • •

See Section

Check if piston is tightened in- 9.11 Piston and Piston Rod cluding piston rod 9.15 Cylinder Check if piston is tightened to 9.20 Crosshead and Connectcrosshead ing Rod Check crosshead clearance Check cylinder space for contamination and foreign matter

Trouble Shooting Trouble Shooting List

7 – 20

7.2.6

18.05.2016

18.05.2016

7.2.7 Safety Shutdown

Compressor Shutdown Cause

Trouble Elimination

Instrumentation

Failure of instrument air (control medium)

•

Repair control medium system TD3)

• Failure of auxiliary supply • Failure of main power supply • Failure of motor purge system • Damaged crankshaft bearing, • connecting rod bearing or •

Repair control voltage system TD3)

Rev. 001/kalajdzisa_a

Location

Failure of control voltage

Main motor

2B1XC2.64_1

Vibration switch/sensor

crosshead pin bearing

Loose connecting rod bolts

Repair control voltage system TD3) Repair power supply

TD3)

Repair purge system

TD3)

Replace bearing shell

9.19 Connecting Rod Bearing

Adjust bearing installation 9.21 Crosshead Pin Bearing

•

IM 200322en

Loose connection piston rod to • crosshead Loose piston nut

See Section

•

Tighten bolts

9.19 Connecting Rod Bearing

Tighten connection

9.11 Piston and Piston Rod

Tighten piston nut

8.9.4 Piston Nut SUPERBOLT® 9.11 Piston and Piston Rod Trouble Shooting Trouble Shooting List

7 – 21

Location

Cause

Trouble Elimination

See Section

Axial lantern clearance

• • • •

9.7 Suction Valves and Discharge Valves

IM 200322en

Broken suction or discharge valve

Inspect lantern Repair/replace lantern Tighten lantern Repair/replace valve

8.10.2 Valve Failures (Malfunction) 8.10.3 Maintenance of Controlled Suction Valves 9.7 Suction Valves and Discharge Valves

Incorrect setting

•

Adjust setting

6)

Trouble Shooting Trouble Shooting List

7 – 22

Safety Shutdown

2B1XC2.64_1 Rev. 001/kalajdzisa_a 18.05.2016

18.05.2016

7.2.8 Interlock

Compressor Start-Up Interlock

Rev. 001/kalajdzisa_a

Location

Cause

Trouble Elimination

See Section

Control system (not delivered by Burckhardt Compression)

Active restart interlock

•

Check control logic

–

Electronic fault

• •

Repair control logic

–

Operate prelubrication pump for necessary duration

CD2)

Prelubrication pump

Prelubrication time not yet elapsed

TD3)

2B1XC2.64_1

Capacity control

Low pressure of control medium

•

Increase control medium pres- CD2) sure TD3)

Flywheel guard

Not correctly closed

• •

Close guard correctly

TD3)

Adjust safety switch

TD3)

Repair power supply

TD3)

Repair purge system

TD3)

Incorrect position of safety switch Main motor

• Failure of motor purge system • For further defects, please re- •

Failure of main power supply

IM 200322en

fer to main motor manufacturer’s instruction

Consult technical documenta- TD3) tion of manufacturer

Trouble Shooting Trouble Shooting List

7 – 23

IM 200322en

Trouble Shooting Trouble Shooting List

7 – 24

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Preventive Maintenance

8 Preventive Maintenance 8.1 8.2

8.3

8.4

8.5 8.6

8.7

8.8

8.9

18.05.2016

Rev. 001/kalajdzisa_a

Importance of Preventive Maintenance . . . . . . . . . . . . . . . Prerequisites for Maintenance . . . . . . . . . . . . . . . . . . . . . . 8.2.1 Depressurize and Purge Plant . . . . . . . . . . . . . . . 8.2.2 Clean Compressor Plant . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plant in General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 Tightening Torques and Method . . . . . . . . . . . . . . Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1 Electric Motor and Coupling . . . . . . . . . . . . . . . . . 8.6.2 Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.3 Flange Connections and Pipe Fastenings . . . . . . 8.6.4 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.5 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . 8.6.6 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.7 Lubricating Oil Specifications . . . . . . . . . . . . . . . . 8.6.8 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.9 Hydrostatic Pressure Test. . . . . . . . . . . . . . . . . . . Compressor in General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 Dimensions, Weights, Space Requirement . . . . . 8.7.2 Marking of Compressor Components. . . . . . . . . . 8.7.3 Cylinder Clearance Measurement . . . . . . . . . . . . 8.7.4 Clearance Measurement Log Sheet. . . . . . . . . . . 8.7.5 Piston Rod Runout . . . . . . . . . . . . . . . . . . . . . . . . 8.7.6 Frame Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.7 Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . 8.7.8 Tensioner SUPERBOLT® . . . . . . . . . . . . . . . . . . . 8.7.9 Locking of Threaded Connections with LOCTITE® 8.7.10 NORD-LOCK® Securing System . . . . . . . . . . . . . Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1 Check Crankshaft Deflection . . . . . . . . . . . . . . . . 8.8.2 Main Bearing and Connecting Rod Bearing . . . . . 8.8.3 Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.4 Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . 8.8.5 Crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.6 Crosshead Pin Bearing. . . . . . . . . . . . . . . . . . . . . 8.8.7 Distance Piece Packing . . . . . . . . . . . . . . . . . . . . 8.8.8 Oil Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2B1XC2.64_1

IM 200322en

8-3 8-3 8-6 8-6 8-6 8-6 8 - 10 8 - 17 8 - 18 8 - 19 8 - 21 8 - 21 8 - 23 8 - 23 8 - 23 8 - 23 8 - 24 8 - 26 8 - 28 8 - 29 8 - 29 8 - 30 8 - 31 8 - 31 8 - 31 8 - 31 8 - 34 8 - 39 8 - 40 8 - 41 8 - 42 8 - 46 8 - 47 8 - 49 8 - 49 8 - 50 8 - 50 8 - 52 8 - 55 8 - 56 8 - 56 8 - 58 8 - 59

8–1

Preventive Maintenance

8.9.1 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.2 Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . 8.9.3 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.4 Piston Nut SUPERBOLT® . . . . . . . . . . . . . . . . . . . 8.10 Suction Valves and Discharge Valves . . . . . . . . . . . . . . . . . 8.10.1 Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 8.10.2 Valve Failures (Malfunction) . . . . . . . . . . . . . . . . . 8.10.3 Maintenance of Controlled Suction Valves . . . . . . 8.11 Complete Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–2

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

8 - 59 8 - 59 8 - 61 8 - 64 8 - 69 8 - 69 8 - 69 8 - 70 8 - 73

18.05.2016

Preventive Maintenance Importance of Preventive Maintenance

8.1

Importance of Preventive Maintenance By doing preventive maintenance at regular intervals, these improvements arises:

• • •

increased life time prevention of breakdowns and damages increased safety for man and machine

We strongly recommend to do all maintenance work under the supervision of a specialist from Burckhardt Compression. For damage caused by nonprofessional maintenance, Burckhardt Compression will not assume any liability.

If you have any questions concerning maintenance procedures, please contact your local Burckhardt Compression Office or Burckhardt Compression Agent. Address see section 1.6 Contact Address. For details visit our website www.burckhardtcompression.com.

8.2 Safety Precaution

Prerequisites for Maintenance Process gas may be dangerous. Read the detailed gas description and warnings in section 2.9 Process Gas and Purge Gas. CAUTION Contamination of process gas! All components coming in contact with process gas must be checked for cleanliness prior to their installation.  When performing overhauls or exchanging spare parts, make sure that all significant surfaces have been cleaned according to the cleaning specification prior to assembly or installation.  If in doubt about cleanliness, repeat cleaning procedure.

18.05.2016

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

8–3

Preventive Maintenance Prerequisites for Maintenance

Maintenance Guidelines

•

Carry out adjustments, preventive and corrective maintenance in due time.

•

Regularly check plant components like pressure vessels, coolers, dampers, separators etc. for deposits and corrosion.

• •

Recondition loose contacts and damaged cables immediately.

•

Before beginning any inspection or repair, turn the current off at the switch box and padlock the switch in the OFF position.

•

Always adhere to local and company safety regulations (e.g. warning sign “Machine under maintenance or overhaul”, put up safe work platforms, setting spectacle flange etc.).

•

Depressurize and purge the compressor plant (see section 8.2.1 Depressurize and Purge Plant).

•

Select “Maintenance” mode at the distributed control system (DCS).

Protect all plant components such as main motor, oil and cooling system pumps, pneumatic or hydraulic control systems etc. against unintended start-up.

For further details on maintenance action see section “Control Description” in chapter 13 Appendix. Lockout and Tagging of Circuits DANGER Unintended start-up of compressor is possible!  Before beginning any inspection or repair, switch off the power at the switch box and padlock the switch in the OFF position.

The first step before beginning any inspection or repair job, switch off the power at the switch box and padlock the switch in the “OFF” position. This applies even on so-called low-voltage circuits. Securely tagging the switch or controls of the compressor or equipment being locked out of service clarifies to everyone in the area which equipment or circuits are being inspected or repaired. Only qualified electricians who have been trained in safe lockout procedures should maintain electrical equipment. No two of the locks used should match, and each key should fit just one lock. In addition, one individual lock and key should be issued to each maintenance worker authorized to lock out and tag the equipment. All employees who repair a given piece of equipment should lock out its switch with an individual lock. Only authorized workers should be permitted to remove it.

Do not start work prior to a written confirmation that safety measures have been taken.

Transport and Lifting of Heavy Components

8–4

IM 200322en

For transport and lifting of heavy components, take care to avoid any damage; please see section 5.2.1 Safety of Transport, for weights see section 5.3 Dimensions, Weights, Space Requirement.

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Preventive Maintenance Prerequisites for Maintenance

Lubricants, Tightening Torques and Methods

For applicable lubricants, mandatory tightening torques as well as appropriate tightening methods: see sections “Lubricating System” and “Compressor” in chapter 13 Appendix.

Restart Compressor

Perform functional test on protective devices after maintenance. Turn flywheel of compressor min. 1 rotation by means of the barring device in running direction and verify that everything is in proper mechanical condition.

1

2

3

PB_L1_0049b_01

4

Fig. 8-1 1 2 3 4

Pneumatic barring device

Flywheel Pawl Proximity probe Barring device

DANGER Rotating components, drawing in and crush hazard! Exposed rotating components can cause severe injury or death.  Check the correct position of barring device! Prevent the catch being engaged into toothing of flywheel.  Do not operate the compressor with flywheel guard removed.  Follow lockout procedure before maintenance.

18.05.2016

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

8–5

Preventive Maintenance Tools

8.2.1

Depressurize and Purge Plant It is the superior authority’s responsibility to ensure safe working conditions. WARNING Compressor/plant still pressurized Severe injuries and damage to equipment can occur if maintenance is started before the compressor and plant are completely depressurized.  Completely depressurize compressor/plant before starting maintenance work!  Check relevant pressure indicators for atmospheric pressure on compressor and pipe system.

Further information, see section “Control Description” in chapter 13 Appendix.

8.2.2

Clean Compressor Plant Assure cleanliness and tidiness of compressor and surrounding area. Use appropriate cleansing agents and materials. For safe use of cleansing agents see section 10.3 Select Cleansing Agent. Please take care of the environment! When using leach, solvents and cleansing agents, observe manufacturer’s instructions for use. When working on the compressor, make sure there is sufficient circulation of fresh air.

8.3

Tools CAUTION Increased risk! Damage to the equipment or risk of injury can occur.  Only use original (OEM recommended) tools.  Only use special tools delivered with compressor.  Clean tools after use and store them in a closed and corrosion-resistant cabinet nearby the compressor.

8.3.1

Standard Tools Txxxxx = code no. for ordering special tools and standard tools.

8–6

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

XA_T9_0005a_01

Preventive Maintenance Tools

Fig. 8-2

Combination spanners

XA_T9_0032a_01

T96100: Set of combination spanners 17–46 mm

Fig. 8-3

Ratchet

XA_T9_0007a_01

T96171: 1"

Fig. 8-4

Flogging spanner

T96114: 50 mm

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LA_T9_0009a_01

Preventive Maintenance Tools

Fig. 8-5

Eye bolt

XA_T9_0025a_01

T96061: 2 eye bolts M24 T96062: 2 eye bolts M20 T96063: 2 eye bolts M16 T96064: 2 eye bolts M12

Fig. 8-6

Lifting ring VLBG

PA_T9_0008a_01

T96291: Lifting ring VLBG, No. 1, 5T, M30

Fig. 8-7

Torque wrench

XA_T9_0009a_01

T96254: Torque wrench, 40–200 Nm, Type 730R/20–1/2"

Fig. 8-8

Extension for sockets

T96031:

8–8

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XA_T9_0010a_01

Preventive Maintenance Tools

Fig. 8-9

Hexagonal socket

X

XA_T9_0052a_01

T96021: 46mm, 1" T96022: 36mm, 1" T96023: 16mm, 1/2"

Fig. 8-10 Hexagonal socket

PA_T9_0026a_01

T96141 Hexagonal socket 10mm–1/2" T96142 Hexagonal socket 9mm–1/2" T96143 Hexagonal socket 8mm–1/2"

Fig. 8-11 Pull-off device for removing crosshead pin

XA_T9_0051a_01

T97070

Fig. 8-12 Stepped mandril

T96311: Stepped mandril/arbor, 1x stepped, No. 1

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XA_T9_0108a_01

Preventive Maintenance Tools

Fig. 8-13 Set of reamers

T96600

8.3.2

Special Tools Txxxxx = code no. for ordering special tools and standard tools.

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1

2

3

PA_T9_0007b_01

4

Fig. 8-14 Dismantle cylinder cover 1 2 3 4

Eye bolt with rope Cylinder cover Bar Cylinder

XA_T9_0036a_01

T97235: Bar dia. 30x1200 mm

Fig. 8-15 Pulling eye bolt

T97271: Pulling eye bolt, No. 1 T97272: Pulling eye bolt, No. 2 T97273: Pulling eye bolt, No. 3

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PA_T9_0009a_01

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Fig. 8-16 Valve mounting spanner

T97431: Valve mounting spanner, No. 1

1

11

2 10 9 3 8 4 5

7

6

2

4 11

PA_T9_0041c_01

3

Fig. 8-17 Valve dismantling and assembling device

1 2 3 4 5 6

Bottom plate Additional guiding bar Guiding bar Guiding plate Mandril Clamping device (movable)

7 8 9 10 11

Ratchet Pick-up disc Centering bolt Spindle Allen screw

T97374: Valve dismantling and assembling device, No. 1

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PB_T9_0077a_01

Preventive Maintenance Tools

Fig. 8-18 Ratchet

PA_T9_0006a_01

T97392

Fig. 8-19 Dismantling and assembling device for connecting rod

T97460

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PA_T9_0024a_01

Preventive Maintenance Tools

Fig. 8-20 Stop for T97460

PA_T9_0022a_01

T97470

Fig. 8-21 Protective sleeve for piston rod

T97450

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1

6 5 4 3

PB_T9_0144b_01

2

Fig. 8-22 Piston rod supporting device

1 2 3

Distance piece Centering shaft Spindle

4 5 6

Support for piston rod Cylindrical pin Oil scraper

T97455 1 2

3

PA_T9_0043a_01

4

Fig. 8-23 Piston rod assembly sleeve

1 2

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Eye bolt Piston rod assembly sleeve

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3 4

Piston rod Piston

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2

PB_T9_0007b_01

T97451: M56

1

Fig. 8-24 Piston assembly steel sheet 1 2

Stopper Piston assembly steel sheet

T97335: Piston assembly steel sheet, No. 1 2

3

PA_T9_0002b_01

1

Fig. 8-25 Dismantling and assembling device for piston 1 2 3

Piston rod Piston Dismantling and assembling device

T97440

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8.4

Maintenance Schedule The indications on the following tables serve as general guideline only. The final schedule should be worked out together with Burckhardt Compression Services. We refer to the specific maintenance requirements in this Instruction Manual.

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8.4.1

Plant

Maintenance Work

See section

Hours of operatio 4000

8000

16000

24000

Drain oil, clean oil strainer, oil tank, crankgear and duplex oil fil- 8.6.5, ter (if applicable). First time after 200 hours of operation. 8.6.5

x

x

x

x

Check set points of the safety devices; conduct function test and complete the corresponding life passports.

8.6.8

x

x

x

x

Piping:

8.6.3 x

x

Check bolted connections, flanges and pipe clamps for tightness Damper(s):

3.3.4

Check proper condition of damper

x

x

x

x

x

x

10

Auxiliaries:

x

Clean compressor-related auxiliaries to avoid dust accumulation on surfaces. Safety and relief valves:

8.6.8

x

Check proper functioning of safety valves

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8.4.2

Compressor

Maintenance Work

See section

Hours of opera 4000

8000

16000

24000

x

x

x

x

5.4

Foundation Cleanliness: Visual check of oil and water Foundation protection: Visual check for cracks and chipping Vibrations: Vibration measurement of connections: Compressor/Frame – Foundation

3.7

Safety and Control Instruments Safety valves: Function, tightness, lead sealing Interlock System: Performance test of control and safety instruments. Check set points of the safety instruments

Annually

PI and TI: Check by comparison instrument and if necessary recalibrate or replace Flow indicator: Check and, if necessary, repeat calibration Valves: Check valves, valve lanterns, valve gaskets and valve seats

8.10, 9.7

Pistons: Check clearance of piston rings and wear of piston and guide rings (rider rings)

8.9.3, 9.11, 8.9.1

Piston rod: Check surface for scoring and wear Cylinder(s) Cylinder liner: Measure diameter and check running surfaces for scoring and surface flaking

x

9.11.9, 9.15.3

Piston rod packing(s): Check sealing elements, wear and axial 8.9.2, clearance 9.13

x

x

x

x

x

x

x

x

x

x

x

x

Cooling spaces: Clean cooling spaces of cylinder, cylinder cover and packing (if any)

8.6.4

Distance Piece(s)

8.8.7, 9.17

x

x

x

x

8.8.8, 9.18

x

x

x

x

8.8.3, 3.7.6

x

x

x

x

x

x

x

Distance piece packing: Check sealing elements as well as wear and axial clearance Distance Piece Oil scraping: Check oil scrapers Crankgear Breather: Clean and check condition Crankshaft seal: Check condition of sealing and shaft surface

Every 8000–16000 hrs., depend treatment

8.8.3, 9.25

Check bearing clearance: check bearing clearances with feeler 8.8.2, 8.8.4, gauge, without dismantling of bearings: 8.8.6, - Crankshaft bearings 9.27, - Connecting rod bearings 9.20, - Crosshead and crosshead liner 9.21 - Crosshead pin and crosshead pin bearing

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Maintenance Work

See section

Hours of operation 4000

8000

16000

24000

x

x

x

Bearings

8.8.2, Random check of bearings by dismantling of bearings as men- 8.8.4, 9.27, tioned 9.21, 9.27, 9.28 8.6.6, Drain oil, clean oil strainer, crankgear and duplex oil filter (if ap- 8.6.5. plicable). First time after 200 hours of operation. Crankgear lubrication:

Oil cooler:

8.6.4, Clean cooling spaces and replace gaskets (depending on foul- 8.6.5 ing factor and water treatment) Prelubrication pump: replace shaft seal

x

8.6.5

x

If shaft seal is leaking

Relief, shut-off and control valve(s): clean and replace sealings 8.6.5, 8.6.8

x

5.11

Drive Alignment of coupling: Compare with manufacturer data (radial and axial deviations)

x

Electric motor: Check insulation resistance

•

If motor is rigidly coupled to crankshaft: check crankshaft deflection by a crankshaft dial indicator,

•

if a flexible coupling is installed: check correct coupling installation by checking crankshaft deflection.

5.11.4

x

(Crankshaft dial indicators may be ordered from Burckhardt Compression) Clean compressor surfaces to avoid dust accumulation.

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x

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x

3

Preventive Maintenance Plant in General

8.5 8.5.1

Plant in General Tightening Torques and Method For specific tightening methods for the compressor please see section 8.7.7 Tightening Methods and a comprehensive table with tightening torques can be found in chapter 13 Appendix.

Tightening Method I

Bolted Connections of Secondary Level

•

This category includes all bolts not being particularly stressed during operation.

•

Tightening is usually done using a standard-sized wrench without extension.

• •

Tightening torques depend on bolt size and material. Torque values are listed in the following table.

Bolt quality class and bolt material are marked on the head of a bolt (see Fig. 8-26).

Should questions arise, please contact Burckhardt Compression Services (address see section 1.6 Contact Address).

XA_XX_0111b_01

1

Fig. 8-26 Marking on bolts 1

Marking (quality class and material)

Data only applicable if no other tightening methods or torque values are specified.

CAUTION If gaskets are used, attentively follow the specifications of the gasket manufacturer!

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Tightening Method

Lubricant

• •

Clean areas of support (connecting parts) free of grease

•

Tighten screw at least twice using torque wrench (tightening torque according to table)

• •

MOLYKOTE® G-N Plus

Apply lubricant to gliding surfaces of bolt (thread, head support and nut support)

Other suitable lubricants

Tightening Torques

Thread

Bolt quality standard

Bolt quality heat-treated

4.6-2, 5.6, G, YK

6.9, 8.8, VCN 35

Nm

mkp

ft-lbs

Nm

mkp

ft-lbs

M12

25

2.5

18.4

39

4

28.8

M14

39

4

28.8

64

6.5

47.2

M16

59

6

43.5

93

9.5

68.6

M18

83

8.5

61.2

132

13.5

97.4

M20

113

11.5

83.3

177

18

130.6

M22

147

15

108.4

245

25

180.7

M24

186

19

137.2

324

33

239

M27

265

27

195.5

461

47

340

M30

343

35

253

638

65.1

470.6

M33

422

43

311.3

834

85

615.2

M36

530

54

390.9

1080

110.1

796.6

M39

667

68

492

1373

140

1012.7

M42

–

–

–

1766

180.1

1302.6

M45

–

–

–

2256

230

1664

Data valid only using MOLYKOTE® G-N Plus!

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8.6 8.6.1 Electric Motor

Plant Electric Motor and Coupling If electric motor has been removed for its overhaul and/or if the crankshaft deflection of the compressor crankshaft is larger than the permitted limit (see section 5.11.4 Check Crankshaft Deflection) the electric motor must be realigned. Realignment is simplified if the position of the main motor had been marked with positioning pins during installation. For realignment proceed according to section 5.11 Install Electric Motor and Coupling.

8.6.2 Cooler, Damper and Separator

8.6.3 Gaskets/Seals Flange Connections/Pipe Fastenings

Pipe Supports

Gas System Plant components under pressure, such as pressure vessels, coolers, dampers, etc. must be inspected periodically for deposits or corrosion according to local and/or work regulations. If pressure test must repeated periodically, see section 8.6.9 Hydrostatic Pressure Test.

Flange Connections and Pipe Fastenings Check gaskets and seals on a regular basis and use them only once. Check all flange connections and pipe fastenings on a regular basis. Retighten all flange connections and pipe fastenings according to specified tightening torques. Defective or loose pipe supports can lead to vibrations and therefore interfere with the smooth running of the compressor. To avoid damage to welds, check coolers, dampers etc. periodically for specified tightening torque. Retighten bolted connections of their supports on a regular basis. Check bolted connections for specified tightening torque on a regular basis. Fit additional pipe supports if necessary. Examples for pipe supports, see section 5.13.6 Recommendation for Pipe Support. Information regarding admissible vibrations, see section 5.16.9 Assess Vibrations.

Pipe System

To avoid damage to pipes, coolers, pulsation dampers etc. due to vibrations, the bolts of the pipe connections must be checked for specified tightening torque and if necessary re-tighten periodically. Loose pipe fastenings may lead to pipe damage and/or to fractures of weld seams. This may also lead to disturbances in the smooth running of the compressor. Examples for pipe supports, see section 5.13.6 Recommendation for Pipe Support.

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For information regarding vibrations, see section 5.16.9 Assess Vibrations. Gas leakage must be repaired immediately. Gaskets may become hard and brittle after a certain time; they must be replaced periodically. Gaskets should be used once only. Pipe connections must be accurately aligned to the design angle with regard to each other. Damaged surfaces of flanges must be re-machined. Flange connections must be checked periodically for specified tightening torque and re-tightened if necessary. Process gas may be dangerous. Read the detailed gas description and warnings in section 2.9 Process Gas and Purge Gas.

8.6.4 Periods of Standstill

Cooling System Avoid stationary coolant. A minimal flow of coolant must always be maintained. During longer periods of standstill (exceeding a month), the system must be purged and the coolant spaces be dried with compressed air. Contamination of the coolant leads to deposits in the piping (reduction of pipe diameter) and to deposits in the cooling chambers. This prevents proper heat transfer and results in insufficient cooling. Increasing discharge gas temperatures, increasing lubricating oil temperatures and decreasing coolant temperatures are a clear sign of deposits in the cooling chambers. To avoid overheating of critical points, cooling chambers must be inspected regularly; the length of the inspection intervals depends on the quality of the coolant. Bubbles in the cooling water indicate that either ambient air or process gas enter the cooling water. Oil in the cooling water indicates leaky oil coolers (if any). WARNING If the ambient temperature and/or process gas temperature drops below 0°C, the cooling water can freeze. If the wrong antifreeze solution is used, the cooling water can freeze in spite of the antifreeze solution.  Add a suitable antifreeze solution.

Inspecting Cooling Chambers

Drain the cooling system(s) and open the covers on each cylinder leading to the cooling chambers. Inspect the cooling chambers of the cylinders and clean them if necessary.

If there are deposits of sand, chalk or algae in the cooling chambers, we recommend to subcontract a specialized company to remove them and to clean the cooling chambers, as they have the necessary know-how and the required materials and equipment.

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Cleaning of cooling chambers and removal of deposits can be carried out by the maintenance personnel as well (this is, however, not recommended). Cleaning is described in the following sections “Removing Deposits of Calcium Carbonate”, “Removing of Algae” and “Removing Deposits of Sand”. Proceed according to following section “Leak Test”. Removing Deposits of Calcium Carbonate

Circulate the cleaning agent by means of a pump in order to ensure a reliable decomposition of the deposit. WARNING Consult manufacturer’s instructions.

Remove calcium carbonate deposits with (for example): Diluted formic acid (HCOOH) or Diluted sulphamic acid (NH2SO3H) with inhibitor. CAUTION Cast iron, steel, nonferrous heavy metals and aluminum must not be corroded by these chemicals.

Proceed according to following section “Leak Test”. Removing of Algae

If the coolant is not properly treated with chemicals, the growth of algae may result. This is particularly the case in open coolant circuits and in cooling towers. WARNING Consult manufacturer’s instructions.

Remove algae with (for example):

• • •

BIOSPERSE 250, DREW AMEROID NALFLOC 7330, NALFLOC VARICID AC, SCHILLING CHEMICAL

The treatment time depends on the extent of algae growth. After removal of algae, the coolant must be carefully filtered and properly treated by a specialized company. Proceed according to following section “Leak Test”. Removing Deposits of Sand

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Remove solidified crusts of sand manually and flush out the cooling chambers afterwards.

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CAUTION Chemicals for dissolving deposits of sand are too aggressive for the metallic components of compressors.

Leak Test

After each cleaning operation, a leak test must be performed. Special attention must be given to the internal cooling pipes and connections. CAUTION Water in the lubricating oil! Do not exceed the maximum permitted coolant pressure!

For set pressure of the relief valve in the coolant line (if installed) see corresponding P&I Diagram in chapter 13 Appendix.

8.6.5

Lubricating System

Prelubrication Pump

For detailed description of the prelubrication oil pump refer to the documentation of the manufacturer (see Technical Documentation).

Non-Return Valve

For detailed description of the non-return valve refer to the documentation of the manufacturer (see Technical Documentation).

Relief, Shut-off and Control Valve

For detailed description of the relief, shut-off and control valve(s) refer to the documentation of the manufacturer (see Technical Documentation).

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XA_P0_0001a_01

Duplex Oil Filter The duplex oil filter consists of two filter housings and is equipped with a differential pressure indicator (or optional with switch). During normal operation, the oil flows through one of the two filter elements. If the degree of contamination exceeds the tolerance threshold (differential pressure between filter inlet and outlet) the operator must switch to the other filter element. The contaminated filter element can be cleaned/replaced whilst the plant continues operating.

Fig. 8-27 Duplex oil filter (typical view)

For detailed description of the duplex oil filter refer to the documentation of the manufacturer (see Technical Documentation).

Check differential pressure and clean/replace filter element if necessary: 1. Check differential pressure on indicator (for tolerance value see section “Instrumentation” in chapter 13 Appendix).

 If pressure exceeds the given tolerance continue to step 2, otherwise no cleaning is necessary. 2. Switch to second filter element (which should be clean) by turning the switch lever.

 The second filter element is now active. 3. Open the cover of the first filter element and dismantle it. Clean/replace the filter element according to manufacturer’s documentation.

 After reassembling the first filter element, it is ready for the next turn-over by switching back from second to first element. Oil Cooler

For detailed description of the oil cooler refer to the documentation of the manufacturer (see Technical Documentation).

Oil Strainer

For detailed description of the oil strainer refer to the documentation of the manufacturer (see Technical Documentation).

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Instrumentation

For detailed description of the instrumentation refer to the documentation of the manufacturer (see Technical Documentation).

8.6.6

Oil Change For lubricating oil specifications see section “Lubricating System” in chapter 13 Appendix. For oil change interval see section 8.4 Maintenance Schedule. Analyze the oil periodically to check if the oil still fulfills the qualitative requirements. Burckhardt Compression recommends to regularly obtain oil analysis from an appropriate lubricant laboratory. In any case the oil must be changed if:

• • •

coolant has penetrated into the oil (oily emulsion). the oil has been diluted by condensation. bearings have been replaced (due to material of damaged bearings inside the oil).

Permissible Values Water content

Neutralisation value

Viscosity (kinematical, at 40 °C)

Metallic traces of wear

max. 0.3% (for mineral oil)

max. 0.2mg KOH/g

not less than 80% of the new oil

max. 150ppm

Tab. 8-1

Oil Quantity

Permissible values of lubricating oil in use (reference values)

The oil reservoir is in the oil tank. The level may be checked at the oil sight glass. When the compressor is at standstill, 3/4 of the oil sight glass must be covered. The working capacity of the oil tank is 425 liters. Additional oil for associated pipes, and auxiliaries as e.g. oil cooler and filters is required. The total oil quantity is approximately 765 liters. When the compressor is running, 1/2 of the oil sight glass should be covered.

Procedure

Proceed as follows when changing oil: 1. Shut down the compressor.

Depressurize the compressor plant (see section 8.2.1 Depressurize and Purge Plant).

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Drain 2. Drain the oil from the oil tank. 3. Drain the piping of the lubricating system. Clean 4. Remove and clean the oil strainer of the oil tank. 5. Clean the oil tank with a new, unused sponge (do not use fibrous textile). 6. Replace (clean) the duplex oil filter in accordance with the manufacturer’s instructions (see Technical Documentation). Refill

Check for proper lubricating oil quality and quantity see sections 8.6.6 Oil Change and 8.6.7 Lubricating Oil Specifications.

7. Shut oil outlets, refit oil strainer, etc. and fill the oil tank with fresh oil.

Use the prelubrication pump to fill the complete oil system.

8.6.7 Oil Quality

8.6.8 Functional Check of Safety Monitoring Systems

Lubricating Oil Specifications Reference is made to the list of recommended lubricating oils in section “Lubricating System”, chapter 13 Appendix.

Safety Devices For technical information about safety devices, e.g. temperature sensors, level switches, vibration switches, etc. please see the respective sections in chapter 13 Appendix. Safety monitoring systems must be checked for their switching points and their indicating values according to the safety requirements (for set points see section “Instrumentation” in chapter 13 Appendix). By means of a suitable electrical circuit, the monitoring devices which switch off the motor can be overridden for checking the individual or collective functional ability of the devices. The safety and monitoring devices must be switched on again after functional checks.

Safety Valves/Relief Valves

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Safety valves and relief valves are the last inline safety devices for vessels and piping. Establish inspection intervals with regard to ambient and/or plant operating conditions as well as regulations and work rules.

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Control and Shut-Off Valves

Maintenance for control and shut-off valves should be carried out regularly according to manufacturer´s instructions. CAUTION Observe instructions of the manufacturer (see Technical Documentation).

8.6.9

Hydrostatic Pressure Test Hydrostatic pressure tests of the pipe system must be carried out by trained specialists only. Parts to be pressure tested must be air vented. Please ask for our technical assistance (address see section 1.6 Contact Address) for permitted design pressure on the gas side. Use approved pressure gauges only. For the gas and oil pipes only treated water must be used. WARNING Pressurized plant components. Incorrect pressure testing may result in bursting plant components!  Do not exceed the maximum permitted pressure!  Observe the correct measuring unit on the pressure gauge.

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8.7 8.7.1

Compressor in General Dimensions, Weights, Space Requirement Please see section 5.3 Dimensions, Weights, Space Requirement for details.

8.7.2

Marking of Compressor Components Compressor parts which must always be fitted in the same position are numbered.

On the assembled compressor, these markings must lie on the right hand side when looking from the drive end towards the non-drive end. The numbering of the individual parts starts with no. 1 from the drive end and ascends to no. 2, 3 etc. towards the non-drive end. Furthermore, the serial no. is marked on important compressor components. Some parts are only marked with a matching number, like the following:

• • • • •

8.7.3 General Remarks

Connecting rod – connecting rod bearing halves Crankshaft bearing cover – crankshaft bearing Distance piece Cylinder – piston (if pistons of identical size) Piston rod packings

Cylinder Clearance Measurement The top cylinder clearance is the gap between the piston and the cylinder cover, if the piston is positioned in the top dead center (TDC). The bottom cylinder clearance is the gap between the piston and the cylinder bottom, if the piston is positioned in the bottom dead center (BDC).

Measure Cylinder Clearance

Prior to measuring, clean all measuring tools, according to chapter 10 Clean and Degrease Plant and Compressor Components.

Option for measuring: You can also measure the cylinder clearances by using a feeler gauge.  Position the piston in the top or bottom dead center.  Insert the feeler gauge into the chamber of the cylinder.

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CAUTION Use of wrong lead wire Wrongly measured or adjusted cylinder clearances can cause major compressor failure.  Use lead wire of appropriate thickness or use a feeler gauge.  Using too thick lead wire can lead to wrong measurement of cylinder clearance.

1. Dismantle one upper valve. 2. Dismantle one lower valve. 3. Insert a soft lead wire at the upper dead center. 4. Insert a soft lead wire at the lower dead center. 5. Move the piston through the lower dead center by turning the crankshaft with the barring gear. 6. Move the piston through the upper dead center by turning the crankshaft with the barring gear. 7. Remove the lead wires. 8. Measure their thickness.

 The thickness of the lead wires represent the upper and lower cylinder clearances. 9. Record measured values in the corresponding log sheet (see 8.7.4 Clearance Measurement Log Sheet). 10. Compare the cylinder clearances that you have measured with the set values in section “Compressor” in chapter 13 Appendix.

 You have installed the piston correctly, if the measured values of the cylinder clearance correspond with the set values. 11. If necessary, adjust the cylinder clearance. Admissible Tolerances not Achieved? Adjust the cylinder clearance by the distance ring between crosshead and hydraulic nut: 1. Move the piston to the upper dead center by turning the crankshaft with the barring gear. 2. Dismantle the piston rod by the hydraulic nut. 3. Move the crosshead by turning the crankshaft with the barring gear until you can remove the flange. 4. Change the distance disc (choose the correct thickness). 5. Mount in reverse order. 6. Measure the cylinder clearance.

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7. Compare the cylinder clearances you have measured with the set values in section “Compressor” in chapter 13 Appendix.

 You have installed the piston correctly, if the measured values of the cylinder clearance correspond with the set values.

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8.7.4

Clearance Measurement Log Sheet TDO_2007034_E01_02.docx

PL2 Clearance Measurement Compressor S/N:

Compressor Type:

Order / Job No.:

All Measurements in mm

Bearing clearance Specified clearance according Instruction Manual

Measured values As found

Radial Main bearing

6

5

Axial

4

3

2

1

Radial

Specified clearance according Instruction Manual

Measured values As built

Radial Main bearing

6

5

3

2

1

Radial

Axial

Measured values

As found

C8 Crankshaft journal bearing

Axial

4

Axial

Radial

C7 Axial

Radial

C6 Axial

Radial

C5

Axial

Radial

C4 Axial

Radial

C3

Axial

Radial

Axial

C2 Radial

C1 Axial

Radial

Axial

Radial

Axial

Crosshead pin bearing Crosshead Measured values

As built

C8 Crankshaft journal bearing

Radial

C7 Axial

Radial

C6 Axial

Radial

C5

Axial

Radial

C4 Axial

Radial

C3

Axial

Radial

Axial

C2 Radial

C1 Axial

Crosshead pin bearing Crosshead Specified clearance according Instruction Manual

Radial

Crosshead

Radial

Radial

Template : TDO 2007034 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev. B

Dat.

Axial

Sig.

03.06.2014

WEISS_M

20.10.2014

KAUFMANN_W

20.10.2014

STAEHLI_P

Ersatz für Replacement for Revision vom / date

Seite 1 von 5 Page 1 of 5 gedruckt / printed: 15.12.2014

PA_XX_0020a_03

Crankshaft journal bearing Crosshead pin bearing

Fig. 8-28 Example sheet for clearance measurement (first page)

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PL2 Clearance Measurement

TDO_2007034_E01_02.docx

Piston rod diameter

HE

C

HE

CE

HE C CE

C

CE

Head end Center Crank end

Manufacture size of Piston rod dia.

mm,

Minimal allowable dia. by wearing out; dia.

Diameter of packing area HE

C2

C3

C4

C5

C6

C7

C8

Diameter of oil scraper area CE

HE

C

CE

0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90°

Template : TDO 2007034 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev.

Dat. 03.06.2014

B

Sig. WEISS_M

20.10.2014

KAUFMANN_W

20.10.2014

STAEHLI_P

Ersatz für Replacement for Revision vom / date

Seite 2 von 5 Page 2 of 5 gedruckt / printed: 15.12.2014

PA_XX_0021a_03

C1

C

mm

Fig. 8-29 Example sheet for clearance measurement (second page)

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PL2 Clearance Measurement

TDO_2007034_E01_02.docx

Joint clearance; P, L Stage

Ring type

Crank

Piston- / Guide ring clearance

Axial clearance; N, F

Required clearance, from / to or max. value

Actual clearance from / to

Actual clearance from / to

Required clearance, from / to or max. value

Ring thickness; O, K Actual size

Number of installed re-used rings.

Minimal allowable thickness

Number of installed new rings.

V V V V V V V V V V V V V V

Table above to complete as following example:

C2

PR

2

12.6 – 13.0

12.5 – 13.5

0.2 – 0.3

0.166 – 0.364

18.50 – 18.70

15.58

3

1

C2

GR

2

8.3 – 8.5

8.1 – 8.75

0.7 – 0.8

0.6 – 0.846

8.0

7.0

0

2

Template : TDO 2007034 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev.

Dat.

Sig.

03.06.2014

B

WEISS_M

20.10.2014

KAUFMANN_W

20.10.2014

STAEHLI_P

Ersatz für Replacement for Revision vom / date

Seite 3 von 5 Page 3 of 5 gedruckt / printed: 15.12.2014

PA_XX_0022a_03

All rings, meant all rings of the same sorts who are mounted on the same piston, need to be checked and recorded like example below. C2, ring type PR, (for Piston rings or GR for Guide rings) at stage 2, are installed with a joint gab clearance between 12.6mm – 13.0mm, required 12.5 – 13.5mm. Additional fill in the actual measure of axial clearance, ring thickness and the amount of rings which are new or re-used. As it shows below, use a second line for the next type of ring on the specific piston. GR, 2. Stage, axial clearance between 8.3 - 8.5mm, required 8.1 – 8.75mm and all rings (GR) replaced by new once. The individual required tolerances are mention in the instruction manual.

Fig. 8-30 Example sheet for clearance measurement (third page)

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TDO_2007034_E01_02.docx

PL2 Clearance Measurement Piston dead space TDC – Top dead center Crank

As found

BDC – Bottom dead center

Specified dimension according Instruction Manual

Actual dimension

Measuring device

As build

Measuring device

Specified dimension according Instruction Manual

Actual dimension As found

As build

C1 C2 C3 C4 C5 C6 C7 C8

1 Lead wire

Dead space checked by:

2 Feeler gauge 3 Depth gauge / slide gauge 4 Dial indicator 5 Cylinder liner bore diameter

Head end

Center Crank end Crank

C

C

C

C

C

C

C

C

Stage Manufacture Ø of cylinder bore Admissible bore Ø of cylinder by wearing out

(Measure of internal dia. of cylinder bore, 90° offset see direction of measurement in the above sketch) Heat end VS - VS 90° Center VS - VS 90° Crank end

90° Template : TDO 2007034 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev. B

Dat.

Sig.

03.06.2014

WEISS_M

20.10.2014

KAUFMANN_W

20.10.2014

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PA_XX_0023a_03

VS - VS

Fig. 8-31 Example sheet for clearance measurement (fourth page)

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TDO_2007034_E01_02.docx

PL2 Clearance Measurement Packing / Oil scraper Axial clearance of each packing element / oil scraper Pressure breaker, S1 S1

Specified clearance

C

C

C

C

C

C

C

C

Packing located in cylinder, S2

S2

R1

R2

S4

Packing located in flange / leak gas

R4

S4

R4

S4

Gas barrier packing / distance piece

S4

R4

R4

S6

Oil scraper, S6

Note: If any packing element are being re-used (R); mark above as:

Place :

Name / Signature BC:

Date:

Name / Signature Customer:

Template : TDO 2007034 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev.

Dat. 03.06.2014

B

Sig. WEISS_M

20.10.2014

KAUFMANN_W

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R 0.35 – 0.43

Seite 5 von 5 Page 5 of 5 gedruckt / printed: 15.12.2014

PA_XX_0062a_01

R6

Oil scraper replaced; (yes / no)

Fig. 8-32 Example sheet for clearance measurement (fifth page)

Table of clearances see section “Compressor” in chapter 13 Appendix.

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8.7.5

Piston Rod Runout TDO_2007033_E01_05.docx

PL2 Piston Rod Runout Compressor S/N:

Compressor Type:

Order / Job No.:

Rod Run-out in [mm] Peak-to-Peak Crank

1

Direction of measurement

Piston rod condition (Code):

Position

Vertical

Vertical

Vertical

-0.03

+0.03

0.00

-0.03

+0.03

0.00

-0.03

+0.03

0.00

-0.03

+0.03

0.00

-0.03

+0.03

0.00

-0.03

+0.03

0.00

-0.03

+0.03

C D

Vertical Horizontal

8

0.00

C D

Horizontal

7

+0.03

C D

Vertical Horizontal

6

-0.03

„As built“ measurement

C D

Horizontal

5

0.00

„As found“ measurement

C D

Horizontal

4

Upper Tolerance limit

C D

Vertical Horizontal

3

Lower tolerance limit

C D

Vertical Horizontal

2

Design

C D

Vertical Horizontal

Condition of Piston rods, Code:

2 = Re-conditioned, (circular grinding)

3 = Used, (Not machined!)

Place:

Name / Signature BC:

Date:

Name / Signature Customer:

TDO 2007033 Rev. Template erstellt / prepared überprüft / reviewed D Freigabe DVS

Date

Sign.

04.12.2014 12.12.2014 12.12.2014

KAUFMANN_W STOCKER_H KAUFMANN_W

Ersatz für Replace for Revision vom / date

PA_XX_0019a_04

1 = New condition

Page 1 / 1

15.12.2014

Fig. 8-33 Example sheet for piston rod runout

Table of clearances see section “Compressor” in chapter 13 Appendix.

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Preventive Maintenance Compressor in General

8.7.6

Frame Alignment PL2/PL4 Frame Alignment

Compressor S/N:

Compressor type:

TDO_2030215_E01_01.docx

Order / Job No.:

All level measurements are in mm/m This view is schematic, measurement faces may vary on different machine types. The delegated person of BC will define adequate measurement location. (Y axis): + = cyl. level or frame to cyl. direction is rising / - = cylinder level or frame to cyl. direction is decreasing (X axis): + = frame level toward coupling is rising / - = frame level toward coupling is decreasing Cyl.no

Cyl.no

Shims a)

Zero Line X

f)

c)

e)

a)

b)

d)

Zero Line Y

Measurement faces: a) b) c)

d) e) f) mm/m

ambient temperature during measuring: approx.

Place:

Name / Signature BC:

Date:

Name / Signature Customer:

Template : TDO 2030215 Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Rev.

Dat. 04.06.2014

A

Sig. WEISS_M

20.10.2014

KAUFMANN_W

20.10.2014

STAEHLI_P

Ersatz für Replacement for Revision vom / date

°C

Seite 1 von 1 Page 1 of 1 gedruckt / printed: 15.12.2014

PA_XX_0051a_02

Dimensional accuracy of spirit level:

Fig. 8-34 Example sheet for frame alignment

Table of clearances see section “Compressor” in chapter 13 Appendix.

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8.7.7

Tightening Methods Please note that just a few methods mentioned here are used on your compressor.

Tightening torques for nuts, screws and bolts that are not specified in the “List of Tightening Torques” in chapter 13 Appendix are to be handled according to section 8.5.1 Tightening Torques and Method.

Preparation

Lubricant Tightening Method II

• •

Clean areas of support (connecting parts) free of grease

•

MOLYKOTE® G-N Plus

Bolted Connections with Specified Torque Values

• • • Tightening Method III

Tightening Method IV

Tightening Method VI

Tightening is done using a torque wrench. If required, use a multiplier with the torque wrench. Torque wrenches are to be calibrated periodically.

Bolted Connections with Specified Torsion Angle

•

Without using force, manually tighten nut several times until the connection is well set.

•

To be able to tighten nut up to specified angle, use wrench extension. For higher values, use extension or multiplier.

Bolted Connections with Specified Bolt Elongation

• • Tightening Method V

Apply lubricant to gliding surfaces of bolt (thread, head support and nut support)

Check length of bolt before tightening. Tighten nut until the bolt elongation is as specified.

SUPERBOLT®

•

For tightening of SUPERBOLT® tensioner on crankgear and/or frame see section 8.7.8 Tensioner SUPERBOLT®.

•

For tightening of piston nut SUPERBOLT® see section 8.9.4 Piston Nut SUPERBOLT®.

Bolted Connections with Specified Hydraulic Pressure

•

Tighten nut according to specified hydraulic pressure.

For mandatory tightening torques, appropriate tightening methods and applicable lubricants: see section “Compressor” in chapter 13 Appendix.

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8.7.8

Tensioner SUPERBOLT®

XA_M0_0006a_01

(Tightening Method V)

Fig. 8-35 SUPERBOLT® Tensioner

Description

This section of the Instruction Manual gives directions for the use of SUPERBOLT® nuts at the exterior and in the crankgear of compressors. The nut must be tightened carefully with the supplied tools (see following section “Tightening Procedure”). The nut is prelubricated with the lubricant MOLYKOTE® G-N Plus. The stamped tightening torque applies for this lubricant only. CAUTION Please contact our Customer Support Service in case: • a unlubricated connection is required, • the admitted lubricant MOLYKOTE® G-N Plus is not available.

Maintenance and Revisions

SUPERBOLT® tensioners do not loose their preload force even after several years in service providing that they are correctly tightened. Nevertheless, we recommend to check the preload force during each revision. Use a torque wrench adjusted to 100 % of the permitted tightening torque. Should some pressure screws unexpectedly have lost some of the preload force the following procedure is recommended: 1. Relieve tension of the tensioner slightly by loosening the pressure screws (1/4 turn only) according to following section “Loosening Procedure”. Thus, the tensioner remains tensioned. 2. Now tense according to following section “Tightening Procedure”, i.e. tighten in circular sequence with full tightening torque, until all pressure screws are tightened.

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Preventive Maintenance

i.e. removal for maintenance purposes: 1. Relieve according to following section “Loosening Procedure”. 2. Treat thread and end of pressure screws with admitted lubricant. 3. A hardened washer may be re-used only once! Before re-installing a used hardened washer by turning it over, •

thoroughly deburr the previously used side with a grinding stone

•

check the hardened washer for indentations. Eliminate indentations by dressing washer with a grinding stone.

4. Tighten again according to following section “Tightening Procedure”. Loosening Procedure

Loosening requires an exact procedure. The pressure screws must be relieved stepwise! Never relieve single screws completely. The remaining screws would have to carry the entire load, which would make it difficult to loosen them. In extreme cases, the pressure screws could jolt and make loosening impossible! 1. Starting with no. 1, loosen every pressure screw in circular sequence by 1/4 turn at most. Do not loosen beyond break loose point. After the first round, pressure screw no. 1 will again be tightened, however, on a lower level of loading.

1/4

1 8

2

2. Repeat step 1 in a 2nd round. 3. Repeat step 1 in a 3rd round.

3

6

4 5

XA_T9_0023a_01

7

4. Relieve pressure screws completely. Now the tensioner can be removed by hand.

Fig. 8-36 Loosening of pressure screws

CAUTION Follow previous section “Preventive Maintenance” and the following section “Trouble Shooting” before reusing the pressure screws!

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Preventive Maintenance Compressor in General

Tightening Procedure Required Tools

• • •

Torque wrench Socket

XA_T9_0016a_01

Lubricant MOLYKOTE® G-N Plus

Fig. 8-37 Required tools

The marked tightening torque is the maximum permitted value. For applicable tightening torques: see section “Compressor” in chapter 13 Appendix.

Preparation Make sure that:

• •

pressure screws do not protrude from the nut. pressure screws are well lubricated.

Procedure

3

1 2 3 4 X

4

Hardened washer Pressure screw Bolt SUPERBOLT® tensioner Gap approx. 1–3 mm

XA_T9_0017b_02

2

X

1

Fig. 8-38 Gap “X”

1. Clean main thread and contact areas. 2. Lubricate main thread and contact areas with admitted lubricant. 3. Firmly tighten the tensioner by hand. 4. Afterwards turn back approx. 1/4 turn. Depending on size the gap will be approx. 1–3 mm.

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The tightening must take place gradually:

1

1 8

4

7 XA_T9_0019a_01

3

2

2

Fig. 8-39 Tighten 4 pressure screws

3

6

XA_T9_0020a_01

Tightening of Nuts Having 8 (Eight) Pressure Screws

4 5

Fig. 8-40 Tighten all pressure screws

1. Tighten 4 pressure screws crosswise with 50 % of the recommended tightening torque. 2. Tighten the same 4 pressure screws crosswise with 100 %. 3. Now change to circular tightening and tighten all pressure screws with 100 % until all pressure screws are equally tightened. The tightening must take place gradually:

1

2

3

XA_T9_0021a_01

1

Fig. 8-41 Tighten 3 pressure screws

6

2

5

3

4

XA_T9_0022a_01

Tightening of Nuts Having 6 (Six) Pressure Screws

Fig. 8-42 Tighten all pressure screws

1. Tighten 3 pressure screws with 50 % of the recommended tightening torque. 2. Tighten the same 3 pressure screws with 100 %. 3. Now change to circular tightening and tighten all pressure screws with 100 % until all pressure screws are equally tightened. Trouble Shooting

Pressure Screws Cannot Be Loosened 1. Try to free at least one pressure screw. 2. Remove pressure screw, lubricate with admitted lubricant and tighten with 110 % of the permitted tightening torque.

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Preventive Maintenance Compressor in General

3. The two neighboring pressure screws should become free. Remove these two pressure screws, lubricate and tighten with 110 %. 4. The next two pressure screws should become free. 5. And so on. 6. Afterwards relieve all pressure screws according to previous section “Loosening Procedure”. Hardened Washers Are Damaged, i.e. after a Long Time in Service Exchange against original (OEM) hardened washers SUPERBOLT®. Pressure Screws Are Damaged or Missing Exchange against original (OEM) pressure screws SUPERBOLT®. CAUTION Do not use commercial screws because they are not suitable for such high loads!

Other Problems? Please contact Burckhardt Compression Services (address see section 1.6 Contact Address).

8.7.9

Locking of Threaded Connections with LOCTITE® LOCTITE® screw locks are one-component adhesives in liquid or semisolid form. They prevent the loss of preload and secure screw connections against loosening caused by vibration and shock loads. The applied product quality for each locked bolted connection is given by the corresponding tightening specification. For detailed information about the fields of application of LOCTITE® products, please refer to the manufacturer’s data sheets, e.g. on the Internet.

LOCTITE® can only be stored for a limited period of time. For complete information, see instruction on LOCTITE® bottle.

Apply LOCTITE® according to the following instructions: 1. Bolt and thread must be degreased thoroughly, if possible with chlorothene or with gasoline. 2. If the bolt was locked before using LOCTITE®, it should be replaced either by a new one or it should be thoroughly cleaned from all LOCTITE® residues using a wire brush. Also clean thread of nut from all LOCTITE® residues.

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3. The greaseless bolt and nut must be absolutely dry, then fill in the liquid LOCTITE® into the thread turns. All turns of thread, (bolts and nuts) must be filled with LOCTITE®. 4. Screw in and tighten as specified. 5. Generally after 1 hour, threaded connections locked by LOCTITE® are ready for operation. For complete information, see instruction on LOCTITE® bottle. Loosening of locked threaded connections is best done by heating them up, since LOCTITE® disintegrates at about 200 °C.

8.7.10

NORD-LOCK® Securing System The NORD-LOCK® securing system consists of a pair of washers with a wedge-locking action meeting DIN 25201. This method uses tension instead of friction. NORD-LOCK® washer pairs positively lock fasteners in a joint which is subjected to vibrations or dynamic loads. Therefore a NORD-LOCK® washer pair may be used only once! CAUTION Wrong installation/reuse of NORD-LOCK® washer pair Cap nut or nut for valve rotates loose. Damage to valves and loss of capacity possible.  Use NORD-LOCK® washer pairs only once!  Install new, unused NORD-LOCK® washer pair every time a cap nut or nut for valves is loosened.  Follow the instructions in this Instruction Manual.

XA_CX_0040a-01

If correctly installed (see Fig. 8-43, Fig. 8-44 and Fig. 8-45), the NORDLOCK® washer is locked in place, only allowing movement across the face of the cams. Any attempt from the bolt/nut to rotate loose is blocked by the wedge effect of the cams. The rise of the cams between the NORD-LOCK® washers () is greater than the pitch of the bolt (). In addition, there are radial teeth on the opposite side. The washers are installed in pairs, cam face to cam face. = locking effect

Fig. 8-43 NORD-LOCK® locking principle

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1 2

2

XA_CX_0074b_01

1

XA_CX_0039b_01

Preventive Maintenance Compressor in General

Cams Radial teeth

Fig. 8-44 NORD-LOCK® washer pair

Fig. 8-45 Correct assembly of NORDLOCK® washer pairs

For lubrication of bolts, please refer to section 8.7.7 Tightening Methods.

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Preventive Maintenance Crankgear

8.8.1

Crankgear Check Crankshaft Deflection 2

y

1

XA_M0_0009b_01

8.8

4

3

Fig. 8-46 Measure crankshaft deflection

1 2 3

Prerequisites

Measuring Procedure

Crank in 12 o’clock position Crankshaft Measuring position of dial indicator

4 y

Dial indicator Measuring distance (y) in mm

•

Set the dial indicator (4) always at the same position (y), at the end of the crank (opposite crankshaft journal).

•

The crankshaft must be properly supported by its bearings (check with a feeler gauge).

• •

Connecting rod on the drive end must be dismounted. Use a dial indicator with an accuracy of 0.01 mm.

1. Measure the crankshaft deflection on the drive end crank in 4 positions according to Fig. 8-46. Record all measured values as well as the measuring position (y) – i.e. offset from crankshaft journal – of the dial indicator.

 For maximum permissible deflection on the dial indicator for a complete turn of crankshaft see Fig. 8-47.

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Preventive Maintenance Crankgear

CD/mm 0.07 0.06 0.05 0.04

0.02 0.01 y/mm 0

100

200

300

400

PA_M0_0001b_1

0.03

Fig. 8-47 Maximum permissible crankshaft deflection CD Crankshaft deflection in mm y Measuring distance (y) in mm

2. If the deflection exceeds this limit, consult Burckhardt Compression Services; address see section 1.6 Contact Address.

8.8.2

Main Bearing and Connecting Rod Bearing The bearings do not normally call for any maintenance. With regular oil changes they sustain only slight wear. We recommend that the bearings are not checked too often by dismantling. Reliable inspection is possible without removal:

• •

measure the clearance between the bearing and crankshaft journal, check oil tank, crankgear, oil strainer and/or duplex oil filter for deposits of white metal.

For applicable clearances see section “Compressor” in chapter 13 Appendix.

If abrasive components of the process gas get in the distance piece/crankgear, they may cause excessive wear of bearings. Consult Burckhardt Compression Services, address see section 1.6 Contact Address.

8.8.3

Crankshaft Seal The crankshaft seal is fitted at the drive end of the compressor and prevents

• •

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oil from leaking to the surrounding area (inner ring) dirt from entering the crankgear (outer ring).

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1 2 3

4 5

7

PB_M1_0002b_01

6

Fig. 8-48 Components of crankshaft seal

1 2 3 4

Flat gasket Fastening bolt 2-piece oil trap cover Allen screw

5 6 7

2-piece cover Centering pin Seal ring (2 pieces)

The seal must be replaced if it has grown brittle and therefore leaky. It cannot be replaced without disassembling the flywheel. If, for any reason, the main motor is removed, the seal should be replaced as well. The shaft seal may begin to leak after a while due to heat and poor crankgear ventilation. This is due to the pump effect of the crosshead at altered ambient conditions (for example cooling, oil, and ambient temperatures) which may lead to somewhat increased pressure in the crankgear. Remedy: clean breather installed on frame cover.

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8.8.4

Connecting Rod Bearing 1 2

3 4 5

PB_M4_0010b_02

6

Fig. 8-49 Components of connecting rod

1 2 3

Connecting rod Crosshead pin bearing Connecting rod bearing

4 5 6

Connecting rod cover Tensioner SUPERBOLT® Threaded bolt

Apart from the maintenance work specified in the maintenance schedule, no special maintenance of the connecting rod is required. The connecting rod bolts must be tightened to a certain elongation (). For applicable tightening torque (elongation) see section “Compressor” in chapter 13 Appendix. We recommend, checking the correct tightening of the connecting rod bolts periodically, every 16000 operating hours. WARNING Loose connecting rod bolts! After a liquid knock, the connecting rod bolts must be checked immediately for mandatory tightening torque!

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Check Connecting Rod Bearing Clearance

Measure clearance of connecting rod bearing. 1. Move the connecting rod in horizontal position by turning the crankshaft. 2. Measure vertical clearance: •

By means of a feeler gauge Measure the clearance outside the chamfer, at least 20 mm from center line (see Fig. 8-50)

•

By means of a dial gauge Lift up connecting rod and measure the clearance with the dialgauge (see Fig. 8-50)

20

20

PA_M4_0014b_02

1

Fig. 8-50 Connecting rod bearing 1

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Dial gauge

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3. Lift up connecting rod by halve the value of measured vertical clearance and maintain connecting rod in this position. 4. Push the connecting rod forward and backward and measure the horizontal clearance on the dial gauge (Fig. 8-51). Compare it with bearing table. 5. Measuring horizontal clearance using feeler gauge, push connecting rod only in one direction and measure the horizontal clearance. Compare it with bearing table.

PA_M4_0013b_01

1

X

Fig. 8-51 Connecting rod bearing 1

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Dial gauge

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8.8.5

Crosshead

1

2

6

4

PB_M3_0036b_01

5

3

Fig. 8-52 Crosshead

1 2 3

Clearance Check

Crosshead shoe Crosshead Set collar

4 5 6

Set screw Circlip Crosshead pin

1. Move connecting rod/crosshead in Top Dead Center (TDC) by turning the crankshaft. 2. Check clearance between crosshead and crosshead bore with the feeler gauge. 3. Move connecting rod/crosshead in Bottom Dead Center (BDC) by turning the crankshaft. 4. Check clearance between crosshead and crosshead bore with the feeler gauge. 5. Keep a record of measured clearances in a log sheet.

For applicable clearances see section “Compressor” in chapter 13 Appendix.

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Clearance Check

Crosshead Pin Bearing The crosshead pin bearing clearance can only be checked in running direction of the piston (Fig. 8-53). The piston/piston rod must be removed.

1

2

PA_M3_0009b_03

8.8.6

3

Fig. 8-53 Crosshead pin bearing 1 2 3

Jackscrew Dial gauge Dial gauge

1. Move connecting rod/crosshead in Top Dead Center (TDC) by turning the crankshaft. 2. Secure connecting rod in this position, for example, with a jackscrew (1). 3. Place dial gauge according to position (2) against connecting rodbearing cover. 4. Place dial gauge according to position (3) against crosshead. 5. Move crosshead forward and backward to its running direction. 6. Read the horizontal clearance of the crosshead pin bearing on dialgauge (3). The hand of the dial gauge (2) must remain at zero position.

For applicable clearances see section “Compressor” in chapter 13 Appendix.

8.8.7 Check Distance Piece Packing Ring Clearance

Distance Piece Packing The distance piece packing is installed in the separating plate of the two distance piece chambers (see Fig. 8-54). The packing rings of the distance piece packing can be dismantled/replaced, without removing the piston rod.

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The description in section 8.9.2 Piston Rod Packing concerning the assembly of the packing of “Zone C” also apply to the distance piece packing. 1 2 3 4

9

8

7

PB_M6_0002b_03

5

6

Fig. 8-54 Distance piece packing (typical view)

1 2 3 4 5

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Housing Cylindrical pin O-ring Cover Garter spring

2B1XC2.64_1

6 7 8 9

Seal element (step bridge cut) Pressure ring Spring Material code

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8.8.8

Oil Scraper As the oil-free operation (if without cylinder lubrication) of the compressor depends to a large extent on the satisfactory condition of the wiper elements and the way they are assembled, these rings must be handled with great care. The same applies to the surface of the piston rod in the area of the wiper elements. The wiper elements shall not show any sign of damage and must lie snug against the piston rod along their entire circumference. The scraping edge (3) must be as sharp as possible (Fig. 8-55). The assembled wiper elements must have a slight pretension when pushed onto the piston rod.

1

2

3

4

7

1

6

PB_M5_0007c_01

Inspection of Wiper Elements

5

9

8

Fig. 8-55 Oil scraper

1 2 3 4 5

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Rollpin Garter spring Scraping edge Contact area Seal element

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6 7 8 9

Wiper element Support ring Cylinder side Crankgear side

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8.9 8.9.1

Cylinder Piston Rod • •

Check piston rod for any surface defects. Check the piston rod for transfer film.

Sometimes it is possible to overhaul replaced piston rods. To assure operational safety of an overhauled piston rod, only perform overhauls after consultation with Burckhardt Compression Services.

8.9.2

Piston Rod Packing The packing rings must be inspected every year by dismantling the piston and piston rod. Inspections at shorter intervals are recommended in case there are the following indications that the rings are badly worn:

• • • • Packing Cups and Rings

leakage of process gas into the distance piece below the packing, reduced discharge rate, changes in the intermediate pressure, increase of packing temperature, etc.

The packing cups are marked with numbers (see Fig. 8-56, Pos. 1). Cups of the same design have the same numbers.

For exact configuration of packing rings see section 9.13.4 Assemble the Piston Rod Packing.

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1st Stage

5

4

3

2.2

1

1

2

B2

B1

A

PB_C5_0081a_02

C

Fig. 8-56 Piston rod packing 1st stage

A B C

Zone A Zone B Zone C

1 2

Markings Gas flow

Zone

C [mm]

B2 [mm]

B1 [mm]

A [mm]

Axial clearance

0.700–0.902

0.300–0.493

0.300–0.493

0.100–0.230

Tab. 8-2

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Axial clearances of packing rings 1st stage

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WARNING Wrongly modified or non-genuine spare parts. Operational safety may be impaired!  Do neither modify parts nor spare parts.  Do not use unsuitable material.  Do not influence clearances on compressor.  Eliminate troubles immediately.  Exchange worn parts.

8.9.3 Check the Pretension of Piston Crowns

Piston The pretension of the piston crowns to the piston skirt is measured when a piston part is replaced or after the interval indicated on the maintenance schedule. This applies also, if a piston nut came loose. Pretension is the value by which the piston crowns are bent inwards when the piston nut is tightened, thereby clamping the piston skirt. Measure distance “A” with the piston crowns clamped together without the piston skirt as shown in the following figure. Pretension = Dimension B - Dimension A A

PB_C1_0022b_01

B

1

2

3

4

5

6

Fig. 8-57 Piston pretension (typical view)

1 2 3

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Lower piston crown Centering ring Piston rod

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4 5 6

Piston nut SUPERBOLT® Upper piston crown Piston skirt

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Stage (Compressor)

Dia. nominal of piston (mm)

Pretension (mm)

1st stage

640

0.08 – 0.54

Tab. 8-3

Piston pretension (3-piece piston)

WARNING Risk of piston seizure or loose piston skirt!  The measured values must be within the tolerances given above.  Tighten piston nut in accordance with section 8.9.4 Piston Nut SUPERBOLT®.

Measure Cylinder Clearance

Option for measuring: You can also measure the cylinder clearances by using a feeler gauge.  Position the piston in the top or bottom dead center.  Insert the feeler gauge into the chamber of the cylinder.

CAUTION Use of wrong lead wire Wrongly measured or adjusted cylinder clearances can cause major compressor failure.  Use lead wire of appropriate thickness or use a feeler gauge.  Using too thick lead wire can lead to wrong measurement of cylinder clearance.

6. Check the cylinder clearance according to section 8.7.3 Cylinder Clearance Measurement. Record measured values in the compressor check list of section 8.7.4 Clearance Measurement Log Sheet. Measure Wear of Piston Rings

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1. Check the gap “Y” by inserting the piston rings into the cylinder.

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Fig. 8-58 Piston rings inserted into cylinder

Y

Y Y 1

2

PB_C1_0083b_01

1

Fig. 8-59 Gap “Y” of piston rings 1 2

Piston ring with scarf joint Guide ring (rider ring)

2. Check the wear of the piston rings by measuring the radial thicknesses according to section “Compressor” in chapter 13 Appendix. 3. Check the dimension of the running surface at the cylinder liner according to section “Compressor” in chapter 13 Appendix. 4. Check the condition of the running surface at the cylinder liner according to section “Compressor” in chapter 13 Appendix. For details concerning piston ring assembly see section 9.11.5 Piston Rings.

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8.9.4

Piston Nut SUPERBOLT®

Fig. 8-60 Piston nut SUPERBOLT®

1 2 3 4

Admitted lubricant Pressure screw Groove for O-ring (used with contaminated gas) Hardened washer

5 6 7 8

Size Bore for piston nut wrench Tightening torque with MOLYKOTE® G-N Plus Piston nut SUPERBOLT®

Piston nuts SUPERBOLT® do not loose their preload force even after several years in service providing that they are correctly tightened. Nevertheless, we recommend to check the preload force during each revision. Use a torque wrench adjusted to 100 % of the permitted tightening torque. Should some pressure screws unexpectedly have lost some of the preload force the following procedure is recommended: 1. Relieve tension of the piston nut slightly by loosening the pressure screws (1/4 turn only) according to following subsection “Loosening Procedure”. Thus, the nut remains tensioned. 2. Now tighten according to following subsection “Tightening Procedure”, i.e. tighten in circular sequence with full tightening torque, until all pressure screws are tightened. Preventive Maintenance

i.e. removal for maintenance purposes: 1. Relieve according to following section “Loosening Procedure”. 2. Treat thread and end of pressure screws with admitted lubricant. 3. A hardened washer may be re-used only once! Before re-installing a used hardened washer by turning it over,

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•

thoroughly deburr the previously used side with a grinding stone

•

check the hardened washer for indentations. Eliminate indentations by dressing washer with a grinding stone.

4. Tighten again according to following section “Tightening Procedure”. Loosening Procedure

Loosening requires an exact procedure. The pressure screws must be relieved stepwise! Under no circumstances relieve single screws completely. The remaining screws would have to carry the entire load, which would make it difficult to loosen them. In extreme cases, the pressure screws could jolt and make loosening impossible! 1. Starting with no. 1, loosen every pressure screw in circular sequence by 1/4 turn at most. Do not loosen beyond break loose point. After the first round, pressure screw no. 1 will again be tightened, however, on a lower level of loading. 2. Repeat step 1 in a 2nd round. 3. Repeat step 1 in a 3rd round.

1/4

4. Relieve pressure screws completely. Now the piston nut can be removed by hand or using the piston nut wrench.

1 8

2

3

6

4 5

XA_T9_0023a_01

7

Due to dirt or a pretensioned piston, it may still not be possible to loosen the piston nut. In this case, use the piston nut wrench carefully to loosen the nut.

Fig. 8-61 Loosening of pressure screws

Follow subsection “Trouble Shooting” in this section before reusing the pressure screws! Tightening Procedure

Required Tools

• • • •

Torque wrench Socket Extension for sockets Lubricant “MOLYKOTE® G-N Plus”

The marked tightening torque is the maximum permitted value. For applicable tightening torques: see section “Compressor” in chapter 13 Appendix.

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Preparation Make sure that:

• •

pressure screws do not protrude from the bottom of the nut, pressure screws are well lubricated.

Procedure 1. Clean main thread and contact areas. 2. Lubricate main thread and contact areas with admitted lubricant. 3. Tighten the piston nut manually.

1

6

5

4

3

LA_T9_0025b_01

X

2

Fig. 8-62 X = gap, approx. 1 mm

1 2 3

Groove for O-ring (with contaminated gas) Piston nut SUPERBOLT® Hardened washer

4 5 6

Piston rod Pressure screw Piston

4. Afterwards turn back approx. 1/4 turn. Depending on the piston size the gap “X” will be approx. 1 mm. If a small piston is used, the 1/4 turn backwards may eliminate the pretension partially or entirely (this does not affect the tightening procedure). Tightening of Piston Nuts Having 8 Pressure Screws

The tightening must take place gradually: 1. Tighten 4 pressure screws crosswise with 25 % of the recommended tightening torque. 2. Tighten the same 4 pressure screws crosswise with 50 %.

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3. Tighten the same 4 pressure screws crosswise with 100 %.

1

1 8

4

2

Fig. 8-63 Tighten 4 pressure screws

3

6

XA_T9_0020a_01

7 XA_T9_0019a_01

3

2

4 5

Fig. 8-64 Tighten all pressure screws

4. Tighten the remaining pressure screws crosswise with 50 % of the recommended tightening torque. 5. Repeat step 4 with 100 %. 6. Now change to circular tightening and tighten all pressure screws with 100 % until all pressure screws are equally tightened. Tightening of Piston Nuts Having 6 Pressure Screws

1. Tighten 3 pressure screws with 25 % of the recommended tightening torque. 2. Tighten the same 3 pressure screws with 50 %. 3. Tighten the same 3 pressure screws crosswise with 100 %.

XA_T9_0021a_01

2

3

Fig. 8-65 Tighten 3 pressure screws

6

2

5

3

4

XA_T9_0022a_01

1

1

Fig. 8-66 Tighten all pressure screws

4. Tighten the remaining pressure screws with 50 % of the recommended tightening torque. 5. Repeat step 4 with 100 %. 6. Now change to circular tightening and tighten all pressure screws with 100 % until all pressure screws are equally tightened.

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Trouble Shooting

Pressure Screws Cannot Be Loosened 1. Remove possible existing dirt from the piston and SUPERBOLT® piston nut. 2. In case of heavy contamination, apply anti seizing or anti corrosion spray to the SUPERBOLT® piston nut and wait approx. 12 hours until this agent has penetrated into the dirt. 3. Try to loosen at least one pressure screw. 4. Turn the loosened pressure screw back as far as possible and apply a lubrication penetrating agent/spray. 5. Tighten this pressure screw with 110 % of the nominal torque 6. The two neighboring pressure screws should loosen. 7. Turn these two pressure screws back as far as possible and apply a lubrication penetrating agent/spray. 8. Retighten these two pressure screws with 110 % of the nominal torque. 9. The next neighboring screws should now loosen. 10. For loosening the rest of the pressure screws proceed in the same manner as mentioned above (paragraphs 4 to 8). 11. For final loosening of all pressure screws proceed according to section “Loosening Procedure”. Hardened Washers Damaged After Multiple Assembly /Disassembly Exchange against original (OEM) hardened washers SUPERBOLT®. Pressure Screws Are Damaged or Missing Exchange against original (OEM) pressure screws SUPERBOLT®. CAUTION Do not use commercial screws because they are not suitable for such high loads!

Piston Nut Cannot Be Loosened Manually Residue caused by dirty process gases can obstruct the nut even though the pressure screws are loosened. In this case, use the piston nut wrench to loosen the piston nut carefully. Other Problems? Please contact Burckhardt Compression Services (address see section 1.6 Contact Address).

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Preventive Maintenance Suction Valves and Discharge Valves

8.10 8.10.1

Suction Valves and Discharge Valves Valve Maintenance Since the compressor valves are among the most delicate components of the compressor, they should be inspected every 6000–8000 hours of service at normal conditions i.e. continuous operation. If the compressor is not running continuously and/or with different gases, the valves must be inspected at shorter intervals. The intervals must be adjusted according operating experience and/or in cooperation with our specialists.

Valve Service CAUTION We strongly recommend having valve overhauls carried out by our specialists on site or in one of our Burckhardt Compression licensed Service Centers. We assume no liability for damage caused by inexpert valve overhauls. We also reject liability for wrongly assembled valves, or when non-genuine spare parts are used.

WARNING Wrongly modified or non-genuine spare parts. Operational safety may be impaired!  Do neither modify parts nor spare parts.  Do not use unsuitable material.  Do not influence clearances on compressor.  Eliminate troubles immediately.  Exchange worn parts.

Valves can be sent to the nearest Burckhardt Compression Service Center to be reconditioned at a competitive price. Address see section 1.6 Contact Address. For dismantling and assembling of valves see section 9.7 Suction Valves and Discharge Valves.

8.10.2

Valve Failures (Malfunction) If uniform service conditions are accompanied by pronounced fluctuations of the interstage pressure, this may indicate broken or clogged valve plates. The temperature fluctuations which follow a broken valve plate may lead to dangerous failures (malfunction) on the compressor. Therefore, defective valve components should be replaced as soon as they occur. If repeated valve failure (malfunction) occurs, the lift of the valves can be reduced or stronger springs be fitted. Such modifications are only to be carried out with Burckhardt Compression’s consent. Since computer programs

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can simulate valve behavior at a specific operating point within the operating range, therefore a set of actual readings (temperatures and pressures) is needed in order to determine the necessary modification. Possible Causes of Valve Failures (Malfunction)

• • • •

Dirt in the process gas lines

•

Controlled suction valve is blocked

Broken valve springs Broken parts of piston rod packing Gas pulsations

Incorrect valve assembly:

8.10.3

• • •

Loose pressure screws  loose valve lantern (broken valve guard)

•

Center cuts of metallic valve plate and damper plate for Burckhardt Plate Valve™ plate do not coincide (see section 9.7 Suction Valves and Discharge Valves).

•

Valve springs for Burckhardt Plate Valve™ not fitted correctly (see section 9.7 Suction Valves and Discharge Valves).

Loose nut of center bolt Valve seat of Burckhardt Plate Valve™ has been re-machined too much  pinhole has not sufficient depth (see section 9.7 Suction Valves and Discharge Valves).

Maintenance of Controlled Suction Valves The clearance “X” (see following illustration) between the tips of the finger unloader and the sealing element must be checked every time before fitting a valve. The fingers of the finger unloader should be adjusted to move freely through the gaps of the valve seat.

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Z

Y

X 3

2

A

B

LA_C3_0018b_02

1

Fig. 8-67 Tolerances and clearances of controlled Burckhardt Plate Valve™ (typical view)

A B 1 2 3

Instructions Regarding Failures (Malfunction) on Controlled Suction Valves

18.05.2016

Valve with metallic valve plates X Valve with non-metallic valve plates Y Non-metallic valve plate Z Damper plate Metallic valve plate

Clearance Clearance Clearance

Blocked suction valves on multi-stage compressors are bound to lead to changes in the interstage pressure and hence to dangerous temperature increases and overloading of the properly working stage. All moving valve components are to be given a light application of a process gas compatible grease.

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The purpose of the following is to indicate the faults which may occur, particularly in the case of the controlled suction valves. The measures to be taken to resolve them are also described briefly. 1. Irregular knocking (hammering) of the piston against the cylinder wall may be the result of the controlled suction valves not operating in the correct manner. This can lead to increased wear of piston. This is associated, in particular, with compressors with large piston diameters and a high pressure ratio. Dismantle the valves and check their compliance with the assembly instruction in this section. 2. Nitrogen supply pressure too low. 3. Differential pressure of control medium for suction valve actuator too low, e.g. back pressure from flare. 4. Even though the actuator operates in a uniform manner, the suction valve does not change to the no load position when the control medium pressure is off: Too much clearance “X” between the tips of the finger unloader and the sealing element (i.e. valve plate or valve disc or poppet), or too much clearance “Z” between pressure pin and pressure sleeve. Replace finger unloader and/or pressure pin or pressure sleeve. 5. One of the suction valves is blocked, i.e. the pressure pin does not move. Dismantle the actuator and the nipple and check pressure pin for ease of movement. Check guiding band and the STEPSEAL®. Replace it if needed. 6. After overhauls: Wrong valve assembly! Wrong actuator and/or pressure pin fitted. Check number and correct dimensions of springs (F) and check correct assembly mode of actuator piston according to table Tab. 9-1 in section 9.5 Suction Valve Actuator. Even though the controlled suction valve components are assembled correctly and control medium pressure is correct, they do not switch from no load to load position or vice versa. This symptom could occur when the complete built length (total assembly) in installed condition is not correct (Distance “Z” in Fig. 8-67). Check for the correct thickness of the valve gasket, the correct length of the pins (see table Tab. 9-1 in section 9.5 Suction Valve Actuator, as well as pressure sleeve. It is advisable to assemble the complete control valve set, valve, lantern, gasket and actuator in a suitable compression device (i.e. press, large vise etc.). Use nitrogen or air to operate the actuator to verify the function of the controlled valve set.

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8.11

Complete Maintenance Commission compressor/plant according to instructions in section 6.2 Commissioning.

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Dismantle and Assemble Compressor Components

9 Dismantle and Assemble Compressor Components 9.1 9.2 9.3 9.4

Prerequisites and Safety Requirements . . . . . . . . . . . . . . . Switch Off Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Off Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.4.2 Dismantle Non-Return Valve . . . . . . . . . . . . . . . . 9.4.3 Assemble and Install Non-Return Valve . . . . . . . . 9.5 Suction Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.5.2 Piston Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Controlled Suction Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.6.2 Dismantle Controlled Suction Valve . . . . . . . . . . . 9.6.3 Assembly of Controlled Burckhardt Plate Valve™ 9.7 Suction Valves and Discharge Valves. . . . . . . . . . . . . . . . . 9.7.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.7.2 Dismantle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7.3 Disassembly and Repair of Burckhardt Plate Valve™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7.4 Assembly of Burckhardt Plate Valve™ . . . . . . . . . 9.7.5 Installing the Valve . . . . . . . . . . . . . . . . . . . . . . . . 9.8 Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.8.2 Dismantle Cylinder Cover. . . . . . . . . . . . . . . . . . . 9.8.3 Install Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . 9.9 Frame Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.9.2 Dismantle and Assemble Frame Covers . . . . . . . 9.10 Drain Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.10.2 Drain and Refill Lubricating Oil . . . . . . . . . . . . . . . 9.11 Piston and Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.11.2 Dismantle Piston and Piston Rod . . . . . . . . . . . . . 9.11.3 Dismantle the Piston. . . . . . . . . . . . . . . . . . . . . . . 9.11.4 Assemble the 3-Piece Piston . . . . . . . . . . . . . . . . 9.11.5 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.6 Install Piston and Piston Rod . . . . . . . . . . . . . . . . 9.11.7 Adjust Piston Rod Runout . . . . . . . . . . . . . . . . . . 9.11.8 Piston Rod Monitoring . . . . . . . . . . . . . . . . . . . . . 9.11.9 Measure the Cylinder Clearance . . . . . . . . . . . . . 9.12 Internal Pipes (Distance Piece) . . . . . . . . . . . . . . . . . . . . .

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9-5 9-5 9-6 9-6 9-6 9-6 9-6 9-6 9-6 9-8 9 - 15 9 - 15 9 - 15 9 - 15 9 - 20 9 - 20 9 - 24 9 - 33 9 - 37 9 - 41 9 - 56 9 - 56 9 - 56 9 - 58 9 - 59 9 - 59 9 - 59 9 - 60 9 - 60 9 - 60 9 - 61 9 - 61 9 - 62 9 - 65 9 - 65 9 - 70 9 - 73 9 - 81 9 - 84 9 - 86 9 - 87

9–1

Dismantle and Assemble Compressor Components

9.13

9.14 9.15

9.16

9.17

9.18

9.19

9.20

9.21

9.22

9.23

9–2

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9.12.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.12.2 Dismantle and Assemble Internal Pipes . . . . . . . . Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.13.2 Piston Rod Packing Design . . . . . . . . . . . . . . . . . . 9.13.3 Dismantle the Piston Rod Packing . . . . . . . . . . . . 9.13.4 Assemble the Piston Rod Packing . . . . . . . . . . . . External Gas Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.15.2 Dismantle and Assemble Cylinder. . . . . . . . . . . . . 9.15.3 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distance Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.16.2 Dismantle and Install Distance Piece . . . . . . . . . . Distance Piece Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.17.2 Dismantle and Assemble Distance Piece Packing Oil Scraping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.18.2 Dismantle the Wiper Elements . . . . . . . . . . . . . . . 9.18.3 Assemble the Wiper Elements . . . . . . . . . . . . . . . Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.19.2 Dismantle the Connecting Rod Bearing . . . . . . . . 9.19.3 Assemble the Connecting Rod Bearing. . . . . . . . . Crosshead and Connecting Rod . . . . . . . . . . . . . . . . . . . . . 9.20.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.20.2 Check the Clearance of Crosshead. . . . . . . . . . . . 9.20.3 Dismantle Connecting Rod and Crosshead . . . . . 9.20.4 Clearance of Connecting Rod Bearing . . . . . . . . . 9.20.5 Parallelism of Connecting Rod Bores . . . . . . . . . . 9.20.6 Rework of a New Crosshead. . . . . . . . . . . . . . . . . 9.20.7 Assemble Connecting Rod and Crosshead. . . . . . Crosshead Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.21.2 Dismantle the Crosshead Pin Bearing. . . . . . . . . . 9.21.3 Assemble the Crosshead Pin Bearing. . . . . . . . . . 9.21.4 Check Clearance of Crosshead Pin Bearing . . . . . Gear Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.22.2 Dismantle Gear Oil Pump . . . . . . . . . . . . . . . . . . . 9.22.3 Assemble Gear Oil Pump . . . . . . . . . . . . . . . . . . . Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23.1 Status and Special Tools . . . . . . . . . . . . . . . . . . . . 9.23.2 Dismantle Electric Motor . . . . . . . . . . . . . . . . . . . .

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9.23.3 Assemble Electric Motor. . . . . . . . . . . . . . . . . . . . 9.24 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.24.2 Transport and Lifting of the Flywheel . . . . . . . . . . 9.24.3 Dismantle the Flywheel . . . . . . . . . . . . . . . . . . . . 9.24.4 Assemble the Flywheel. . . . . . . . . . . . . . . . . . . . . 9.25 Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.25.2 Dismantle and Assemble the Crankshaft Seal . . . 9.25.3 Trigger Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.26.2 General Checks for Fitting New Bearings . . . . . . 9.27 Crankshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.27.2 Dismantle Crankshaft Bearing . . . . . . . . . . . . . . . 9.27.3 Assemble Crankshaft Bearing . . . . . . . . . . . . . . . 9.27.4 Measuring the Clearance . . . . . . . . . . . . . . . . . . . 9.28 Axial Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28.1 Status and Special Tools. . . . . . . . . . . . . . . . . . . . 9.28.2 Dismantle Axial Bearing . . . . . . . . . . . . . . . . . . . . 9.28.3 Assemble Axial Bearing . . . . . . . . . . . . . . . . . . . . 9.29 Dismantle Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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9–3

Dismantle and Assemble Compressor Components

9–4

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Dismantle and Assemble Compressor Components Prerequisites and Safety Requirements

9.1

Prerequisites and Safety Requirements

Chapter Structure

The structure of this chapter follows a step by step philosophy to explain the complete dismantling or assembling. It starts with the procedure to switch off the compressor and ends up with the dismantling of the crankshaft as the last unit.

Prerequisites before Dismantling

Before you start any inspection or repair activity take all safety measures according to section 8.2 Prerequisites for Maintenance. DANGER Unintended start-up of compressor is possible!  Before beginning any inspection or repair, switch off the power at the switch box and padlock the switch in the OFF position.

Prerequisites before Assembly CAUTION Contamination of process gas! All components coming in contact with process gas must be checked for cleanliness prior to their installation.  When performing overhauls or exchanging spare parts, make sure that all significant surfaces have been cleaned according to the cleaning specification prior to assembly or installation.  If in doubt about cleanliness, repeat cleaning procedure.

9.2 Status Special Tools Switch Off

Switch Off Compressor Completed activities: none none 1. Switch off the compressor. 2. Before you start any maintenance or trouble shooting activity take all safety measures according to section 8.2 Prerequisites for Maintenance.

Required Checks

Switch On

Make sure, that:

•

the compressor and the surrounding plant components are in good condition,

• •

all compressor parts are fixed correctly and no personnel is staying within danger zones.

1. Re-insert the safety switch. 2. Start the compressor according to section “Control Description” in chapter 13 Appendix.

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9–5

Dismantle and Assemble Compressor Components Switch Off Cooling System

Final Checks

9.3 Status

See section “Control Description” in chapter 13 Appendix.

Switch Off Cooling System Completed activities:

• Special Tools Switch Off

9.2 Switch Off Compressor

none 1. Switch off the cooling system by turning the main switch to off position.

 The compressor is now switched off and ready for maintenance 2. If the dismantling of the coolant pipes is required, then drain the coolant. Please remember to collect the glycol mixture if used in your cooling system! Switch On and Final Checks

9.4 9.4.1 Status

Please see section 5.16.2 Cooling System.

Non-Return Valve Status and Special Tools Completed activities:

• Special Tools

9.4.2

9.2 Switch Off Compressor

none

Dismantle Non-Return Valve Dismantle the non-return valve according to manufacturer’s instructions.

9.4.3

Assemble and Install Non-Return Valve Assemble and install the non-return valve according to manufacturer’s instructions.

9.5 9.5.1 Status

Suction Valve Actuator Status and Special Tools Completed activities:

•

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9.2 Switch Off Compressor

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Small hook or prepared screw driver as shown in Fig. 9-1.

XA_C3_0011a_01

Special Tools

Fig. 9-1

Special tool

2

XA_T9_0030b_01

1

Fig. 9-2 1 2

Mounting device for TURCITE® STEPSEAL®

Bar Bush

T97182: (can be ordered from Burckhardt Compression)

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9–7

Dismantle and Assemble Compressor Components Suction Valve Actuator

9.5.2

Piston Actuator

Dismantle Option (18)

19

1 17 16 15 3

Mode B

14 2 (F)

4 13 5 6 12 6 11

9 10 8 7

XA_C3_0053b_01

Option

Fig. 9-3

1 2 3 4 5 6 7 8 9 10

9–8

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Suction valve actuator

Cover to actuator Spring Piston ring GLYD Housing Vent valve TURCITE® STEPSEAL® Circlip (Option) Scraper ring (Option) O-Ring Nipple (guiding piece)

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11 12 13 14 15 16 17 18 19 F

Pressure pin Guiding band USIT ring Actuator piston (Mode B) O-Ring Screw Vent Position indicator (Option) Plug Lower spring

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Dismantle and Assemble Compressor Components Suction Valve Actuator

Dismantling Procedure 1. Disconnect piping of control medium. 2. Remove actuator from valve cover. 3. Mark position of cover to actuator (1) against housing (to remount the cover in the right position afterwards). 4. Remove 2 diametrically located screws (16) of cover to actuator (1). 5. Fit screws of extended length to handle the actuator spring(s) (2) being under tension. 6. Remove all screws (except the two long ones). 7. To release the tension of the spring(s), loosen the two long screws crosswise. 8. Mark/record position of piston (14) assembly, i.e. the assembly mode (A/B). 9. Record position of spring (F). 10. Remove piston (14) with pressure pin (11).

XA_C3_0012a_01

11. Disassemble the upper TURCITE® STEPSEAL® (6) as shown in (see Fig. 9-4). To remove the TURCITE® STEPSEAL® use a small hook or a prepared screw driver (see Fig. 9-1).

Fig. 9-4

Disassemble TURCITE® STEPSEAL®

12. Disassemble the lower TURCITE® STEPSEAL® (6) after you have removed the nipple (10) as shown in Fig. 9-4.

Do not reuse the dismantled notched ring, mount a new one.

13. If necessary: remove guiding band (12). Required Checks

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Check for correct dimensions and number of springs “F” and for correct assembly mode of actuator piston as follows:

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9–9

Dismantle and Assemble Compressor Components Suction Valve Actuator

1st Stage Spring

Pressure Pin

Item

Dimension in mm

C

-

D

-

F

4x40x71

Dia.

14

LT Actuator piston Tab. 9-1

345 Mode B

Dimensions of spring(s) for suction valve actuator

LT Total length of pressure pin (pin dismantled) Assemble New or Used Parts

Prior to assembly, slightly lubricate all parts exposed to friction.

1. Check all seals/O-rings and replace them if necessary. 2. If the piston ring GLYD (3) is worn, the complete piston (14) must be replaced. During loosening of the piston nut, do not damage pressure pin surface (11). 3. If the pressure pin (11) shows corrosion spots, polish or replace it. 4. Install new USIT ring (13) and piston (14) according to marked surface. 5. Consider correct mounting of TURCITE® STEPSEAL® by using the special mounting device (see Fig. 9-5).

Do not reuse a dismantled TURCITE® STEPSEAL®, mount a new one.

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Dismantle and Assemble Compressor Components Suction Valve Actuator

Fig. 9-5

Assembly device for TURCITE® STEPSEAL®

6. Install spring (2) and disk (if applicable) at its correct position. 7. Fit cover to actuator (1) by means of the screws with extended length. Required Checks

When the suction valve actuator is assembled, and before continuing with the installation, do the following checks: 1. Determine the clearance KVG (see Fig. 9-6) by using a depth gauge and compare value with Tab. 9-2. 2. Determine the reference dimension KS (see Fig. 9-6) and compare value with Tab. 9-2. Note: The actuator must be in the released state during this measurement. 1st Stage Item

Dimension in mm

Pressure Pin

KS

229.0

Clearance

KVG

233.3

Tab. 9-2

Dimensions for installation of suction valve actuator

KS Reference dimension of actuator when actuator is dismantled KVG Clearance between edge of valve cover and pressure sleeve for controlled suction valve

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Dismantle and Assemble Compressor Components Suction Valve Actuator

1st Stage

1

3

LT

4

KS

6

7

8

KVG

9

10

XA_C3_0028e_01

11

Fig. 9-6

Controlled suction valve with actuator (typical view)

LT Total length of pressure pin KS Reference dimension actuator KVGClearance valve cover–pressure sleeve 1 Cover to actuator 2 – 3 Housing 4 Pressure pin

Install Suction Valve Actuator

5 6 7 8 9 10 11

– Threaded bolt Pressure screw Valve cover Lantern Cylinder Controlled suction valve

1. Fit and tighten all screws. 2. Replace both long screws by the original ones. 3. Attach actuator to valve cover. 4. Connect the piping.

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Required Checks

Checks at Hydraulics and Pneumatics 1. Check connections for leakages.

1 2

3

PB_C3_0001b_02

4

Fig. 9-7 1 2 3 4

Water drain (cylinder: typical view)

Cylinder Actuator Plug with vent Vent downwards: water can drain off

2. Close unused connection for control pressure with plug. Mount actuator in a manner that water cannot enter and condensation water can drain off (downward, see Fig. 9-7). 3. Check differential pressure of control medium – pressure difference between above and below the actuator pistons – using a pressure gauge.

The differential pressure must reach at least the specified control pressure!

4. Check during released state: no differential pressure must be measured.

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Dismantle and Assemble Compressor Components Suction Valve Actuator

2

Fig. 9-8 1 2

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2

1

XA_C3_0069b_01

1st Stage

Connecting arrangement for one piston actuator operated by medium

Control medium line Equalizing line

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Dismantle and Assemble Compressor Components Controlled Suction Valve

9.6 9.6.1 Status

Controlled Suction Valve Status and Special Tools Completed activities:

• • Special Tools

9.6.2

9.2 Switch Off Compressor 9.5 Suction Valve Actuator

none

Dismantle Controlled Suction Valve DANGER Falling machine parts! Serious injury or death  Heavy equipment may only be lifted according to manufacturer’s instructions.  Do not stand underneath suspended loads.  Protect carrying ropes against sharp edges!

Carefully dismount controlled suction valves.

9.6.3

Assembly of Controlled Burckhardt Plate Valve™

Fig. 9-9

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Controlled Burckhardt Plate Valve™ (typical view)

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Dismantle and Assemble Compressor Components Controlled Suction Valve

Assembly of Controlled Suction Valve 1

2

3

14

4 5

13

12

11 6

10

7

LA_C3_0017b_01

8

9

Fig. 9-10 Components of controlled Burckhardt Plate Valve™ (typical view)

1 2 3 4 5 6 7

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Pressure sleeve Rollpin Cap nut Compression spring NORD-LOCK® washer pair Lift washer Valve spring

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8 9 10 11 12 13 14

Cylindrical pin Valve guard Center bolt Damper plate Valve plate Valve seat Finger unloader

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Dismantle and Assemble Compressor Components Controlled Suction Valve

Assemble New or Used Parts

For installation of NORD-LOCK® washer pairs see section 8.7.10 NORDLOCK® Securing System.

1. Check for correct parts (compression spring, finger unloader). 2. Clean all parts according to chapter 10 Clean and Degrease Plant and Compressor Components. 3. The suction valve must be assembled in accordance with section 9.7 Suction Valves and Discharge Valves, but without the hexagonal nut (will be substituted by cap nut). Assembly Procedure: 4. Assemble compression spring (Fig. 9-10, 4), finger unloader (14), NORD-LOCK® washer pair, and cap nut (3). 5. Tighten cap nut (3). For tightening torque refer to Tab. 9-4. 6. Consult enlarged view for correct fitting position of the rollpin (see Fig. 9-11). 7. Mount pressure sleeve (1) with rollpin (2).

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Dismantle and Assemble Compressor Components Controlled Suction Valve

1 2 3

GH

4

5 6

7

LA_C3_0019c_02

8

Fig. 9-11 Assembly sequence of controlled suction valve (typical view)

1 2 3 4 5

Pressure sleeve Rollpin Cap nut Finger unloader Compression spring

6 7 8 GH

NORD-LOCK® washer pair Valve seat Valve guard Overall length

Required Checks

The clearances X and Y must be checked every time before fitting a controlled suction valve.

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Dismantle and Assemble Compressor Components Controlled Suction Valve

Z

Y

X 3

2

A

B

LA_C3_0018b_02

1

Fig. 9-12 Tolerances and clearances of controlled Burckhardt Plate Valve™ (typical view)

A B 1 2 3

Valve with metallic valve plates X Valve with non-metallic valve plates Y Non-metallic valve plate Z Damper plate Metallic valve plate

Clearance Clearance Clearance

Checking Procedure: 1. Check clearances X and Y, compare with values of Tab. 9-3. 2. If clearance X or Y is beyond the tolerance, use space washers to meet the tolerances.

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9 – 19

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

3. Check overall length GH of assembled valve. 4. Functional check: actuate the controlled suction valve using a hand press or pneumatic device.

 The finger unloader must be able to completely open the valve. 1st Stage Dimension in mm Overall length

GH

173.7 Range

Clearance

X

1.2–2.2

Clearance

Z

1.0–6.0

Clearance

Y

0.3–0.8

Tab. 9-3

Dimensions of controlled suction valve

GH see Fig. 9-11

Clearance X, Y, Z see Fig. 9-12.

Thread size

9.7.1 Status

max.

min.

max.

M8

5

6

11

13

M10

11

13

21

26

M12

19

23

38

47

M16

42

53

95

116

M20

84

105

189

231

M24

126

158

315

368

IM 200322en

Tightening torques, only valid if “Burckhardt Lubrication Grease” BLG05

Suction Valves and Discharge Valves Status and Special Tools Completed activities:

• •

9 – 20

Torque for nut in Nm

min.

Tab. 9-4 is used

9.7

Center bolt torque in Nm

9.2 Switch Off Compressor 9.6 Controlled Suction Valve

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

XA_T9_0036a_01

Special Tools

PA_T9_0009a_01

Fig. 9-13 Pulling eye bolt

Fig. 9-14 Valve mounting spanner

1

11

2 10 9 3 8 4 5

7

6

2

4 11

PA_T9_0041c_01

3

Fig. 9-15 Valve dismantling and assembling device

1 2 3 4 5 6

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Bottom plate Additional guiding bar Guiding bar Guiding plate Mandril Clamping device (movable)

2B1XC2.64_1

7 8 9 10 11

Ratchet Pick-up disc Centering bolt Spindle Allen screw

IM 200322en

9 – 21

PB_T9_0077a_01

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

XA_T9_0051a_01

Fig. 9-16 Ratchet

Fig. 9-17 Stepped mandril

9 – 22

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

Recommended Tools (Not Delivered with Compressor)

Recommended: valve service device (for assembly and disassembly)

Fig. 9-18 Valve service device (T98000)

The valve service device can be ordered from our Spare Parts Division. The device is not included in the delivery. This tool has the following advantages:

• •

simple handling

•

following valves can be dismantled and assembled with this device:

it prevents the valve seat and valve guard as well as the valve plate and damper plate from twisting against each other. – – – –

• • •

18.05.2016

Burckhardt Plate Valve™ Burckhardt Poppet Valve™ Manley® Valve non-Burckhardt Compression valve

can be fixed in a simple bench vise noncorrosive design delivered in a handy transport box

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

9 – 23

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

9.7.2 Special Tools Dismantle

Dismantle Valve For special tools please refer to section 9.7.1 Status and Special Tools. Removal of Suction Valves (Top of Cylinder) 1. Remove cap nut for pressure screws. 2. Remove valve cover nuts. 3. Remove valve cover. 4. Remove gasket. 5. Remove lantern. CAUTION Heavy material! Cover, lantern and valve are heavy: Prevent them from falling down.  Don’t remove any nut from threaded bolt until lantern and valve are removed.

6. Install valve mounting spanner. 7. Remove valve. Removal of Discharge Valves (Bottom of Cylinder)

Vertical dismantling of discharge valves For cylinders with vertical dismantling of the discharge valves, the valve dismantling and assembling device is simplified: • no Allen screws for fixation of pick-up disc, • no additional guiding bar. These components are not needed and therefore not delivered with the valve dismantling and assembling for the corresponding stage(s).

WARNING Heavy valves and lanterns! Incorrect handling of valves and lanterns through inappropriate use of valve dismantling and assembling device may lead to defective equipment and malfunctioning of compressor/plant. In addition severe injuries are possible.  The valve dismantling and assembling device must be operated with care and technical expertise.  It is recommended that the tool is operated by 2 people.  In case of heavy valves and lanterns, 2 operators are a must.

Additional required tools:

9 – 24

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

In addition to the valve dismantling and assembling device, have the following tools at your disposal

• • •

1 Allen key: 8 mm,

•

MOLYKOTE® G-N Plus (for lubrication of the pick-up disc).

1 combination spanner: 24 mm, 1 combination spanner per stage, size: appropriate for the respective valve cover nuts,

Procedure: 1. Select the proper valve dismantling and assembling device for the valves to be dismantled. 2. Remove cap nut for pressure screws (if applicable). 3. Remove valve cover nuts. 4. Remove valve cover and gasket. 5. Fit the base unit of the valve dismantling and assembling device onto the bolts for the valve cover (see Fig. 9-19).

 The spindle (1) of the valve dismantling and assembling device must be on the bottom right or left. 6. Push the base plate (4) upwards (5) to its stop (perpendicular to valve cover bolts (see Fig. 9-19).

Reason: later on, the weight of the tool, valve and lantern will press the entire packet slightly down and the tool will be centered.

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2B1XC2.64_1

IM 200322en

9 – 25

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

7. Install valve cover nuts (2) to fix base unit of tool. 2

3

4

5

PB_T9_0091b_03

1

6

Fig. 9-19 Correctly installed base unit (spindle on bottom left)

1 2 3

Spindle 4 Nut (for valve cover, here used for 5 base plate) 6 Locking pin (for lantern)

Base plate Direction of pushing Guiding plate

8. Lubricate the thread and contact surfaces (3) of the pick-up disc (2) with the guiding plate (1) with MOLYKOTE® G-N Plus (see Fig. 9-20).

 The pick-up disc will be easily turnable.

9 – 26

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

9. Put the lubricated pick-up disc into the base unit. 1

2

PB_T9_0092c_02

3

Fig. 9-20 Install pick-up disc

1 2

Guiding plate Pick-up disc

3

Grease contact surface with MOLYKOTE® G-N Plus

10. Fit the additional guiding bar (Fig. 9-21, 2) to base plate and tighten slightly with a bolt. 2

PB_T9_0091c_03

1

Fig. 9-21 Fit additional guiding bar

1

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Rev. 001/kalajdzisa_a

Bore for bolt

2B1XC2.64_1

2

Additional guiding bar

IM 200322en

9 – 27

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

11. Push up guiding plate by hand and secure it with the movable clamping rings on the guiding bars. Then screw up the nut of the spindle (nut is below the guiding plate).

You may also move up the guiding plate with the ratchet.

12. Insert centering bolt (2) from below into pick-up disc (see Fig. 9-22). 2

PB_T9_0095b_02

1

Fig. 9-22 Insert centering bolt

1

Mandril

2

Centering bolt

13. Push the centering bolt (Fig. 9-23, 1) up to the valve center bolt (2) and screw it on by 2 or 3 turns with the mandril. 2

PB_T9_0096b_02

1

Fig. 9-23 Connect centering bolt to valve center bolt

1

9 – 28

IM 200322en

Centering bolt

2B1XC2.64_1

2

Valve center bolt

Rev. 001/kalajdzisa_a

18.05.2016

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

CAUTION Centering bolt screwed in too much! If the centering bolt is screwed right up to the valve center bolt, it may not be possible to loosen it later on. In addition, the center bolt of the valve may become loose and the valve risks to become disassembled while being dismantled.  Screw in centering bolt by 2 or 3 turns only!

14. Fit washer and nut (Fig. 9-24, 1) to centering bolt (at lower side of guiding plate) and tighten hand-tight.

PB_T9_0097b_02

1

Fig. 9-24 Tighten centering bolt 1

Washer and nut for centering bolt

15. Slightly move up the guiding plate (with lantern and valve) by 0.5 to 1.0mm – by turning the spindle with the ratchet.

 Lantern and valve become loose from the locking pin (2) and can be rotated. 2

3

4

PB_T9_0103b_02

1

Fig. 9-25 Lift guiding plate to unlock lantern

1 2

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Rev. 001/kalajdzisa_a

Pick-up disc Locking pin

2B1XC2.64_1

3 4

Lantern groove Base plate

IM 200322en

9 – 29

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

16. Carefully align the groove in the lantern (2) and the locking pin (1) in the cylinder by turning the guiding plate (including lantern and valve) with the big mandril. 2

PB_T9_0102b_02

1

Fig. 9-26 Align lantern groove and locking pin

1

Locking pin

2

Lantern groove

 Lantern and valve can be removed now. 17. Loosen clamping rings on guiding bars. 18. Begin to move down guiding plate (with lantern and valve) by turning down the nut on the spindle (Fig. 9-27, 1) with the ratchet. Stop immediately when the locking pin reaches the lantern groove.

2

PB_T9_0100c_02

19. Loosen the nut for the centering bolt (2).

1

Fig. 9-27 Loosen the nut for the centering bolt

1

Nut for spindle

2

Nut for centering bolt

 Lantern and valve can move more freely.

9 – 30

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

20. Slowly move down guiding plate (with lantern and valve) with the ratchet (Fig. 9-28, 2). 2

PB_T9_0099b_02

1

Fig. 9-28 Move down guiding plate with ratchet

1

Clamping ring (movable)

2

Ratchet

PB_T9_0104a_02

21. Loosen and remove the centering bolt with the mandril.

Fig. 9-29 Remove centering bolt

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9 – 31

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

3

2

1

PB_T9_0090b_03

22. Remove additional guiding bar (Fig. 9-30, 2) from base plate.

Fig. 9-30 Valve and lantern are dismantled

1 2

Valve Additional guiding bar

3

Lantern

23. Carefully remove valve (1) and then lantern (3). CAUTION Heavy material! Lantern and valve together are heavy: Prevent them from falling down.  Carefully remove them one at a time.

9 – 32

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

9.7.3 Special Tools

Disassembly and Repair of Burckhardt Plate Valve™ For special tools please refer to section 9.7.1 Status and Special Tools.

Disassembly of Valves This compressor is equipped with original Burckhardt Plate Valves™.

Fig. 9-31 Burckhardt Plate Valve™ (typical view)

XA_T9_0029a_02

1. Order the valve service device from Spare Parts division, including booklet on how to handle valves with this device or send defective valve(s) to the nearest Burckhardt Compression Service Center for repair. Contact address: see section .

Fig. 9-32 Incorrect handling

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9 – 33

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

Never clamp valve in a vise to disassemble or to loosen the locking nut from the center bolt.

2. Disassemble the valve according to the instructions provided with the valve service device. 3. With the NORD-LOCK® washer pair removed, separate the seat from the guard. Keep the seat and sealing elements the way they came apart. Required Checks after Dismantling

1. Clean all components. Use a cleaning fluid and a soft brush, taking particular care to free the ports of the seat and the guard from all foreign matter to ensure full seat area in operation. Never use wire brushes or tools with sharp edges to clean the seats and plates. 2. Check the valves, inspect individual components for damage and wear and replace them, if necessary. 3. Inspect lanterns, they shall not be cracked or have any damage to the seating faces. 4. Generally, the valve gaskets should be replaced. 5. Replace NORD-LOCK® washer pair with new, unused NORD-LOCK® washer pair every time a cap nut or nut for valves is loosened.

If valve components are only inspected but not replaced, they must be reassembled with the same valve seat and installed in the same location as before removal.

9 – 34

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

Repair of Valve Seats

If the accurately machined surfaces of the seal ridges on the valve seat become damaged due to hammering, etc., they can be machined on a lathe according to Tab. 9-5 and Fig. 9-33. C B A 3

D

1

2

3

4

0.5 mm

8

XA_CX_0043b_01

0.5 mm

Min.

N6

5

3

7

1

6

0.5 mm

0.5 mm

Fig. 9-33 Valve seat

1 2 3 4

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Rev. 001/kalajdzisa_a

Pinhole Tapped hole Seal ridge Discharge valve seat with tapped hole (new design)

2B1XC2.64_1

5 6 7 8

Discharge valve seat with tapped blind hole (old design) Suction valve seat Through boring Tapped blind hole

IM 200322en

9 – 35

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

Valve Plate Diameter [mm]

A [mm]

B [mm]

C [mm]

Min. [mm]

60–196

4.00

4.50

5.50

2.50

212–266

5.00

5.50

7.00

3.50

310

6.50

7.00

9.00

4.50

D = Re-machining of surface is not permitted Tab. 9-5

Re-machining limits

Re-machining quality of surface (3): N6 fine machined. Check pinhole (1) for sufficient depth, drill deeper if necessary.

For controlled suction valves only: check clearance X according to Tab. 9-3 in section 9.6.3 Assembly of Controlled Burckhardt Plate Valve™.

Repair of Valve and Damper Plates

Neither valve nor damper plates may be reworked, e.g. by grinding. Only lapping-in with the associated valve seat is possible.

9 – 36

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2B1XC2.64_1

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18.05.2016

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

Special Tools Key to Valve Type Designations

Assembly of Burckhardt Plate Valve™ For special tools please refer to section 9.7.1 Status and Special Tools. Example:

122.YYY.YYY.200 1

CSV 202 - 100 - BC - X - S - 80 - 32 - 300 - T

2

3

4

5

6

7

8

9

10

11

XA_CX_0008b_01

9.7.4

Fig. 9-34 Valve type designation

1 2

3 4 5 6

Number

Drawing number Valve: CSV = controlled suction valve, SV= suction valve, DV = discharge valve Valve size Pressure class Valve type: BC = Burckhardt Plate Valve TM Valve plate material: X = 5CrNiCuNb174, H = HASTELLOY C, I = Polyimid, F = FP, C = customized specification

Valve type

per stage

7

8 9 10 11

Size of thread for

Lift washer

center bolt

piece x mm

Type of damper plate: S = standard damper plate, P = Belleville damper plate, D = double damper plate, O = without damper plate Dia. spring wire (in 1/100 mm) Number of springs Lift (in 1/100 mm) Special design: S = standard, T = low temperature, I = indicator

Lift in mm

Spring

Wire dia. in mm

piece

1st Stage Suction

8

308-16-32-BC

M24

3 x 0.7

2.1

24

0.9

Discharge

8

308-16-32-BC

M24

3 x 0.7

2.1

24

0.9

Tab. 9-6

Valve design

If failures (malfunction) occur repeatedly, valve lifting can be reduced or stronger springs fitted. Such modifications are only to be carried out with our approval. Please contact Burckhardt Compression Services, address see 1.6 Contact Address.

General Remarks

Clean all parts according to chapter 10 Clean and Degrease Plant and Compressor Components.

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9 – 37

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

CAUTION Standstill damage possible! Due to the numerous possibilities of installation and employment of our compressors, instructions on preservation depend on application.  Please contact Burckhardt Compression Services, address see section 1.6 Contact Address.

The valve configuration was simulated by a computer program and optimized for each compressor/application. The configuration of the valve components is dictated by its application. Therefore, it is not advisable to change parts and configuration without consultation of Burckhardt Compression Services. The proper functioning of the valves depends largely on the correct assembly. The most important factors are the lift of the valve and the spring force of the valve springs. Required Checks

Check the marking “X5”: 1 HS 1 2

HS 2 HS 3

4

HS

5

XA_CX_0027b_01

3

Fig. 9-35 X5 Marking

1 2 3

Assemble New or Used Parts

Valve guard Damper plate Valve plate

4 Valve seat 5 Marking X5 HS Lift washer

Instruction for Fitting of Valve Springs To prevent the valve springs from rotating around their longitudinal axis during operation, they seat flush in the valve guard. Usually, these springs must be slightly pressed in when fitting into the appropriate spring guide. The springs must be adjusted vertically in the cylindrical part of the guide of the valve guard. Take care that they do not interfere with damper plate. For assembly, push the springs in a counterclockwise motion into the guide of the valve guard.

9 – 38

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

2

3

4

5

6

XA_CX_0028b_01

1

Fig. 9-36 Correct position of valve springs

1 2 3

Valve plate Incorrect position Valve guard

4 5 6

Spring Correct position Damper plate

It is essential, that valve parts are always assembled in accordance with the following instructions: Tab. 9-7 – For tightening torques Fig. 9-36 – For fitting of the valve springs The nuts must be tightened thoroughly.

For installation of NORD-LOCK® washer pairs see section 8.7.10 NORDLOCK® Securing System.

The center slanting cuts on valve and damper plates must coincide (see Fig. 9-37). 2

XA_CX_0030b_02

1

Fig. 9-37 Positioning of damper plate and valve plate 1 2

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Correct position Incorrect position

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2B1XC2.64_1

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9 – 39

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

Thread size

Center bolt torque in Nm

Torque for nut in Nm

min.

max.

min.

max.

M8

5

6

11

13

M10

11

13

21

26

M12

19

23

38

47

M16

42

53

95

116

M20

84

105

189

231

M24

126

158

315

368

Tab. 9-7 is used

Tightening torques, only valid if “Burckhardt Lubrication Grease” BLG05

1 2 3 4 5 6 7 8 9 10

A 1 2

3

Nut NORD-LOCK® washer pair Valve seat, suction side Valve plate Lift washers Center bolt Damper plate Cylindrical pin Springs Valve guard, suction side

4

5 6 7 5

10

XA_C2_0007b_01

8 9

Fig. 9-38 A Suction valve

9 – 40

IM 200322en

2B1XC2.64_1

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18.05.2016

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

1 2 3 4 5 6 7 8 9 10 11 12

B 1 2 11 9 8 5

Nut NORD-LOCK® washer pair – Valve plate Lift washers Center bolt Damper plate Cylindrical pin Springs – Valve guard, discharge side Valve seat, discharge side

7 6 5

12

XA_C4_0009b_01

4

Fig. 9-39 B Discharge valve

9.7.5 Special Tools Fit Valves into Cylinder

Installing the Valve For special tools please refer to section 9.7.1 Status and Special Tools. The sealing surfaces between the valves and the cylinders are lapped in. Avoid damages of the sealing surfaces during installation of valves. The lanterns on the suction side are shorter than those on the discharge side. Important General Remarks

XA_CX_0031a_01

STOP

Fig. 9-40 Correct installation of valves

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9 – 41

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

WARNING Wrongly installed valves can lead to compressor damage.

Observe the following information to install the valves on the correct side of the compressor:

•

A suction valve cannot be inserted in a valve cavity on the discharge side, because its diameter is larger than the diameter of a valve cavity on the discharge side.

•

A discharge valve, however, can be inserted into a valve cavity on the suction side, because its diameter is smaller than the diameter of a valve cavity on the suction side. A discharge valve that has been inserted into a valve cavity on the suction side can nonetheless not be properly installed, because its lantern can then not be moved into its correct position.

9 – 42

IM 200322en

• •

In suction valves, the center bolt is threaded in the guard.

•

Due to valve design, the lanterns for the suction side are shorter than those for the discharge side.

In discharge valves, the center bolt is threaded in the seat.

2B1XC2.64_1

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18.05.2016

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

S

G

D

1 2 3 4 5

ø<

ø>

6 7

PB_CX_0001b_01

8 G

Fig. 9-41 Suction valve diameter > discharge valve diameter

S D G Ø 1 2

Installed suction valve Installed discharge valve Gas flow Valve diameter Cap nut for pressure screw Pressure screw

3 4 5 6 7 8

Valve cover O-ring Discharge valve Lantern Suction valve Locking pin

Install Suction Valves 1. Insert valves with their lanterns into the correct valve cavities (use eye bolts). In general, proceed in reverse order to dismantling of suction valves.

 The inserted lantern must fit properly. The inserted lanterns must stand approx. 10 mm back from the cylinder face. Install Discharge Valves

Vertical installation of discharge valves For cylinders with a vertical installation of the discharge valves, the valve dismantling and assembling device is simplified: • no Allen screws for fixation of pick-up disc, • no additional guiding bar. These components are not needed and therefore not delivered with the valve dismantling and assembling for the corresponding stage(s).

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9 – 43

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

WARNING Heavy valves and lanterns! Incorrect handling of valves and lanterns through inappropriate use of valve dismantling and assembling device may lead to defective equipment and malfunctioning of compressor/plant. In addition severe injuries are possible.  The valve dismantling and assembling device must be operated with care and technical expertise.  It is recommended that the tool is operated by 2 people.  In case of heavy valves and lanterns, 2 operators are a must.

Additional required tools: In addition to the valve dismantling and assembling device, have the following tools at your disposal

• • •

1 Allen key: 8 mm,

•

MOLYKOTE® G-N Plus (for lubrication of the pick-up disc).

1 combination spanner: 24 mm, 1 combination spanner per stage, size: appropriate for the respective valve cover nuts,

Procedure: 1. Select the proper valve dismantling and assembling device for the valves to be dismantled. 2. Remove valve cover and gasket (if not already done). 3. Fit the base unit of the valve dismantling and assembling device onto the bolts for the valve cover (see Fig. 9-42).

 The spindle (1) of the valve dismantling and assembling device must be on the bottom right or left. 4. Push the base plate (4) upwards (5) to its stop (perpendicular to valve cover bolts (see Fig. 9-42).

Reason: later on, the weight of the tool, valve and lantern will press the entire packet slightly down and the tool will be centered.

9 – 44

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

5. Install valve cover nuts (2) to fix base unit of tool. 2

3

4

5

PB_T9_0091b_03

1

6

Fig. 9-42 Correctly installed base unit (spindle on bottom left)

1 2 3

Spindle Nut for valve cover Locking pin (for lantern)

4 5 6

Base plate Direction of pushing Guiding plate

6. Mark the position of the locking pin in the cylinder on the base plate with a felt tip pen.

 The marking facilitates inserting the lantern into the cylinder later on (locking pin – lantern groove). 7. Grease the thread and contact surfaces (see Fig. 9-43, 3) of the pickup disc (2) with MOLYKOTE® G-N Plus.

 The pick-up disc will be easily turnable. 8. Put the pick-up disc into the base unit as shown in Fig. 9-43. 9. Fix the pick-up disc to the guiding plate with 3 Allen screws (1).

The Allen screws will only be delivered for really heavy valves. If they are not delivered, it means that lantern and valve can be installed without them. Proceed with the next step.

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9 – 45

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

1

2

PB_T9_0092b_02

3

Fig. 9-43 Install pick-up disc

1 2

Allen screw Pick-up disc

3

Grease contact surface with MOLYKOTE® G-N Plus

 Lantern and valve will be more easily inserted into the cylinder because the tool is more stable. No getting jammed. 10. Put lantern (see Fig. 9-44, 1) on pick-up disc. 2

PB_T9_0093b_02

1

Fig. 9-44 Install lantern

1

Lantern

2

Groove

11. Carefully align the groove (see Fig. 9-44, 2) in the lantern and the locking pin in the cylinder.

9 – 46

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

PB_T9_0094a_02

12. Carefully put valve on lantern (see Fig. 9-45).

Fig. 9-45 Install valve

 The nut for the center bolt must face downwards. 13. Insert centering bolt (2) from below into pick-up disc (see Fig. 9-46). 2

PB_T9_0095b_02

1

Fig. 9-46 Insert centering bolt

1

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Mandril

2

2B1XC2.64_1

Centering bolt

IM 200322en

9 – 47

Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

14. Push the centering bolt (see Fig. 9-47, 1) up to the valve center bolt (2) and screw it on by 2 or 3 turns with the mandril. 2

PB_T9_0096b_02

1

Fig. 9-47 Connect centering bolt to valve center bolt

1

Centering bolt

•

2

Valve center bolt

It may be necessary to press lantern and valve upwards manually in order to fix the centering bolt of the tool to the thread of the valve center bolt.

CAUTION Centering bolt screwed in too much! If the centering bolt is screwed right up to the valve center bolt, it may not be possible to loosen it later on. In addition, the center bolt of the valve may become loose and the valve risks to become disassembled while being dismantled.  Screw in centering bolt by 2 or 3 turns only!

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15. Fit washer and nut (see Fig. 9-24, 1) to centering bolt (at lower side of guiding plate) and tighten hand-tight.

PB_T9_0097b_02

1

Fig. 9-48 Tighten centering bolt 1

Washer and nut for centering bolt

16. Check that lantern groove and locking pin in cylinder are still aligned. Correct if necessary. 17. Fit the additional guiding bar (see Fig. 9-49, 2) to base plate and tighten slightly with a bolt.

PB_T9_0098b_02

1

2

Fig. 9-49 Fit additional guiding bar

1

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Additional guiding bar

2B1XC2.64_1

2

Bore for bolt

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

18. Slowly move up guiding plate (with lantern and valve) by turning the nut on the spindle upwards with the ratchet (see Fig. 9-50, 2).

The clamping rings (1) on the guiding bars can be used to lock the packet in any position.

2

PB_T9_0099b_02

1

Fig. 9-50 Move up guiding plate with ratchet

1

Clamping ring (movable)

2

Ratchet

19. Remove the 3 Allen screws (see Fig. 9-51, 1) shortly before the lantern grooves reaches the locking pin in the cylinder. Lock packet with the clamping rings. 20. Align lantern groove and locking pin by turning the guiding plate with the mandril (see Fig. 9-51, 2). 21. Continue to move up guiding plate (with lantern and valve) with the ratchet. Stop immediately when the locking pin reaches the lantern groove. 22. Check that locking pin really is in the groove by turning the guiding plate slightly to the right and left using the mandril.

 The lantern must be blocked on both sides after a couple of millimeters.

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23. Loosen the nut for the centering bolt (3).

3

2

PB_T9_0100b_03

1

Fig. 9-51 Insert valve and lantern into cylinder

1 2

Allen screw Mandril

3

Nut for centering bolt

 Lantern and valve are freely movable. They will not get jammed in the cylinder or the valve cavity. 24. Continue to move up guiding plate (with lantern and valve) with the ratchet. •

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If lantern and valve get jammed in the cylinder, slightly move the guiding plate back down.

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

•

When it gets free, continue to move it up again.

•

To increase the play of lantern and valve even more, the nuts on the base plate (see Fig. 9-52, 1) may be loosened slightly. 2

PB_T9_0101b_02

1

Fig. 9-52 Loosen nuts on base plate slightly

1

Nut on base plate

2

Combination spanner

25. As soon as the locking pin (see Fig. 9-53, 2) in the cylinder becomes visible beneath the lantern (3), remove the ratchet. 2

3

PB_T9_0102c_02

1

Fig. 9-53 Locking pin becomes visible beneath lantern

1 2

Marking with felt tip pen Locking pin

3

Lantern

26. Tighten nut for centering bolt again (beneath guiding plate).

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27. Rotate guiding plate (with lantern and valve) with the mandril. 2

3

4

PB_T9_0103b_02

1

Fig. 9-54 Lock lantern with locking pin

1 2

Pick-up disc Locking pin

3 4

Lantern groove Base plate

•

If the guiding plate (with lantern and valve) has been moved up all the way to its stop, the valve seat is pressed against the valve cavity of the cylinder. As a result, it can not be rotated as required.

•

Slightly move down the guiding plate (with lantern and valve) by 0.5 to 1.0mm with the ratchet. Make sure that the lantern is still behind the locking pin.

•

Now rotate guiding plate (with lantern and valve) by a couple of degrees by means of the mandril.

 Valve and lantern are locked. The locking pin (see Fig. 9-54, 2) prevents them from falling out. 28. Loosen nut for centering bolt again (see Fig. 9-55).

PB_T9_0104a_02

29. Loosen and remove the centering bolt from the valve center bolt with the mandril.

Fig. 9-55 Remove centering bolt

30. Lock guiding plate by means of the clamping rings (if not already done). 31. Turn down nut of spindle manually.

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Dismantle and Assemble Compressor Components Suction Valves and Discharge Valves

PB_T9_0105a_02

32. Carefully loosen the clamping ring(s) while securing the guiding plate manually. Then move down the guiding plate by hand.

Fig. 9-56 Move down guiding plate

Alternatively, the guiding plate can be moved down with the ratchet.

33. Remove pick-up disc. 34. Remove nuts on base plate. 35. Carefully remove base unit of valve dismantling and assembling device. Install Valve Covers Installed valves and their lanterns are pressed to their seating surfaces by pressure screws (6). There is a gap between valve covers and installed lanterns/valves.

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1

2

3

4

5

PA_CX_0004b_02

7

6

Fig. 9-57 Valve cover

1 2 3 4

O-ring Nut Flat gasket Plug screw

5 6 7

Valve cover Pressure screw Lantern

1. Turn back pressure screws (6) of valve covers until they no longer protrude from the inner surface of the valve cover. Lubricate all parts to avoid fretting of bolts and sealing surface of cap nut. 2. Put O-ring (1) and valve cover (5) on cylinder and tighten the nuts (2) slightly. 3. Tighten the nuts diagonally, applying specified torque. 4. Tighten pressure screws (6), applying specified torque. 5. Fit gaskets for cap nuts. 6. Fit cap nuts and tighten them firmly.

For mandatory tightening torques: see section “Compressor” in chapter 13 Appendix.

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Dismantle and Assemble Compressor Components Cylinder Cover

9.8 9.8.1 Status

Cylinder Cover Status and Special Tools Completed activities:

• •

9.3 Switch Off Cooling System

Bar 30 x 1200mm, mandril

LA_T9_0009a_01

Special Tools

9.2 Switch Off Compressor

Fig. 9-58 Eye bolt

9.8.2 Measure Cylinder Clearance

Dismantle Cylinder Cover 1. Dismantle a valve at the Bottom Dead Center (BDC) and a valve at the Top Dead Center (TDC) of the cylinder.

 The cylinder clearance is now accessible CAUTION Use of wrong lead wire Wrongly measured or adjusted cylinder clearances can cause major compressor failure.  Use lead wire of appropriate thickness or use a feeler gauge.  Using too thick lead wire can lead to wrong measurement of cylinder clearance.

2. Check the cylinder clearance according to section 8.7.3 Cylinder Clearance Measurement. Record measured values in the compressor check list of section 8.7.4 Clearance Measurement Log Sheet. Dismantle

Dismantle Cylinder Cover 3. Remove all nuts of the cylinder cover. 4. Fit an eye bolt to the cylinder cover. 5. Remove cylinder cover according to Fig. 9-59.

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1

2

3

PA_T9_0007b_01

4

Fig. 9-59 Dismantle cylinder cover 1 2 3 4

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Eye bolt with rope Cylinder cover Bar dia. 30 x 1200 mm Cylinder

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Dismantle and Assemble Compressor Components Cylinder Cover

9.8.3 Required Checks

Install Cylinder Cover 1. Check if all O-rings are in perfect condition. 2. Replace O-rings if required.

Assemble New or Used Parts

Prepare Cylinder Cover 3. Install O-rings. 4. Install eye bolt on cylinder cover and attach it to the crane. 5. Install cover as shown in Fig. 9-59 by using the crane and the bar. Install Nuts for Cylinder Cover 6. Tighten the nuts slightly. 7. Tighten the nuts diagonally, applying specified torque.

Required Checks

Measure Cylinder Clearances CAUTION Use of wrong lead wire Wrongly measured or adjusted cylinder clearances can cause major compressor failure.  Use lead wire of appropriate thickness or use a feeler gauge.  Using too thick lead wire can lead to wrong measurement of cylinder clearance.

8. Check the cylinder clearance according to section 8.7.3 Cylinder Clearance Measurement. Record measured values in the compressor check list of section 8.7.4 Clearance Measurement Log Sheet. Compare them to the values in section “Compressor” in 13 Appendix.

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Dismantle and Assemble Compressor Components Frame Covers

9.9 9.9.1 Status

Frame Covers Status and Special Tools Completed activities:

• Special Tools

9.2 Switch Off Compressor

none

9.9.2

Dismantle and Assemble Frame Covers

Dismantle and Assemble

1. Remove all screws at the margin of the covers.

PB_M0_0037a_01

2. Lift off the covers according to following figure and stow them away.

Fig. 9-60 Frame cover removal

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Dismantle and Assemble Compressor Components Drain Lubricating Oil

9.10

Drain Lubricating Oil

9.10.1

Status and Special Tools

Status

Completed activities:

• Special Tools

9.10.2

9.2 Switch Off Compressor

none

Drain and Refill Lubricating Oil For further information about handling the oil skid and its elements, i.e. drain from oil tank, quantities, etc., please see “Technical Documentation”.

Drain

For details about the draining procedure, please refer to section 8.6.6 Oil Change.

Refill

For details about the refilling procedure, please refer to section 8.6.6 Oil Change.

Check for proper lubricating oil quality and quantity see sections 8.6.7 Lubricating Oil Specifications and 8.6.6 Oil Change.

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9.11

Piston and Piston Rod

9.11.1

Status and Special Tools

Status

Completed activities:

• • • • •

9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.9 Frame Covers

barring gear, mandril, spirit level, assembly cone, assembly sheet

PA_T9_0022a_01

Special Tools

9.2 Switch Off Compressor

Fig. 9-61 Protective sleeve for piston rod

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Dismantle and Assemble Compressor Components Piston and Piston Rod

1

2

3

5

PB_T9_0078a_01

4

Fig. 9-62 Piston rod supporting device

1 2 3

Distance piece Piston rod supporting device Base bracket

Spindle with height adjusting screw Support for piston rod

2

3

PA_T9_0002b_01

1

4 5

Fig. 9-63 Dismantling and assembling device for piston 1 2 3

9.11.2

Piston rod Piston Dismantling and assembling device

Dismantle Piston and Piston Rod

Preparation

1. Record value of proximity probes with the piston in BDC on the installed monitoring system before dismantling.

Dismantle

1. Remove the leak gas and the piping of the lubricating oil, if necessary. 2. Remove the distance piece cover.

 You can reach the crosshead.

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3. Position the crosshead to the top dead center by turning the flywheel with the barring device.

 You can reach the connection between the crosshead and the piston rod. 4. Dismount the piston rod nut SUPERBOLT® (6). See section 8.9.4 Piston Nut SUPERBOLT® for detailed description. 5. Position the crosshead to the bottom dead center by turning the flywheel with a barring gear. 6. Fit the dismantling and assembling device to the piston.

Information. For assembling the new piston, you also need the installed protective sleeve.  Do not remove it, after you will have dismantled the worn piston.

7. Pull the piston out of the cylinder (see Fig. 9-64).

Fig. 9-64 Pull-out the piston (typical view)

8. Remove the dismantling and assembling device from the piston.

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Dismantle and Assemble Compressor Components Piston and Piston Rod

Required Checks

•

Check the alignment of the cylinder (liner) and the crosshead bore by using a spirit level (see Fig. 9-65).

Fig. 9-65 Check cylinder alignment with a spirit level 1 2

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Cylinder Spirit level

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9.11.3

Dismantle the Piston

Special Tools

torque wrench

Dismantle 3 2

6

PB_C1_0180b_01

1

5

4

Fig. 9-66 Dismantled piston 1 2 3 4 5 6

Piston rod Center ring Lower piston crown Piston skirt Upper piston crown Piston nut SUPERBOLT®

For loosening procedure of piston nut SUPERBOLT® see 8.9.4 Piston Nut SUPERBOLT®. Piston Rings 9. Remove piston rings (for required checks, see section 9.11.5 Piston Rings).

9.11.4 Special Tools Check the Pretension of Piston Crowns

Assemble the 3-Piece Piston torque wrench The pretension of the piston crowns to the piston skirt is measured when a piston part is replaced or after the interval indicated on the maintenance schedule. This applies also, if a piston nut came loose. Pretension is the value by which the piston crowns are bent inwards when the piston nut is tightened, thereby clamping the piston skirt. Measure distance “A” with the piston crowns clamped together without the piston skirt as shown in the following figure. Pretension = Dimension B - Dimension A

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Dismantle and Assemble Compressor Components Piston and Piston Rod

A

PB_C1_0022b_01

B

1

2

3

4

5

6

Fig. 9-67 Piston pretension (typical view)

1 2 3

Lower piston crown Centering ring Piston rod

Piston nut SUPERBOLT® Upper piston crown Piston skirt

Stage (Compressor)

Dia. nominal of piston (mm)

Pretension (mm)

1st stage

640

0.08 – 0.54

Tab. 9-8

Assemble the Piston

4 5 6

Piston pretension (3-piece piston)

1. Put one piston crown onto a suitable support. 2. Assemble the piston as shown in Fig. 9-68.

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1

2

3

PA_C1_0007b_01

2

Fig. 9-68 Clamp piston halves together 1 2 3

Eye bolt Piston crown Piston skirt

3. Clamp the assembled piston together by using two vises. 4. Fit the piston onto the piston rod.

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Dismantle and Assemble Compressor Components Piston and Piston Rod

2

3

4

PA_C1_0006b_01

1

Fig. 9-69 Fit piston onto piston rod 1 2 3 4

Vise Piston Piston rod Fixation device

5. Lubricate the thread of the piston rod by using MOLYKOTE® G-N Plus. 6. Fit the support and the seal rings onto the piston nut SUPERBOLT®.

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7. Secure, that they are assembled according to Fig. 9-70. 1

2

3

4

5

6

7

PB_C1_0052b_01

8

9

Fig. 9-70 Piston details (typical view)

1 2 3 4 5

Piston rod Oil shield Center ring Lower piston crown Piston skirt

6 7 8 9

Upper piston crown Piston nut SUPERBOLT® O-ring Support ring

 This seal protects the inside of the piston against contamination. 8. Screw the piston nut SUPERBOLT® onto the piston rod and tighten it firmly by hand. 9. Tighten the piston nut SUPERBOLT® according to section “Compressor” in chapter 13 Appendix.

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9.11.5

Piston Rings Completed activities:

• • • • • • Special Tools Procedure

9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.11 Piston and Piston Rod 9.14 External Gas Pipes

Micrometer 1. Check the gap “Y” by inserting the piston rings into the cylinder.

Fig. 9-71 Piston rings inserted into cylinder

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Y

Y Y 1

2

PB_C1_0083b_01

1

Fig. 9-72 Gap “Y” of piston rings 1 2

Piston ring with scarf joint Guide ring (rider ring)

2. Check the wear of the piston rings by measuring the radial thicknesses according to section “Compressor” in chapter 13 Appendix. 3. Check the dimension of the running surface at the cylinder liner according to section “Compressor” in chapter 13 Appendix. 4. Check the condition of the running surface at the cylinder liner according to section “Compressor” in chapter 13 Appendix. 5. Check pistons for flawed ring grooves and score marks. Replace pistons if necessary. Piston Rings

The more the radial thickness of the piston rings are worn, the bigger is the gap. Before you will install the new piston rings  check the gap.  check the axial clearance of the piston rings in the piston groove according to section “Compressor” in chapter 13 Appendix

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Dismantle and Assemble Compressor Components Piston and Piston Rod

Conventions of designation for piston ring with scarf joint with left (L) or right (R) cuts. Look at the outer (sealing) surface of the piston ring: • left cut (L): the cut goes from bottom left to top right, • right cut (R): the cut goes from bottom right to top left.

1. Secure, that you insert the different types of the piston rings in the correct grooves of the piston. 1st Stage 5

4

1

6

7

8

3

2

10

9

10

11

R PB_C1_0226b_01

L

11

Fig. 9-73 Assembly of Redura® piston rings

1 2 3 4 5 6

Piston rod Oil shield Center ring Lower piston crown Pretension Piston skirt

7 8 9 10 11

Upper piston crown Hydraulic piston nut Guide ring (rider ring) Piston ring with scarf joint (left cut) Piston ring with scarf joint (right cut)

2. Secure, that the Y gaps are offset with 180° to each other as shown in Fig. 9-74.

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Fig. 9-74 Horizontal arrangement of the joint gaps

3. After installation of piston/piston rod carry out a mechanical test run.

9.11.6

Install Piston and Piston Rod CAUTION All components coming into contact with process gas must be clean (oilfree and free of grease). When using solvents, observe the safety precautions of the manufacturer.

Presetting Adjusting Screws

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1. Measure the diameter X of the crosshead.

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Dismantle and Assemble Compressor Components Piston and Piston Rod

X 1 2 3 4 5 6 7

8

9

10

11

PB_M3_0001c_01

12

Fig. 9-75 Connection between crosshead and piston rod

X 1 2 3 4 5 6

Diameter Piston rod Locking plate Set collar Set screw Shim Piston rod nut SUPERBOLT®

7 8 9 10 11 12

Crosshead Crosshead pin bearing Crosshead pin Circlip Connecting rod Cylindrical pin

2. Measure the inner diameter Y of the adjusting ring according to Fig. 9-76.

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Fig. 9-76 Measure diameter Y

Fig. 9-77 Preset set screws 1

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Set screw

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3. Preset the lateral screw and the bottom screw at the adjusting ring.

 You are able to put the adjusting ring onto the crosshead without jamming. 4. Put the adjusting ring onto the crosshead. 5. Restrict the adjusting ring by regulating the two remaining screws uniformly. 6. If not already done: install the piston rings on the piston. Proceed according to section 9.11.5 Piston Rings. Installation with Assembly Sheet (1st Stage)

1. Fit the assembly sheet around the piston.

 The piston rings are fixed on the piston by the assembly sheet during installing.

Fig. 9-78 Piston with assembly steel sheet

2. Check that the sheet is tight enough, so that the piston rings are correctly fitted in the piston grooves. 3. Fit the protective sleeve on the piston rod (see Fig. 9-79).

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Fig. 9-79 Protective sleeve

4. Fit the dismantling and assembling device to the piston. 5. Lift the piston according to Fig. 9-80.

Fig. 9-80 Lift of piston

6. Install the piston in the cylinder. 7. Secure, that the stopper of the assembly sheet at the piston is positioned at the cylinder liner according to Fig. 9-81.

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Fig. 9-81 Assembly steel sheet with stopper 1 2 3

Cylinder Assembly steel sheet Stopper

8. Proceed with the installation as described in sub-section “Further Installation Steps for all Stages”. 1. Push the piston into the cylinder until the protective sleeve passes the piston rod packing according to Fig. 9-82.

Fig. 9-82 Piston rod passes the piston rod packing 1 2

Protective sleeve Piston rod packing

2. Fit the oil shield on the piston rod (see Fig. 9-83).

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Fig. 9-83 Fit the oil shield 1 2 3

Protective sleeve Oil shield Distance piece packing

3. Push the piston into the cylinder until the protective sleeve passes the wiper elements. 4. Remove the protective sleeve. 5. Push the piston rod into the crosshead. 6. Screw the tensioner SUPERBOLT® on piston rod.

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Fig. 9-84 Tighten the tensioner SUPERBOLT® 1 2 3 4

Connecting rod Torque wrench Crosshead Tensioner SUPERBOLT®

7. Tighten the pressure screws of the tensioner SUPERBOLT® by applying the defined value of the tightening torque (see section “Compressor” in chapter 13 Appendix). Further Steps and Final Checks

8. Check, and if necessary, readjust runout according to section 9.11.7 Adjust Piston Rod Runout. 9. Install proximity sensor for piston rod monitoring (see section 9.11.8 Piston Rod Monitoring). 10. Install the cylinder cover (see section 9.8 Cylinder Cover). 11. Check the cylinder clearance: TDC and BDC (see section 8.7.3 Cylinder Clearance Measurement). 12. Carry out a mechanical test run.

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9.11.7

Adjust Piston Rod Runout The runout of the piston rod must be checked in horizontal and vertical direction. Check the runout of the piston rod and readjust it, if it is too low or too high via the adjusting screws.

The runout may be readjusted with one dial gauge only. Measure at the points indicated in Fig. 9-86 successively.

Fig. 9-85 Check piston rod runout: dial gauge near piston rod packing 1 2

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Piston rod Dial gauge

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Readjust the Piston Rod Runout

1. Place dial gauge near piston rod packing in such a way that the displacement can be measured according section A-A in Fig. 9-86. 1

3

2

4

5

6

4

A

7

A

7

PB_M3_0029b_02

A-A

Fig. 9-86 Place dial gauges for vertical runout check

1 2 3 4

Crosshead at BDC Crosshead bore Piston rod Dial gauge (Y-axis)

5 6 7

Piston Cylinder Dial gauge (X-axis)

2. Turn crank to bottom dead center (BDC). 3. Set both dial gauges to zero position. 4. Move crank to top dead center (TDC) by means of the barring device and in one swift movement. 5. Check dial gauges. 6. Adjust the piston rod runout via its adjusting ring.

1 2 3 4

PA_M3_0007b_02

5

Fig. 9-87 Adjust piston runout 1 2 3 4 5

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Adjusting screw Adjusting ring Set screw Piston rod Crosshead

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7. Move crank back to BDC, set dial gauges to zero position and recheck runout as described above. 8. Repeat these steps until runout is within the tolerances specified in the runout log sheet in the Quality Documentation. 9. Record measured values (see example sheet in section 8.7.5 Piston Rod Runout). 10. When the vertical runout is adjusted, repeat these steps with laterally positioned dial gauges until horizontal runout is also within the tolerances specified in the runout log sheet in the Quality Documentation. 11. Record measured values (see example sheet in section 8.7.5 Piston Rod Runout).

 The axis of the crosshead, the piston rod and the cylinder are positioned horizontally according to Fig. 9-88. 2

3

1

5

PA_M3_0008b_01

6

4

Fig. 9-88 Piston rod axis

1 2 3

Further Steps and Final Checks

Runout is not adjusted Adjusting ring Partially worn piston ring

4 5 6

Piston rod axis Crosshead axis Runout is adjusted

12. Install proximity sensor for piston rod monitoring (see section 9.11.8 Piston Rod Monitoring). 13. Install the cylinder cover (see section 9.8 Cylinder Cover). 14. Check the cylinder clearance: TDC and BDC (see section 8.7.3 Cylinder Clearance Measurement). 15. Carry out a mechanical test run.

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9.11.8

Piston Rod Monitoring

Status

Completed activities:

• • • • • • Special Tools Preparation

Dismantle and Assemble

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9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.9 Frame Covers 9.11.6 Install Piston and Piston Rod

none 1. Record value of proximity probes with the piston in BDC on the installed monitoring system before dismantling. For detailed description of dismantling and assembling of proximity probe(s) and piston rod monitoring refer to the corresponding section in document “Functional Description” in the Technical Documentation.

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Dismantle and assemble the proximity probe according to Fig. 9-89. 1

2

3

4

PB_C1_0067b_02

X

Fig. 9-89 Location of proximity probe 1 2 3 4 X

Required Checks

Distance piece Piston rod packing flange Proximity probe Piston rod Clearance = 1.25 mm

With New Guide Rings (Rider Rings)

•

Check installation of proximity probe (3) in accordance to the above illustration and adjust clearance X.

With Used Guide Rings (Rider Rings)

•

Check voltage on the installed monitoring system and compare with recorded value. –

If necessary adjust with thread on proximity sensor.

The rod is monitored with one vertical proximity probe on each piston rod. The rod proximity probe detects excessive rod vibration. The guide ring (rider ring) wear is also evaluated based on the signal of this sensor.

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9.11.9

Measure the Cylinder Clearance

Status

Completed activities:

• • • • • • Special Tools

9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.9 Frame Covers 9.11.6 Install Piston and Piston Rod

Barring device, optionally: feeler gauge

Procedure

Option for measuring: You can also measure the cylinder clearances by using a feeler gauge.  Position the piston in the top or bottom dead center.  Insert the feeler gauge into the chamber of the cylinder.

CAUTION Use of wrong lead wire Wrongly measured or adjusted cylinder clearances can cause major compressor failure.  Use lead wire of appropriate thickness or use a feeler gauge.  Using too thick lead wire can lead to wrong measurement of cylinder clearance.

1. Check the cylinder clearance according to section 8.7.3 Cylinder Clearance Measurement. Record measured values in the compressor check list of section 8.7.4 Clearance Measurement Log Sheet. Compare them to the values in section “Compressor” in 13 Appendix.

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9.12

Internal Pipes (Distance Piece)

9.12.1

Status and Special Tools

Status

Completed activities:

• • Special Tools

9.2 Switch Off Compressor 9.9 Frame Covers

none

9.12.2

Dismantle and Assemble Internal Pipes Dismantle and assemble the internal pipes according to Fig. 9-90. 1

2

1

2

3

A

7

8

7

6

5

6

5

PB_M6_0020b_02

B

4

4

Fig. 9-90 Internal pipes in the distance piece

A B 1 2 3

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Distance piece from top Distance piece from bottom Coolant pipe (outlet) Screw plugs Packing flange

2B1XC2.64_1

4 5 6 7 8

Buffer gas pipe (inlet) Coolant pipe (inlet) Gas leakage pipe Oil return Buffer gas to the distance piece packing

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9.13 9.13.1 Status

Piston Rod Packing Status and Special Tools Completed activities:

• • • • • • Special Tools

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9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.11 Piston and Piston Rod 9.12 Internal Pipes (Distance Piece)

none

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9.13.2

Piston Rod Packing Design

1st Stage

5

4

3

2.2

1

1

2

B2

B1

A

PB_C5_0081a_02

C

Fig. 9-91 Piston rod packing 1st stage

A B C

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Zone A Zone B Zone C

1 2

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Markings Gas flow

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9.13.3 Special Tools

Dismantle the Piston Rod Packing none

Dismantle CAUTION Observe defective components! Check also all accessible compressor components, e.g. the wear of the piston rings, the guide rings (rider rings), the piston, the piston rod, the cylinder liner, etc.  If necessary replace or repair the worn and the defective components respectively.

1. Remove the piston according to chapter 9.11 Piston and Piston Rod. 2. Remove the packing flange. 3. Remove the packing cartridge.

Fig. 9-92 Removed piston rod packing 1

Centering pin

4. Disassemble the piston rod packing.

All components coming into contact with process gas must be clean and free of grease and oil. When using solvents, observe manufacturer’s safety precautions.

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8

7

6

5

4

3

2

1

PB_C5_0001b_01

Dismantle and Assemble Compressor Components Piston Rod Packing

Fig. 9-93 Dismantled packing cartridge (typical view)

1 2 3 4

Required Checks

O-ring Basic bush for packing Pressure breaker Threaded bolt

5 6 7 8

O-ring Support ring and seal element Packing cups Nut

Piston Rod Packing 5. Remove O-rings from packing cups. 6. Check O-rings and replace them if necessary. 7. Check the cooling channels and drilled holes for fouling/plugging and clean it if necessary according to chapter 10 Clean and Degrease Plant and Compressor Components. CAUTION Contamination! Damaged O-rings leads to contamination of the coolant.  Always replace the complete set of O-rings.

8. Check condition of packing elements (see Fig. 9-91 and Fig. 9-93). Replace them if necessary. 9. Measure axial clearance of the packing rings with a feeler gauge (see Fig. 9-94). 10. Compare measured values:

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Zone

C [mm]

B2 [mm]

B1 [mm]

A [mm]

Axial clearance

0.700–0.902

0.300–0.493

0.300–0.493

0.100–0.230

Tab. 9-9

Axial clearances of packing rings 1st stage

Fig. 9-94 Example: Measure axial clearance

1 2

O-ring Feeler gauge

3 4

Packing cup Threaded bolt

11. If necessary replace or re-machine worn components.

 You have removed the piston rod packing and disassembled it. Piston Rod 12. Check the surface of the piston rod for scratches.

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CAUTION Scratches on piston rods, which are tungsten carbide coated! The seal rings wear out fast, if there are scratches on the piston rod.  replace the piston rod or  remove damaged coating and coat piston rod newly.

13. Check the piston rod for transfer film. CAUTION Increased wear and thermal failure of the sealing rings. A thick transfer film on the piston rod deteriorates the heat removal from the contact area (packing rings – piston rod).  Remove the black transfer film by using emery cloth.  Never use any solvent or lubricant for removing transfer film.

Typical colors of transfer films:

• • •

Filled PTFE: grey to dark grey Polymer blends: light grey, brown Modified PEEK: light grey

Fig. 9-95 Transfer film on piston rod

9.13.4 Special Tools Redura® Brand

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Assemble the Piston Rod Packing none Redura® is the brand of Burckhardt Compression AG for piston rings and packings. With the brand Redura® Burckhardt Compression provides a comprehensive product line of rings and packings for reciprocating compressors. It stands for reliable, durable and advanced sealing elements. the product line includes standard rings and packings as well as specifically inhouse developed, designed and patented products. The entire engineering of piston/piston rod sealing system is done with an in-house developed sealing system software.

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Configuration of Zone A (Cylinder Side)

A

2

3

PB_C5_0095b_01

1

®

Fig. 9-96 Redura pressure breaker RB110 A 1 2 3

Zone A Crankgear side Cylinder side Pressure breaker (throttle ring)

Pressure Breaker RB110 The pressure breaker is installed in the packing bush. The 3 segments of the pressure breaker are assembled with a radial cover ring and a garter spring. To prevent gap alignment of cover ring and ring segments, the cover ring is held in position by a pin. In order to work properly, the 3-piece ring must face the pressure. The 3 ring segments have engraved figures:

• •

on 2 segments the figures are at the end on 1 segment the figure is in the middle.

The segments are arranged properly if the 2 segments with their figures engraved at their end are positioned in such a way that the figures are located side by side.

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Configuration of Zone B1 B1

2

4

3

PB_C5_0093b_02

1

Fig. 9-97 Redura® pressure breaker RB210 with support ring RC800 B1 1 2 3 4

Zone B1 Crankgear side Cylinder side Pressure breaker (crown ring) Support ring

Pressure Breaker RB210 The pressure breaker (crown ring) is a 3-piece packing ring. The pressure breaker is assembled with a garter spring. In order to work properly, the rings have to be installed with the grooves of the crown ring facing the pressure. The 3 ring segments have engraved figures:

• •

on 2 segments the figures are at the end on 1 segment the figure is in the middle.

The segments are arranged properly if the 2 segments with their figures engraved at their end are positioned in such a way that the figures are located side by side. Do not, not ever, interchange segments of different pressure breakers. Support Ring RC800 The support ring is an endless 1-piece ring (without gap) that prevents the sealing ring from creeping into the gap between ring chamber and piston rod. In a seal element, the support ring is always furthest away from the pressure.

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Configuration of Zone B2 B2

2

3

4

5

PB_C5_0124b_01

1

Fig. 9-98 Redura® seal element RS310 with support ring RC800 B2 1 2 3 4 5

Zone B2 Crankgear side Cylinder side Support ring Packing ring with step bridge cut Packing ring with radial cut

The seal element RS310 consists of a packing ring with step bridge cut and a packing ring with radial cut. Support Ring RC800 The support ring is an endless 1-piece ring (without gap) that prevents the sealing ring from creeping into the gap between ring chamber and piston rod. In a seal element, the support ring is always furthest away from the pressure. Packing Ring with Step Bridge Cut The packing ring with step bridge cut is a 3-piece sealing ring, assembled with a garter spring. It may be installed in combination with

• •

a side-loaded pressure ring (in the packing flange) or an support ring and a cover ring (as a seal element)

In a seal element, the step bridge cut ring is installed between the support ring and the cover ring. The step bridge cut and cover ring are fixed against each other by a pin. Packing Ring with Radial Cut The radial cut ring is a 3-piece ring, assembled with a garter spring. It is used as cover ring for a sealing ring. The radial cut ring is fixed against the sealing ring by a pin. In order to ensure proper working of the seal element, the cover ring must face the pressure.

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Configuration of Zone C (Crankgear Side)

C

2

3

4

4

3

PB_C5_0100b_01

1

Fig. 9-99 Redura® seal elements RS900 C 1 2 4 3

Zone C Crankgear side (low pressure side) Cylinder side (higher pressure side) Packing ring with step bridge cut Pressure ring

A seal element RS900 consists of a pressure ring and two packing rings with step bridge cut. Pressure Ring The side-loaded pressure ring is a 2-piece ring that is assembled with a garter spring. This pressure ring is equipped with springs and combined with 2 sealing rings. All three rings together form the seal element RS900. Depending on the application, the arrangement of the seal element(s) in the packing flange varies. In order to work properly the pressure ring(s) must be placed on the side with the higher pressure. Check all pressures (of process gas, buffer or purge gas and in the distance piece) and install accordingly. Packing Ring with Step Bridge Cut The packing ring with step bridge cut is a 3-piece sealing ring, assembled with a garter spring. It may be installed in combination with

• •

a side-loaded pressure ring (in the packing flange) or an support ring and a cover ring (as a seal element)

In a seal element, the step bridge cut ring is installed between the support ring and the cover ring. The step bridge cut and cover ring are fixed against each other by a pin. The 3 ring segments have engraved figures:

• •

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on 2 segments the figures are at the end on 1 segment the figure is in the middle.

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The segments are arranged properly if the 2 segments with their figures engraved at their end are positioned in such a way that the figures are located side by side. Do not, not ever, interchange segments of different step bridge cut rings! Assemble New or Used Parts

Assemble Cartridge 1. Assemble the components of the piston rod packing according to the numbering in Fig. 9-91 and Fig. 9-93. Install Packing Cartridge in Cylinder Sleeve 2. Install the packing cartridge into the cylinder sleeve.

4

2

PB_C5_0033b_01

1

3

Fig. 9-100 Insert packing cartridge into cylinder sleeve

1 2

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Packing cartridge Cylinder sleeve

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3 4

Support Support

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Install Piston Rod Packing 3. Install the packing cartridge into the cylinder in reversed order as described in section 9.13.3 Dismantle the Piston Rod Packing. 4. Fit the packing flange. 5. Tighten the nuts of the packing flange by applying the defined value of the tightening torque (see section “Compressor” in chapter 13 Appendix). Connect Piping 6. Connect the buffer gas pipe. 7. Connect the cooling water pipe. 8. Connect the piping of the leak gas pipe.

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Dismantle and Assemble Compressor Components External Gas Pipes

9.14

External Gas Pipes

Status

Completed activities:

• Special Tools Dismantle and Assemble

9.15 9.15.1 Status

none For details concerning external gas pipes please see section “General Arrangement” in chapter 13 Appendix.

Cylinder Status and Special Tools Completed activities:

• • • • • •

9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.11 Piston and Piston Rod 9.14 External Gas Pipes

spirit level

XA_T9_0025a_01

Special Tools

9.2 Switch Off Compressor

Fig. 9-101 Lifting ring VLBG

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Dismantle and Assemble Compressor Components Cylinder

Fig. 9-102 Flogging spanner

9.15.2 Dismantle

Dismantle and Assemble Cylinder Take care to avoid any damage; please refer also to section 5.7 Lifting Procedure. 1. Remove coolant pipes from cylinder. 2. Dismantle connection between cylinder and cylinder support. 3. Remove the SUPERBOLT® nuts from the threaded bolts. DANGER Suspended loads! Falling loads can cause serious injury or death.  Lift cylinder only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads.

4. Attach carrying ropes in the safe manner, described and illustrated in section 5.7 Lifting Procedure. 5. Lift off the cylinder. Be careful that the threaded bolts do not touch the bores in the frame. Required Checks

6. Check if the O-ring (between cylinder and distance piece) is in perfect condition. 7. Replace O-ring, if necessary.

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Installation

All components coming into contact with process gas must be clean and free of grease and oil. When using solvents, observe manufacturer’s safety precautions.

Fit Cylinder to Distance Piece Take care to avoid any damage; please refer also to section 5.7 Lifting Procedure. DANGER Suspended loads! Falling loads can cause serious injury or death.  Lift cylinder only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand beneath suspended loads. 1. Apply MOLYKOTE® G-N Plus to threaded bolts. 2. Fit the bolts to the cylinder. 3. Fit the round cord to the bottom of the cylinder. 4. Lift cylinder with proper attachment gear and attach it to the crane (see section 5.7 Lifting Procedure). 5. Put a spirit level on top of the cylinder and level the cylinder accurately. It must be ensured, that the cylinder is kept absolutely horizontal in all directions.

 The cylinder is absolutely horizontal. 6. Slide cylinder bolts carefully through the bores of the distance piece. 7. Re-check levelling of cylinder with the spirit level. Tighten Nuts for Cylinder 1. Install and tighten nuts.

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Install Cylinder Support 2

3

PB_M6_0053a_02

1

Fig. 9-103 Location of cylinder support (typical view) 1 2 3

Crankgear Cylinder Cylinder support

1. Put a spirit level into the cylinder liner and into the crosshead guide. 2. Lift cylinder max. 0.5 mm and fit cylinder support. 3. Re-check leveling, correct height of support until leveling is perfect. 4. Attach cylinder support to cylinder. 5. Re-check leveling. 6. Loosen ropes of attachment gear by moving down the crane hook. 7. Re-check leveling. Correct, if necessary.

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9.15.3

Cylinder Liner Completed activities:

• • • • • • Special Tools

9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.11 Piston and Piston Rod 9.14 External Gas Pipes

Micrometer

Preparations

Hone or ground the running surfaces of the cylinder liner, which feature excessive wear or score marks. Cylinder liners, you have also treated may only be honed or grounded to a limited extend.  Do not increase 0.2 % of the nominal diameter by honing or grinding the surfaces of untreated cylinder liners.  Contact our customer support service, if you need further information.

1. Measure the dimensions of the cylinder liner by using an inside micrometer.

Fig. 9-104 Measure cylinder liner 1 2 3

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Dismantle

1. Remove the cylinder liner (1) by using stud bolts with nuts (2) and a steel plate (3).

 Stud bolts are installed, so that force can be applied to the steel plate. 2

3

PB_C0_0092a_01

1

Fig. 9-105 Remove cylinder liner 1 2 3

Cylinder liner Stud bolt with nut Steel plate

2. Loosen the cylinder liner by tightening the nuts. 3. Remove the cylinder liner carefully. Use a lifting device. Assemble

Fitting of the Centering Pin and Installation of Cylinder Liner 1. Fit the centering pin before installing the cylinder liner. 2. Install pin and cylinder liner according to the following illustration(s).

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Dismantle and Assemble Compressor Components Cylinder

3

4

5

2

1

6

7

PB_C0_0004b_01

2

X

1

Fig. 9-106 Cylinder liner

1 2 3 4

Cylinder Cylinder liner Piston O-ring

5 6 7 X

Groove for centering pin Centering pin Cylinder cover Protrusion = 10mm

The protrusion of the centering pin (distance X, see Fig. 9-106) must correspond to the set value. Fit the centering pin from the valve chamber side, for example before installating the valves.

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9.16.1 Status

Distance Piece Status and Special Tools Completed activities:

• • • • • • Special Tools

9.16.2 Dismantle and Assemble

9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.9 Frame Covers 9.15 Cylinder

none

Dismantle and Install Distance Piece The distance piece is built as shown in Fig. 9-107. 1

2

10

3

9

4

8

5

7

1

PB_M6_0001b_01

9.16

6

Fig. 9-107 Double compartment distance piece

1 2 3 4 5

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Attachment gear (eye bolt) Breather SUPERBOLT® connection crankgear–distance piece Buffer gas to the distance piece packing Distance piece cover

2B1XC2.64_1

6 7 8 9 10

SUPERBOLT® connection distance piece –cylinder Chamber at cylinder side Distance piece packing Chamber at crankgear side Oil scraper

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Dismantle and Assemble Compressor Components Distance Piece Packing

Dismantle and assemble the distance piece according to the above illustration. For tightening and loosening of the tensioner SUPERBOLT®, please refer to section 8.7.8 Tensioner SUPERBOLT®.

9.17 9.17.1 Status

Distance Piece Packing Status and Special Tools Completed activities:

• • • Special Tools

9.17.2 Dismantle

9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.9 Frame Covers

none

Dismantle and Assemble Distance Piece Packing The distance piece packing is installed in the separating plate of the two distance piece chambers. The description in section 9.13 Piston Rod Packing concerning the assembly of the piston rod packing of the zone “C” also applies to the distance piece packing. 1. Remove the cover (4) from the housing (1). 2. Remove the packing rings (6/7) from its housing. The packing rings of the distance piece packing may also be dismantled/ replaced, without removing the piston rod.

Assemble

1. Mount the packing rings of the distance piece packing.

There is a position pin at one of the seal rings and at the other one, there is a pinole. The seal elements are positioned accurately, if the position pin and the pinole match on each other.

The serial number on the seal rings may not positioned onto the face.  Turn the seal elements, that the stamped serial numbers do not contact the face.

2. Install the packing rings (6/7) to its housing. 3. Install the cover (4) to the housing (1).

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1 2 3 4

9

8

7

PB_M6_0002b_03

5

6

Fig. 9-108 Distance piece packing (typical view)

1 2 3 4 5

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6 7 8 9

Seal element (step bridge cut) Pressure ring Spring Material code

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9.18

Oil Scraping For dismantling and assembling of the 3-piece wiper elements it is not necessary to remove the piston rod from the cylinder.

9.18.1 Special Tools

9.18.2

Status and Special Tools none

Dismantle the Wiper Elements CAUTION Damage to wiper elements! The operation of the compressor depends on the condition of the wiper elements and on the way, how they are assembled.  Handle the wiper elements with great care.  Handle the surface of the piston rod in the area of the wiper elements with great care.

1

2

3

4

10 9

8

7

6

5

PB_M5_0008b_01

11

Fig. 9-109 Oil scraping

1 2 3 4 5 6

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O-ring Spring plate Cover Screw Seal element Wiper element

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7 8 9 10 11

Cylindrical pin Oil scraper plate Allen screw Prewiper element Pre oil scraper cover

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1. Remove the cover (3) from the oil scraper plate (8). 2. Remove the spring plate (2) from the oil scraper plate. 3. Remove the garter springs from the 3-piece wiper elements. 4. Remove the wiper elements (6) and seal element (5) from the oil scraper plate.

9.18.3 Final Checks

Assemble the Wiper Elements •

Check the piston rod for any surface defects.

CAUTION Damaged wiper elements! The wiper elements shall not show any sign of damage and must lie snug against the piston rod along their entire circumference.  The scraping edges must be as sharp as possible.  The wiper elements must have a slight pretension when pushed onto the piston rod.

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Dismantle and Assemble Compressor Components Oil Scraping

2

3

4

7

1

6

PB_M5_0007c_01

1

5

9

8

Fig. 9-110 Oil scraper

1 2 3 4 5

Rollpin Garter spring Scraping edge Contact area Seal element

6 7 8 9

Wiper element Support ring Cylinder side Crankgear side

1. Check all items to be fitted for damage. 2. Check if the piston rod surface is in perfect condition. Should a piston rod be damaged, contact our Technical Service Support. 3. Assemble the 3-piece wiper elements with garter springs onto the piston rod. 4. Install the wiper elements, support rings and seal elements into the oil scraper plate. •

Check the correct sequence of the oil scraper according to Fig. 9-110.

5. Fit the spring plate and the cover to the oil scraper plate.

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9.19 9.19.1 Status

Connecting Rod Bearing Status and Special Tools Completed activities:

• • • • • •

9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.9 Frame Covers 9.11 Piston and Piston Rod

plastic hammer

PA_T9_0006a_01

Special Tools

9.2 Switch Off Compressor

Fig. 9-111 T97460 dismantling and assembling device

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PA_T9_0024a_01

Dismantle and Assemble Compressor Components Connecting Rod Bearing

Fig. 9-112 Stop for T97460

9.19.2 Special Tools Dismantle

Dismantle the Connecting Rod Bearing plastic hammer, T97460 dismantling and assembling device, stop for T97460 1. Measure the clearance of the connecting rod bearing. 2. Write the values of the measured clearances in a log sheet. 3. Turn the crank to the upper vertical position. 4. Attach the dismantling and assembling device to the connecting rod according to Fig. 9-113.

9 – 114

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Dismantle and Assemble Compressor Components Connecting Rod Bearing

Fig. 9-113 Dismantling and assembling device for connecting rod 1 2 3

Crankshaft Connecting rod Dismantling and assembling device for connecting rod

5. Remove the SUPERBOLT® nuts of the connecting rod. 6. Remove the bearing cover of the connecting rod according to Fig. 9-114.

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Dismantle and Assemble Compressor Components Connecting Rod Bearing

Fig. 9-114 Bearing cover removal 1 2 3 4

Dismantling and assembling device for connecting rod Connecting rod Connecting rod bearing cover Crankshaft

7. Remove the bearing cover carefully and ensure that the crankshaft and bearing shell will not get damaged. 8. Knock carefully against the bearing shell of the bearing cover by using a plastic hammer.

 The bearing shell of the bearing cover loosens. 9. Turn the crankshaft away from the connecting rod.

9 – 116

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Dismantle and Assemble Compressor Components Connecting Rod Bearing

Fig. 9-115 Removed connecting rod 1 2 3 4

Dismantling and assembling device for connecting rod Connecting rod Connecting rod bearing Crankshaft

10. Knock carefully against the bearing shell of the connecting rod by using a plastic hammer.

 The bearing shell of the connecting rod loosens. Required Checks

9.19.3

• •

Clean all contact surfaces of the connecting rod and its bearing. Check the diameter of the bearing journal.

Assemble the Connecting Rod Bearing

Special Tools

plastic hammer, T97460 dismantling and assembling device, stop for T97460

Assemble

1. Secure that the crank is still turned to the upper vertical position. 2. Install the new bearing shells carefully to the connecting rod. 3. Move the crankshaft until it fits to the connecting rod bearing. 4. Install the bolts to the connecting rod. 5. Assemble the bearing cover of the connecting rod with the bearing shells. 6. Grease by using MOLYKOTE® G-N Plus

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Dismantle and Assemble Compressor Components Connecting Rod Bearing

•

the thread

Fig. 9-116 Thread lubrication

•

the contact surface of the tensioner SUPERBOLT®.

Fig. 9-117 Contact surface lubrication

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7. Fit the tensioner SUPERBOLT® of the bearing covers according to Fig. 9-118.

Fig. 9-118 Mount tensioner SUPERBOLT® 1

Tensioner SUPERBOLT®

8. Tighten the tensioner SUPERBOLT® by applying the defined value of the tightening torque (see section “Compressor” in chapter 13 Appendix). Required Checks

Measure the clearances of the connecting rod bearing. 1. Move the connecting rod in horizontal position by turning the crankshaft. 2. Measure the vertical clearance •

by using a feeler gauge: Measure the clearance outside the chamfer, at least 20 mm from center line (see Fig. 9-119).

•

by using a dial gauge: Measure the clearance by lifting up the connecting rod (see Fig. 9-119).

3. Compare the measured values with the set values in the table of clearances (see section “Compressor” in chapter 13 Appendix).

 You have assembled the connecting rod bearing correctly, if the values of the measured clearances correspond with the set values in the table of clearances.

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

20

20

PA_M4_0014b_02

1

Fig. 9-119 Measure vertical clearance (two methods) 1

9.20 9.20.1 Status

Crosshead and Connecting Rod Status and Special Tools Completed activities:

• • • • • • Special Tools

9.20.2 Special Tools Check Clearance

Dial gauge

9.2 Switch Off Compressor 9.3 Switch Off Cooling System 9.8 Cylinder Cover 9.9 Frame Covers 9.11 Piston and Piston Rod 9.19 Connecting Rod Bearing

feeler gauge, micrometer gauge

Check the Clearance of Crosshead feeler gauge, micrometer gauge 1. Move the connecting rod/crosshead to the top dead center (TDC) by turning the crankshaft with the barring gear. 2. Check the clearance between the crosshead and its bore by using the feeler gauge. 3. Move the connecting rod/crosshead to the bottom dead center (BDC) by turning the crankshaft with the barring gear. 4. Check the clearance between the crosshead and its bore by using the feeler gauge.

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

5. Write the values of the measured clearances in a log sheet. 6. Compare the measured values with the set values in the table of clearances (see section “Compressor” in chapter 13 Appendix). 7. If necessary (e.g. for new crosshead), rework crosshead (see section 9.20.6 Rework of a New Crosshead) or exchange crosshead or crosshead shoes.

9.20.3

Dismantle Connecting Rod and Crosshead CAUTION Compressor failures! Damages to compressor components caused by careless handling can lead to major compressor failure.  Always handle all compressor components with great care.

Special Tools Dismantle

feeler gauge, micrometer gauge 1. Turn the crank to the lowest vertical position according to Fig. 9-120.

Fig. 9-120 Crank on lowest position

2. Pull the connecting rod and the crosshead out of the crosshead bore according to Fig. 9-121.

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

Fig. 9-121 Pull-out conneting rod

3. Lift the connecting rod and the crosshead out of the crankgear according to Fig. 9-122.

Fig. 9-122 Lift the connecting rod

Required Checks

9 – 122

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4. Check the clearances of the connecting rod bearing on the dismantled connecting rod (see section 9.20.4 Clearance of Connecting Rod Bearing).

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

9.20.4 Special Tools

feeler gauge, micrometer gauge 1. Measure the bearing diameter at the positions 1, 2 and 3. See Fig. 9-123.

3

20mm

Check Clearance

Clearance of Connecting Rod Bearing

1

PA_M4_0002b_01

20mm

2

Fig. 9-123 Measure the bearing diameter 1 2 3

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Measure position 1 Measure position 2 Measure position 3

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

1

2

XA_T9_0031b_01

2. Measure the diameter of the crank beside the coupling and beside the oil pump.

Fig. 9-124 Measure the diameter 1 2

Micrometer gauge Crank

3. Calculate the clearances of the bearing:

•

radial clearances = diameter (Pos. 3, Fig. 9-123) – diameter of the crankshaft journal

•

axial clearances = diameter (Pos. 2, Fig. 9-123) – diameter of the crankshaft journal or axial clearance = diameter (Pos. 1, Fig. 9-123) – diameter of the crankshaft journal

 The axial clearance is larger than the radial clearance. The values of the measured clearances correspond with the set values in the table of clearances.

9.20.5

Parallelism of Connecting Rod Bores The parallelism of the big and small connecting rod bores (with both bearings installed) has to be checked if one or more of the following components was replaced:

• • • Procedure

connecting rod bearing (connecting rod dismantled), crosshead pin bearing, connecting rod.

1. Disassemble connecting rod and crosshead by dismantling the crosshead pin (see section 9.21.2 Dismantle the Crosshead Pin Bearing). 2. Check the bores of the connecting rod for parallelism.

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

CAUTION Differences of the bores in the connecting rod. The measured parallelism must correspond with the set value.  Measure the parallelism of the bores.  Compare the measured value with the set value.  Replace the connecting rod if necessary.

A

2

3 PA_M4_0003b_01

1

A–A

Fig. 9-125 Parallelism of connecting rod bores (typical view) 1 2 3

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Connecting rod Set value B-B (// 0.02mm) Connecting rod cover

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

9.20.6

Rework of a New Crosshead Scrape the running surface of the crosshead according to Fig. 9-126.

Fig. 9-126 Scraped surface of crosshead

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

9.20.7

plastic hammer

PA_T9_0006a_01

Special Tools

Assemble Connecting Rod and Crosshead

PA_T9_0024a_01

Fig. 9-127 T97460 dismantling and assembling device

Fig. 9-128 Stop for T97460

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Dismantle and Assemble Compressor Components Crosshead and Connecting Rod

Procedure

1. Lift the connecting rod and the crosshead into the crankgear according to Fig. 9-122. 2. Oil the running surface of the crosshead with the oil, which is defined for the compressor according to Fig. 9-129.

Fig. 9-129 Oil crosshead

3. Insert the connecting rod and the crosshead into the crosshead bore.

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4. Oil the crank and the bearing shell by turning the crankshaft. Use the oil, which is defined for the compressor.

Fig. 9-130 Oil crankshaft

5. Install the bearing cover according to chapter 9.19 Connecting Rod Bearing. Further Steps and Checks

6. Install piston rod and piston (see 9.11 Piston and Piston Rod). 7. Adjust the piston rod runout (see section 9.11.7 Adjust Piston Rod Runout). 8. Install the cylinder cover (see section 9.8 Cylinder Cover). 9. Check the cylinder clearance according to section 8.7.3 Cylinder Clearance Measurement. Record measured values in the compressor check list of section 8.7.4 Clearance Measurement Log Sheet.

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Dismantle and Assemble Compressor Components Crosshead Pin Bearing

9.21 9.21.1 Status

Crosshead Pin Bearing Status and Special Tools Completed activities:

• • • • • • • •

9.3 Switch Off Cooling System 9.7 Suction Valves and Discharge Valves 9.8 Cylinder Cover 9.9 Frame Covers 9.11 Piston and Piston Rod 9.19 Connecting Rod Bearing 9.20 Crosshead and Connecting Rod

Press, feeler gauge, jackscrew, circlip pliers, combination spanner, pulling eye bolt

PA_T9_0026a_01

Special Tools

9.2 Switch Off Compressor

Fig. 9-131 Pull-off device for removing crosshead pin

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Dismantle and Assemble Compressor Components Crosshead Pin Bearing

Dismantle the Crosshead Pin Bearing 1

5

2

4

3

PA_M3_0029b_02

9.21.2

Fig. 9-132 Dismantle the crosshead pin bearing 1 2 3 4 5

Connecting rod Crosshead Crosshead pin bearing Crosshead pin Circlip

1. Put the crosshead and the connecting rod onto a suitable table. 2. Dismount the crosshead pin. 3. Push the worn crosshead pin bearing out of the bore of the connecting rod with a press. Required Checks

1. Clean the bore of the connecting rod and the crosshead pin. 2. Check the diameter of the crosshead pin and of its bearing. 3. Compare the values of these diameters with the set values in the table of clearance (see section “Compressor” in chapter 13 Appendix).

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Dismantle and Assemble Compressor Components Crosshead Pin Bearing

9.21.3

Assemble the Crosshead Pin Bearing CAUTION Deformation! The connecting rod could deform caused by irregular heating-up. A burner or a blower would only heat-up certain positions on the connecting rod.  Always heat-up the connecting rod in hot oil.

1. Heat-up the connecting rod in hot oil with 60°C until 80°C. 2. Put the connecting rod on a level surface (see Fig. 9-133).

1

2

3

X

4

PA_M4_0004b _02

X

Fig. 9-133 Connecting rod on shims 1 2 3 4 X

Connecting rod Crosshead pin bearing Marking Shims Protrusion of crosshead pin bearing

3. Check the protrusion of the crosshead pin bearing (4). It must be X = 5mm. 4. Insert the new crosshead pin bearing by respecting its markings (3) into the bore of the connecting rod.

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Dismantle and Assemble Compressor Components Crosshead Pin Bearing

CAUTION Jammed bearing! You cannot correct the position of the crosshead pin bearing after a few seconds due to thermal expansion and due to thermal shrinkage of the connecting rod.  The crosshead pin bearing must be inserted in a one-step procedure.

5. Secure that the crosshead pin bearing inside the bore rests on the surface below. 6. Secure that the markings (3) are correctly positioned. 7. Wait until the crosshead pin bearing and the connecting rod will have reached ambient temperature. 8. Check the diameter of the crosshead pin bearing. 9. Check the parallelism of the two bores of the connecting rod (see section 9.20.5 Parallelism of Connecting Rod Bores). 10. Check the diameter of the crosshead pin. 11. Measure the inner diameter of its bearing. 12. Calculate the clearances of the bearing.

 radial clearance = diameter of the pin bearing - diameter of the pin 13. Install the circlip on the lower side of the crosshead.

Fig. 9-134 Connecting rod - crosshead assembling

14. Put the crosshead and the connecting rod onto a suitable table (see Fig. 9-134).

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PA_M3_0022a_01

Dismantle and Assemble Compressor Components Crosshead Pin Bearing

Fig. 9-135 Lift crosshead pin

15. Lift the crosshead pin (see Fig. 9-135). 16. Oil the crosshead pin with an oil, which is defined for the compressor. 17. Heat-up the crosshead with a burner to about 80°C (see Fig. 9-136).

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Fig. 9-136 Heat-up crosshead (typical view) 1 2 3

Connecting rod Crosshead Burner

18. Align the bore of the crosshead to the bore of the connecting rod (see Fig. 9-137). 19. Insert the crosshead pin into the bores of the crosshead and the connecting rod (see Fig. 9-137).

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Dismantle and Assemble Compressor Components Crosshead Pin Bearing

Fig. 9-137 Insert crosshead pin (typical view) 1 2

Crosshead Crosshead pin

20. Wait until the crosshead and the connecting rod will have reached ambient temperature. 21. Fit the second circlip. 22. Measure the clearances of the crosshead pin bearing with a feeler gauge. 23. Write the values of the measured clearances in a log sheet. 24. Compare the measured values with the set values in the table of clearances (see section “Compressor” in chapter 13 Appendix). Final Checks

9.21.4 Special Tools Clearance Check

9 – 136

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25. Check the clearance of the crosshead pin bearing, which you have installed (see section 9.21.4 Check Clearance of Crosshead Pin Bearing).

Check Clearance of Crosshead Pin Bearing dial gauge, jackscrew The crosshead pin bearing clearance can only be checked in running direction of the piston (). The piston/piston rod must be removed.

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1

2

PA_M3_0009e_01

Dismantle and Assemble Compressor Components Crosshead Pin Bearing

3

Fig. 9-138 Crosshead pin bearing 1 2 3

Jackscrew Dial gauge Dial gauge

7. Move connecting rod/crosshead in Top Dead Center (TDC) by turning the crankshaft. 8. Secure connecting rod in this position, for example, with a jackscrew (1). 9. Place dial gauge according to position (2) against connecting rodbearing cover. 10. Place dial gauge according to position (3) against crosshead. 11. Move crosshead forward and backward to its running direction. 12. Read the horizontal clearance of the crosshead pin bearing on dialgauge (3). The hand of the dial gauge (2) must remain at zero position.

For applicable clearances see section “Compressor” in chapter 13 Appendix.

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Dismantle and Assemble Compressor Components Gear Oil Pump

9.22 9.22.1 Status

Gear Oil Pump Status and Special Tools Completed activities:

• • Special Tools

9.22.2

9.2 Switch Off Compressor 9.10 Drain Lubricating Oil

none

Dismantle Gear Oil Pump 1. Remove external oil pipes. 2. Dismantle the gear oil pump according to Fig. 9-139.

9.22.3

Assemble Gear Oil Pump 1. Assemble the gear oil pump according to Fig. 9-139. 2. Install external oil pipes. 2

7

3

6

4

5

PA_M2_0008b_02

1

Fig. 9-139 Crankshaft-driven gear oil pump (typical view)

1 2 3 4

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Housing for gear oil pump coupling 5 Coupling halves 6 Intermediate flange 7 Gear oil pump

2B1XC2.64_1

Hexagonal screw Spider Allen screw

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Dismantle and Assemble Compressor Components Electric Motor

9.23 9.23.1 Status

Electric Motor Status and Special Tools Completed activities:

• Special Tools

9.23.2

9.2 Switch Off Compressor

none

Dismantle Electric Motor 1. Remove flywheel guard. 2. Release electric motor from coupling.

9.23.3

Assemble Electric Motor For detailed assembly instructions see chapter 5.11 Install Electric Motor and Coupling.

9.24 9.24.1 Status

Flywheel Status and Special Tools Completed activities:

• Special Tools

9.24.2

9.2 Switch Off Compressor

fine file or scraper

Transport and Lifting of the Flywheel For transport and lifting of flywheel, take care to avoid any damage; please see section 5.2.1 Safety of Transport. DANGER Suspended loads! Falling loads can cause serious injury or death.  Lift flywheel only in the correct manner as described and illustrated in this Instruction Manual.  Check correct tightening torque for attachment gear.  Make sure that the carrying capacity of the hoist corresponds at least to the heaviest individual component weight.  Protect carrying ropes/straps against sharp edges.  Do not stand underneath suspended loads.

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PA_L1_0002a_01

Dismantle and Assemble Compressor Components Flywheel

Fig. 9-140 Transport and lifting of flywheel

Dismantle the Flywheel

1

2

3

PB_L1_0004b_02

9.24.3

Fig. 9-141 Flywheel 1 2 3

Dismantle

9 – 140

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Allen screw Flywheel Crankshaft flange

1. Attach carrying ropes in the safe manner as illustrated in this Instruction Manual.

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Dismantle and Assemble Compressor Components Flywheel

2. Remove Allen screws (1). 3. Lift flywheel (2) away from crankshaft flange (3).

9.24.4

Assemble the Flywheel DANGER Falling machine components! Serious crushes of body and death.  The carrying capacity of the hoist must at least correspond to the heaviest individual component weight.  Do not stand underneath suspended loads.  Protect carrying ropes against sharp edges.  Store flywheel securely - this means, prevent it from overturning, for example when it is pushed by crane load, cart, etc.  Notice the corresponding weights according to chapter 5.3 Dimensions, Weights, Space Requirement.

Assemble New or Used Parts Required Checks

For detailed assembly instructions see chapter 5.10.3 Flywheel. 1. Check radial and face runout as illustrated in Fig. 9-142. 2

3

4

PA_L1_0001b_01

1

Fig. 9-142 Radial and face runout 1 2 3 4

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Dismantle and Assemble Compressor Components Crankshaft Seal

Tolerance of radial and face runout must not exceed 0.04 mm. When checking the face runout, push the crankshaft to the drive end side up to its stop. The axial clearance of the crankshaft must be eliminated.

9.25 9.25.1 Status

Crankshaft Seal Status and Special Tools Completed activities:

• • Special Tools

9.25.2

9.2 Switch Off Compressor 9.24 Flywheel

none

Dismantle and Assemble the Crankshaft Seal Dismantle or assemble the crankshaft seal according to Fig. 9-143. For applicable tightening torques see section “Compressor” in chapter 13 Appendix.

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Dismantle and Assemble Compressor Components Crankshaft Seal

A

1

2

3

4

PB_M1_0003b_01

A

Fig. 9-143 Components of crankshaft seal 1 2 3 4

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Gasket 2-piece oil trap cover Seal ring (2 pieces) 2-piece cover

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Dismantle and Assemble Compressor Components Crankshaft Seal

9.25.3 Special Tools Dismantle and Assemble

Trigger Sensor none Dismantle and assemble the trigger sensor/Keyphasor® according to Fig. 9-144.

1

2

3

4

5

6

PB_M1_0007b_01

7

Fig. 9-144 Location of probe

1 2 3 4

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2-piece oil trap cover Probe Cylindrical pin Crankshaft seal

2B1XC2.64_1

5 6 7

Crankshaft Trigger sensor/Keyphasor® connection Plug

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Dismantle and Assemble Compressor Components Bearings

9.26 9.26.1 Status

Bearings Status and Special Tools Completed activities:

• • Special Tools

9.26.2

9.2 Switch Off Compressor 9.9 Frame Covers

none

General Checks for Fitting New Bearings 1. Check the bearing clearances with a feeler gauge: •

We provide this method by considering deviations due to the problem of inserting the gauge in the limited space and also because of the round surfaces, which are to be checked.

2. Measure the bearing clearances with a dial indicator: •

This is a method, which do not require any disassembly. Depending on the compressor design, it could be difficult to position the dial indicator optimally. Measure the relative movement -this is the bearing clearance- between the bearing and journal with an indicator.

3. Check the bearing bore and the bearing journal: •

Check the shaft surface on wearing.

•

Compare the diameter with the defined value of the clearances.

•

Check the bores of the frame and the shells for damages and burrs.

•

Position the bearing shells correctly.

4. Check the gap of the bearing: The bearing shells must be positioned firmly with a certain pretension at the bore of the frame, The pretension avoids the bearing shells to be lifted from the bore of the frame and it avoids the bearing to follow the turning movement.

•

The bearings are jammed or do not have enough clearance.

PA_M4_0005a_01

•

Fig. 9-145 Check gap of bearing

5. Check the contact of the bearing:

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Dismantle and Assemble Compressor Components Bearings

Check the contact during installation of the bearing shell by using a feeler gauge. Protruding burrs or bearing shells, which jam, prevent the contact of the bearing shell with the bore of the frame. The bore of the bearing may be reduced and become eccentric. This causes too small bearing clearances or even marks.

•

Rework the burrs slightly: max. 0.1 mm x 45°.

PA_M4_0006a_01

•

Fig. 9-146 Check contact of the bearing

6. Check the edges: Rework sharp edges slightly.

PA_M4_0007a_01

•

Fig. 9-147 Check edges

7. Check the position of the shells: The upper bearing shell must fit to the lower one.

PA_M4_0008a_01

•

Fig. 9-148 Check position

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Dismantle and Assemble Compressor Components Crankshaft Bearing

9.27 9.27.1 Status

Crankshaft Bearing Status and Special Tools Completed activities:

• • Special Tools

9.27.2 Special Tools

9.2 Switch Off Compressor 9.9 Frame Covers

Dial indicator, hydraulic jack

Dismantle Crankshaft Bearing dial indicator, hydraulic jack

You can change the crankshaft bearing without dismantling the crankshaft. If you have to replace all bearings  dismantle the crankshaft and  install the bearings according to this instruction.

Required Checks

1. Check the clearance of the crankshaft bearing according to section 9.27.4 Measuring the Clearance. 2. Record measured values in the log sheet.

1

7

2

3 PA_M1_0012c_01

4 5 6

Fig. 9-149 Crankshaft bearing 1 2 3 4 5 6 7

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Threaded bolt for crankshaft bearing cover Hexagonal nut Crankshaft bearing cover drive end Crankshaft bearing shell drive end Tie rod for crankshaft bearing cover Frame Crankshaft bearing covers center and non-drive end

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Dismantle and Assemble Compressor Components Crankshaft Bearing

Important Note

First dismantle the tie rods (horizontal bearing cover bolts), and only afterwards dismantle the vertical bearing cover bolts.

Dismantle Horizontal Bearing Cover Bolts (Tie Rods)

1. Remove the tensioners SUPERBOLT® from the tie rods for the covers of the crankshaft bearings. For loosening procedure, see section 8.7.8 Tensioner SUPERBOLT®.

Dismantle Vertical Bearing Cover Bolts Remove Bearing Cover

2. Dismantle hexagonal nuts from the vertical bearing cover bolts.

3. Lift the cover of the crankshaft bearing (see Fig. 9-150).

Fig. 9-150 Lift bearing cover 1 2 3 4

Remove the Drive End Crankshaft Bearing

Sling Shackle Eye bolt Bearing cover

Lift Crankshaft 4. Position the dial indicator (1) according to Fig. 9-151. 5. Lift the crankshaft (3) or the flywheel (2) with a hydraulic jack (4) for max. 0.5 mm

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1

2

3

PA_L1_0005b_02

4

Fig. 9-151 Jack-up crankshaft 1 2 3 4

Dial indicator Flywheel Crankshaft Hydraulic jack

Remove Bearing Shells 6. Rotate the bearing shells to 90°. 7. Lift the now upper bearing shell out off the crankshaft. 8. Rotate the lower bearing shell at the drive end 180°. 9. Lift the lower bearing shell out off the crankshaft. Required Checks

10. Check the surface of the crankshaft for any damage. 11. If necessary, rework the surface of the crankshaft. 12. Check the new bearing shell for any damage.

Install New Bearing Shells

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13. Proceed with installing the new bearing shells on the drive end side according to section 9.27.3 Assemble Crankshaft Bearing.

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Dismantle and Assemble Compressor Components Crankshaft Bearing

Always replace old with new bearing shells in one step. Before you replace the center and non-drive end bearings proceed according section 9.27.3 Assemble Crankshaft Bearing, “Assemble Drive End Crankshaft Bearing”.

Remove the Non-Drive End Crankshaft Bearings

14. Install the hydraulic jack inside of the frame. 15. Lift the crankshaft approximately 0.20 mm by using a hydraulic jack. 16. Rotate the bearing shells to 90°. 17. Lift the now upper bearing shell out off the crankshaft. 18. Rotate the lower bearing shell at the drive end 180°. 19. Lift the lower bearing shell out off the crankshaft.

Required Checks

20. Check the surface of the crankshaft for any damage. 21. If necessary, rework the surface of the crankshaft. 22. Check the new bearing shell for any damage.

Install New Bearing Shells

23. Proceed with installing the new bearing shells according to section 9.27.3 Assemble Crankshaft Bearing.

Always replace old with new bearing shells in one step. Before you replace the other crankshaft bearings proceed according section 9.27.3 Assemble Crankshaft Bearing, “Assemble Center Crankshaft Bearing”.

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Dismantle and Assemble Compressor Components Crankshaft Bearing

9.27.3 Special Tools General Remarks

Assemble Crankshaft Bearing dial indicator, hydraulic jack The crankshaft bearings are installed as illustrated in the following illustration:

1

7

2

3 PA_M1_0012c_01

4 5 6

Fig. 9-152 Crankshaft bearing 1 2 3 4 5 6 7

Assemble Drive End Crankshaft Bearing

Threaded bolt for crankshaft bearing cover Hexagonal nut Crankshaft bearing cover drive end Crankshaft bearing shell drive end Tie rod for crankshaft bearing cover Frame Crankshaft bearing covers center and non-drive end

1. Check the new bearing shells for any damage. 2. Lift the crankshaft approximately 0.20 mm by using a hydraulic jack. 3. Oil the inner side of the bearing shell by using compressor oil. 4. Position the new bearing shell onto the crankshaft. 5. Rotate the bearing shell to 180°. 6. Place the second bearing shell onto the crankshaft. 7. Rotate the bearing shells by 90°. 8. Lower the crankshaft with the hydraulic jack.

Required Checks

1. Check the clearance of the crankshaft bearing according to section 9.27.4 Measuring the Clearance. 2. Record measured values in the log sheet.

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Dismantle and Assemble Compressor Components Crankshaft Bearing

Assemble Non-Drive End Crankshaft Bearings

1. Check the new bearing shells for any damage. 2. Install the hydraulic jack inside of the frame. 3. Lift the crankshaft approximately 0.20 mm by using a hydraulic jack. 4. Oil the inner side of the bearing shell by using compressor oil. 5. Position the new bearing shell onto the crankshaft. 6. Rotate the bearing shell to 180°. 7. Place the second bearing shell onto the crankshaft. 8. Rotate the bearing shells by 90°.

3

2

1

PB_M1_0006b_02

9. Lower the crankshaft with the hydraulic jack.

Fig. 9-153 Correctly installed bearing non-drive end 1 2 3

Install Bearing Covers

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Crankshaft Main bearing non-drive end Threaded bolt for bearing cover

1. Install the bearing covers.

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Dismantle and Assemble Compressor Components Crankshaft Bearing

Fig. 9-154 Lift bearing cover 1 2 3 4

Install Nuts for Vertical Bearing Cover Bolts

Sling Shackle Eye bolt Bearing cover

2. Fit the hexagonal nuts to the vertical bolts for the cover of the crankshaft bearing. 3. Tighten the hexagonal nuts with the mandatory tightening torque (see section “Compressor” in chapter 13 Appendix).

Install Nuts for Horizontal Bearing Cover Bolts (Tie Rods)

Required Checks

4. Fit the tensioners SUPERBOLT® to the horizontal bolts (tie rods) for the cover of the crankshaft bearing. 5. Tighten the tensioners SUPERBOLT® according to section 8.7.8 Tensioner SUPERBOLT®. Apply the mandatory tightening torque (see section “Compressor” in chapter 13 Appendix). 6. Check the clearance of the crankshaft bearing according to section 9.27.4 Measuring the Clearance. 7. Record measured values in the log sheet.

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9.27.4 Status

Measuring the Clearance Completed activities:

• Special tools

9.27.2 Dismantle Crankshaft Bearing

Feeler gauge CAUTION Always measure the clearance of the crankshaft bearing at both sides!  For example, measure the clearance at the oil pump side and at the coupling side.

1. Secure, that the W, Y and Z measuring points are accessible by turning the crankshaft.

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W

PA_M1_0009a_01

X

Y

Z

Fig. 9-155 Measuring points W X Y Z

Measuring points for axial clearance Clearance (chamfer) Measuring point for radial clearance Measuring point for radial clearance

1. Measure the radial clearance between the crankshaft and the crankshaft bearing at the W, Y and Z measuring points by using a feeler gauge. 2. Measure the radial clearance of the Y measuring point outside the chamfer, at least 20 mm from the center line.

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Dismantle and Assemble Compressor Components Axial Bearing

3. Measure the axial clearance of the W measuring point between the axial bearing and the crankshaft. 4. Write the values of the measured clearances in a log sheet. 5. Compare the measured values with the set values in the table of clearances (see section “Compressor” in chapter 13 Appendix).

9.28 9.28.1 Status

Axial Bearing Status and Special Tools Completed activities:

• • • Special Tools

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9.2 Switch Off Compressor 9.9 Frame Covers 9.27 Crankshaft Bearing

none

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Dismantle and Assemble Compressor Components Axial Bearing

1

2

6

3

4

PA_M1_0005b_02

5

Fig. 9-156 Axial bearing

1 2 3

Frame Axial bearing Crankshaft

4 5 6

Axial bearing half Axial bearing half Crankshaft main bearing

The axial bearing (2) at the drive end side is equipped with two axial bearing halves (4/5). The axial bearing limits the axial movement of the shaft system – crankshaft and motorshaft.

9.28.2

Dismantle Axial Bearing 1. Lift the bearing cover. 2. Turn crankshaft and axial bearing halves simultaneously about 180°. 3. Take the bearing halves out.

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9.28.3

Assemble Axial Bearing 1. Install the axial bearing halves. 2. Install the bearing cover.

9.29

Dismantle Crankshaft We strongly recommend that crankshaft dismantling is carried out by our specialists at site. We assume no liability for damage caused by inexpert crankshaft dismantling. Please contact our Technical Support Service (TSS), address see section 1.6 Contact Address.

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Clean and Degrease Plant and Compressor Components

10 Clean and Degrease Plant and Compressor Components 10.1 Cleaning Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 10.1.1 Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 10.1.2 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 10.1.3 Required Level of Cleanliness . . . . . . . . . . . . . . . 10 - 3 10.1.4 Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4 10.1.5 Safety Measures. . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4 10.1.6 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4 10.2 Working Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5 10.2.1 Workplace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6 10.2.2 Tools and Facility . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6 10.3 Select Cleansing Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6 10.4 Cleaning Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 9 10.4.1 Mechanical Cleaning . . . . . . . . . . . . . . . . . . . . . . 10 - 9 10.4.2 Chemical Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10 10.4.3 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10 10.4.4 Immersion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10 10.4.5 Wiping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10 10.4.6 Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10 10.4.7 Degreasing with Solvent Vapor . . . . . . . . . . . . . . 10 - 11 10.4.8 Ultrasonic Cleaning . . . . . . . . . . . . . . . . . . . . . . . 10 - 11 10.5 Preserve Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11

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Clean and Degrease Plant and Compressor Components Cleaning Specification

10.1 10.1.1

Cleaning Specification Scope and Purpose This chapter deals with the cleaning of plant components and compressor parts to assure that all parts and surfaces exposed to process gas are cleaned to the required level of cleanliness. Care must be taken that all parts and surfaces of the plant components exposed to process gas are compatible with the process gas and free from contaminants.

Applicability

The cleaning specification is applicable during manufacturing, installation of the compressor plant on site as well as during preventive maintenance or repair. It also applies to gas pipes made and/or adapted on site. For acid pickling and passivation of gas pipes – with the exception of stainless steel pipes welded with inert gas – see section 5.13.4 Pickle and Passivate Piping. Prior to dispatch, all assembled parts of the compressor as well as accessories coming in contact with process gas have been cleaned either in our works or by sub-suppliers. Parts from sub-suppliers have been checked for cleanliness. CAUTION Contamination of process gas! All components coming in contact with process gas must be checked for cleanliness prior to their installation.  When performing overhauls or exchanging spare parts, make sure that all significant surfaces have been cleaned according to the cleaning specification prior to assembly or installation.  If in doubt about cleanliness, repeat cleaning procedure.

Existing company-internal cleaning instructions must be taken into account too.

10.1.2 Significant Surface

10.1.3

Terms Any surface which is exposed to process gas.

Required Level of Cleanliness It is the superior authority’s responsibility to ensure safe working conditions.

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Significant surfaces must be dry and free of contaminants including:

• • •

10.1.4

hydrocarbon oils or greases, conventional paints, varnishes, fluxes or organic rust preventatives, loose or potentially loose parts such as slug, rust, welding residual matter, abrasive particles (e.g shot peening remains).

Principles Adapt cleaning process to type and extent of contaminant present.

10.1.5

•

Accomplish adequate cleaning whilst manufacturing, installation and testing in order to avoid residual contamination and the subsequent recontamination of cleaned components.

• •

Prevent risk and dangers by careful selection of cleansing agents.

• •

Use effective facilities for checking the level of cleanliness.

Use only solvents which have been declared acceptable by national authorities. Provide effective measures to keep the cleaned component parts clean until they are used.

Safety Measures Personnel who use cleansing agents must take safety precautions according to the Material Safety Data Sheets (MSDS) when working with such materials. For general information refer to section 2.4.9 Handling Chemicals. DANGER Health hazard and fire hazard! Chemicals can be toxic, caustic, flammable and explosive.  Do not eat, drink or smoke in the proximity of chemicals!  Before handling any chemicals, • pay attention to the warning symbols, peril indications and safety advice on the label of the storage container, • familiarize yourself with procedures in the event of contamination, poisoning, corrosion, spilling, leakage of unknown substance.  Always wear adequate protective clothing when handling chemicals.

10.1.6 Hazards

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Responsibility The superior authority is obliged to inform the personnel handling chemicals about possible dangers to humans and the environment.

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Hazard classification can be made according to:

• • •

flash point, toxicity, MAC-value (Maximum Allowable Concentration for working area).

The superior authority is obliged to instruct personnel using cleansing agents about their safe use. He must ensure that all necessary precautions have been are taken when using such chemicals. Our field supervisor will inform customer personnel about the risks involved when using cleansing agents. He must be supported by the client’s personnel in charge to ensure safe use and handling. Training

The personnel must be fully trained by the superior authority to carry out the correct cleaning methods and their attention must be drawn to the serious consequences of faulty cleaning. The personnel shall take special notice of:

10.2

• •

classification and properties of the cleansing agent,

• • • • •

safety precautions for handling cleansing agents,

possible dangers (explosion and/or fire risks and other health concerns), dealing with an incident, manufacturer’s instructions, appropriate cleaning methods, disposal procedures.

Working Environment Technical aspects to be considered:

•

Location where cleaning is carried out: – –

•

Period when cleaning is carried out: – – – –

•

assembled, disassembled.

Complexity: – –

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during manufacturing, installation, pre-commissioning, maintenance/repair.

State of equipment to be cleaned: – –

•

in the workshop, on installation site.

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big or elongated (pipes) parts, complicated/dead ends, gaps.

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10.2.1

Workplace The workplace for cleaning and installation has to be clean and as far from heavy manufacturing and machine tools as possible. Its arrangement shall make an inadvertent mix-up of cleaned and uncleaned components as well as the utilization of non-approved material for assembly impossible. The cleanliness of the workplace must correspond to the commonly accepted work place for light assembly and testing. Harmless cleaning agents should preferably be applied. The use of harmful cleaning agents must be limited to a minimum. Components cleaning must be carried out in closed facilities. DANGER Health hazard! Cleansing agents may impair your health.  Avoid concentrations higher than the MAC-value (Maximum Allowable Concentration for working area).  Provide adequate ventilation in areas where cleaning operations are performed.

DANGER Fire hazard! Flammable organic solvents, acids or lyes.  Provide adequate ventilation in areas where cleaning operations are performed.  No open fire.  No smoking.

10.2.2

Tools and Facility Tools and equipment used for cleaning must either be stored cleanly and separate from other tools and installations or be cleaned carefully before each use. This also applies to testing equipment which is used on the cleaned component parts. Working surfaces must be cleaned before use and covered with clean, strong packing paper or polyethylene sheeting.

10.3

Select Cleansing Agent Special care shall be given to the properties of the cleansing agent regarding compatibility with process gas, flammability, toxicity, corrosion effect, and environmental impact. Personnel who use cleansing agents must take safety precautions according to the Material Safety Data Sheets (MSDS) when working with such materials. For general information refer to section 2.4.9 Handling Chemicals.

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Health Aspects

The ideal agent is non-toxic or at least has a low toxicity. The main factors to take into consideration are inhalation effects, skin effects and eye effects.

Environmental Aspects

There are four main issues concerning the environment: emission to water, waste disposal, emission to air and energy. Emission to Water Contamination of water arises from improper waste disposal, inadequate waste water treatment or in case of solvents, accidental spillage caused by improper handling or storage. Waste Disposal Degreasing with solvents gives rise to a residue containing oils and greases. The solvent content can easily be reduced by distillation either in house or by licensed recycler, thus recovering useful quantities of solvent. The residue – a highly concentrated final waste – should be disposed by a licensed contractor, meeting local regulations. Cleaning in an aqueous system generates effluent containing chemical products necessary for the cleaning process and may be contaminated with oils and greases. This residue must be treated in a waste water treatment plant. Emission to Air The limit values of emissions to air due to organic solvents are given in national regulations. Energy When a drying procedure is required, aqueous cleaning processes can be more energy intensive than those using solvents.

Organic Solvents

The increasingly stringent environment regulations of the last years, regulations including the phasing out of most chlorofluorocarbons (CFC), restrictions in the use and banning of some volatile organic compounds (VOC) led to the necessity to develop alternatives. CFCs contribute to the depletion of the ozone layer, VOCs are a major source of photochemical smog and ground level ozone that have harmful effects on human health and the environment.

Potential users should determine whether the solvent has been declared acceptable by national authorities.

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Acetone For the cleaning of significant surfaces, we recommend the use of acetone.

•

Clean parts with a paint brush or a clean, lint-free cleaning tissue soaked in acetone.

• •

Completely remove liquid and vapors after cleaning. Purge cleaned spaces with oil-free compressed air till no trace of the solvent can be detected.

WARNING Fire and health hazard! Acetone is flammable. Vapor may cause flash fire. Harmful if swallowed or inhaled. Causes irritation to skin, eyes and respiratory tract. Affects central nervous system.  Always wear adequate protective clothing when handling chemicals.  Restrict the use of acetone to a minimum.  No open fire.  No smoking.

Cleansing Agent BLG05 Use Cleansing Agent BLG05 to remove Burckhardt Lubrication Grease BLG05.

Other cleansing agents can be used for surfaces that are not exposed to process gas.

Water Soluble Cleansing Agents

The manufacturer’s specification for application of the cleansing agent shall be strictly observed. After cleaning using water soluble cleansing agents (e.g. alkaline detergents), thorough rinsing and drying of all components is essential.

Air and Nitrogen

Water

Corrosion Inhibitors

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Air and nitrogen used for purging, drying or testing after final cleaning (= cleaning with acetone or other cleansing agents) must be clean, dry (dew point –29 °C or lower) and oil-free. Compressed air can be used. Careful control of the filter system is vital. Water used for making solutions or for flushing must be tap water or of equivalent quality. Any inorganic corrosion inhibitor may be used to minimize rusting of ferrous items. Any inorganic corrosion inhibitor may be used in the hydrostatic pressure test or rinse water to minimize rusting of ferrous items. Sodium nitrite (approximately 0.5 % by weight) or borax (approximately 1.5 % by weight) is recommended. The use of these substances must be limited to the specific applications.

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Clean and Degrease Plant and Compressor Components Cleaning Methods

10.4

Cleaning Methods Prior to dispatch, all assembled parts of the compressor as well as accessories coming in contact with process gas have been cleaned either in our works or by sub-suppliers. Parts from sub-suppliers have been checked for cleanliness. CAUTION Contamination of process gas! All components coming in contact with process gas must be checked for cleanliness prior to their installation.  When performing overhauls or exchanging spare parts, make sure that all significant surfaces have been cleaned according to the cleaning specification prior to assembly or installation.  If in doubt about cleanliness, repeat cleaning procedure.

Principles

•

Each – or a combination – of the cleaning methods listed below can be used depending on the facilities available, size and shape of item, nature of the contamination, accessibility, etc.

•

Sandblasting is the preferred method to achieve grey, metallic surfaces for carbon steel items such as gas piping, vessels etc. Except for thoroughly removing particles by blowing out, wiping or vacuum cleaning, no further cleaning is required. The term sandblasting includes shot, bead, and grit blasting.

•

Large objects such as long pipes must be cleaned and degreased before welding together. Open ends of the pipes must be covered with a temporary leak proof cover to prevent ingress of foreign matter.

• •

Do not clean parts just for better appearance. The result of the cleaning must meet the requirements of section 10.1.3 Required Level of Cleanliness.

Select the appropriate method of cleaning according to required level of cleanliness.

10.4.1

Mechanical Cleaning For example wire brushing, blast cleaning, scraping or other physical removal of contaminants from equipment. It is generally used as a preliminary cleaning method or in combination with other methods. This method is not used for accurately dimensioned components as the method can cause uneven material loss.

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10.4.2

Chemical Cleaning Normally a preliminary cleaning operation for piping and vessels. This includes acid pickling (descaling), passivation, derusting, bright dipping, alkaline cleaning, etc. Conventional chemical solutions are acceptable providing they do not leave a residue or are followed by final cleaning. The manufacturer’s specification for application of the cleansing agent and necessary safety precautions must be strictly observed. For detailed instruction of acid pickling and passivation of piping – with the exception of stainless steel pipes welded with inert gas – see section 5.13.4 Pickle and Passivate Piping.

Since oil and grease generally cannot be removed by acids, these contaminants – if present – must be removed with an organic solvent or alkaline solution prior to acid pickling.

10.4.3

Flushing With this method, the equipment to be cleaned is filled with a flowing solvent or heated cleansing agent which is agitated if possible. Thorough rinsing with clean water and subsequent drying with oil-free dry air or nitrogen is required if a detergent is used. If a solvent is used, the vessel must be thoroughly purged with oil-free, dry air or nitrogen.

10.4.4

Immersion With this method, the equipment to be cleaned is submerged in a solvent or cleansing agent and scrubbed, if possible. When many parts are to be cleaned, use two baths, the first to remove most of the contaminants and the second to remove the remaining contaminants. When the first bath becomes dirty, it is discarded and the second becomes the first and a new, clean, final bath is provided. Briefly immerse non-metallic parts or wipe with a tissue as described below.

10.4.5

Wiping Components with readily accessible surfaces may be cleaned with this method using a solvent or cleansing agent. Typical examples are vessels that can be entered (using only cleansing agents and observing all applicable safety procedures). Non-metallic parts that cannot be immersed because the solvent causes them to swell, may be cleaned by wiping with a clean tissue moistened with solvent or cleansing agent.

10.4.6

Spraying The cleansing agent – solvent or detergent – is discharged at high velocity through nozzles specially chosen for particular applications. This method is frequently used on large equipment or piping.

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10.4.7

Degreasing with Solvent Vapor With this method, cleaning is carried out by the flushing action of solvent vapor which condenses on the cool surface of the component being cleaned. It has the advantage of continually distilling the solvent so that only pure solvent contacts the surface. Components must be positioned to ensure complete drainage. Components with dead ends or pockets from which condensate cannot be drained should be cleaned with an alternative method. Do not vapor degrease non-metallic materials. Limit to brief immersion or wipe with a tissue moistened with a solvent or cleansing agent.

10.4.8

Ultrasonic Cleaning The cleaning solution is agitated with high frequency by the use of an ultrasonic generator, so that contaminants will be detached and thin layers will lacerate. Especially effective for cleaning of small parts with dead ends or pockets and crevices.

10.5

Preserve Cleanliness Freshly cleaned component parts, which are not immediately installed, must be protected against re-contamination during transportation and storing by covering them with polyethylene sheeting, clean strong packing paper or rust preventing paper. The packing shall not be opened until the equipment is ready to be installed. Cleaned components must be stored until installation in a suitable dedicated area free from contamination and always separate from uncleaned parts to avoid accidental mix-up. Prior to installation, the cleanliness must be checked again to ensure that the required level of cleanliness has been maintained.

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Decommissioning and Waste Disposal

11 Decommissioning and Waste Disposal 11.1 11.2 11.3 11.4

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Preserve Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . Maintain Plant during Decommissioning. . . . . . . . . . . . . . . Recommission Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dispose Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2B1XC2.64_1

IM 200322en

11 - 3 11 - 5 11 - 5 11 - 6

11 – 1

Decommissioning and Waste Disposal

11 – 2

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Decommissioning and Waste Disposal Preserve Compressor Plant

11.1 Period of Standstill Exceeds 2 Months

Preserve Compressor Plant If the standstill period of a compressor plant exceeds 2 months, the compressor and its auxiliary equipment must be protected against possible standstill damage by taking appropriate measures for the respective period of time. CAUTION Standstill damage possible! Due to the numerous possibilities of installation and employment of our compressors, instructions on preservation depend on application.  Please contact Burckhardt Compression Services, address see section 1.6 Contact Address.

General Procedure

The following procedure is intended to provide general advice. Depending on your application, our instructions on preservation are liable to amendment or supplement at any time. 1. Drain the cooling chambers of the compressor and the coolers. Leave the drain valve open. 2. Fill oil system with lubricating oil. A special corrosion protecting oil from a reputable supplier may be used during the standstill period. 3. Oil the piston rods well by hand up to the oil shield. Turn the flywheel min. 1 rotation by means of the barring device in running direction. Generally, the gas conducting compressor and plant components should not be protected by oil or grease (leave surfaces dry and untreated). 4. Fill the compressor or the entire compressor system with dry, oil-free nitrogen. During the whole standstill period, the plant/compressor should be flushed continuously through with nitrogen, or kept under a slight overpressure of 0.05 bar g/0.005 MPa g/0.05 kg/cm2 g. DANGER Pressurized vessel or pipe! Plant/compressor under nitrogen pressure.  Fit a corresponding warning sign on the installation.  Depressurize plant before you start working.

Under all circumstances, prevent moist air from entering the compressor/ system.

18.05.2016

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

11 – 3

Decommissioning and Waste Disposal Preserve Compressor Plant

DANGER Health hazard! Risk of suffocation! Nitrogen gas is an asphyxiant and presents a health hazard by displacing the oxygen in the atmosphere. At high concentrations, unconsciousness or death may occur.  Depressurize the installation before you open the compressor.  When working on the compressor, make sure there is sufficient circulation of fresh air.  Be aware of any signs of dizziness or fatigue. Exposures to fatal concentrations of nitrogen could occur without any significant warning symptoms.  During an emergency situation, before entering the area, check for oxygen-deficient atmospheres.

5. Alternative solution: To prevent corrosion in the vicinity of the cylinder insert moisture absorbent agent – e.g. VCI mats (Volatile Corrosion Inhibitor) – in the cylinder, valve spaces and distance piece. Experience has shown that in the area of the lubricated crankgear, absorbent agents are not necessary. CAUTION Forgotten absorbent agent mats can damage the compressor!  Record number and location of absorbent agent packs/mats in the compressor.  Make sure the flywheel can still be turned manually.

11 – 4

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Decommissioning and Waste Disposal Maintain Plant during Decommissioning

11.2

Maintain Plant during Decommissioning 1. Check condition of moisture absorbent agent every six months and replace if necessary. 2. To protect the bearings and to check that everything is in proper working condition, switch on the prelubrication pump for about 5 to 10 minutes every week and, at the same time, turn the flywheel (min. 1 rotation). Be careful of absorbent agent packs in the cylinders! 3. Large differences between day and night temperatures can lead to condensation in the electric motor. Due attention should be given to this occurrence during the standstill period and before putting into operation again (dry out, heat, ventilate, check insulation resistance, etc.).

For the description of the electric motor refer to the documentation of the motor manufacturer.

4. Annually conduct a condition check of the complete compressor system.

11.3

Recommission Plant Carefully check the complete compressor system before recommissioning.

•

In particular, the functionality and operation of the mechanical and electrical safety devices.

•

Perform a hydrostatic pressure test of all the cooling chambers, using the specified pressure test data.

We advise customers to arrange for one of our specialists to be present when this work is carried out.  Please contact Burckhardt Compression Services, address see section 1.6 Contact Address.

For the description of the electric motor refer to the documentation of the motor manufacturer.

Commission compressor/plant according to instructions in section 6.2 Commissioning.

18.05.2016

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

11 – 5

Decommissioning and Waste Disposal Waste Disposal

11.4 Compressor Components

Lubricants

Chemicals

Cleansing Agents

Waste Disposal At the end of their lifetime, the compressor components must be disposed of according to all applicable regulations. We recommend contacting a company specializing in recycling and waste disposal.

• •

Oils must be recycled, return them to the supplier.

•

It is strictly forbidden to dispose of lubricants in toilets, cleaning rooms, water drains or to discharge to the ground or waste containers etc.

•

Take care of the environment: dispose of chemicals according to national regulations.

•

It is strictly forbidden to dispose of chemicals in toilets, cleaning rooms, water drains, into the ground or waste containers etc.

Take care of the environment: dispose of lubricants according to national regulations.

Degreasing with solvents gives rise to a residue containing oils and greases. The solvent content can easily be reduced by distillation either in house or by licensed recycler, thus recovering useful quantities of solvent. The residue – a highly concentrated final waste – should be disposed by a licensed contractor, meeting local regulations. Cleaning in an aqueous system generates effluent containing chemical products necessary for the cleaning process and may be contaminated with oils and greases. This residue must be treated in a waste water treatment plant.

11 – 6

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Spare Parts

12 Spare Parts 12.1 Order Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.1 Burckhardt e-ShopTM . . . . . . . . . . . . . . . . . . . . . . 12.1.2 Original Spare Parts Only! . . . . . . . . . . . . . . . . . . 12.1.3 Importance of Spares Inventory . . . . . . . . . . . . . . 12.1.4 Spare Parts Recommendation . . . . . . . . . . . . . . . 12.2 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 Spare Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18.05.2016

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

12 - 3 12 - 4 12 - 4 12 - 5 12 - 6 12 - 8 12 - 15

12 – 1

Spare Parts

12 – 2

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Spare Parts Order Spare Parts

12.1 Required Data

Order Spare Parts When ordering spare parts, always provide the following data:

• • • • Stage Dependent Code Numbers

Compressor serial no.: 200322 Compressor type: 2B1XC2.64_1 Spare part designation Code no.

When ordering stage dependent spare parts, consider the following example: C4*330 C4*310

C4*360

C4*350 C4*400 C4*390

C4*320

C4*430

C4*370

XA_CX_0044b_02

C4*380

Fig. 12-1 Example for stage dependent code numbers

* = placeholder for stage. Example: code no. for a 1st stage discharge valve is C41200 1st stage: 2

C41200

nd

stage: C42200

rd

C43200

3 stage: and so on

A 0 (zero) in the third position of a code no. (on spare parts drawings and/ or in spare parts lists) signifies that this spare part is identical for all stages.

A code no. in brackets ( ) indicates spare parts, which are not always implemented and may not be applicable for your plant.

Approach

18.05.2016

1. Find the demanded spare part on respective spare parts drawing in section 12.3 Spare Parts Drawings and note the corresponding code no.

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

12 – 3

Spare Parts Order Spare Parts

Illustrations may only be examples. Thus, you must not read out exact dimensions nor detailed visual appearance. Bold printed code no. on spare parts drawings refer to detail drawing of the respective spare part.

2. Consult the spare parts list in section 12.2 Spare Parts List and look up the related spare part designation. 3. Order spare parts (address see section 1.6 Contact Address) providing compressor type and serial no.

12.1.1

Burckhardt e-ShopTM In the Burckhardt e-ShopTM, you can access an on-line catalog for information or to order spare parts. You can find in it all drawings, spare parts and spare part recommendations related to your compressor. In this way, you can not only simplify your maintenance planning and speed up your orders, the system also contains various features to help you with the identification and selection of the parts needed. Last but not least, you will have the latest drawings available at any time. For more details or to register to the Burckhardt e-ShopTM, please contact [email protected].

12.1.2

Original Spare Parts Only! We only assume liability for original spare parts which have been supplied by Burckhardt Compression. Spare parts and plant accessories which have not been delivered by us may not correspond to the original or modified design. CAUTION Increased risk! The specially designed characteristics of the compressor or related plant components and/or their operational safety may be impaired.  Do not modify parts/spare parts.  Only use original spare parts.  Never use unsuitable material.  Exchange worn parts.

Please note that specific fabrication and supply specifications often exist for parts supplied by Burckhardt Compression as well as by sub-suppliers. We can always offer you spare parts which correspond to the latest technical standards and comply with the newest legal regulations.

12 – 4

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Spare Parts Order Spare Parts

12.1.3

Importance of Spares Inventory A stock of the most important replacement and wear parts at the compressor site is a key factor for the on-going operation and service availability of the compressor. A distinction must be made between different kind of spare parts on stock:

• •

Commissioning spare parts.

•

Capital spare parts for break down situations (section 12.1.4 Spare Parts Recommendation, column “C”). These parts are not always available in stock. We therefore advise you to have your own stock-keeping.

Wear parts for 2 years operation (section 12.1.4 Spare Parts Recommendation, column “W”).

The quantity (section 12.1.4 Spare Parts Recommendation, column “Qty”) reflects the number of recommended wear/capital spare parts for 1 compressor as described in this manual. For some parts a quantity of “0” may appear, because such parts are:

•

Non built-in options to the specific compressor described in this manual.

•

Assemblies containing wear/capital spare parts quantified elsewhere in the column.

For specific details see the respective spare parts drawing(s) in section 12.3 Spare Parts Drawings.

Our Spare Part division of Customer Support Service will be glad to provide you with a corresponding tender for wear parts and/or capital spare parts. Contact address see section 1.6 Contact Address.

18.05.2016

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

12 – 5

Spare Parts Order Spare Parts

12.1.4

Spare Parts Recommendation We recommend keeping the following spare parts in the listed quantities in stock: (W = wear parts, C = capital spare parts)

Code No Designation

12 – 6

W

C

Qty

X

1

C01400

Cylinder liner 1st stage

C01415

O-ring for cylinder liner 1st stage

X

4

C01620

O-ring for cylinder cover 1st stage

X

2

C11110

Piston skirt 1st stage

C11261

Piston ring, scarf joint, right 1st stage

X

4

C11262

Piston ring, scarf joint, left 1st stage

X

4

C11280

Rider ring for piston (guide ring) 1st stage

X

8

C11500

Piston rod 1st stage

C11700

Oil shield for piston rod, complete 1st stage

X

2

C21016

O-ring for suction valve cover 1st stage

X

8

C21330

Center bolt to suction valve 1st stage

X

4

C21350

Locking disc for suction valve 1st stage

X

8

C21370

Lift washer no. 1 for suction valve 1st stage

X

24

C21380

Valve plate for suction valve 1st stage

X

8

C21390

Damper plate for suction valve 1st stage

X

4

C21400

Valve spring for suction valve 1st stage

X

192

C31001

Controlled suction valve, complete 1st stage

C31030

Special nut 1st stage

X

4

C31040

Spring dowel pin 1st stage

X

16

C41016

O-ring for discharge valve cover 1st stage

X

8

C41200

Discharge valve, complete 1st stage

C41330

Center bolt for discharge valve 1st stage

X

4

C41350

Locking disc for discharge valve 1st stage

X

8

C41370

Lift washer no. 1 for discharge valve 1st stage

X

24

C41380

Valve plate for discharge valve 1st stage

X

8

C41390

Damper plate for discharge valve 1st stage

X

4

C41400

Valve spring for discharge valve 1st stage

X

192

C51400

Packing cartridge, complete, per piston rod 1st stage

C51499

Pressure breaker (crown ring) for packing 1st stage

X

2

C51517

Seal element (Pair of seal rings) 1st stage

X

6

C51519

Pressure breaker, no. 1(throttle ring) 1st stage

X

2

C51521

Support ring for piston rod packing 1st stage

X

8

C51528

Seal element, complete 1st stage

X

4

C51529

O-ring No. 1 for packing cup 1st stage

X

86

IM 200322en

2B1XC2.64_1

X

X

X

X

X

Rev. 001/kalajdzisa_a

1

1

4

4

1

18.05.2016

Spare Parts Order Spare Parts

18.05.2016

Code No Designation

W

C51534

O-ring No. 4 for basic bush 1st stage

X

M10200

Crankshaft bearing

X

1

M10401

Axial guide ring

X

2

M10735

V-seal ring

M30015

Crosshead shoe

X

2

M30600

Crosshead pin

X

1

M40300

Connecting rod bearing

X

1

M40410

Crosshead pin bearing

X

1

M50526

Wiper element, multisegmented

X

4

M50530

Seal element in 2-pieces

X

2

M50535

Supporting ring for wiper element

X

2

M50545

Spring plate

X

2

M60005

O-ring for distance piece/crankgear

X

2

M60205

Gasket for distance piece cover

X

4

M60206

Gasket for distance piece cover

X

4

M60350

Seal element, complete for M60300

X

4

Rev. 001/kalajdzisa_a

C

2

X

2B1XC2.64_1

IM 200322en

Qty

2

12 – 7

Spare Parts Spare Parts List

12.2

Spare Parts List Code No Designation

12 – 8

IM 200322en

W

A10000

Internal piping

A10025

Gasket to Oil pipe

A10030

O-ring No.1 to oil pipe

A10035

O-ring No.2 to oil pipe

A20490

Socket ball valve

A40301

Gasket for oil pipe no. 1

A40302

Gasket for oil pipe no. 2

C0*001

Cylinder

C0*061

Cylinder base

C0*065

O-ring for cylinder base

C0*070

Cylinder sleeve for packing

C0*130

O-ring for cylinder/distance piece

C0*200

Threaded bolts for cylinder/frame, distance piece

C0*210

Threaded bolts for cylinder cover

C0*212

Threaded bolts for cylinder base

C0*215

Hexagonal nut for cylinder cover

C0*219

Hexagonal nut for cylinder base

C0*220

Threaded bolt for suction valve cover

C0*225

Threaded bolts for discharge valve cover

C0*230

Hexagonal nut for valve cover

C0*250

Threaded bolts for piston rod packing

C0*255

Hexagonal nut for packing

C0*270

Threaded bolts for connection suct. & disch. line

C0*275

Hexagonal nut for pipe connection suc./ dis. line

C0*400

Cylinder liner

C0*405

Cylinder liner, complete

C0*415

O-ring for cylinder liner

C0*519

Gasket for suction-/discharge pipe

C0*605

Cylinder cover, complete

C0*620

O-ring for cylinder cover

C00206

SUPERBOLT® nut for cylinder/frame

C01001

Cylinder 1st stage

C01140

Cleaning cover, large no. 1, for cylinder 1st stage

C01145

Gasket for large cylinder cleaning cover no. 1, 1st stage

2B1XC2.64_1

C

X X

X

Rev. 001/kalajdzisa_a

18.05.2016

Spare Parts Spare Parts List

Code No Designation

18.05.2016

W

C01155

Cleaning cover, small no. 1, for cylinder 1st stage

C01156

Cleaning cover, small no. 2, for cylinder 1st stage

C01160

Gasket for small cylinder cleaning cover no. 1 1st stage

C01166

O-Ring for small cylinder cleaning cover no.2 1st stage

C01180

Screw plug, small 1st stage

C01185

Gasket for small screw plug 1st stage

C1*000

Piston & piston rod

C1*010

Piston complete incl. piston rod &piston rings

C1*110

Piston skirt

C1*120

Upper piston crown

C1*130

Lower piston crown

C1*230

Piston back-up ring

C1*261

Piston ring, scarf joint, right

X

C1*262

Piston ring, scarf joint, left

X

C1*280

Rider ring for piston (guide ring)

X

C1*500

Piston rod

C1*550

SUPERBOLT® nut for piston

C1*610

O-ring for SUPERBOLT® nut

C1*700

Oil shield for piston rod, complete

C2*010

Valve cover, suction valve with actuator

C2*016

O-ring for suction valve cover

C2*020

Valve lantern for suction valve

C2*025

Pressure screw, suction side

C2*045

Cap nut for pressure screw, suction side

C2*050

Gasket for cap nut, suction side

C2*320

Suction valve seat

C2*330

Center bolt to suction valve

X

C2*350

Locking disc for suction valve

X

C2*360

Suction valve guard

C2*370

Lift washer no. 1 for suction valve

X

C2*380

Valve plate for suction valve

X

C2*390

Damper plate for suction valve

X

C2*400

Valve spring for suction valve

X

C2*430

Cylindrical pin for suction valve

C3*000

Controlled suction valve with actuator

C3*001

Controlled suction valve, complete

Rev. 001/kalajdzisa_a

2B1XC2.64_1

C

X

X

IM 200322en

X X

X

12 – 9

Spare Parts Spare Parts List

Code No Designation

12 – 10

IM 200322en

W

C3*020

Pressure sleeve

C3*030

Special nut

X

C3*040

Spring dowel pin

X

C3*060

Compression spring

C3*070

Finger unloader, complete

C3*409

Washer to TURCITE®

C3*410

Actuator, complete

C3*412

O-ring for actuator housing

C3*413

Nipple

C3*414

Gasket for nipple

C3*415

STEPSEAL® TURCITE®

C3*416

Circlip

C3*417

Guiding band for actuator

C3*418

Screw plug, complete

C3*419

Pipe union for actuator, complete

C3*420

Gasket for pipe union, actuator

C3*421

Pressure pin, actuator

C3*422

Strain washer USIT / flat gasket

C3*423

Washer

C3*424

Self locking hexagonal nut

C3*426

O-ring for actuator

C3*427

Cylindrical head screw, short

C3*430

Screw plug, complete

C3*431

Venting valve for actuator, complete

C3*435

Position indicator, complete for actuator

C3*436

Indicator bolt

C3*437

Screw plug

C3*438

O-ring for position indicator

C3*440

Actuator piston incl. GLYD- and O-ring

C3*445

Spring no. 3, medium, for actuator piston

C3*446

Circlip for actuator

C3*447

Scraper for actuator

C3*475

Cylindrical head screw, long

C3*480

Actuator housing, compl.

C4*000

Installation of discharge valve

C4*005

Valve cover, discharge valve

C4*016

O-ring for discharge valve cover

C4*020

Valve lantern for discharge valve

C4*025

Pressure screw, discharge side

2B1XC2.64_1

Rev. 001/kalajdzisa_a

C

X

18.05.2016

Spare Parts Spare Parts List

Code No Designation

18.05.2016

W

C4*045

Cap nut for pressure screw, discharge side

C4*050

Gasket for cap nut, discharge side

C4*096

Screw plug for valve cover, discharge valve

C4*097

Gasket for screw plug, discharge valve

C4*200

Discharge valve, complete

C4*310

Hexagonal nut for discharge valve

C4*320

Discharge valve seat

C4*330

Center bolt for discharge valve

X

C4*350

Locking disc for discharge valve

X

C4*360

Discharge valve guard

C4*370

Lift washer no. 1 for discharge valve

X

C4*380

Valve plate for discharge valve

X

C4*390

Damper plate for discharge valve

X

C4*400

Valve spring for discharge valve

X

C4*430

Cylindrical pin for discharge valve

C5*002

Packing, complete, per piston rod

C5*400

Packing cartridge, complete, per piston rod

C5*499

Pressure breaker (crown ring) for packing

C5*500

Packing flange

C5*502

Basic bush for packing

C5*503

Basic ring/Packing cup No. 1

C5*504

Packing cup No. 2

C5*505

Packing cup No. 3

C5*506

Packing cup No. 4

C5*507

Packing cup No. 5

C5*517

Seal element (Pair of seal rings)

X

C5*519

Pressure breaker, no. 1(throttle ring)

X

C5*521

Support ring for piston rod packing

X

C5*528

Seal element, complete

X

C5*529

O-ring No. 1 for packing cup

X

C5*534

O-ring No. 4 for basic bush

X

C5*545

Cover for flange

C5*546

Stud bolt complete for packing

L00100

Anchor bolts for compressor

L00110

Nut for anchor bolt

L00117

Protecting sleeve to nut

L10000

Drive

L10010

Flywheel

Rev. 001/kalajdzisa_a

2B1XC2.64_1

C

X

IM 200322en

X X

12 – 11

Spare Parts Spare Parts List

Code No Designation

12 – 12

IM 200322en

W

C

L10120

Coupling bolt

L10130

Hexagonal nut

L10140

Split pin for L10120

M00000

Crankgear

M00015

Crankcase

M00045

Threaded bolt for bearing cover

M00060

Tie rod for crankshaft bearing cover

M00065

Nut for crankshaft bearing

M00068

Protecting sleeve to nut

M00070

SUPERBOLT® nut for frame

M00100

Threaded bolt for distance piece

M00105

SUPERBOLT® nut for distance piece

M00110

O-ring for frame/distance piece

M00215

Cover for bearing bracket, non-drive end

M00220

Gasket for cover of bearing bracket, nondrive end

M00410

Frame cover, large

M00415

Gasket for large frame cover

M00440

Frame cover, small-sized

M00445

Gasket for small-sized frame cover

M00900

Breather for crankgear/distance piece

M00910

Spare cartridge for breather

M10005

Crankshaft

M10200

Crankshaft bearing

X

M10401

Axial guide ring

X

M10600

Oil trap & crankshaft seal

M10615

Gasket for oil trap

M10630

Oil trap cover in 2-pieces

M10660

Trigger sensor

M10661

Reduction for keyphasor

M10662

Gasket for keyphasor

M10730

Cover in 2 pieces for crankshaft seal

M10735

V-seal ring

M20000

Gear oil pump complete

M20001

Gear oil pump Typ R, complete

M20015

Housing for oiler drive

M20016

Gasket for housing of oiler drive

M20030

O-ring No. 1 for oil pump

M20060

Driving gearwheel

M20090

Driven gearwheel

2B1XC2.64_1

X

Rev. 001/kalajdzisa_a

18.05.2016

Spare Parts Spare Parts List

Code No Designation

18.05.2016

W

M20120

O-ring No. 2 for oil pump

M20150

Crankshaft seal for oil pump

M20155

Circlip for crankshaft seal

M20160

Intermediate piece for oil pump

M20165

Intermediate flange for oil pump

M20170

Coupling for pump drive

M20180

O-ring No. 3 for oil pump

M20200

O-ring No. 4 for oil pump

M30000

Crosshead-piston rod connection

M30006

Crosshead body

M30015

Crosshead shoe

M30115

Hydraulic nut for crosshead

M30195

Washer for crosshead

M30206

Locking plate for screw

M30207

Washer for screw

M30210

Set collar for crosshead

M30215

SUPERBOLT® nut for crosshead/piston rod

M30220

Set screw, complete for set collar

M30225

Allen srew for crosshead shoe

M30230

Strain washer for allen screw

M30600

Crosshead pin

M30620

Circlip for crosshead pin

M4*000

Connecting rod, complete with bearings

M4*410

Crosshead pin bearing

M40000

Connecting rod, complete with bearings

M40010

Connecting rod, without bearings

M40020

Connecting rod bolt

M40050

SUPERBOLT® nut for M40000/10

M40300

Connecting rod bearing

M50001

Oil scraping

M50400

Oil scraper plate

M50410

O-ring for oil scraper plate

M50420

Cover for oil scraper plate

M50425

Cover for oil scraper plate

M50501

Set of wiper elements, complete (set per piston rod)

M50526

Wiper element, multisegmented

X

M50530

Seal element in 2-pieces

X

M50535

Supporting ring for wiper element

X

M50545

Spring plate

X

Rev. 001/kalajdzisa_a

2B1XC2.64_1

C

X

X

X

X

IM 200322en

12 – 13

Spare Parts Spare Parts List

Code No Designation

12 – 14

IM 200322en

W

M50555

Prewiper element

M60001

Distance piece

M60005

O-ring for distance piece/crankgear

M60075

Gasket for nipple

M60200

Cover for distance piece

M60201

Cover for distance piece

M60202

Cover for distance piece

M60205

Gasket for distance piece cover

X

M60206

Gasket for distance piece cover

X

M60300

Distance piece packing

M60320

Housing

M60330

O-ring for distance piece packing

M60340

Cover for distance piece packing

M60350

Seal element, complete for M60300

2B1XC2.64_1

Rev. 001/kalajdzisa_a

C

X

X

18.05.2016

Spare Parts Spare Parts Drawings

12.3

Spare Parts Drawings Illustrations may only be examples. Thus, you must not read out exact dimensions nor detailed visual appearance. Bold printed code no. on spare parts drawings refer to detail drawing of the respective spare part.

Overview Title

Drawing No.

Compressor layout

126003420

Drive System Title

Drawing No.

Drive

126000935

Lubricating System Title

Drawing No.

Gear oil pump, type R

126000285

Gear oil pump, type R

126000286

Oil pipe in the carter

126001232

Crankgear Title

Drawing No.

Crankgear

126001128

Oiltrap and crankshaft seal

126000707

Connecting rod

126001108

Crosshead-piston rod connection

126000361

Distance Piece

18.05.2016

Title

Drawing No.

Distance piece

126001188

Oil scraping

126001196

Distance piece packing

126000702

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

12 – 15

Spare Parts Spare Parts Drawings

Cylinder

12 – 16

IM 200322en

Title

Drawing No.

Cylinder

126001428

Piston

126003421

Piston rod packing

126002287

Controlled suction valve with actuator

126000937

Controlled suction valve

126000088

Actuator for controlled suction valve

126000517

Installation of discharge valve

126000765

Assembly of discharge valve

126000089

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

C01001

M00900 M00910

M60001

M00215 M00220

M00900 M00910

M60001

C01001

C01156 C01166

C01140 C01145

C01155 C01160

C01180 C01185

M60200 M60205

A20490

M60200 M60205

M60202 M60206

A40301

M00000

L10000

M60075

M60201 M60206

A40302

M00440 M00445

M00410 M00415

M20000

A20490

M60075

M20015 M20016

C01140 C01145

A20490

C01155 C01160

C01156 C01166

Compressor layout Kompressor Ansicht

2B1XC2.64_1

SA55/ae

Original 123 606 130 200

22.04.2016

Rev. 0

126 003 420

Drive Antrieb

L10000

L10010

Center 1st crank Mitte 1. Kurbel

L10120

L10130 L10140

CO20/bk

Original 122 856 649 200

12.05.2009

Rev. 0

126 000 935

Gear oil pump, type R Zahnradölpumpe, Typ R

M20000

M20000

M20160

CO20/kw

M20170

M20120

Original 122 853 333 200

M20165

17.06.2010

M20030

Rev. 1

M20001

126 000 285

Gear oil pump, type R Zahnradölpumpe, Typ R

M20180

M20060

M20090

CO20/gw

M20001

Original 122F65109

M20150

M20155

M20200

07.01.2013

Rev. 4

126 000 286

Oil pipe in the carter Ölleitung im Kurbeltrog

A10000

A10025

A10035

CO20/ekn

A10030

Original 122 855 758 200

08.07.2010

Rev.0

126 001 232

Crankgear

M00000

Kurbeltrieb

M00045 M00065

M00015 M10200

M00068 M00070

M00060

M30000

M00015

A10000

M40000

M00100 M00110

L00110 L00100 L00117

M10200

M00015 M00045

M10401

M10005

M10600

CO20/bk

Original 122 863 872 200

16.09.2014

Rev. 2

126 001 128

Oil trap & shaft seal Ölfang & Wellendichtung

M10600

Option:

M10660

M10661

M10662

M10735

M10615

CO20/bk

M10730

M10630

Original 122 854 672 200

28.02.2011

Rev. 2

126 000 707

Connecting rod Schubstange

Stage* Stufe

Code No. *

1 2 3 4 5 6

M41000 M42000 M43000 M44000 M45000 M46000

*

M4*000

select stage as applicable, e.g.: Connecting rod, complete with bearings 2nd stage M42000 entsprechende Stufe auswählen, z. B. Schubstange, komplett, inkl. Lager 2. Stufe M42000

M4*410

M40010 M40300

M40020

M40050

CO20/ekn

Original 122 863 074 200

25.03.2010

Rev. 0

126 001 108

Crosshead-Piston rod connection Kreuzkopf-Kolbenstangenverbindung

M30000

M30015 M30225 M30230 M30006

M30210 M30195

M30207

M30220

M30215 Option M30115 M30620

M30206

M30600

CO20/bk

M30620

Original 122 852 926 200 122 852 908 200

M30006

15.09.2011

Rev. 8

126 000 361

Distance piece Distanzstück

M60001

M60300

M60005

M50001

C00206

M00105

CO20/SaM

Original 122 861 514 200

31.05.2010

Rev. 1

126 001 188

Oil scraping Ölabstreifung

M50425

M50001

M50555

M50400 M50410 M50545

M50420

M50501 M50535

CO20/bk

Original 122 852 840 200

29.09.2010

M50526

Rev. 1

M50530

126 001 196

Distance piece packing Distanzstückpackung

M60300

M60320 M60330 M60340

M60350

M60350

CO20/SaM

Original 122 852 849 200

M60350

19.06.2009

Rev. 1

126 000 702

Cylinder Zylinder

stage * Stufe 1 2 3 4 5 6

*

C0*001

C3*000

C1*000

C0*270 C0*275 C0*519

Code No. * C01001 C02001 C03001 C04001 C05001 C06001

entsprechende Stufe auswählen, z. B. Zylinder 2. Stufe C02001 select stage as applicable, e.g.: Cylinder 2nd stage C02001

C0*620

C0*219 C0*212 C0*130

C0*605

C0*070

C5*002

C0*210 C0*215 C0*250 C0*255

C0*200

C0*061

C0*065

C4*000

C0*415

C0*400 C0*405

CO20/gw

Original 122 871 336 200

07.08.2014

Rev. 3

126 001 428

Piston Kolben

Stage * Stufe

Code No. *

1 2 3 4 5 6

C11010 C12010 C13010 C14010 C15010 C16010

C1*000

*

select stage as applicable, e.g.: Piston complete incl. piston rod & piston rings 1st stage C11010 entsprechende Stufe auswählen, z. B. Kolben komplett, inkl. Kolbenstange & Kolbenringe 1. Stufe C11010

C1*010

C1*130

C1*500

C1*700

C1*230 C1*610

C1*550

C1*120 C1*110

C1*261

SA55/ae

Oiriginal 123 606 451 200

C1*262

20.04.2016

C1*280

Rev. 0

C1*261

C1*262

126 003 421

Piston rod packing Kolbenstangenpackung

C5*002

Stage * Stufe 1 2 3 4 5 6

C5*500

C5*507

C0*255 (C0*250)

C5*506

C5*505

C5*504

C5*503

C5*502

C5*534

*

C5*002 C5*545

Code No. * C51500 C52500 C53500 C54500 C55500 C56500

select stage as applicable, e.g.: Packing flange 2nd stage C52500 entsprechende Stufe auswählen, z. B. Packungsflansch 2. Stufe C52500

C5*529 C5*400

C5*400

C5*529

C5*546 C5*528

CO20/rmi

Original 122 877 511 200

C5*521

C5*517

C5*521

14.04.2016

C5*499

C5*529

C5*519

Rev. 1

126 002 287

Controlled suction valve with actuator Gesteuertes Saugventil mit Stellzylinder

Stage * Stufe

Code No. *

1 2 3 4 5 6

C31410 C32410 C33410 C34410 C35410 C36410

*

C3*000

select stage as applicable, e.g.: Actuator for controlled suction valve 1st stage C31410 entsprechende Stufe auswählen, z. B Stellzylinder zu gesteuertem Saugventil 1. Stufe C31410

C3*410

C2*045 C0*220 C0*230

C2*010 C2*050 C2*025

C2*016

Variant Variante

C2*020

C3*001

C2*016

CO20/SaM

122 855 926 200 mod.

18.01.2010

Rev. 2

126 000 937

Controlled suction valve Gesteuertes Saugventil

Stage * Stufe 1 2 3 4 5 6

Code No. * C31001 C32001 C33001 C34001 C35001 C36001

C3*001

stage as applicable, * select e.g.: Controlled suction valve, complete, 2nd stage C32001 entsprechende Stufe auswählen, z.B. Gesteuertes Saugventil, komplett , 2. Stufe C32001

C3*001

C3*020 C3*040 C3*030 C2*330 C3*070 C3*060

C2*320

C2*380 C2*390 C2*360

C2*430

CO20/ae

C2*350

C2*370

08.04.2010

C2*400

Rev. 13

126 000 088

Actuator for controlled suction valve

C3*410

Stellzylinder zu gesteuertem Saugventil

Stage * Stufe 1 2 3 4 5 6

C3*430

C3*435

Option

Code No. * C31410 C32410 C33410 C34410 C35410 C36410

C3*437 C3*427 C3*438 C3*436 C3*475

*

select stage as applicable, e.g.: Actuator, complete 1st stage C31410

C3*426

entsprechende Stufe auswählen, z. B. Stellzylinder, komplett 1. Stufe C31410

C3*424

C3*410

C3*423

C3*422

C3*440

C3*431 C3*445 C3*421

C3*416 C3*409

(C3*418) (C3*419) (C3*420)

C3*415

C3*412

C3*417

C3*413

C3*414

C3*480

C3*415

Option

C3*447 C3*446

CO20/kw

Original 122 854 926 200

03.06.2010

Rev. 4

126 000 517

Installation of discharge valve Druckventil, Einbau

Stage* Stufe 1 2 3 4 5 6

Code No. *

*

C4*000

select stage as applicable, e.g.: Discharge valve 2nd stage C42200 entsprechende Stufe auswählen, z. B. Druckventil 2. Stufe C42200

C41200 C42200 C43200 C44200 C45200 C46200

Variant Variante

C4*016

C4*200

C4*020

C4*025

C4*016 C4*005

C0*230 Option

C4*045

C0*225

C4*050

C4*097 C4*096

CO20/ekn

Original 122 856 872 200

22.02.2011

Rev. 3

126 000 765

Assembly of discharge valve Druckventil, Zusammenbau

Stage * Stufe 1 2 3 4 5 6

C4*200

Code No. * *

select stage as applicable, e.g.: Discharge valve 2nd stage C42200

C41200 C42200 C43200 C44200 C45200 C46200

entsprechende Stufe auswählen, z.B. Druckventil 2. Stufe C42200

C4*200

C4*330 C4*310

C4*360

C4*350

C4*400 C4*390 C4*380 C4*320

C4*430

CO20/ae

C4*370

28.03.2010

Rev. 8

126 000 089

Appendix

13 Appendix P & I Diagram Title

Drawing No.

Sheet No.

P & I DIAGRAM GAS SYSTEM

125608116

E01

P & I DIAGRAM PURGE SYSTEM

125608124

E01

P & I DIAGRAM CAPACITY CONTROL

125608127

E01

P & I DIAGRAM COMPRESSOR MONI- 125608126 TORING

E01

Technical Data Title

Drawing No.

Sheet No.

2001754 Performance Summary

2047744

S10

Utility Consumption List

2048026

E01

Title

Drawing No.

Sheet No.

GEN. ARRANGEMENT OVERALL

125608129

E01

GEN. ARRANGEMENT OVERALL

125608129

E02

GEN. ARRANGEMENT OVERALL

125608129

E03

Drawing No.

Sheet No.

Drawing No.

Sheet No.

Title

Drawing No.

Sheet No.

Motor Dimension Drawing

122F80116

E01

Motor Sole Plate Drawing

122F80014

E01

General Arrangement

Control Description Title In Process Foundation Title In Process Drive System

18.05.2016

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

13 – 1

Appendix

Lubricating System Title

Drawing No.

Lubrication of BCA Piston Compressors

VBCA546005 (VSB)

Sheet No.

Lubricating Oils ISO VG 150 Categories 1001135 (VSB) C/CL Cooling System Title

Drawing No.

Cooling Water Quality Requirements

VBCA200050

Sheet No.

Compressor Title

Drawing No.

Sheet No.

COMPRESSOR OUTLINE

123606130200

D01

COMPRESSOR OUTLINE

123606130200

D02

Bearing Clearance Table

2051650

000

Maintenance of Compressor

2051647

000

2051648

000

Tightening Torques Cylinder (Drawing) Tightening torques crankgear 2B1X (Drawing) Tightening Torques 2001754

13 – 2

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

RecipCalc™

Compressor Performance Summary

Customer

Tecnicas Reunidas

Project

PRPC PENGERANG-09

Job Site

JOHOR, MALAYSIA

Item No.

1510-K-151

Compressor Type

2B1XC2.64_1

Units

1

Customer Reference

02260

Burckhardt Compression Ref. No.

2001754

Table of Contents 1.1 Summary operation data

2

1.2 Gas properties

4

1.3 Summary loading data

4

1.4 Compressor design data

5

1.5 Summary coolant data

5

1.6 Summary auxiliary data

5

1.7 Compressor sketch

6

1.8 Torque diagrams

7

1.9 Starting torque

9

1.10 Unbalanced forces and moments

9

1.11 Sound pressure level

REV.INDEX: 03 PREPARED

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

10

KELLER_J

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

2047744-S10 PAGE OF

1 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RecipCalc™

Customer: Project: Application: Compressor type:

Tecnicas Reunidas PRPC PENGERANG-09 REF 2B1XC2.64_1

BCA Tender No.: BCA Contract No.: BCA Equipment No.: Customer Reference:

Q-003595-A-00-SZ00 2001754 200322 02260

1.1 Summary operation data Start-up Start-up Pre-refor Long Loop Long Loop mer (Design) (50% VU) heatup

Operating conditions at battery limit

Design

Type of control Suction pressure at battery limit Suction temperature Rel. humidity (inlet H2O) Discharge pressure at battery limit Discharge temperature Capacity wet Capacity dry Standard volume flow (0°C/1.013bar a) Inlet volume flow Specified capacity wet Shaft power (coupling) Recommended motor power Speed

bar a °C % bar a °C kg/h kg/h Nm3/h m3/h kg/h kW kW rpm

Operating conditions at cylinder flange Active compression chambers/stage Clearance pockets active (yes/no/-) Mole weight

kg/kmol

Suction pressure at cylinder flange Suction temperature Discharge pressure at cylinder flange Adiabatic discharge temperature Predicted discharge temperature Capacity wet (inlet) Capacity dry (inlet) Standard volume flow (0°C/1.013bar a) Inlet volume flow Volumetric efficiency Condensate flow upstream stage Delta temp. to dew point Bypass flow across stage Side stream Shaft power

bar a °C bar a °C °C kg/h kg/h Nm3/h m3/h % kg/h °C kg/h kg/h kW

%

Design

MT shift heatup (100% N2) MT shift Pre-reform heatup er heatup (100% N2)

Suction Suction Suction Suction valve valve valve valve unloaders unloaders unloaders unloaders 8.00 8.00 8.00 8.00 8.00 50 50 50 50 50 0.00 0.00 0.00 0.00 0.00 15.00 15.00 11.70 11.90 12.39 120 121 95 96 98 49630 24180 26212 26101 27800 49630 24180 26212 26101 27800 39691 19337 20963 20874 30825 5948 2898 3142 3128 4627 48503 24251 15666 24000 24740 1102 613 436 449 632 1300 1300 1300 1300 1300 370 370 370 370 370 1 100 28.0 7.92 50 15.15 115 120 49630 49630 39691 6008 84.7 0 223

1102

1 50 28.0

1 50 28.0

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

KELLER_J

1 50 28.0

1 75 20.2

7.92 50 15.15 115 121 24180 24180 19337 2927 83.7 0 223

7.92 50 11.82 88 95 26212 26212 20963 3173 90.6 0 223

7.92 50 12.02 90 96 26101 26101 20874 3160 90.3 0 223

7.92 50 12.52 94 98 27800 27800 30825 4673 88.2 0 228

613

436

449

632

Manufacturer capacity including API618 requirements with tolerances as follows:

REV.INDEX: 03 PREPARED

MT shift heatup (30% H2) MT shift heatup (30% H2)

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

specified capacity +3/-0 % shaft power +3/-3 %

2047744-S10 PAGE OF

2 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RecipCalc™

REV.INDEX: 03 PREPARED

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

KELLER_J

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

2047744-S10 PAGE OF

3 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RecipCalc™

Gas-Library: PPDS2

Model: 10 (LKP/LKP)

1.2 Gas properties Start-up Start-up MT shift Pre-reform Long Loop Long Loop heatup er heatup (Design) (50% VU) (100% N2) MT shift Pre-reform formula Design Design heatup er heatup (100% N2)

Operating conditions

Chem.

Stage Gas comp. at cyl. inlet flange [mole %]: Nitrogen Hydrogen (normal)

N2 H2

1

1

1

1

100.00

100.00

100.00

100.00

MT shift heatup (30% H2) MT shift heatup (30% H2) 1 70.00 30.00

1.3 Summary loading data Start-up Start-up MT shift Pre-reform Long Loop Long Loop heatup er heatup (Design) (50% VU) (100% N2) MT shift Pre-reform Design Design heatup er heatup (100% N2)

Operating conditions

Stage (cylinder flange) Max. allowable gas rod load Max. allowable combined rod load (C/T) Gas rod load compression Gas rod load tension Combined rod load compression Combined rod load tension Combined rod load at relief valve set C Combined rod load at relief valve set T Rod reversal at normal op. condition Rod reversal at safety valve setting

REV.INDEX: 03 PREPARED

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

kN kN kN kN kN kN kN kN deg deg

KELLER_J

1 350 350 266 256 276 254 312 289 175 175

1 350 350 26 254 87 247 85 282 80 75

1 350 350 26 146 100 176 92 289 95 75

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

MT shift heatup (30% H2) MT shift heatup (30% H2)

1 350 350 26 153 96 179 92 289 95 75

1 350 350 171 162 201 184 302 276 90 75

2047744-S10 PAGE OF

4 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RecipCalc™ 1.4 Compressor design data Running Stage

Dry

No. of cylinders per stage Acting (single=s/double=d) Piston diameter Piston rod diameter Stroke Average piston speed Piston displacement Spacer ring height Clearance volume (average) Valve type No. of suction valves per cylinder Suction valve size Suction valve pressure class Suction valve lift Suction valve gas velocity (average) No. of discharge valves per cylinder Discharge valve size Discharge valve pressure class Discharge valve lift Discharge valve gas velocity (average) Unloader type No. of clearance pockets per stage

2 d 640 75 250 3.08 7093 -/22.0 plate 4 BCAG-308 16/32 2.10 21.56 4 BCAG-308 16/32 2.10 21.56 finger n.a.

1

mm mm mm m/s m3/h mm % -

mm m/s -

mm m/s -

1.5 Summary coolant data Serial no.

Name/Coolant

Operating Case / max. cooling power

Element

Cylinder (Water)

Start-up Long Loop (Design) VR1.1 VR1.2 VR2.1 VR2.2 PF1 PF2

Oil (Water)

Start-up Long Loop (50% VU) Start-up Long Loop (Design) Start-up Long Loop (50% VU) Start-up Long Loop (Design) Start-up Long Loop (Design) Start-up Long Loop (Design) Start-up Long Loop (Design) Start-up Long Loop (Design)

oil cooler

Tin Tout Capacity Power [°C] [°C] [m3/h] [kW] 34 40 10.2 70.7

34

39

2.46 2.37 2.46 2.37 0.33 0.33 1.46

17.1 16.5 17.1 16.5 2.3 2.3 8.5

1.46

8.5

Remarks: VR: compression chamber PF: piston friction KL: gas cooler

1.6 Summary auxiliary data Relief valve setting Suction side 1st stage Discharge side 1st stage Cooling water system

REV.INDEX: 03 PREPARED

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

bar g bar g bar g

KELLER_J

15.5

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

2047744-S10 PAGE OF

5 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RecipCalc™

1.7 Compressor sketch

Crank Stage Stroke [mm] Piston diameter [mm] Number of suction valves Number of discharge valves Valve size Valve manufacturer Clearance volume [%] Stage Piston displacement

REV.INDEX: 03 PREPARED

C1 1/1 250 640 2/2 2/2 308 BC 21.8/22.2

m3/h

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

KELLER_J

C2 1/1 250 640 2/2 2/2 308 BC 21.8/22.2 1 7131

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

2047744-S10 PAGE OF

6 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RecipCalc™

1.8 Torque diagrams Maximum torque Start-up Long Loop (Design) Design

Operating conditions

Torque diagram (compressor excitation torque before flywheel)

Mt0 Mtmax Mtmin Delta A/A Inertia compr. Inert. flywheel Inert. motor Irregularity* Pad Shaft power (coupling) Speed

[kNm] [kNm] [kNm] [-] [kgm2] [kgm2] [kgm2] [1/...] [kW]

28.432 69.815 -3.143 0.18441 13 2256 874 142 971.9

ord. j 1 2 3 4 5 6

Fourier-Analysis Mt=Mt0+SUM[Mt(j)*COS[j*ABS(w)*t-phi(j)]] amp. Mt(j) [kNm] phi(j) [deg] 3.414 332.5 30.276 188.3 3.771 162.0 2.897 325.2 0.795 359.8 2.461 230.3

[kW]

1101.9

7

0.892

200.3

[rpm]

370

8 9 10 11 12

1.952 0.805 0.639 0.375 0.149

343.8 336.0 116.6 129.8 320.0

*Considering compressor, motor and flywheel (if available). The whole train is assumed fully rigid.

REV.INDEX: 03 PREPARED

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

KELLER_J

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

2047744-S10 PAGE OF

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RecipCalc™

Maximum irregularity Start-up Long Loop (50% VU) Design

Operating conditions

Torque diagram (compressor excitation torque before flywheel)

Mt0 Mtmax Mtmin Delta A/A Inertia compr. Inert. flywheel Inert. motor Irregularity* Pad Shaft power (coupling) Speed

[kNm] [kNm] [kNm] [-] [kgm2] [kgm2] [kgm2] [1/...] [kW]

15.824 62.582 -13.346 0.50448 13 2256 874 93 483.2

[kW]

613.1

[rpm]

370

ord. j 1 2 3 4 5 6

Fourier-Analysis Mt=Mt0+SUM[Mt(j)*COS[j*ABS(w)*t-phi(j)]] amp. Mt(j) [kNm] phi(j) [deg] 21.567 99.0 18.296 157.2 3.423 354.0 2.453 325.0 2.790 74.4 0.653 206.2

7

0.904

196.1

8 9 10 11 12

0.849 0.173 0.472 0.227 0.235

330.6 26.7 99.9 219.4 253.5

*Considering compressor, motor and flywheel (if available). The whole train is assumed fully rigid.

REV.INDEX: 03 PREPARED

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

KELLER_J

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

2047744-S10 PAGE OF

8 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RecipCalc™

1.9 Starting torque 1.10 Unbalanced forces and moments Related to point Z = 396 mm from 1st bearing Q = time * angular velocity Q = t(sec) * (360/60 * 370) (deg/sec) Speed = 370 rpm Mt = Motor torque

Resulting forces Horizontal

FH [kN]

= +

Vertical

FV [kN]

= +

Resulting moments Horizontal

MH [kNm]

= +

Vertical

MV [kNm]

= +

Max. amplitudes Forces Horizontal, FH [kN] Vertical, FV [kN] Moments Horizontal, MH [kNm] Vertical, MV [kNm]

1st order

0.000 0.000 0.000 0.000 44.553 4.612 11.138 0.000 2nd order

1st order 2nd order 1st order 2nd order * cos(Q - 180.0) * cos(2 * Q - 180.0) * cos(Q - 90.0)

1st order 2nd order 1st order 2nd order

Rotating (*)

Resultants

0.000 0.000

0.000 0.000

0.000 0.000

0.000 0.000

44.553 11.138

4.612 0.000

11.138 11.138

49.143 11.138

(*) for information only, included in 1st order

REV.INDEX: 03 PREPARED

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

KELLER_J

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

2047744-S10 PAGE OF

9 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RecipCalc™

1.11 Sound pressure level Valid for free field sound radiation at 1 m distance from compressor and low basic noise at n = 370.0 rpm According ISO 2151 Lp = 86.5 dB(A)

Octave spectrum of sound pressure level f [Hz] Lp [dB]

63 84.5

125 86.5

250 84.5

500 82.5

1000 81.5

2000 79.5

4000 75.5

8000 70.5

f: frequency, Lp: sound pressure level

REV.INDEX: 03 PREPARED

04.09.2015

APPROVED 09.11.2015 2001754/PRPC PENGERANG-09[03]&ORDER

KELLER_J

DOK.NR.: (TDO)

HATT_M RecipCalc V 04.00.00

2047744-S10 PAGE OF

10 10

This document contains inf ormation which is conf idential and shall not be giv en to any third party without the written consent of Burckhardt Compression

RAPID PROJECT PACKAGE 3

EQUIPMENT (ITEM AND DESCRIPTION) 1510-K-151 - N2 Compressor SUB SUPPLIER IDENTIFICATION

TR PROJECT NO. 02260 PURCHASE ORDER NUMBER 0226005040 REVIEW RESPONSE BY PURCHASER:

Purchaser review and comments do not indicate either responsibility or liability for accuracy and completeness of this document or alter any contractual terms and conditions: Rejected

Reviewed Without Comments

Reviewed With Comments

Comment As Noted

For Information

Reviewed As built

DATE:

VOID

DOCUMENT DATA VENDOR IDENTIFICATION: Burckhardt Compression AG

DOCUMENT TITLE:

Utility Consumption List

VENDOR DOCUMENT NO.:

TSP 2048026

REV:

A

CODE:

LIS-0007

PURCHASER DOCUMENT NO.:

V-02260-1510-K-151-0001

REV:

A

CLASS:

O

OWNER DOCUMENT NO.:

RAPID-P0003-3004-MEC-LST-1510-0009

REV:

A

DOCUMENT NUMBER Project Package RAPID P0003

Originator 3004

V-02260-1510-K-151-0001_A Discipline Doc. Type Unit nº MEC LST 1510

Serial nº 0009

Rev

Page

A

1/2

PETRONAS RAPID PROJECT (PACKAGE 3)

Utility Consumption List

OWNER approval: Name: Date (DD-MMM-YY): Signature:

Document Class:

0

Pages modified under this revision:

1

26.01.2016

IFA - Issued for Approval

FEUSI_M

MUELLER_H

FEUSI_M

0

22.05.2015

First Issue

GERBER_M

GERBER_M

MUELLER_A

A

27.01.2016

IFR ‐ Issued for Review

GERBER_M

MUELLER_H

FEUSI_M

REV.

DATE DD-MMM-YY

WRITTEN BY

CHECKED BY

(name & signature)

(name & signature)

APPROVED BY (name & signature)

STATUS-REVISION MEMO

Sections changed in last revision are identified by a vertical line in the right margin. Electronic Filename: RAPID-P0003-TRSA-MEC-LST-1510-0009_A.xls

UTILITY CONSUMPTION LIST PRELIMINARY to be finalized according to design CLIENT LOCATION PROJECT No. UNIT TYPE DOCUMENT No. UNIT/ EQUIP. No.

PRPC REFINERY AND CRACKER SDN BHD Johor, Malaysia 2260 OFF GAS COMPRESSOR TSP 2048026 DESCRIPTION

1510-KM-161

OFF GAS COMPRESSOR DRIVE MOTOR

MH-01

MOTOR SPACE HEATER

1510-PM-161B

AUX LUBE OIL PUMP MOTOR

1510-K-151-PM03

MAIN MOTOR HYDROJACKING PUMP MOTOR

1510-K-151

SOLENOID VALVES (VALVE UNLOADERS)

1510-K-151

LOCAL OPERATING PANEL

TOTAL NOTES:

UNIT No./ CODE

1510-K-151

CHANGE

CASE

DATE ORIG. BY APP. BY

ELECTRIC POWER kW MOTOR/ MECH. ELEC. LOAD RUNNING OPER RATING LOAD LOAD 1300

Burckhardt Compression Project:

PLANT CAPACITY

HHP STM

STEAM kg/hr HP STM

MP STM

LP STM

REV.

A

SHEET

16.07.2015

1

GERBER_M

OF

FEUSI_M CONDENSATE kg/hr MP LP COLD/VAC COND COND COND

3 BFW

DEMIN WATER

REMARKS

Rev.

kg/hr LOSSES

kg/hr

1104

A 0.7

(1)

3.0

A A

~1

A 3x 20W

(2)

~0.5

~1304

2001754

A A

~1.3

A

Solenoids are not reported in this document

MOTOR/LOAD RATING: NAMEPLATE RATING OF MOTOR OR LOAD

(1) INTERMITTENT PRODUCER/CONSUMER

MECH. RUNNING LOAD: MOTOR SHAFT POWER

(2) INTERMITTENT PRODUCER/CONSUMER (10 times per hour)

ELECT. OPERATING LOAD: POWER ABSORBED BY MOTOR (MECH. LOAD/ EFFY AT DESIGN CONDITION)

UTILITY CONSUMPTION LIST PRELIMINARY to be finalized according to design CLIENT LOCATION PROJECT No. UNIT TYPE DOCUMENT No. UNIT/ EQUIP. No.

PRPC REFINERY AND CRACKER SDN BHD Johor, Malaysia 2260 OFF GAS COMPRESSOR TSP 2048026 DESCRIPTION

Burckhardt Compression Project:

PLANT CAPACITY UNIT No./ CODE

1510-K-151

CHANGE

CASE

ELECTRIC POWER kW MOTOR/ MECH. ELEC. LOAD RUNNING OPER RATING LOAD LOAD

DATE ORIG. BY APP. BY

HHP STM

STEAM kg/hr HP STM

MP STM

LP STM

REV. A

SHEET

16.07.2015

2

GERBER_M

OF

FEUSI_M CONDENSATE kg/hr MP LP COLD/VAC COND COND COND

3 BFW

DEMIN WATER

LOSSES

Rev.

kg/hr A

TOTAL MOTOR/LOAD RATING: NAMEPLATE RATING OF MOTOR OR LOAD MECH. RUNNING LOAD: MOTOR SHAFT POWER (1) INTERMITTENT PRODUCER/CONSUMER

REMARKS

kg/hr

NO COOLING WATER SKID

NOTES:

2001754

ELECT. OPERATING LOAD: POWER ABSORBED BY MOTOR (MECH. LOAD/ EFFY AT DESIGN CONDITION)

UTILITY CONSUMPTION LIST PRELIMINARY to be finalized according to design CLIENT LOCATION PROJECT No. UNIT TYPE DOCUMENT No. UNIT/ EQUIP. No.

PRPC REFINERY AND CRACKER SDN BHD Johor, Malaysia 2260 OFF GAS COMPRESSOR TSP 2048026 DESCRIPTION

UNIT No./ CODE

COOLING WATER TEMP. FLOW RISE m³/hr °C

LUBE OIL COOLER A

2

5.00

1510-E-151B

LUBE OIL COOLER B

2

5.00

1510-KM-151

MAIN MOTOR, PURGE

1510-K-151

COMPRESSOR, PURGING + BUFFERING N2

1510-K-151

CAPACITY CONTROL

1510-X-151

PNEUMATIC BARRING DEVICE

1510-K-151

CYLINDER COOLING WATER FLOW

TOTAL

1510-K-151

CHANGE

CASE

1510-E-151A

NOTES:

Burckhardt Compression Project:

PLANT CAPACITY

TEMP. RISE °C

DATE

FLOW kg/hr

UTILITY WATER m3/h

DESAL WATER m3/h

SHEET

16.07.2015

3

ORIG. BY

GERBER_M

OF

APP. BY INST. AIR Nm3/hr

FEUSI_M PLANT AIR NITROGEN 3 Nm /hr Nm3/hr CONT. INTER CONT. INTER M'ENT M'ENT

3 MINERAL OIL Kg/h

FUEL FIRED NOTE 1

REMARKS

A HOLD

A 17.0 0.6

A (2)

0.2

0.8

6

for 1 Crankshaft Revolution

~11

~21

Rev.

A

151

(2) Continuous=> Nm3/h running at 50% load, 5 actuations per hour; Intermitt.=>Nm@startup to run 0%load (1) INTERMITTENT PRODUCER/CONSUMER

REV. A

2001754

Common

151

0.8

17.6

0.2

A

A

A

Diego Freitas 2016.03.04 16:35:26 -03'00'

Luiz Dal Bo 2016.03.04 17:47:28 -03'00'

Luiz Dal Bo 2016.03.04 17:47:47 -03'00'

Diego Freitas 2016.03.04 15:13:02 -03'00'

Luiz Dal Bo 2016.03.04 17:47:03 -03'00'

Luiz Dal Bo 2016.03.04 17:47:14 -03'00'

Gilt für / Valid for

BCAG

Verteiler / Distribution

Intranet: Qualitaet / VBCA

Lubricating Oil Specifications

Lubrication of BCAG Piston Compressors Scope of Application This specification applies to the lubrication of BCAG secondary compressors (hyper compressors), process gas compressors ® and open/closed (pressure resistant) labyrinth piston compressors (Laby ).

General The cylinder lubricating oil of the process gas compressors with lubricated cylinders comes into contact with the compressed gas and is partially carried over to the process downstream. ® In closed (pressure resistant) labyrinth piston compressors (Laby ) the process gas generally comes in contact with the lubricating oil in the crankgear. This has to be considered for the choice of the lubricating oil.

a) Crankgear Lubrication a1) For the lubrication of the crankgear, mineral oil according to the Lubricating Oil Specification (VSB) 1001132 is used. Exception: labyrinth piston compressors (pressure resistant). a2) For the lubrication of the crankgear of closed (pressure resistant) labyrinth piston compressors, oil according the “Allocation Table Crankgear Lubrication” (VSB) 1001300 must be used ®

a3) For LNGM (Laby -GI) applications see paragraph d).

b) Cylinder Lubrication b1) In most cases, mineral oil according to the Lubricating Oil Specification (VSB) 1001133 is used for cylinder lubrication of BCAG process gas compressors. Exceptions: • Primary compressors for LDPE production: Applicable lubricants: - Same cylinder lubricating oil as in the secondary compressor. See Lubricating Oil Specification (VSB) 1001134 - Same cylinder lubricating oil (ISO VG 100) as for cooling and flushing of secondary compressor (model year 2007 and onwards). See cooling and flushing oil secondary compressor Specification (VSB) 1006423. • Compressors for NH3, corrosive gases etc.: Check with Burckhardt Compression. b2) For the cylinder lubrication of BCAG secondary compressors, white oils and polyalkylene glycols (PAG) according to the Lubricating Oil Specification (VSB) 1001134 are used. ®

b3) For LNGM (Laby -GI) applications see paragraph d).

c) Cooling and Flushing Oil For “Cooling and Flushing Oil” of secondary compressors the following qualities are admissible: c1) ISO VG 68 for compressor model 2006 and before Technical or pharmaceutical white oil Mineral oil categories C and CL according to Lubricating Oil Specification (VSB) 1001303 c2) ISO VG 100 for compressor model 2007 and after Technical or pharmaceutical white oil Mineral oil categories C and CL according to Lubricating Oil Specification (VSB) 1006423 Rev. Index

F

Dat.

Sig.

ausgestellt von / issued by

03.07.2015

KAUFMANN_W

überprüft / reviewed

03.07.2015

CRUZ_R

Freigabe DVS

03.07.2015

ARZTMANN_R

VBCA546005

(VSB)

ersetzt / replaces Revision vom / from

VBCA546005

E 02.04.2015

Seite / Page

1

von / of

2

Gilt für / Valid for

BCAG

Verteiler / Distribution

Intranet: Qualitaet / VBCA

Lubricating Oil Specifications ®

d) For LNGM (Laby -GI) applications

General lubrication information

VBCA 546005 – Lubrication of BCAG Piston Compressors

Crankgear lubrication

VBCA 1001132 – Crankgear Lubrication Mineral Oil

Fuel Gas Supply System (FGS) with regular low pressure re-liquefaction systems (side stream < 30bar a)

Fuel Gas Supply System (FGS) with regular high pressure re-liquefaction systems (side stream > 200bar a)

VBCA 1001133

VBCA 1001301

Cylinder Lubrication Mineral Oil

Laby

Cylinder lubrication

Rev. Index

F

Dat.

Sig.

ausgestellt von / issued by

03.07.2015

KAUFMANN_W

überprüft / reviewed

03.07.2015

CRUZ_R

Freigabe DVS

03.07.2015

ARZTMANN_R

®

Polyalkylene Glycol Lubricants (PAG)

VBCA546005

(VSB)

ersetzt / replaces Revision vom / from

VBCA546005

E 02.04.2015

Seite / Page

2

von / of

2

1001135

General This list contains a selection of lubricating oils of the viscosity class ISO VG 150 in the categories C (DIN 51 517 Part 1) and CL (DIN 51 517 Part 2). The listing is in alphabetical order according to manufacturer’s and/or brand names. It is intended for the use with “Lubricating Oil Specifications” (VSB) 1001132 and (VSB) 1001133.

Lubricating Oil Categories Lubricating oil category C (according to DIN 51 517 Part 1): Ageing-resistant mineral oils without additives Lubricating oil category CL (according to DIN 51 517 Part 2): Mineral oils with additives to increase corrosion protection and ageing resistance. This list contains only lubricating oils without zinc dialkyl dithiophosphate (ZDDP, ZDTP, ZDP) additive. Category (DIN 51 517)

Brand Name

Name

VG

Remarks

AGIP

Radula 150

150

C

AGIP

Acer 150

150

CL

BP Amoco

Energol CS 150

150

C

Castrol

Magna 150

150

C

Chevron (Texaco)

Regal R&O 150

150

CL

ExxonMobil

Mobil DTE 10 Excel 150

150

CL

ExxonMobil

Mobil Vacuoline 128

150

CL

Shell

Morlina S1 B 150

150

C

Shell

Morlina S2 B 150

150

CL

Total

Cirkan RO 150

150

CL

Total

Dacnis 150

150

CL

Strub

Vulcobase P

150

C

ISO

Burckhardt Compression AG does not assume any responsibility for the quality and properties of the subsupplied lubricating oils. Further relevant BCAG specifications etc.: MI-76en

Safe Handling of Lubricants

Rev. Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

E

Dat.

Sig.

07.01.2015

KAUFMANN_W

07.01.2015

CRUZ_R

08.01.2015

ARZTMANN_R

Ersatz für Replacement for Revision vom / date

1001135 2 07.05.2004

Seite 1 von 1 Page 1 of 1

Revision

(VSB)

Lubricating Oils ISO VG 150 Categories C/CL

1.

(VSB)

VBCA200050

Scope of Document This standard covers the minimum set of parameters for cooling water to be defined in order to protect compressors and their accessories from following effects:  Corrosion on metallic materials and/or  Formation of fouling in piping systems, cylinder water jackets, heat exchangers, etc. Cooling water which deviates from the values and limitations indicated in below table (ref. to table 1), might have negative influence on compressor performance and lifetime of components in direct contact with the coolant. In order to guarantee the product performance and expected lifetime, the selection of suitable materials and/or type of cooling water system is essential. The values given in the below table shall be understood as a general guideline for cooling water circuits connected to BCAG compressor systems. Reference is made to the engineering standard published by “The Association of German Engineers (VDI)”, standard no. VDI 3803.

2.

Responsibilities

1. Purchaser shall inform BCAG concerning project related cooling water quality during bidding stage by submitting detailed cooling water analysis. Grade of cooling water quality might have influence on project costs. Purchaser by minimum to inform about the values of the cooling water parameters as listed in the table below (ref. to table 1). In special cases, BCAG can provide specific detailed questionnaire “Evaluation criteria for cooling water quality and water treatment methods” (ref. to VSB VBCA200050 E02).

2. BCAG will review provided cooling water analysis and inform purchaser whether the given values are acceptable or special care has to be taken with respect of material selection and/or type of cooling water system.

3. In case of conflicting deviations to the defined standard cooling water quality, the following procedures might apply: a. Material selection for components in contact with cooling water will be reviewed by

BCAG internal material specialists. Alternative material selection might be required. b. Alternative type of cooling water system will be evaluated together with the purchaser. c. Cooling water treatment to improve coolant quality.

4. In case of no cooling water analysis is provided by purchaser, design and selection of materials for compressor and accessories (heat exchangers, piping system, etc.) is based on below water quality parameters (ref. to table 1).

It is in the responsibility of the purchaser to inform BCAG concerning any changes to the cooling water analysis during the complete bidding and project phase. Deviating actual cooling water quality from information available during bidding stage might be related to design changes during project phase and cost adders for changes might apply resp. delivery delay might occur.

Rev. Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Dat.

Sig.

26.01.2016

REGEZ_R

26.01.2016

BOSSHARD_K

26.01.2016

TUERKMEN_N

Ersatz für Replacement for Revision vom / date

Seite 1 von 3 Page 1 of 3

Revision

Cooling Water Quality Requirements

3.

(VSB)

VBCA200050

Limitation of Liabilities Compliance to the BCAG standard cooling water quality guideline (refer to table 1) is a basic requirement for the trouble-free operation of the compressor plant. All deficiencies caused by non-conformance of the cooling water quality to the standard parameters listed in table below resp. non-conformance to the deviations which have been explicitly agreed by BCAG are excluded from BCAG’s guarantee and liability. Recommended Guide Values for Cooling Water for Compressor Systems Parameter Conductivity pH-value m-alkalinity Calcium Chloride Sulphate Carbonate hardness KMnO4-consumption Microbial count Total Organic Carbon Suspended solids Fouling factor

Abbr.

Unit

Range

2+ Ca Cl SO4 TOC -

[μS/cm] [-] [meq/l] [mg/l] [mg/l] [mg/l] [°dH] [mg/l] [CFU/ml] [mg/l] [mg/l] 2 [m K/W]

< 2’200 7.5 – 9.0 < 4.0 >20 < 150 < 325 < 4.0 < 100 < 10’000 < 30 < 10 -4 1.8 x 10

Remarks @ reference temp. of 20°C

For coolant T ≥ 50°C, < 100

Table 1 – minimum parameters for cooling water quality Periodic, monthly sampling of cooling water is recommended in order to ensure proper quality 4.

Coolant Temperature Requirements General reference is made to API 618 5th edition, chpt. 6.1.7 table 1 – Cooling Systems Conditions. In case of process gas might form condensation, coolant inlet temperature shall be maintained at a minimum of 6K above the gas inlet temperature (refer to API 618, para 2.6.3.3). In order to minimize fouling effects, BCAG defines the coolant flow and velocity over the heat exchanger surfaces. Coolant flow and related velocities are selected to prevent solids, suspended in the coolant, from depositing and causing increased fouling. For compressors equipped with water jackets on cross head and guide bearings (Laby® design), a minimum supply temperature of 15°C shall be guaranteed all-the-year.

Rev. Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Dat.

Sig.

26.01.2016

REGEZ_R

26.01.2016

BOSSHARD_K

26.01.2016

TUERKMEN_N

Ersatz für Replacement for Revision vom / date

Seite 2 von 3 Page 2 of 3

Revision

Cooling Water Quality Requirements

5.

(VSB)

VBCA200050

Cooling Water Treatment In order to prevent freezing in closed cooling water circuits, antifreeze additives are normally added. In the same way anticorrosion agents, biocidal products and similar products may need to be added to the cooling water. Please contact a specialized company for detailed information and services concerning water treatment. BCAG is not able to provide detailed information concerning water treatment. The responsibility of cooling water treatment remains with the compressor operator. Local environmental regulations shall be respected. In case demineralized water is used as make-up water in closed circuits, a special selection of materials is required and/or additives are to be added. BCAG must be explicitly informed about the additives used. Additives can have a chemical aggressiveness and a galvanic effect in the cooling water circuit.

Rev. Erstellt / Prepared Überprüft / Reviewed Freigabe / Approval DVS

Dat.

Sig.

26.01.2016

REGEZ_R

26.01.2016

BOSSHARD_K

26.01.2016

TUERKMEN_N

Ersatz für Replacement for Revision vom / date

Seite 3 von 3 Page 3 of 3

Revision

Cooling Water Quality Requirements

LAGERSPIELTABELLE BEARING CLEARANCE TABLE TABLEAU DES JEUX DE PALIER Kunde Client / Client

Maschinen Nr. Machine n°. / No. de la machine

Typ Type / Type

2B1XC2.64_1

Técnicas Reunidas, S.A.

200322

Kunden ref. Client ref. / Client réf.

Auftrags-Nr. Job n° / Commission no.

PRPC PENGERANG-09

2001754

D

B

Kurbelwelle Crankshaft Vilebrequin

Schubstange Connecting rod Bielle de poussée

A

Gegenstand

Hersteller Nennmass [mm]

Object

Manifactured dimension

Objet

Cote nominale d'usinage

Führungs- und Hauptlager Radialspiel [A] Main + Guide bearing lateral clearance Palier de guidage et principal jeu radial Führungslager Axialspiel [A] Axial clearance of guide bearing Palier de guidage jeu axial Kurbelzapfenlager Radialspiel [B] Crank pin bearing lateral clearance Palier de maneton jeu radial Kreuzkopfzapfenlager Radialspiel [C] Crosshead pin bearing lateral clearance Coussinet de tourillon de cross jeu radial

C 1)

Max. zul. Spiel [mm]

Kontrollpunkte

Bearing clearance normal

Max. allowed clearance

Checkpoint

Jeu normal de palier

Jeu maximum admissible

Point de contrôle

1. 2. 3. 4.

Normales Lagerspiel

[mm]

0.24 - 0.348 225

Trennfuge Parting joint Joint médian

0.398

144

0.200 - 0.600

0.8

0.24 - 0.348 225

Trennfuge Parting joint Joint médian

0.398

1. 2. 3. 4.

135

0.092 - 0.172

0.22

1. 3. 4.

250

0.30 - 0.40

0.45

1. 3. 4.

340

0.23 - 0.337

0.5

1. 3. 4.

Axialspiel [C] Axial clearance Dégagement axial

Kreuzkopf

Radialspiel [D]

Crosshead

Lateral clearance

Crosse

Jeu radial

1) Lagerspiele nach Zeichnungsmassen. Wenn Spiele mit Fühlerlehre gemessen werden, können obige Spiele wie folgt kleiner sein: min. ≤0.1mm = 0.01mm und min. >0.1mm = 0.015mm

1.

2.

Kontrolle des Wellen- und Lagerdurchmessers. Check of bearing gap. Contrôle du diamètre d'arbre et du coussinet. Kontrolle der Lagerauflage in der Grundbohrung. Check of bearing application in basic bore. Contrôle de l'assise du coussinet dans l'alésage.

1) Clearances acc.to dimensions on drawing. If clearances measured by feeler gauges, the above values can be less as follows: min. ≤0.1mm = 0.01mm und min. >0.1mm = 0.015mm

3.

4.

UEBERPRUEFT / REVIEWED GENEHMIGT / APPROVED

Kontrolle des Lagerspieles. Check of bearing clearance. Contrôle du jeu de palier. Spezielle Kontrolle je nach Maschinenteil. Special check depending on part of machine. Contrôle spécial selon la partie de la machine.

DOK.-NR.:

REV. INDEX ERSTELLT / PREPARED

23.11.2015 27.11.2015 27.11.2015

2. 3.

BONADIO_M FEJZULI_B FEJZULI_B

(TDO)

2051650 SEITE / PAGE

SW / 15-02-00 / rev. 0

VON / OF

1 1

WARTUNG DES KOMPRESSORS MAINTENANCE OF COMPRESSOR Kunde Client

Maschinen Nr. Serial no.

Typ Type

Técnicas Reunidas, S.A.

200322

2B1XC2.64_1

Projektdefinition Job name

Auftrags-Nr. Job no.

Kurbel Nr. Crank no.

PRPC PENGERANG-09

2001754

1/2

Kolbendurchmesser Piston diameter

Kolbenspiel Piston clearance UTP BDC

[mm]

640

Stufe Stage

1 Hub Stroke

[mm]

1.5 - 2.5

OTP TDC

3.5 - 4.5

[mm]

250

Kolbendurchmesser Piston diameter

Ø 640 mm

Kolbenringe Piston rings

4*

Kolben Piston

1

PTFE PTFE

Sphäroguss Nodular cast iron

D

Ø75

E

55

F

0.66 - 0.895

G

Ø615

Ø74.9

Ra 0.15 - 0.25 *** Ra 0.1 - 0.2 ****

H I

1.0 - 1.415

K

12

L

11.8 +0 / +1.3

10.8

M

15

N

0.186 - 0.332

O

25

P

7.7 +0 / +0.7*

Q

Ø634

R

55

S

15

0.4 16

70

Ra 0.2 - 0.4

0.2 8

PTFE PTFE

C

Ø641

0.1 4

4

B

Ø690

µm µ in

Führungsringe Guide rings

WC-beschichtet TC-coated

Ø640

18.7

Ra

1

A

Rauheit [µm] Roughness

Max. Rauheit Max. roughness

Kolbenstange Piston rod

EN-GJLP EN-GJLP

Zulässiges Mass infolge Abnutzung [mm] Service limit dimension

N5

1

Nennmass [mm] Nominal dimension

N4

Zylinderbüchse Cylinder liner

Werkstoff Material

N3

Menge Quantity

Rauheitsklassen Classes of roughness

Benennung Description

* Schrägschnitt / Diagonal cut Bemerkungen

zur Berechnung: ** Überlappt / Bemerkungen Overlapped zur Berechnung: *** Packungsbereich / Packing area **** Ölabstreiferbereich / Oilscraper area REV. INDEX ERSTELLT / PREPARED

DOK.-NR.:

23.11.2015

BONADIO_M

(TDO)

GEPRUEFT / REVIEWED FREIGABE DVS / RELEASE DVS

KT / 02.02.10 / Rev.3

2051647 SEITE / PAGE

1

VON / OF

1

Anzugsdrehmomente

Process Cylinder

Tightening torques

002

006-1

CO20/SaM

004-1

004-11

004-12

27.09.2011

003-1

001-1

005-1

TIM-ID 28821

Rev. 001

Anzugsdrehmomente

Crankgear 2BX

Tightening torques

009 011 012

014

008

CO20/rmi

013

007

010

14.03.2016

TIM-ID 54941

Rev. 001

TIGHTENING TORQUES BX 2001754

Pos

Bolt / Location

Dimension

001 -1

Cylinder cover 1st Stage

M30 x 158

Method

Torque

A193 B16

II

650 Nm

-1

Cylinder bottom 1st Stage

M30 x 158

A193 B16

II

650 Nm

-1

Pipe connection gas piping Recycle

M30 x 168

A193 B16

II

250 Nm

-1 -11 -12

Valve cover 1st Stage Pressing bolt ss1) Pressing bolt ds2)

M24 x 114 G1/2” x 95 G1/2” x 95

A193 B16 34CrMo4 34CrMo4

II II II

330 Nm 100 Nm 60 Nm

-1

Piston nut 1st Stage

SB M56x4

1.7225-B7M

V

49 Nm

M24 x 159

A193 B16

II

330 Nm

002

003

004

005

006

Material

Angle

Rev.

A

Packing 1st Stage

-1 007

Frame – Distance Piece

SB M42x3

1.7225

V

51 Nm

008

Distance Piece – Cylinder

SB M42x3

1.7225

V

51 Nm

009

Connecting rod

SB M42x3

1.7225

V

58 Nm

010

Piston rod – Crosshead

SB M56x4

1.7225

V

65 Nm

011

Main bearing cover vertical *) after the gap is closed

M30x2

A193 B16

III

012

Main bearing cover horizontal SB M42x3

1.7225

V

40 Nm

013

Foundation bolt

SB M48x5

1.7225

V

74 Nm

014

Coupling bolts

M52x3 x 345

34CrNiMo6

III

1)

ss = Suction Side

2)

ds = Discharge Side

*) 65°

35 – 45°

Lubricate all bolt connections. Lubricate all the other bolt connections according to the instructions, stated in data sheet MBN707

DOK.-NR.: (TDO)

REV. INDEX ERSTELLT / PREPARED

26.04.2016

BONADIO_M

UEBERPRUEFT / REVIEWED GENEHMIGT / APPROVED

SW / 11-04-00 / rev. 0

2051648 SEITE / PAGE

1

VON / OF

1

Index

14 Index A Absorbent agent 5-99, 11-4 Acids 2-9 Actuator 4-6, 4-35, 4-36, 6-12 Address 1-5 Algae 8-25 Align electric motor 5-47 API 618 4-32 API standard 1-6 Assemble compressor 5-36 Assemble compressor components Assemble electric motor 9-139 Assemble gear oil pump 9-138 Assess vibrations 5-94 Axial bearing 9-156 assemble 9-158 dismantle 9-157

9-1

B Barring device 3-4, 5-43 proximity probe 3-14 Bearing axial 4-14 center 4-14 main 4-10, 4-12, 4-14 Bearings 9-145 Brands 1-10 Breather 3-13 Buffer gas 3-6, 6-6 Burckhardt Plate Valve™ 4-31, 4-32, 9-33 Burckhardt Poppet Valve™ 4-31, 4-33 Bypass control 4-36 C Calcium carbonate deposits 8-25 Capacity control 4-35, 6-11 CE conformity 2-3 Check crankshaft deflection 5-50, 8-49 Check fabrication 5-62 Chemical handling 2-8 Clean compressor plant 8-6 Cleaning tools and facility 10-6 working environment 10-5 workplace 10-6 Cleaning method chemical cleaning 10-10 degreasing with solvent vapor 10-11 flushing 10-10 immersion 10-10 mechanical cleaning 10-9 spraying 10-10

18.05.2016

Rev. 001/kalajdzisa_a

ultrasonic cleaning 10-11 wiping 10-10 Cleaning methods 10-9 Cleaning of compressor plant 2-12 Cleaning specification 10-3 Cleansing agent 10-6 Clearance measurement 8-39, 8-34, 8-39 Clearance of crosshead pin bearing 9-136 Clearance pocket control 4-36 Commissioning 6-4 Commissioning after maintenance 2-13 Compressor design data 6-3 overview 4-3 Compressor designation 1-5 Compressor maintenance 2-13 Compressor operation 2-12 Connecting rod 4-15, 9-120 parallelism of bores 9-124 Connecting rod bearing 4-16, 8-50, 8-52, 9-113 Control elements 3-10 Controlled suction valve 6-12, 9-15 Controlled suction valves 4-36, 8-70 Cooling system 3-7, 8-24 Copyright 1-3 Crankcase 4-7, 4-7 Crankgear 4-7, 8-49 Crankgear lubricating system 5-89 Crankshaft 4-13 Crankshaft bearing 9-147 assemble 9-151 dismantle 9-147 Crankshaft deflection 5-35 Crankshaft main bearing 8-50 Crankshaft seal 4-10, 8-50, 9-142 Crosshead 4-15, 4-16, 8-55, 9-120 lubrication 4-16 reciprocating movement 4-7, 4-13 Crosshead coupling 4-26 Crosshead pin bearing 4-16, 8-56, 9-130 Crosshead-piston rod connection 4-16 Cylinder 4-21, 8-59, 9-100 water cooled 4-21 Cylinder clearance 4-27, 9-86 measurement 8-31 Cylinder cover 9-56 dismantle 9-56 install 9-58 Cylinder liner 9-104 Cylinder support 5-36

2B1XC2.64_1

IM 200322en

14 – 1

Index

Grout sole plates 5-51 Grout supporting surface Grouting Material 5-13

D Damper 5-52 Definitions for this document 1-1 Deposits 3-8 Deposits of sand 8-25 Depressurize plant 8-6 Dimensions 5-10, 8-31 Discharge pressure 6-3 Discharge valves 4-31, 8-69, 9-20 Disclaimer 1-3 Dismantle compressor components 9-1 Dismantle crankshaft 9-158 Dismantle electric motor 9-139 Dismantle gear oil pump 9-138 Disposal 11-6 Dispose components 11-6 Distance piece 4-17, 9-107 internal pipes 9-87 Distance piece packing 8-56, 9-108 Drain lubricating oil 9-60 Drive end 4-9 Drive system 3-3 Duplex oil filter 3-9, 8-27 E Electric motor 5-45, 9-139 Electric motor rating 6-3 Electrical hazard 2-6 Electrical installation 5-85 Electrical motor and coupling 8-23 Emergency stop 3-12 Emergency stop during pre-commissioning Explosion protection 2-11 Explosion risk 2-11 External gas pipes 9-100

H Hazard identification diamond 2-14 Hazard seriousness 1-7 caution 3-5 danger 1-7 warning 1-7 Hydraulic pressure test 5-85, 8-30 Hydraulically tightened piston nut 4-28 I Importance of cleanliness 5-3 Important notes 5-3 Inspect compressor plant 5-98 Install compressor 5-28 Install coupling 5-45 Install electric motor 5-45 Install pipe work 5-58 Install plant components 5-52 Installation 5-1 Instruction Manual applicability 1-4 document structure 1-6 revision sheets 1-3 symbols 1-7 target group 1-4 warnings 1-7 Intended use 2-11 5-88

F Fabricate piping 5-59 Flange connections 8-23 Flywheel 5-40, 9-139 Flywheel guard 3-14 Foundation 5-12 Frame Alignment 8-40 Frame covers 9-59 dismantle and assemble 9-59 G Gas specification 2-14 Gas system 3-5, 8-23 check cleanliness 5-90 Gear oil pump 4-11, 9-138 General design and function of compressors Grounding wire 5-85 Grout foundation bolts 5-30 Grout Foundation Bolts 5-49

14 – 2

IM 200322en

5-32

4-1

J Jackscrews

5-15

L Lantern 4-31 Legal regulation 2-3 Level compressor 5-28 Level indicator 3-14 Level monitoring 3-14 LIB 3-11 Lift compressor 5-19 Lift crankgear 5-20 Lift crankgear with distance piece 5-21 Lift cylinder 5-24 Lift cylinder with distance piece 5-22 Lift distance piece 5-23 Lift plant components 5-25 Lifting procedure 5-18 Local instrument board LIB 3-11, 5-56 Local operator panel LOP 3-11 LOCTITE® 8-46 Log sheet 6-8 LOP 3-11 Lubricant handling 2-7

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Index

Lubricating oil drain and refill 9-60 Lubricating system 3-8, 8-26 instrumentation 8-28 non-return valve 8-26 Lubrication crosshead 4-16 external oil pump 4-8, 4-11 gear oil pump 4-8, 4-11 prelubrication pump 4-8 Lyes 2-9 M Maintain plant during decommissioning 5-100, 115 Maintenance compressor in general 8-31 control valve 8-26 plant 8-21 prerequisites 8-3 relief valve 8-26 shut-off valve 8-26 Maintenance practices 2-12 Maintenance schedule 8-17 compressor 8-19 plant 8-18, 8-23 Mandatory tightening torques 5-3 Manley® valve 4-31, 4-34 Marking of compressor components 8-31 Marking of packages 5-6 Mass flow 6-3 Mechanical hazard 2-6 Mechanical test run 5-91 Monitor Operation 6-8 N Name plate 1-5 NFPA-Rating 2-14 Nitrogen 2-16 Nitrogen test run 5-94 Non-drive end 4-11 Non-return valve 3-13, 5-85, 9-6 NORD-LOCK® Securing System 8-47 O Obligations 2-3 Oil change 8-28 Oil cooler 8-27 Oil drain 3-10 Oil level switch 3-10 Oil quality 8-29 Oil quantity 8-28 Oil scraper 9-110, 8-58 Oil scraping 9-110 Oil shield 4-27

18.05.2016

Rev. 001/kalajdzisa_a

Oil sight glass 3-10 Oil skid 3-8, 5-56 Oil specifications 8-29 Oil strainer 3-10, 8-27 Operating elements 3-10 Operation 6-1 monitoring 6-8 prepare 6-4 safety precaution 6-5, 8-3 Operation with process gas 6-5 Organic solvents 2-10 Orifice plates 3-7 P Passivate piping 5-64 Pickle piping 5-64 Pipe fastenings 8-23 Pipe support 5-68 Pipe work blowing out 5-92 fabrication 5-58 sandblast 5-68 Piping final assembly 5-83 Piston 4-26, 8-61, 9-61 assemble the 3-piece piston 9-65 dismantle 9-65 Piston and piston rod install 9-73 dismantle 9-62 Piston nut 4-28 Piston nut SUPERBOLT® 4-28, 4-28 Piston rings 9-70 Piston rod 4-26, 8-59, 9-61 runout 4-29, 8-39 Piston rod monitoring 9-84 Piston rod packing 8-59, 9-88 design 9-89 dismantle 9-90 Piston rod runout adjust 9-81 Place compressor 5-28 Plant overview 3-3 Plant configuration and function 3-1 Pneumatic barring device 3-4 Pre-commissioning 5-1 cooling system 5-88 of compressor plant 5-88 prerequisite 5-88 Prelubrication pump 8-26 Prepare assembly 5-36 Prepare installation 5-15, 5-52 Preserve cleanliness 10-11

2B1XC2.64_1

IM 200322en

14 – 3

Index

Preserve compressor plant 11-3 Preserve compressor plant after installation Pressure monitoring 3-13 Pressure screw 4-31 Preventive maintenance 8-1 Process gas 2-14 Protection against loud noise 2-7 Proximity probe 3-14 Pulsation damper 3-7 Purge gas 2-14 Purge plant 8-6 Purge system 3-5 Purging during normal operation 3-5, 6-7 Purging prior to maintenance 3-6 Purging prior to normal operation 3-6 R Recommission plant 5-100, 11-5 Reference documents 1-4 Refill lubricating oil 8-29, 9-60 Registered trademarks 1-10 Relief valve 3-13, 8-29 Revisions 1-3 Rotation speed 6-3 Rotation speed control 4-36 Runout adjust 9-81 S Safety preventive measures 2-5 Safety advice 2-1 Safety devices 2-6, 3-11, 8-29 Safety measures 2-5 Safety of transport 5-5 Safety valve 3-13, 8-29 Scope of supply 5-8 Serial number 1-5 Shaft power (coupling) 6-3 Shipping condition 5-7 Shipping Package 5-5 Single-compartment distance piece 4-17 Space requirement 5-10, 8-31 Spare parts 12-1 ordering 12-3 original 12-4 Spare parts drawings 12-15 Spare parts list 12-8 Spare parts recommendation 12-6 Spares inventory 12-5 Standard volume 6-3 Standstill 5-98, 6-13, 11-3 Store components 5-8 Suction pressure 6-3 Suction strainer 3-5

14 – 4

IM 200322en

5-98

Suction temperature 6-3 Suction valve actuator 9-6 Suction valves 4-31, 8-69, 9-20 Suction volume 6-3 SUPERBOLT® 8-64 loosening procedure 8-43 preventive maintenance 8-43 tightening procedure 8-44 SWAGELOK® 5-79 Switch off compressor 9-5 Switch off cooling system 9-6 T Target groups 1-4 Technical Documentation 1-4 Technical support 5-3 Temperature monitoring 3-12 Tensioner SUPERBOLT® 8-42 Term cross reference to API standard 1-6 Thermal hazard 2-6 Tighten foundation bolts 5-33 Tightening methods 8-41 Tightening torques and method 8-21 Tightening torques for attachment gear 5-18 Tools 8-6 special 8-10 standard 8-6 Transport 5-1, 5-5 Trigger Sensor 4-10, 9-144 Trouble shooting 7-1 compressor noise 7-15 compressor shutdown 7-21 compressor start-up interlock 7-23 compressor vibrations 7-19 cooling system 7-7 lubricating system 7-10 prerequisites 7-3 process gas system 7-4 SUPERBOLT® 8-45 Trouble shooting list 7-3 Tube fittings 5-71 Turn flywheel 5-43, 5-90 Two-compartment distance piece 4-18 U Unload compressor

5-7

V Valve assembly 9-15, 9-37 disassembly 9-33 disassembly and repair 9-33 dismantling 9-15, 9-24 installation 9-41 Valve failures 8-69

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016

Index

Valve maintenance 8-69 Valve service 8-69 Valve types 4-31 Valves 4-31, 8-69 diameter 4-32 fixation 4-31 location 4-31 VCI mat 5-99, 11-4 Vibration measurement 5-97 Vibration monitoring 3-13 W Warning signs at compressor site Warning symbols 1-8 Warranty 1-3 Weights 5-10, 8-31 Y Year of manufacture

18.05.2016

2-5

6-3

Rev. 001/kalajdzisa_a

2B1XC2.64_1

IM 200322en

14 – 5

Index

14 – 6

IM 200322en

2B1XC2.64_1

Rev. 001/kalajdzisa_a

18.05.2016