@ GEPS Oil & Gas Nuovo Pignone INSTALLATION, OPERATION AND MAINTENANCE MANUAL (CENTRIFUGAL COMPRESSOR BCL 506/N) Volume I Description & Operation NUOVO PIGNONE JOB N.P. SERIAL NUMBERS CUSTOMER PLANT LOCATION PLANT OR UNIT ITEM N° SERVICE DOCUMENT N° MANUFACTURER {SIMEBPORA TENGIZCHEVROIL TE frso--soouas nm 110.1756 C1212 PARSONS FLUOR DANIEL FOR TENGIZ CHEVROIL TENGIZ FIELD - KAZAKHSTAN TENGIZ SOUR GAS INJECTION PROJECT 72-GC-1901 BOOSTER COMPRESSOR PACKAGE MAN 1101756 @ GEPS Oi & Gas Nuovo Pignone Via F. Matteucci, 2 50127 Florence - Italy Telephone (055) 423211 Telefax (055) 4232800 11-02-E Moo INRAISMLE 1200 1756 P.1-di as Nuovo Pignone GEPS 011 & G MANUAL ~ VOLUME 1 NP. Job: 110.1756 Description & Operation (CENTRIFUGAL COMPRESSOR BCL 506/N; PARSONS FLUOR DANIEL FOR TENGIZ CHEVROIL; TENGIZ FIELD - KAZAKHSTAN) 11-02-E 1756 Ped@ GEPS Oil & Gas Nuovo Pignone INSTRUCTIONS MANUAL Status and description of the revisions Sais Brean] Baa] Fate] Connaine | appa essa Ss Revlon status | Date | Prepered| Checked | Approved Desciplon of he revisions First Issue 05.11.02 |ISSELnord| ISSUE, Second Issue | 07.07.03 |ISSELnord] ISSUE | 3rd issve Hepes] 4 Geer Kosi eee = © 2001 Nuovo Pignone S.p.A., tutti diritti riservati ‘NUOVO PIGNONE PROPRIETARY INFORMATION {Questo documento include informazioni confienzial@ i propieté di Nuovo Pignone @ non pud essere rirodotto, copato, 0 fomito a torza pata senza il preventivo consonso serio di Nuovo Pignone. | destinatar accettano di prendere ogni ragionevole precauzione per protegger® tall information! da uso non autorizzato 0 dala loro divulgazion. ©2001 Nuovo Pignone S.p.A., all rights reserved NUOVO PIGNONE PROPRIETARY INFORMATION This document includes proprietary and confidential information of Nuovo Pignone and may not be repreduced, copied, oF fumished to third parties without the prior writen consent of Nuovo Pignone. Focipiont agrees to take reasonable steps fo protect such information from unauthorized use or disclosure, DATE: 05.11.2002 NP. JOB: 110.1756 Pd Moo INRRSMU PE ove@ GEPS Oil & Gas Nuovo Pignone After Sales Service Introduction to Nuovo Pignone after-sales service Nuovo Pignone organization is structured in such a way as to guarantee a comprehensive and effective after-sales service for its machinery. Here is briefly described the organization of the company, based on its experience as a manufacturer and on a continuous effort to meet customers needs. Being aware of the importance of maintenance in all operational activities, Nuovo Pignone deals with its various aspects from the design stage, through: - the use of design criteria that enhance maintainability, - the continuos research of innovative solutions to improve availability, =the selection of components and advanced technologies to enhance equipment maintenance, - the inspection procedures and topics, to be used in connection with a detailed schedule of maintenance operations, the choice of the spare parts to be Kept in stock, optimizing investment cost vs plant downtime. In late years Nuovo Pignone after-sales service has also been brought up-to-date to guarantee the best support to its customers. In more details: - worldwide, where Nuovo Pignone has been operating for tens of years, the structure consists of a service network which is the natural expansion of the “Customer Service Division" in Florence. ‘There are localized Service Units and authorized Service Shops at strategic points of the world, to cover areas where plants with Nuovo Pignone machinery are located. - in Florence, ( Headquarters) specialized depts. which are active from the receipt of the enquiry, to the issue of the offer and, in ‘case of an order, to the management of all activities connected with the job, up to its completion. ‘This organization, available for all customers, ensures a qualified interface to refer to for any requirements in connection with operation/maintenance of machinery. ‘The names and address for localized Service Units and authorized Service Shops are available at GE POWER SYSTEM WEB SITE (URL: http://www.gepower.com) selecting from its home page the following choices: Business site/GE Nuovo Pignone/Sales Organization (complete URL: hup:/www.gepower.com/geoilandsas/oil_gasbrands/inuovo_pignone/sales_org.htm)). In the section “Service” of this page are available the names and addresses of localized Service Units divided into geographical areas. In the above indicated web site, in the section “New Units” are available the names and addresses of the Branch Offices Abroad divided into geographical areas. 06-01-E After-Sales Service P12@ GEPS Oil & Gas Nuovo Pignone Nuovo Pignone has been managing for many years special after sales "Support Packages”. These packages typically include: - diagnostic analysis of machines in oper - consultancy in scheduling maintenance based on operational requirements - field maintenance - refurbishing of worn components - original spare parts supplies - technical expertise in updating machines Product engineering departments are staffed with experts in analysing machinery operating data, who provide users with technical consulting services aimed at optimizing use of equipment. The entire service organization guarantees users get the most suitable maintenance to restore original design conditions and the total information relevant to all technological innovations introduced in Nuovo Pignone's products as applicable to the installed machinery. Full flexibility allows us to adapt each maintenance contract upon User's needs.Service Agreements in force today, range from "On call" basis to "Global Service” 06-0-E ‘After-Sales Service P.22 Noo WRRSVLDLIPF. 0601@ GEPS Oil & Gas Nuovo Pignone VOLUMES INDEX The complete instructions of the compressor unit are subdivided into six volumes as follows: - DESCRIPTION & OPERATION Volume I - COMPRESSOR DRAWINGS AND PARTS LIST Volume II Tome 1-2 - AUXILIARY EQUIPMENT Volume II - INSTRUMENTATION Volume IV - INSTALLATION AND PRECOMMISSIONING ACTIVITIES Volume V Each Volume is subdivided into Sections. Each Section can be subdivided into Paragraphs and/or Parts. Each Volume includes a Main Index which refers to relevant content of Volume. 10-02-E 1756 PL@ GEPS Oil & Gas Volume I Nuovo Pignone Contents COMPRESSOR INSTRUCTIONS MAIN INDEX Section - GENERAL. General Overall dimensions and main we Operating conditions Performance curves Data sheet As tested curves - SYSTEM DESCRIPTION Description — compressor BCL type Compressor BCL 506/N - general Casing Diaphragms Rotor Balance drum Journal bearings Thrust bearing Labyrinth seals (internal) Shaft end seals - mechanical gas seals Lube oil system - general Lube oil lines Lube oil pressure to bearings Seal gas system - general Seal gas lines Filters Gas pressure control valve (8) Instruments 11-02-E 1736@ GEPS Oil & Gas Volume I Nuovo Pignone Contents Section - SAFETY INSTRUCTIONS 3 Definitions Symbols used in the manual Introduction Tdentification of danger zones Safeguarding (safety devices and guards) Residual risks Information on hazards in case of failure Intended use of machine General warning information - OPERATION 4 Foreword Antisurge and gas system Preliminary safety check Stop devices ‘Compressor unit operation - general Seal gas system preparation, flushing system starting ‘Lube oil system preparation and starting Unit start-up Unit shut down Instrument setting Routine checks Operating oil pressure and temperature, seal gas pressure - MAINTENANCE 5 Foreword Safety device maintenance General Inspection and maintenance list General recommendations Procedure for stud bolts tightening of casing Instructions for use of the hydraulic equipment for tightening case nuts and bolts Procedure for tightening bolts and nuts for all the compressors Procedure for tightening tie rods and nuts 11-02-E 1756 P.23@ GEPS Oil & Gas Volume I Nuovo Pignone Contents Section Journal bearing on end opposite to thrust bearing Journal bearing and thrust bearing Check of tilting pad bearing clearance Check of thrust bearing axial clearance Check of rotor axial displacement Positioning of axial position probe Mechanical gas seals Rotor, labyrinth seals and diaphragms To establish rotor center position relative to diaphragms Lube oil specification - general Oil pipings - erection - flushing Areas to be cleaned and interventions schedule Protective compound and cleaning solvent Preservation of the compressor for shipment Procedure for preservation and auxiliary equipment Tools - parts list Tools - sketches - INSTALLATION 6 Foreword General delivery, unpacking, storage, handling Main equipment weights Foundations Positioning Alignment - TROUBLE SHOOTING 7 Trouble shooting - DISMISSION AND ENVIRONMENTAL IMPACT 8 Environmental impact Dismission 1-028 1756 P33@ GEPS Oil & Gas Nuovo Pignone General Section 1 GENERAL, SPECIFICATION AND DESCRIPTION Contents Page - GENERAL co - OVERALL DIMENSIONS AND MAIN WEIGHTS 13 - OPERATING CONDITIONS 15 - PERFORMANCE CURVES | SOS 7247067/4 16 - DATA SHEET SOS 9952360/4 - AS TESTED PERFORMANCE, CURVES SOS 7247445/4 TOE “1756 Pid@ GEPS Oil & Gas Nuovo Pigrone General 14 GENERAL ‘The instructions contained in this manual are referred to a Booster Gas Compressor Plant. The process gas is compressed from 40.2 Bar a (4020 kPa a) 0 90 Bar a (9000 kPa a) by one compression stage utilizing a centrifugal compressor of type BCL S06/N. The compressor is driven by means of a Gas Turbine MS 3002/J (supplied by Nuovo Pignone) coupled to the compressor by means of a coupling. ‘The machines are assembled on a separated baseplates. ‘The arrangement of the machines comprised in the unit is shown on the simplified drawing at page 1-2. The operating conditions of the centrifugal compressor unit are shown in the following pages of this section. This volume of the instructions manual includes: the description of the manufacturing fea- tures, the instruction of installation, operation, maintenance and preservation; the descrip- tion of the lube oil and seal gas systems and of the assembling/disassembling tools. The instructions of the "Auxiliary Equipment’ (Volume II of this Manual) and "Instru- mentation" (Volume TV of this Manual) supplied by Nuovo Pignone for this compressor are included in separated volumes of this manual. For the arrangement of the machines and for installation dimensions refer to "Turbocom- pressor Foundation Drawing" dwg. SOK 6738174/1 (571501-4-3001-D1/0034), included in the “Drawings” Section 1, Volume II of this Manual. 1003-6 1756 P12@ GEPS Oil & Gas Nuovo Pignone General 1-2 DISCHARGE SUCTION COUPLING ‘MS 3002/5 BASEPLATE FOUNDATION Compression unit arrangernent - Simplified drawing 102E 1756 P. 2-2 Moo. neAsvL/Pe 1200@ GEPS Oil & Gas Nuovo Pignone General 13 OVERALL DIMENSIONS AND MAIN WEIGHTS For the overall dimensions see drawing at following page. MAIN WEIGHTS EEE Denomination CO/CE BCL 506/N ROTOR 1000 MAXIMUM WEIGHT FOR MAINTENANCE 8000 (rotor/diaphagm bundle) TOTAL COMPRESSOR SKID 29100 BASEPLATE 6240 11-028 1736 PldNuovo Pignone @ GEPS Oil & Gas 14 Overall dimension draving P.22 “1756 102, Moo. wensvue-. 1200@ GEPS Oil & Gas Nuovo Pignone General 15 OPERATING CONDITIONS (GUARANTEED POINT) CONDIZIONI DI FUNZIONAMENTO GUARANTEED POINT OPERATING CONDITIONS (NORMAL) FASE DI COMPRESSIONE aes COMPRESSOR STAGE (RATED) GAS COMPRESSO SWEET GAS. (METHANE 80 51%) GAS HANDLED (Main components) STHANE 14.69%) PORTATA WEIGHT FLOW gh ae) CONDIZIONT ALL ASPIRAZIONE SUCTION CONDITIONS Peso molecolare 5 Molecular weight ee cpcy oe Score 1282 Compressible Compressivlity Ce Pressione Pressure Bara 402 Temperanra Temperature *c a CONDIZIONTALLA MANDATA DISCHARGE CONDITIONS Pressione o Pressure Bara Temperatura Temperature xc a POTENZA ALLASSE os SHAFT POWER kw VELOCITA’ SPEED om GS SENSO DI ROTAZIONE (vist dl lato azionamento) “ANTIORARIO ROTATION DIRECTION (viewed from driver end) COUNTERCLOCKWISE NOISE SPECIFITACION SEE COMPRESSOR DATA SHEET TrOse 1756 PiCUENTE “CUSTOMER TENGIZCHEVROIL (TCO) ov! TEHTSUWEBPOMNT (TLIO) fGnoi FRENZE TOGALITA'- LANT LOCATION ‘TENGIZ FIELD (KAZAKHSTAN) INOWAQKA TEHIH3 (KAZAXCTAH) coMESsA-Jo8 THPIRRTO FN. 1101756 ‘TENGIZ SOUR GAS INJECTION PROJECT MPOEKT HATHETAHHA CEPHACTOI0 HE@TAHOTO TAA [| mecTopoMneHMs TEHrMS TTOLo- TLE TCO ASSET OevELOPMENT PROSECTS as spots taomeoron eneo Ta © Proto pea MS SS FFD Venda Ramee ~~ HUOWS PGNORE Farchase Ova Nor | SHSOTA SOOT ST ee ete — rarer ee a [sent So [Sescemi Poo is) oe 3 Roxy [Bee Coser — oa ee ain aR swoon Proswrponurprare mo naze opewant. Banerjee enon, Reed ane epee eon Copy BEREDRTPEO ST Paamec xrpeoreararweceeoenna tomes pant Sept Essence Sc tansee CASTRATE | te aT TET z se a Sa TATA RT igecunpen: epee ropes penn i yoo moe sn ienoonth Purser ar pares tperoenr oer Zoemaann sare C.D, E Soo a ante ipemina opcra epemneeacems skevan eotactpes recs rerepedore 7 ieemercen Wenmrsapose Rots reewedn passat canna CERTIFIED FINA Sera aie mcesa eens ‘Authersation to does notreleve Vendor / Contractor ofits responsibly or labilty under te purchase order contrack. ‘Apropuzauymn va nopoxon x Asicransu wo ocaoGoxaaor Mocrasua Tloapnasara ov ero oGnoannooTod wi OreoTorBeNNOGTH no 28435) Ha noeTa FROMTHE. Trew 7 [SES RISRTERRELATO iene SO Foaeaal aoe 1] ADDED LABEL "CERTIFIED FINAL" ON PAG. 1 12042 | _N. SOS 7247067 fa 1 | EMESSO - ISSUED Zoroaroa | UNGUA-UING. | PAGINA -SHEET [nev] OeSCRZONE - DESCRIPTION me_[orom | mae fomoe| A-G 412 T pesee roar prt NUOVO PGNONE A avin eieggs op b aan. [SOSTITUSCE I -REPLAGES ras deco bw popu ot NLOVO PINON. Al gh at waar acetsagtetaw. | SOSTITUTOO8 REPLACED BY.Booster ‘STAGE OVERALL, ‘OPERATING POINT RATED sycTEP CTYNEH HOMHOCTENO —-—-HOMHHAMIBHA PABOWASI TONKA s20 BAR-ABS g LR DABIIEHVE HATHETAHVA, BAP - ABC. 8 DISCHARGE PRESSURE 3 58 s g 8 2§ sno g8 ge BE E8 eo is z ge Be ao ag p-4 = 3 ‘2000 ectmiafad 2000 3000+ «4000 «| «5000 | «6000 |«7000«——«an0 INLET FLOW wa/H BXOQHOANOTOK KEM ‘THESE CURVES ARE VALID IN THE FOLLOWING CONDITIONS. ‘9TH KPUBBIE IPHMEHHME! B CIEZVIOUWX YCOBHAX GAS HANDLED BOOSTER GAS PAGOWMA TAS BYCTEPHEI TAS MOLECULAR WEIGHT 10296 MO) BEC INTAKE PRESSURE. 402 BARA AABNEHME BAYCKA 40.2 BAP ABC. INTAKE TEMPERATURE 00 0E6-C TENEPATYPA BIYCKA 500 TPARUENLCHA COMPRESS. AT SUCTION KOMNPECHA IPH BCACHIBAHIM RATIO OF SPEC. HEATS. KOD@OHLBIEHT CNEL TENNOBLX GOOEXTOB ogee 1282 eM Be5t85 E=AC50 JOB 1101758 HAPS 1101756 2 [Row Nuovo Pignone FIRENZE ex. [ 0ESORIBONE DESCRIPTION N. SOS 7247067 14 TTITLE TEIGRCIEVRCR. PREDICTED PERFORUAICE SR GENTRFUGAL COMPRESSOR BOGEN TOLO-TNLE ForeEceRe CURVES FOF Renee PACOUMS XAPAKTEPHCTHON AD UEHTPOSERHOTO ROMAPECCOPA BLOAN TDNGUA-LANG, | PAGIA-GHEET A-G 213pleas BoosTER STAGE OVERALL ‘OPERATING PONT RATED syerep CYTE MOMHOCTsIO ——_-HOMIMANBHAR PABOYAR TOUKA 2.20 ge z= tr a 2s ES 2.00 g Pst ew w # J 2 hr BS 10 4 a pW} PN mate zudo 3000” 4000~~«s0v0.” ead ~——«7000 «| «0009000 160 140 =— c 320 100 DISCHARGE TEMPERAT. TEMMEPATYPA HATHETAHVA, °C = L [ ZT PT £ Im rm 80 ne zo” 3000 000=| «S000 «6000 «7000«|=« 60009000 INLET FLOW 3/H BXODHOMNOTOK KEM ‘THESE CURVES ARE VALID IN THE FOLLOWING CONDITIONS. ‘9TH KPHBBIE NPHMEHHME B CREAVIOUWX YCROBHAX cans HanoLED |00sTER GAs em PABOWMH FAS BYCTEPHbIA TAS. OB/MAAH MOLECULAR WEIGHT ose Stemes 05200 Moneormrran Bec ems teas INTAKE pressuRE 1020884 eases ‘aanenne sIycKA {0268p asc. SARE TEMPERATURE soca TENEPATYPABIIVONA SnorPARLENsCHA Cannes, At SUCTION owe OMRPEC Gi HPN BOACHIBALIIN Fano OF SPES. HERTS tame JOB 1101756 ROBSOMLMEHT CNEL TENROBLE 98OEKTOB HAPSIEL 1101756 Nuovo Pignone A ence Jev._[ DeSCAMmONE - DESCRIPTION N. SOS 7247067 /4 Foie TITLE” Taeaevane. PEDSTEOPERTORANCE CORTES TORENTRFUGA CouPRESTOROELDUN | UNGUA-UANG. | PAGHIA- SHEET PACMETHIE PABONHE XAPAKTEPHCTHKH (900 YEHTPOBERHOTO KOMMIPECCOPA BCLSOUN A-G 314 Tipnsri Gonmare & pepde NUOVO PIGNONE A wre ol gps co dito b avai. [SOSTITUSCE m= REPLACES rhe soosrers na pony el OVO PINON. A wo essed sostsng olan. | SOSTITUITO OA=REPLAGED BY |ke B00sTER STAGE OVERALL OPERATING POINT RATED eyeree CIMMENG NOMHOCTE:O ——_HOMMTHAMIBHAST PABO4AR TOUKA 180 i | [ ge 28 120 J ae a S 3 2s lc BS 00 ¥ — ef At > 55 — SS 60 ai #8 ~_ 20 zoo" 3000" «a0 S00” 6000 | 7000 ~—»«8000 «9000 , om ic ES So.600. ESS ae A Eeg 3 0.200. oso s0g0 odo” 000 e000 7000~=”=«gODO cad INLET FLOW (M3/H ‘BXOMHOMITIOTOK HOB ‘THESE CURVES ARE VALID IN THE FOLLOWING CONDITIONS ‘STH KPMBDIE NPHMENIIMD! B CNEADIOUNX YCROBHS. GAs HANDLED BOOSTER GAS Rem PABOUHR TAS aoe BYCTEPHEIA TAS OB/MAH MOLECULAR Séee5' D-s200 MONEKYAAPHEIA BEC Land B=6485 | E4550 INTAKE PRESSURE 4028ARA ese aanerine anvora soz eaP asc. INTAKE TEMPERATURE sooece TENIEPATYPA BIDIKA Sno PPARUENCI COMPRESS, AF SUCTION aoe OUnEcCin Ps BCACHIBAH : Ratio oF SPEC. HEATS a Oe TNCETORAGE JOB s101786 FOF OMAHA ROMAHLY HAPS] 1101756 Nuovo Pignone = | Row. FRENZE Jee. | DESCAIZIONE - DESCRIPTION N. SOS 7247067 14 GLO TTTLE TaRaZe V4 WABCTED PENANCE CURIS FOR CEITSTGNLCONPRERTORDGUIAR | UNGUA-LANG. | PAGNA- GREET Fin ve ar acrerncro ADA UPOSEIITO KOMNPELCCPARLEEN A-G 415 Tanne doaaern 6 pep NUOVO PIGNONE A ene legge oot ce oanato. [ SOSTITUSOE | — REPLACES rae does propa INLOVO PONONE. A ph ve sore exrsgtoaw. | SOSTITUTODA=REPLACED BY}BOOSTER STAGE OVERALL ‘OPERATING POINT RATED BYCTEP CTYTEH’ MONHOCTIO = HOMMHANILHAS PABOMAR TOMKA 180 2 i= fg a eg SS 0 a g we ss ae A BR a0 et fe 86 SE a0 — gf F e [> “ cS ra : 2b" 3000 odo gobo 6000” 080 e000 9000 12000 EE sooo «8 1 r oe Bt ro & [4 0000 & 8 ‘ z § aa 2 ec gee gs tz Bg rt moe 2000" 2000” odo” S000" 6000" 7000" odo” 000 INLET FLOW 43/4 BXOAHON NOTOK KYE.MAL THESE CURVES ARE VALIO INTHE FOLLOWING CONDTONS ‘Sh KPHBGIE RPMMEHe B GREA/IOUNR YCMOBHEX cas nanouso BOOSTER GAS row PAGOWA TAS (BYCTEPHDIN TAS OB/MAH MOLECULAR WEIGHT ae Seates’ O=5200 (MONIEKYAAPHEIA BEC B=6500 E=4961 INTAKE PRESSURE sa2pana Case eases iearvera Soeerase. ‘RTAKE TEMPERATURE srabece TENEPATYPA BIDS Srereanuenscrn Couness af SUCTION ome OUPcor Bcacuea nano OF Sees. HER 3 OSSOnbeNT CEU TennosuxooaeKro8 vam acetates Nuovo Pignone = [rex raenze iev,_| DESCRIZIONE - DESCRIPTION N. SOS 7247067 14 TOLD TILE ERSRGaPEOCTCO PEERING COTES OR COTRAUR SOOPERE DOR | UNGUA-UNG. | PRGA SEET _PACHETHBIE PABO'ME XAPAKTEPHCTHRH A718 WEHTPOBEXHOFO KOMTPECCOPA BCLEDEIN 5/6 T prea ocaoro ba propels RIOVO PIGNONE Amin igo cor to teva. ‘is onset th propery ef NUOVO PINON Al ag er xaos coorBOOSTER ‘STAGE OVERALL ‘OPERATING POINT RATED. BYCTEP CTYNEHE MOMHOCTEIO —_-HOMHHANIBHASI PABOUAR TOUKA eos I] i a OTHOWIEHME AABNEHMM PRESSURE RATIO 2 KI 2 a o8 120 [> = ek ¢; g = BS MY r gf BE hl we 3 Pe BE rd IN as mM ae eo 2000" 3000” 4000 | sado 6000 | 7000 «| endo | 9000 INLET FLOW ¥3/H BXOIHOMNOTOK BMY THESE CURVES ARE VALID IN THE FOLLOWING CONDITIONS. ‘STM KPHBDIE NPHMEHIMB & CNEDDVIOUD YCNOBHAX as HanoueD BoosTen cas eM PasouMh TAS BYCTEPHLI TAS oenn MOLECULAR WEIGHT a 6025" 06200 MONERTDPHA DEC Bees00 | E490" INTAKE PRESSURE 59.2 BARA cas860 Faass0 AABIEHNE BNYCKA 53.2 BAP ABC. INTAKE TEMPERATURE aravece TENEPATYPA BIDYCKA S78 rPARUENGOHA COMPRESS. AT SUCTION Aen OUNPECCI NbH BCACLIBAHAH RATIOOF SPEC. HEATS. 297 JOB 1101756 OSDOMLPIEHT CNEL. TENNOBEX 200EKTOS eer ioe Nuovo Pignone = The RENE }ev. | DESCRIZIONE - DESCRIPTION N. SOS 7247067 14 frioLo-TivLE” eweoyenog racbcTeprerona anv ron Cvmrvan CounEsSORGELDaH | UNGUA-LANS. | PAGRA- SHEET PACHETHBIE PAGONME XAPAKTEPHCTHKM [UNS YEHTPOGEMHOTO KOMMPECCOPA BCLSOEM A-G 617 Ten dona prope NUOVO FGHONE, Atami dloge op ite 8 eons, | SOSTITISCE H ~AEPLACES, Te sc na py of LOW PIONORE. A gt we exons eoxasegto law. | SOSTITUTO OA =REPLAGEO BYBoosTeR STAGE OVERALL ‘OPERATING POINT RATED | Byers EHIMENSROMMOCTENO — HONIMANBHAGEPABOHAR TOWA i’ g* SE 38 10 soo L ge ese aes. BE gp.o. 388 gee 0.260. ‘uo s000 soto" odo" sao 7000" e000” s0co INLET FLOW ‘M3/H BXOLHOMNOTOK fom THESE CURVES ARE VALIO INTHE FOLLOWING CONDITIONS "STH APMBDIE NPVMEWUe! 8 CAEAIOUIUX YCNOBHAX cots nanoteD BoosTER GAS rem Pasowonn fas EYCTEPHLE FAS oon MOLECULAR WEIGHT ese Rites’ ons200 MOEN BEC Sree Ecaaet INTAKE pressure 22 8ARA Cisse | Frasso ‘Duane srvera ezeaPacc. fhraKe TEMPERATURE Srepeee TE/EPATYPA BIGEA Srereanuenscien ComPnese SUCTION ce onnPecevo rip Bonceleasian RAO OF See. MEATS te Fone et Ca reronn sone JoB t1ot756 FLANGE TOFLANGE PAU HOT OMAHA KONARLY HAPSHZ] 1101756 Nuovo Pignone 2 [fe a Jev, [DESCRZIONE . DESCRIPTION N. SOS 7247067 14 TOLD THLE” Tensacen POSTOPEN CORT TORCOTRPVOR COOPRSOR TEEN | UNGOR-mNG | PAEWA- SHEET sae _PACHETHUIE PAGOMME XAPAKTEPHCTHKH JNA WEXTPOBERNOFO KOMNPECCOPA BCLSO6A A-G 77 Tac cao a pies WS PNERE Rear db oration, | SOSTTUSSEN = REPACES ‘his deca cpr of RLOVO PRONONE, Al phar sors eccoxsrpto lan. | SOSTITUITO DA REPLACED BYC.D, Nuovo Pignone CLENTE-CUSTOMER “Tp ENGIZCHEVROIL (TCO) Pence TGGAIIR-PORTIOORTOR 7 rep stan (7 ‘CONMESSA-JOB TWRIANTO-PANT 1101756 TiroLo-TMLe F ‘TCO ASSET DEVELOPMENT PROJECTS ai . RPOEKTo| PASPAGOTIA AKTHBOB TIUO 2 PFO Prof No, -Mipore Nem: 571500, veNooR DOCUMENT COVER SHEET CCOnPCOORMTEREHEA MCTOX KAOKYMEHTALUAROCTABLYAKA BOOSTER COMPRESSOR PAPKAG) [NUOVO PIGNONE (S08 caerssae l0S72.60-100% 571501-4-3001.01005% CENTRIFUGAL COMPRESSOR BCLEOBIN DATA SHEET relieve Vendop omgactor ft responsi or iabty under the ae he a \ranayes!Monpnan or ero oBsaieneTes ie " z R oice Eo 7 REVSON, Faioo | Fateo |” Sati | 00? |N, SOS9952360_/4 3, = SUE Falco | Foroo | botaio | osama] UNGUALANG. | PAGRNA-SHEET i SCRIPTION paaro | cocaco | arraerro | ONTKOATE A 412 festa ey OH SE IIOTORTDTEKe Wegp pT Seaee wane. | SOSTIUISCE IL - REPLACES rk ecu ongoery ef MOIOPSNONE Ags we essed sxasegioten __ | SOSTITUITO DA REPLACED BYNuovo Pignone FIRENZE aa ‘CENTRIFUGAL COMPRESSOR ‘API617-8th EDITION. oe SPECIFICATION SHEET rama Fan SRS NETO STMET ea he Oe [sean Fewer aaa a [aera palo! [paren ° ° ° ° ETASEED io HOTS Ts TR], Aa ape TE be maT TTS ae N. $0$9952360_/4 UNGUALNG, | PAGINA-SHEET BESCRPTON A 2a ea popes MOTO PRONE A ean eae pu to Tamra. | SOSTTUSOEL “REM ACES te ene ANNO ee hye see cog 'SOSTITUTO DA. REPLACED BYNuovo Pignone FIRENZE aa) Onset 0872-60801 CENTRIFUGAL COMPRESSOR ‘API 617-6th EDITION SPECIFICATION SHEET ‘appra cy = Cade orc Aor ComEGL Clone tS Wine 20) — Yen Tepestates 0459 No Fare Aneto on sana Yes Ss ee ent eee WALI) Vin Sas ACSC EX MASI OF T PPM WOU RUS JEREGURATIONS-EGUVALENF4W2AROOUG AREA OZONE Sontoransnietote gaunt donage scsureg oes mt ry N. SOS9952360__/4 1 UNGUALANG. | PAGINASHEET foe aves GESCRETION Teese Tas he pepeny ef AUTIO PGNME Aight ese acag oa ie ep MOTO RENEE K care TRG OT GIST TS A 3/4 SORTS CREPES SOSTTUTSOA-RERLAGED EYNuovo Pignone FIRENZE ‘bats shoe 9. 08.72-60-1901 CENTRIFUGAL COMPRESSOR ‘API617-5th EDITION ‘SPECIFICATION SHEET ala fasts OEE Mars pce Reglst (2.23) {eee — = [Cisse cn = 3 fie | = = [snes cae = 6 oe aaa TT tee a | ierteareeereeoeg— a = fs = aI == = = a = : \ a : a 7 Eee = any Trem N. SO$9952360_/4 UNGUMLANG. | PAGINA SHEET A 4/5 [SOSTTUSCETL- REPLACES [SOSTTUITO DA- REPLACED AYNuovo Pignone FIRENZE om ita sbet 9 0572.60.10 Grd CENTRIFUGAL COMPRESSOR API617-Sth EDITION ‘SPECIFICATION SHEET leseeeeescssaarenteey eeu ten ey UBe ERE ENS (1) shutdown furkon, rust bearfag active side only iene N. SOS9952360_/4 UNGuALs, | PAGNA-SHEET A 5 6 cr SSRPTION rr peson ep b= MOTO ENDNE Kc agp WaT. “Ts coment a pry o AUD PONONE Ad hs ae es coring ten ‘SOSTTUBCE NL REPOCES 'SOSNTUITO DA REPLACED BYNuovo Pignone FIRENZE. ata sent 0, 05:7266-201 tr PFD CENTRIFUGAL COMPRESSOR — | emp: Teco ——2 API 677-6th EDITION e EI SPECIFICATION SHEET i Sea Ui List and +s [ere Beefs ouy Over snTER oa Ford Tense ies a aT he “ae a fs con ag roe ROUTING PRES Tap ened SF OST lasaeeges seca eu N. $OS9952360__/4 (ena UNGURLANG, | PAGINA-SHEET 1 est -CESCRETION A 1 preset oP & pon VOWO ERINE Acie Gop OF io @ Toews, — | SOSTHUSCE REPLACES he doument yr opey of MVD REMONE Ais we eed ecoring oa 'SOSTTUTO DA. REPLAGED BYNuovo Pignone FIRENZE Data sheet no, DS-72-60-4910 CENTRIFUGAL COMPRESSOR API 617-6th EDITION ‘SPECIFICATION SHEET Tr poor ic Pag EOF dts ences [omnaeeer Yo ie Ds Prac 2437) Ties ak To CR Te TERAL REPLION N. SOS9952360__/4 PAL RIAISION UNGURUING, | PAGINASHEET INE - DESORPTION A 77 Tee Tee 0 oh ROOT POE Ane Rape Oo aan eth ero BUCH NE es re see zg aw SOSTHURGEE REDUCES -SOSTITUITO DA- REPLACED BYNuovo Pignone FIRENZE to PRT PLANTT ‘COMMESSA- JOB 1101756 WNPTANTO - PLAN ‘CLIENTE - CUSTOMER ‘TENGIZCHEVROIL (TCO) TION TENGIZ FIELD - KAZAKHSTAN BOOSTER COMPRESSOR PACKAGE ‘TCO ASSET DEVELOPMENT PROJECTS. POEKTE| PASPABOTHN AKTHBOB TWO PFO Project No, = Npoaxr OAL Me: 571800 VENDOR DOCUMENT COVER SHEET ‘CONPOBOBNTENEHLA CTO KAOKYMENTALMIA ROCTABUBIKA, SOSTEaT v + foto sors aie tread sept a pees aseiora vf + om Lom arses 7 fesccles specced ana gcse ‘Authorisation to proceed does nottlleve Vendor Contractor a ts rosponsibiy or labity under the Dutchase order eonract. ‘Asropioatu na nepexon x aparouas we ocooGoxsaer Rhoeraeuyma /NoapnA\na oF or OGmaHNOCTER, tina oreereraenocta no axa3y Ha mocrane YORTPBEY. 0 | BMSSIONENSSUE Mi Peleta Tev_[ DEScRIZIONE DESCRIPTION oe T pean evr popes RIOVO HORNE Aaa Ssib0 oom Go 8 ana “Ti cosrmet te propery HOOVO ENON tis a reseed ove UISCE IL - REPLACES SOSTITUITO DA = REPLACED BY 14. dG LNGUALANG.. | PAGINAGHEET Teese | OxTADAT A a2ona = 16.1490 ATA = 07/04/08 (Pnegorte sy PLOTTER we cacaue «vers. 4/0avoeu cwucsos (ens. 20/0e/08u 1 lp COMPRESSOR STAGE OVERALL OPERATING POINT RATED CONDITION 130 2 a < g o 440 4, 4S w — 2 g r—~ B 2% Pe g oY —| # {| & — uw o ec) | = x = a F, NS 8 a ~ so 2500 | 3500 | 4500 | 500 | 6500 | 7500 500 9500 16000. 2 r20004 « g — 2 aAL—t : 1 = e000 7 a | t & ot z et B wooo | + - & rt g 8 : + i 2soo | 3500500500500 7500 wD | «900 INLET FLOW MC/H THESE CURVES ARE VALID IH THE FOLLOWING CONDITIONS GAS MaNOLED NATURAL Gas Few MOLECULAR HEIGHT 19.24 axso0s Y "bessso INTAKE PRESSURE 40.2 BAR-A 86485 E=5200 INTAKE TEMPERATURE 50.0 DEG-C 6=6170 Fea550 COMPRESS. aT. SUCTION 33° PER Bus EQUATION RATIO OF ‘SeEC, FEATS AS PER BuRS EQUATION vos 1101756 Nuovo Pignene oes 4 ev. | cescnizine — cesourion Tae [earora|rwma| omer |NSOS7247445 /4} Thea TICE TENGIZ_ GODSTER COWBRES , THRE] TA SET AS teateD. Pepomiace™ conves | Fon 7 AIFUGAL A ZS TRE I ots a Orson mae eon neg: mewn, | STIS TCREPLACES SSE ts Ne RE ear am pemen P SSETUREE eas—HP COMPRESSOR STAGE OVERALL OPERATING POINT RATED CONDITION 130 2 a + g o 410 4 A a 8, > @ TI 2 — rm g 5 @ |__| rp 8 a g 8 F s| 8 . o i = Ih. 2500’ 3800 4500 ~~ 6500 «500.7500» 88008800 159 2 + > 8 l—~ i] 0 18 a — L g g a ect + 2 a9 & e . £, @ -— i [== | = i 3B rm % s20 D [S — & : = 3 Feel r—~ | 2° £ 5 \~> e| & 38 : “ : | 2500 3500 ~~ 4500«| «S500 6007500 «85009500, 148 T 3 L a _| 5 =! : B z] oO 128 .. i E i & owl & 4 Et: i - 2 TN wy — al © rm a] = es fe a s| 8 gE] 3 2 a 68 2 2sgo | 3500 4500 ~-«5800«| «65007500 ~=+«BS00«= «9500 : INLET FLOW MC/H THESE CURVES ARE VALID IN THE FOLLONING CONDITIONS GAS HANOLED NATURAL GAS ‘ec0cs"eszoo 3 MOLECULAR. REIGHT 16.24 : g INTAKE PRESSURE 53.2 BAR-A B-6.495 4620 3 INTAKE. TEMPERATURE 37-8 oee-c cn5e50 FH4550 : COMPRESS. AT SUCTION AS PER Bus EQUATION 3 RATIO OF SPEC. FEATS AS PER BHAS EQUATION E 3 JOB 1101756 : Nuovo Pignone g rrmenee [Reve] cescnicione ~ cescniorton wee [acoxo|mume] evan |N.SOS7247445 /4 i)frreswmerTeNgI7 BOOSTER COMPRES. Tees PROT SET ince cue z NIRIFUGAL CONPEeSSDA ScLSOE/N TYPE A est 3 Ses mess 1S CSE Uneersecmens sees | es SOSTETUITO OH-REPLACED 6,HP COMPRESSOR STAGE OVERALL OPERATING POINT NORMAL CONDITION 180 cd 2 w J | . Tt] TP 2 AL B 100 2 Q a 3 FL al PN = 60 Hoa i] 2 mS g 20 2500-3800 a500.«=| «5005007500500 3500 1.000. 8 3 A 0.800. 5 — * a KI S 4 © 0.600. & 5 g a 3] 2 0.400] 15 §) & a 0.200. £ 2500" 3500 | 4500 | 5500 6500 | 7500 «| «8500 | abu 3 INLET FLOW MC/H & THESE CURVES ARE VALID IN THE FOLLOWING CONDITIONS GAS_HANOLED NATURAL GAS PH MOLECULAR WEIGHT 19.24 Ax6625 05200 & INTAKE PRESSURE 5312 BAR-A greaas E4620 a INTAKE TEMPERATURE 37/a pec-c 2 COMPRESS. AT SUCTION AS PER BRS EQUATION i RATIO OF SPEC. HEATS AS PER WAS EQUATION 3 é v FLANGE To FLANGE eB 1101756 2 Nuovo Pignone 3 - arene [nev | cescntzione ~ cescniPrion rare |eononopmemo| anrene |NSOS7247445 /4 § recom TENGTZ BOOSTER COMPRES THEO] Pasi SET AS TESTED PERFORMANCE CURVES FOR A 47/2 3 | ____cEnralrtigal “Cowpresson Bc. 506/N' TYEE 1g | % meen csamowo & snomiets® NUOVO PIGNONE. a vomine o« LEEct oom oust E ». |_SOSTITUISCE TL-REPLACES: 3 | REGO Sar ws ee Seer Tae DeaEeCaeasTer@ GEPS Oil & Gas Nuovo Pignone System description Section 2 SYSTEM DESCRIPTION Contents Page = DESCRIPTION COMPRESSOR BCLTYPE 2 - COMPRESSOR BCL 506/N - GENERAL 22 - CASING 24 - DIAPHRAGMS 25 - ROTOR 26 - BALANCE DRUM 28 - JOURNAL BEARINGS , 2-9, - THRUST BEARING 212 - LABYRINTH SEALS (INTERNAL) 2-13 - SHAFT END SEALS - MECHANICAL GAS SEALS 214 - LUBE OIL SYSTEM - GENERAL 2-16 - LUBE OIL LINES 2418 - LUBE OIL PRESSURE TO BEARINGS 2:19 - SEAL GAS SYSTEM - GENERAL 2:20 102E 1756 P12@ GEPS Oil & Gas Nuovo Pignone System deseription Section 2 Contents Page - SEAL GAS LINES 2.22 - FILTERS 224 - GAS PRESSURE CONTROL VALVE (S) 2-26 - INSTRUMENTS 227 1028 1756 P22@ GEPS Oil & Gas Nuovo Pignone System description 2A DESCRIPTION COMPRESSOR BCL TYPE The Nuovo Pignone centrifugal compressors are designated by a series of capital letters and numbers. ‘The capital letters describe the casing features; BCL indicates a compressor with the verti- cally split casing (barrel shaped casing type). ‘The iumbers, after the letters, describe the compressor nominal “size” and the impellers number. Example: the designation BCL 406 indicates a compressor of nominal “size” 400, with one ‘compression stage, by vertically split casing and containing a rotor with six impellers. In the case when a smalll letter (a, b, c, d) is placed afier the numbers, this shows the casing design pressure which is higher than the standard design for this compressor type. This compressor has one compression stage and consists essentially of a static unit (casing, casing heads, covers, diaphragms, seals and bearings) and a moving unit (rotor formed by shaft, impellers and balance drum). ‘The BCL compressor type is expressly designed to deliver gases at high pressure. from 06-84E 02-01-11-0 PLL to 02-896 ‘Moo, NERS PE. 1200@ GEPS Oil & Gas Nuovo Pignone System description 22 COMPRESSOR BCL 506/N- GENERAL ‘The compressor described in the title page is a BCL SO6/N. ‘The suction and discharge flange of these compressors are turned upward. The BCL 506/N centrifugal compress 500 mm has a shaft with six impellers. r with a compression stage and nominal "size" of ‘The casing of this compressor is designed for a standard pressure. ‘The actual impeller diameters are shown in the compressor rotor dwgs. included in the "Drawings" section or volume of this manual. The compressor casing is provided of drains. The assembly sectional drawings, included in the "Drawings" section or volume of this manual is: - SOS 93958/0 for BCL S06/N included in the Volume Il, Section 2, The simplified drawing on the following pages identify the main components of this com- pressor. 1-02E 1756 P12@ GEPS Oil & Gas Nuovo Pignone System deseri 23 RADIAL, CASING DIFFUSER CASING CHANNEL BALANCE RADIAL PROBE HEAD | DRUM PROBE srup \ DISCHARGE / stup BOLT, \ BOLT COVER COVER __| z = END ch, COVER, j J ff 7 iL cabrainra COMPRESSOR SHAFT LL i » | SEALS es AXIAL PROBE l UU ‘THRUST BEARING I JOURNAL JOURNAL BEARING BEARING BUNDLE MECHANICAL POSITIONING MECHANICAL GAS SEALS KEY DIAPHRAGM COUNTERCASING ROLLER() DRAIN GAS SEALS Simplified assembly drawing of BCL 506/N compressor T02E 1736 P22@ GEPS Oil & Gas Nuovo Pignone System description 24 CASING BCL - 2BCL ‘The casing of the BCL compressors is barrel shaped and closed at the ends by two vertical flanges (casing heads). The casing heads and casing matchirig surfaces are accurately machined for the best as- sembly. Casing heads and casing are held firmly together by casing stud bolts. ‘The suction and discharge nozzles are welded to the casing. Four feet projecting from the horizontal center line and laid on special pillars support the casing. The feet at the coupling end (or main coupling end) are provided with feather keys to position the machine in longitudinal direction, Two feather keys welded to the casing along the compressor longitudinal centerline fit, in special corresponding guides welded to the baseplate, and position the machine in the transverse direction. This arrangement permits thermal expansion without changing the machine alignment, The two casing heads installed on the casing ends each carry the housing for rotor bearings and the housings for the end seals which prevent the gas leaking from the casing. The casing heads are funnel shaped to provide a greater pressure strength and to reduce the span between the journal bearings. 02-90-E 02-02-11-0 Pil@ GEPS Oil & Gas Nuovo Pignone System description 25 DIAPHRAGMS BCL (Refer to typical sketches after para. "Rotor") The diaphragms assembly, built up around the rotor assembly, make-up the stationary parts of the compression stages. ‘Annular passages through the diaphragms constitute the diffusers, where the kinetic energy of the gas at impeller outlet is turned into pressure. These passages constitute also the return channels that convey the gas efficiently into the eye of the impellers. All diaphragms are in halves being split at the horizontal center line; the diaphragm halves are assembled into a countercasing split on the horizontal center line as well; making up two separate half bundles. The upper halves of diaphragms are kept in their position in the countercasing by setscrews along the center line, thus allowing to lift the upper half-casing without any danger for dia- phragms falling out. Labyrinth seals are installed in the diaphragms at all internal close-clearance points to minimize the gas leakages from discharge to suction pressure areas of the impellers. Ring seals, installed in groves machined at the periphery of the countercasing, prevent high pressure gas leaking to a lower pressure areas. {A set of rollers is placed on the discharge side of the lower countercasing to facilitate the insertion of the complete diaphragm/rotor bundle into the casing; where it is retained and located axially by means of a casing head and a positioning key placed between bundle and casing 05.94 (02-04-13-1 PEL@ GEPS Oil & Gas Nuovo Pignone System description 26 ROTOR (Refer to typical sketches in the following pages) It consists of a shaft on which impellers and spacers are assembled. The spacers are shrunk on the shaft and they axially position the impellers and protect the shaft sections, between the impellers, from contact with the gas. ‘The impeller is the part of the centrifugal compressor that adds velocity to the gas. ‘The impellers are of enclosed backward-bladed type and are shrunk and keyed on to the shaft. Before being mounted on the shaft each impeller is dynamically balanced and tested at a speed 15% higher than the maximum continuous speed. During the compressor operation the rotor is subjected to an axial thrust in the direction of the suction and generated by the pressure difference acting on the shroud and disk of each impeller. The majority of the thrust is balanced by the balance drum. ‘The resulting axial thrust is absorbed by the thrust bearing. 10.86E 02-05-01-0 PLL@ GEPS Oil & Gas Nuovo Pignone System description 27 SHROUD (COVER) ——_BLADE_ _INLET VOLUTE DISK (HUB) NUT LABYRINTH SEAL SUCTION DIAPHRAGM INTERMEDIATE SUCTION DIAPHRAGM / Ki 7 DIAPHRAGM BLADE RETURN CHANNEL LABYRINTH SEALS SLEEVE (SPACER) ‘Typical sketch B- Compressor inner components 05-02-E “173031 22@ GEPS Oil & Gas Nuovo Pignone System description 28 BALANCE DRUM The centrifugal compressor rotor is subjected to an axial thrust towards the suction end due to the differential pressure generated on the disk and cover of each impeller. The majority of thrust is balanced by the balance drum fitted on the end of the shaft adja- cent to the last stage impeller. The balance drum and relevant labyrinth seal form, together with labyrinth seal provided on the shaft end, the so called balancing chamber. This is accomplished by subjecting the area on the outboard side of the balance drum to a low pressure (approximately suction pressure), thereby creating a pressure differential op- posite in direction to that on the impellers. This low pressure is achieved by connecting the area behind the balance drum to the suction of the compressor by a balance gas line. The size of drum is such that the axial thrust, though not entirely balanced, is considerably reduced, the remaining thrust being absorbed by the thrust bearing, which ensures that the rotor cannot move in axial direction, The balance drum is heat shrunk on to the shaft. The impellers, spacing sleeves and balance drum assembly are held on the shaft by a locking collar. After the balance drum has been fitted to the rotor, the assembly is dynamically balanced again. 1091-6 (02-06-01-0 Pid@ GEPS Oil & Gas Nuovo Pignone System description 29 JOURNAL BEARINGS (Refer to simplified dwg. in the following page) The journal bearings are of the tilting pad type with forced lubrication. Oil under pressure flow the bearings radially, and passes through holes to lubricate pads and blocks. It is then Jaterally discharged. Bearings pads (A) are of steel, internally lined with white metal. They are integral with blocks of steel (B), and are located into the proper seat formed by the shell (C) and by two oil guard rings (E). ‘The pads can swing inside the shell both in the radial and axial direction for the maximum dampening of radial vibration of the rotor. The rotation of pads inside the shell is prevented by pins protruding from screws (D) screwed in the shell. ‘The bearing is axially fixed to the casing head, or compressor casing, by means of screws. 02-90-E 02-07-02-0 P12@ GEPS Oil & Gas Nuovo Pignone System description 2-10 JOURNAL BEARINGS BCL-S06/N: | THRUST BEARING OPPOSITE SIDE: SEAT IN TWO HALVES SEAT A (SHELL) >| DIRECTION OF ROTATION RY Is] 7 Simplified dwg. = Refer to proper dwg. included in the "Drawings" Volume Il, Section 2 of this manual. 1102E 1756 P.23@ GEPS Oil & Gas Nuovo Pignone System description 2 JOURNAL BEARINGS BCL506/N: | THRUST BEARING SIDE: SEAT IN ONE PIECE. SECT.AA cpap iG LP DIRECTION OF ROTATION Simplified dwg. ~ Refer to proper dwg. included in the "Drawings" Volume II, Section 2 of this manual. 11-02-E 1756 P33@ GEPS Oil & Gas Nuovo Pignone System description 212 THRUST BEARING The thrust bearing, mounted on one casing end, is of the double acting type and is posi- tioned at both sides of the rotor thrust collar. It is designed to absorb the residual axial thrust, operating on the rotor, that is not com- pletely balanced by the balance drum. It is provided with an oil control ring (O.C.R.) to minimize the power loss due to churning of the oil in the bearing cavity under high speed operation. In other cases a thrust bearing holder ring forms an annular chamber around the collar that makes the function of the OCR. The specified clearance between the bearing pads and the thrust collar is shown on the "Clearance data sheet" included in the "Drawings" volume or section of this manual. More detailed instructions proper of the thrust bearing are included in the "Auxiliary Equipment" volume of this manual. *from 10-84-E 02-08-01-0 Pid to 04-898 Moo mensnu Pe 1200@ GEPS Oil & Gas Nuovo Pignone System description 213 LABYRINTH SEAL (INTERNAL) The internal seals, used between rotating and stationary parts of the compressor to reduce ‘gas leakage between areas of different pressure, are labyrinth type. ‘The labyrinth seal consists of a ring the periphery of which is shaped on a seties of fins having small clearance with the rotor. ‘These rings are manufactured in 2 halves or quarters of a soft alloy resistant to corrosion to avoid damage to the rotor in the event of an accidental contact. The upper halves of the rings are fastened to relevant diaphragm. The lower halves of the rings can be easily removed by rotating them in their grooved seat in the diaphragms. ‘The positions of the rotor incorporating the labyrinth seals are: the impeller shroud, the shaft sleeves between the impellers and the balance drum, The same type of seals is located at the shaft end to limit the gas leakage out of the com- pressor. The clearances between the labyrinths and the rotor are shown on the "Clearance data sheet" included in the "Drawings" section or volume of this manual. *02-90-E 02-09-01-0 PEL@ GEPS Oil & Gas Nuovo Pignone System description 244 SHAFT END SEALS MECHANICAL GAS SEALS AND TERTIARY SEALS (BARRIER) Seals are assembled at the two ends of each shaft of the compressors to prevent gas from ‘escaping out of the machines. These seals consist of tandem mechanical gas seals with barrier seals (tertiary) and laby- rinth seals. ‘The mechanical gas seals with proper tertiary seals are supplied by JOHN CRANE UK LTD and are type T.28AT. ‘The Nuovo Pignone drawings of mechanical gas seals and tertiary are: BCL 506/N thrust bearing side SOS 9952819/1 and thrust bearing opp. side SOS 9952820/1 included in Volume Il, section 2 The mechanical gas seals consist of two mechanical seals with lapped faces, side by side, of two rotating rings (seat), in tungsten carbide or silicon nitrite and two stationary rings (seal face) in silicon carbide. ‘The inner part (gas side) of each mechanical seal is the part that supports the pressure of the seal gas, while the outer part is stand-by to it. In additional at this tandem seal arrangement the complete mechanical gas seal includes two additional carbon rings: tertiary seal. The tertiary seal is used to prevent the lube oil contamination on bearing housing chamber and the lube oil migration to the secondary tandem seals rings. A typical seal assembly dwg. on compressor rotor is shown at following page. For further details regarding constructional and operating features of the mechanical seals refer to the "Auxiliary Equipment" Volume of this manual. ‘At page 2-21 is reproduced the simplified dgm. that represents schematically the seal ar- rangement and operation as well as the sealing means 11-02-E 1756 P12@ GEPS Oil & Gas Nuovo Pignone System description 215 PRIMARY SECONDARY VENT ‘VENT Gas INTERMEDIATE, ” ANJECTION N INJECTION INJECTION 4 STATIONARY RING ‘STATIONARY RING (SEALFACE) | (SEALFAC ROTATING ROTATING CARBON RINGS RING (SEAT) IRING (SEAT) (TERTIARY SEALS) cassie. | | _gyroror LL. Lea ‘MOSPHERIC SIDE (INNER) $F (OUTER) > ‘Typical mechanical gas seals assembly dwg. Refer to proper dwg. SOS 9952819/1 and SOS 9952820/1 included in the "Drawings" section or volume of this manual. 11-02-E 1756 P22@ GEPS Oil & Gas Nuovw Pignone System description 216 LUBE OIL SYSTEM GENERAL The lube oil is supplied by the oil system of the Gas Turbine that drives the compressor. The oil system of the Gas Turbine supplies cooled and filtered oil, at the required tem- perature and pressure, to the lubricating points of the compressors, as illustrated on dem, SOM 09990/1 (571501-4-3001-01/004) Sheet 8/9, included in the "Drawings" section 5, Volume II of this manual. ‘The simplified drawing on the following page shows the main components of the Lube oil system, 10-03-E 1756 P12@ GEPS Oil & Gas NuovoPignone System description 2-17 FROM LUBE Sn LUBE OIL HEADER ‘CENTRIFUGAL FROM COMPRESSOR SEAL GAS SYSTEM TO LUBE OIL SYSTEM DRAIN HEADER Lube oil system simplified dgm. 102E 1756 P22 Moo. MRAISHUPE. 1200@ GEPS Oil & Gas Nuovo Pignone System description 2-18 LUBE OIL LINES The oil filtered and at required temperature arrives to a header into which the lube oil bearing lines are tapped. The oil pressure in the lube oil header is maintained at a constant pressure of approx. 1.75 Barg - 175 kPa g, by Gas Turbine lube oil system. A calibrated orifice (72 FO 19226+19228) is fitted, in each bearing oil line, this adapts a proper pressure level. The pressure level is indicated by a local pressure gauge (72 PG 19251). ‘Thermoelements to check the white metal temperature, are installed on each bearing. Flow glasses (72 FG 19229-19230) and local temperature gauges (72 TG 19239-19240) are installed in the oil outlet lines from the lubrication points. The oil outlet lines are tapped into a single receiver from which the oil is carried to the main reservoir. 03-94-E 04-08-17-1 Pt@ GEPS Oil & Gas Nuovo Pignone System description 219 LUBE OIL PRESSURE TO BEARINGS ‘The lube oil pressure to the bearings is controlled by means of the calibrated orifice pro- vided in each oil inlet line or conduit to bearings. ‘An oil pressure of 0.9 to 1.3 Bar g, 90 to 130 kPa g to journal bearings and of 0.3 to 0.5 Bar g, 30 to 50 kPa g, to thrust bearing, Check the regular lube oil flow through the bearings by means of the flow glass indicators. + 05-92 (04-09-11-1 Pll@ GEPS Oil & Gas Nuovo Pignone System description 2.20 SEAL GAS SYSTEM GENERAL The system supplies filtered seal (buffer) gas to seals assembled at the two ends of the compressor shaft (o prevent the process gas from escaping out of the machine, as illustrated on dgm. "Seal gas diagram" SOM 09990/1 (571501-4-3001-01/004) sheet 9/10 included in the "Drawings" section or volume of this manual. The simplified drawing on the following page shows the main components and the opera- tion of the seal gas system. DURING OPERATION OR REPAIR OPERATIONS ON SEAL GAS SYSTEM, BE EXTREMELY CAREFUL IN ORDER TO PREVENT ANY FIRE OR EXPLOSION OF THE APPLIANCE OR ITS AUXILIARY SYSTEMS. 10-03-E 1736 P12MAIN re fe ranazt x} Fy] STAND-BY ‘TO COMPRESSOR LUBE OIL SYSTEM. DISCHARGE SIDE + SUCTION SIDE Ls tt BALANCING GAS STAND TOCOMPRESSOR LURE OIL SYSTEM, @ GEPS Oil & Gas Nuovo Pignone Systerm description 2241 _ (} _ —& @HeH |——+ RECOVERY SYSTEM I+ ro rare SEAIS AND CHAMBERS DENOMINATION MECHANICAL GAS SEAL INNER RING MECHANICAL GAS SEAL OUTER RING TERTIARY SEALS. SEAL GAS CHAMBER BALANCE DRUM GAS CHAMBER MECHANICAL GAS INNER CHAMBER MECHANICAL GAS OUTER CHAMBER FLUSHING CHAMBER BETWEEN MECHAN. SEAL AND JOURNAL BEARING ADJUSTING FLOW ORIFICE OUTER SEAL LIQUID DRAWN VALVE INNER LABYRINTH BALANCE DRUM LABYRINTH SEAL. INTERMEDIATE CHAMBERS. mone pene szz03 Seal gas system simplified dgm, - Refer to proper dgm. SOM 0990/1 (57 1501-4-30(1-01/004) sheet 9/10 included in the "Drawings" section or volume of this manual. 10-03-E, Moo neASWyRF. 1290 “1756@ GEPS Oil & Gas Nuovo Pignone System description 2-22 SEAL GAS LINES The discharge gas of the compressor, which comes out between the labyrinth seal "N" and the balance drum, goes into the chamber "B" and returns to the compressor suction com- pressor by means of an external connection called the "balance gas line". The above mentioned connection likewise provides for balancing the axial thrust on the rotor, as described in the para. "Balance drum" included in this section. In this way both ends of the rotor have a pressure close to the suction one and that permits to use two similar groups of sealing rings and the same seal (buffer) gas pressure for both ends of the rotor. Labyrinth seals and mechanical seals (with tertiary seals) form five chambers at suction end of the rotor and six chambers at discharge end of the rotor. In order to prevent the process gas from escaping through the labyrinth seals "! bers "A" are pressurized. , cham- To be sure that the seals operate with clean and without condensate gas, is made an injec- tion of filtered gas (buffer gas) at a pressure a little higher than the suction pressure. Process gas from compressor discharge is used as seal gas. This purpose is assured by a differential pressure control system between the buffer gas, (chamber "A") and balancing gas (chamber "B"). The seal gas pressure in the chamber "A" is controlled by means of a pressure differential control valve (72 PDV 19220) that is provided of a differential transmitter/controller groups as indicated in the paragraph "Gas pressure control valves". ‘This system assures the corrected differential pressures between the seal gas and the bal- ancing gas line. The control valve is provided of: block valve and one by-pass lines, pro- vided of a calibrated orifice. 102-E 1756 P12@ GEPS Oil & Gas Nuovo Pignone System description 2.23 Primary vent lines The seal gas that escapes from chambers "A" through the rings on the inner side of the me- chanical seals (one for each seal) reaches the chambers "C” from where it is sent to recoy- ery system through, adjusting flow orifice valves by means of lines called "Primary vent lines". Pressure transmitter, installed downstream of the adjusting flow orifice valves, consent: to trip the unit in case of high-high differential pressure. Safety valves assure the vent to flare in case of excess of gas pressure. THE PRIMARY VENT FLOWS MAY DIFFER BETWEEN THE TWO SHAFT ENDS (DRIVE END/NON DRIVE END). THIS IS A NORMAL FACT DUE TO THE SENSITIV- ITY OF DRY GAS SEAL CARTRIDGES (WHICH OPERATE ON VERY NARROW GAPS OF APPROX. 5 MICRONS) TO MANUFACTURING VARIABILITY WITHIN ACCEP- TANCE TOLERANCES. N.P. CONSIDER ACCEPTABLE A DIFFERENCE IN FLOWS BETWEEN THE TWO SHAFT ENDS SUBJECT THE FOLLOWING CONDITIONS ARE MET: 1) NO LOW OR HIGH FLOW ALARM IS ACTIVATED. 2) MASS FLOW AMONG THE TWO ENDS DIFFERS LESS THAN 100% IN DYNAMIC CONDITIONS (I.E, THE HIGHER MASS FLOW DO NOT EXCEEDS TWICE THE LOWER MASS FLOW). IN ALL OTHER CASES, THE N.P. SERVICE SHALL BE CONTACTED. Secondary vent lines The remaining seal gas, that escaping from seal outer rings (one for each seal), reaches the chambers "D" where it encounters the flushing gas counterflow becoming from the cham- bers "E" and it is vented to atmosphere through a piping system called "Secondary vent". The chambers "E" are obtained between the barrier seals (tertiary) "3" and "3". Flushing gas The flushing gas pressure is controlled by a pressure control valve (72 PCV 19257) that is provided of block valves and by-pass line with orifice. This gas is sent to chambers "E” through adjusting flow orifices valves. ‘The flushing gas pressure is sent also to intermediate chambers "P" through adjusting flow orifices valves, The flushing gas in chambers "E" prevents any gas escaping from chambers through the tertiary seals and rotor and prevents also that the oil vapour, drained from ioe journal bearings, to becomes in contact with the mechanical gas seals. The chambers can be drained opening the proper manual valves. In the flushing chamber drain line are installed automatic traps (LCV) to assure the lube oil drain, 1003-6 1756 P22@ GEPS Oil & Gas Nuovo Pignone System description 2.24 FILTERS In the main seal gas line / In the flushing gas line Twin gas filters are provided in the main seal gas line (coalescer type) and in the flushing gas line (72-F-1909A/B). Each twin gas filters are piped in a parallel (72-F-1908A/B) ar- rangement utilizing a continuous flow transfer valve. The transfer valve is installed between the filters to direct the gas through either filter and into the gas line. ‘This feature permits either filter to be cut out of service for inspection or maintenance without interrupting gas flow to the machine. The filters are of the replaceable cartridge type. The cartridges are to be replaced whenever the pressure drop across the filter, measured by a differential pressure gauge, approaches the set value indicated in “Instruments List” SOM 6602063/3 (571501-4-3001-0223) or once a year regardless of the pressure drop. ‘An equalization flow line, provided with a restriction orifice, connects the two filters to permit the filling of the spare filter and ease the operation of the transfer valve. ‘The procedure for changing over the filter, while the seal gas system is operating, includes the following steps: ~ Check that the drain valve of the filter not in use is closed. - Open the isolating valve(s) of the filter not in use. - Open the valve on the fi ing (or equalizing flow) line connecting the two filters. - Vent the air from the spare filter for a period of time that will assure the air is com. pletely vented from the filter which is now full with seal gas, then close the vent valve. - Operate the transfer valve to bring the spare filter into operation. - Close the valve on the filling line, crack open the vent valve of the filter not more in use for releasing the gas pressure and then fully open the vent and drain valves. = Close the isolating valves of the filter not in use. 1003-8 “1756 PA?@ GEPS Oil & Gas Nuovo Pignone System description 2.25 = Inspect and clean the filter not in use, replace the cartridges. - Close the vent and drain valves of the filter not in use. 06-01-E 1643 P22@ GEPS Oil & Gas Nuovo Pignone System description 2-26 PRESSURE CONTROL VALVES 1. Flushing gas pressure control valve (72-PCV 19257) This control valve maintains a constant pressure of about 1 Bar g, 100 kPag, in the flushing gas line to assure the pressurizing of the outer seals chambers (tertiary). A flow orifices maintain a pressure of about 7:8 Bar g, 700+800 Kpa g in the flush- ing gas intermediate lines. 2. Differential pressure control valve (72-PDV 19220) in the seal gas line The seal (buffer) gas pressure in the seal gas line, is maintained constantly higher than the pressure in the balancing gas, by means of differential pressure control valve. This automatic valve, installed in the seal (buffer) gas line, is controlled by differen- tial pressure controller and differential pressure transmitter, installed between seal (buffer) gas line and balancing gas line. The seal (buffer) gas is maintained in our case at a pressure of about 3 Bar g, 300 kPag higher than the balancing gas line. It assures a reverse flow from internal to external of the compressor, by means of in- ternal labyrinth seals, preventing the gas process to blow in the compressor inner casing. 1-02E 1756 Pot@ GEPS Oil & Gas Nuovo Pigrrone System description 2.27 INSTRUMENTS The instruments installed in the lube oil and seal gas systems (pressure transmitters, gauges, etc.) are suitable to ensure the correct operation of the system and provide warning of malfunctions, start-up, shut-down of the equipment, etc. in case of impending damage. The complete list of the instruments (supplied by NUOVO PIGNONE), the setting values and the exact tag numbers of them are shown in the “Instruments List” SOM 06602063/3 (571501-4-3001-0223) included in the “Drawings” section or volume of this manual . 10-03-E 1756 Pill@ GEPS Oil & Gas Nuovo Pignone Safety instructions Section 3 SAFETY INSTRUCTIONS Contents Page - DEFINITIONS 34 - SYMBOLS USED IN THE MANUAL 3-4 - INTRODUCTION, 3-5 - IDENTIFICATION OF DANGER ZONES 36 - SAFEGUARDING (SAFETY DEVICES AND GUARDS) 38 - RESIDUAL RISKS 39 - INFORMATION ON HAZARDS IN CASE OF FAILURE. 3-22 - INTENDED USE OF MACHINE 3.23 - GENERAL WARNING INFORMATION 3-25 0601-8 ‘Safety Instruction std, - COCE Pid@ GEPS Oil & Gas Nuovo Pignone Safety instructions 34 3.1 DEFINITIONS OPERATOR Person or persons assigned to the installation, operation, adjustment, maintenance, clean- ing, repair or transport of the machine. DANGER ZONE Any zone inside of or in proximity to a machine in which a person is exposed to the risk of injury or damage to health, - THE DANGER WHICH CAUSES THE RISK CONSIDERED IN THIS DEFINITION: - IS EITHER PRESENT PERMANENTLY DURING THE INTENDED USE OF THE MA- CHINE (MOVEMENT OF DANGEROUS MOBILE ELEMENTS, ELECTRIC ARC DUR- ING WELDING, ETC.), OR - CAN OCCUR UNEXPECTEDLY (SUDDEN/UNEXPECTED STARTING, ETC.). HAZARD Source of possible injury or damage to the health. -THE TERM “HAZARD” IS GENERALLY USED ALONG WITH OTHER WORDS WHICH DEFINE ITS ORIGIN OR THE NATURE OF THE INJURY OR DAMAGE TO HEALTH INVOLVED: ELECTROCUTION HAZARD, CRUSHING HAZARD, SHEAR- ING HAZARD, INTOXICATION HAZARD, ETC. RISK Combination of probability and severity of possible injuries or damage to the health in a dangerous situation. 06-01-E Safety Instruction std. - COCE P12@ GEPS Oil & Gas Nuovo Pignone Safety instructions 32 RESIDUAL RISK Risk which subsists after having adopted safety measures. SAFEGUARDING Safety measures consisting of utilizing the specific technical means known as safeguarding (guards, safety devices) to protect persons from hazards that cannot reasonably be elimi- nated or sufficiently limited by planning. SAFETY DEVICES Device (other than a guard) which eliminates or reduces risk, either alone or associated with a guard. GUARD Element of a machine used in a specific manner to provide protection through a physical barrier. Depending on its construction, a guard may be called hood, cover, screen, door, fence, etc. NOTE A GUARD CAN ACT: - ALONE; IT IS THUS EFFECTIVE ONLY WHEN CLOSED; - ASSOCIATED WITH AN INTERLOCKING DEVICE WITH OR WITHOUT GUARD LOCK; IN THIS CASE PROTECTION IS ASSURED REGARDLESS OF THE POSI- TION OF THE GUARD (“CLOSED” MEANS, FOR A FIXED GUARD, “RETAINED IN POSITION”). 06-01-E ‘Safety Instruction std, - COCE P23@ GEPS Oil & Gas Nuovo Pignone Safety instructions 33 INTENDED USE OF A MACHINE Use to which the machine is destined in accordance with the indications fumished by the manufacturer, or that which is considered usual in relation to its design, construction and function. Intended use also implies respect for the technical instructions found in the manual of in- structions and taking into consideration the incorrect use which can be reasonably ex- pected. AS CONCERNS INCORRECT USE, THE FOLLOWING BEHAVIOR IN PARTICULAR SHOULD BE TAKEN INTO CONSIDERATION IN ESTIMATING RISK: - THE PREDICTABLE INCORRECT BEHAVIOR THAT RESULTS FROM NORMAL NEGLIGENCE AND NOT FROM THE DELIBERATE INTENTION OF USING THE MACHINE INCORRECTLY; - THE INSTINCTIVE REACTION OF A PERSON DURING USE, IN CASE OF MAL- FUNCTION, ACCIDENTS, FAILURE, ETC. - BEHAVIOR DERIVING FROM TAKING THE “LINE OF LEAST RESISTANCE” IN CARRYING OUT A TASK 06-01-E ‘Safety Instruction std. - COCE P33@ GEPS Oil & Gas Nuovo Pignone Safety instructions 34 3.2. SYMBOLS USED IN THE MANUAL General ‘These warnings have been subdivided into three categories depending on the type of in- formation given and the problem evidenced, and in particular: DEFINITIONS THIS SYMBOL EVIDENCES A PROCEDURE, A PRECAUTION OR A CONDI- TION WHICH, IF NOT OBSERVED, CAN CAUSE SEVERE, EVEN FATAL PER- SONAL INJURY TO THE OPERATOR. THE TERM OPERATOR INDICATES A PERSON OR PERSONS ASSIGNED TO THE INSTALLATION, OPERATION, ADJUSTMENT, MAINTENANCE, CLEANING, OR REPAIR OF THE MA- CHINES AND THEIR AUXILIARY EQUIPMENT. THIS SYMBOL EVIDENCES A PROCEDURE, PRECAUTION OR CONDITION WHICH, IF NOT OBSERVED, CAN CAUSE DAMAGE, EVEN SEVERE, TO THE EQUIPMENT. THIS SYMBOL EVIDENCES ONE OR MORE DATA NECESSARY TO PERSONNEL TO CARRY OUT AN OPERATING OR MAINTENANCE PROCEDURE CORRECTLY. This symbology has been used throughout the manual. The following subparagraphs pres- ent a list of general information concerning DANGER and WARNINGS which the opera- tor must always keep in mind before operating on the equipment. 06-01-8 ‘Safety Instruction std. - COCE Plt@ GEPS Oil & Gas Nuovo Pignone Safety instructions 35 3.3. INTRODUCTION In compliance with the applicable directives and standards, this section contains important information, a knowledge of which is fundamental for the operator to be able to work in safe conditions. Personnel operating on the plant must have sufficient knowledge of the functioning of the plant itself and must have read this manual carefully, and must then apply the provisions given in it and follow the instructions received from the manufacturer. Moreover, the op- erator must have acquired sufficient training for the activity he is to carry out. For this reason the operator must have received proper training, also through an initial training period, provided by the GEPS Oil & Gas Nuovo Pignone Training Center. For all situations not described in this manual and in any case where specifically indicated, it will be necessary to contact the Nuovo Pignone Assistance Service. Updated lists of contacts can be found also at the site www.gepower.com. Before beginning any activity the operator must also take note of the particular safety pre- scriptions issued by the manufacturers of the individual devices. These prescriptions are found in the Manuals for the auxiliary equipment and the instrumentation. The safety pre- scriptions contained in this manual are to be utilized in the operating procedures for run- ning the plant. ‘The machinery and its auxiliaries have been designed and constructed in such a way as to reduce to a minimum any risk to the operator. The residual risks and relevant precautions are reported both in this section (for those of general nature) and in the various sections pertinent to the relevant activities and the ensuing possible damage to things or persons. Failure to observe safety regulations and/or the removal or modification of safeguards will nullify the manufacturer’s guarantee and make the user fully liable. For the purpose of favoring immediate consultation of this manual, it is recommended that it be made easily accessible, as well as known, to all of the users involved. 06-01-E, Safety Instruction std. - COCE PL Moo, weRSM PS: 1900@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-6 3.4 IDENTIFICATION OF DANGER ZONES During the stages of installation and maintenance on the compressor and its auxiliaries, hazards relevant to the specific activity carried out are present. The safety warnings con- cerning such hazards are reported in the respective sections of this manual. During normal operation of the compressor and its auxiliaries, hazards of various kinds are present, due to: ~ presence of gas at high and very high pressures in the process systems and the auxiliary systems; = presence of fluids at high pressure in the regulation, lubrication and control systems; ~ utilization of medium and high voltages in the auxiliary and control systems (medium voltage); - presence of surfaces with extreme temperature (hot or cold) on the compressor and the auxiliary systems; - presence of loud noise; - presence of dangerous gas (inflammable, explosive or toxic), These hazards can give tise to risks even at a notable distance; ~ presence of slippery surfaces around the machine and its auxiliary systems Enclosure or acoustic hood over the compressor and its auxiliaries When an enclosure or acoustic hood is provided, within it are present both the hazards in- dicated in the preceding paragraph and those deriving from the presence of a fire-fighting system (asphyxiating gas, insufficient oxygen, etc.). The area inside the enclosure (or hood) is thus always to be considered a high-risk zone and, as such, access to it must be prohib- ited. Access is allowed only with the machine off and after the cool-down period (about 1 hour) has elapsed. It should in fact be kept in mind that even with the machine stopped but during the cool-down period, some of the hazards indicated above are still present. Should it be necessary to gain access to the enclosure (or hood), it will be essential to fol- low an access procedure. Minimum requisites include the presence of at least two persons (one of whom will remain outside in contact with the operator who enters the enclosure). The operators must be adequately trained and equipped with suitable means of personal protection. The time spent inside the enclosure must be as brief as possible. The procedure will pro- vide for the operations to be carried out on the fire-fighting system in order to eliminate risk to the operators. 10-03-E 1756 P12@ GEPS Oil & Gas Nuovo Pignone Safety instructions 37 IN THE PRESENCE OF A PRESSURIZED ACOUSTIC HOOD OR ENCLOSURE, THE ACCESS DOORS CAN PRESENT A CRUSHING HAZARD. THE VENTI- LATION, IN FACT, EXERTS PRESSURE ON THE DOOR, DETERMINING ITS MOVEMENT. Putting the Machine in Safe Conditions Prior to Maintenance ‘Maintenance on the compressor and its auxiliaries described in section “Maintenance” is to be carried out only after the Cool-down period has elapsed. Maintenance operations are those which are statistically most dangerous. For maintenance operations inside the enclosure or acoustic hood, proceed to cut off the discharge piping of the fire-fighting system (by locking the valves) so as to eliminate the risk of accidental discharge. In addition, adequate fire extinguishers must be easily accessible. Prior to operating on the compressor or its auxiliaries, it is indispensable to put them in safe conditions. To do this it is necessary to: - if necessary, mark off with signaling tape or similar the area of operation, lim- iting it by access signs ~ isolate it from any source of extemal power (electric, pneumatic, hydraulic power, etc.) so that they cannot be accidentally reactuated during the period (Lock-out) - indicate with cards placed on the switches, on the control panel, on the cut off elements, that the source of power must not be reactuated (Tag-out) - discharge any sources of internal power (such as springs, pressure vessels, c: pacitors , electric and pneumatic accumulators, etc.) = upon completing maintenance, prior to reactuating the power supplies, check (twice) that any guards that have been removed have been put back in. place, and that the components of the hydraulic and pneumatic lines have been cor- rectly tightened (according to the seal check procedure). The aforesaid prescriptions shall be incorporated in Lock-out Tag-out procedures prepared by the plant manager. 10-03-E 1756 P.22@ GEPS Oil & Gas Nuovo Pignone Safety instructions 38 3.5 SAFEGUARDING (SAFETY DEVICES AND G' !ARDS) Installed on the compressor and its auxiliary systems are guards and safety devices. These devices should not be removed or eluded during any stage of operation of the machine and its auxiliaries. Furthermore, they must be maintained and periodically checked to ensure their efficiency. ‘The guards are of the fixed mechanical type and consist in general of: oil sumps, coupling guards and shielding aimed at preventing access to hazardous zones (mechanical parts in movement, hot surfaces, live electric parts). The safety devices are of both mechanical and electronic type, managed by the control system of the machine or the station, The mechanical safety devices installed on the compressor, on its auxiliaries and on the process piping consist mainly of pressure release valves, and check valves where applica- ble (see Process Gas P & I'D) SOM 09990/1 (sheet 22/22) (571501-4-3001-01/004). Other mechanical safety devices are provided on the driver (Gas turbine, Electric Motor, Steam Turbine, etc.) for the purpose of determining the arrest of the entire train. For such devices reference should be made to the relevant machine manuals. The safety devices of electronic type are divided according to the functions of alarm and tip, In general an alarm indicates malfunction in the machine and its auxiliaries, but not such as to produce immediate danger. Such malfunction must however be eliminated as rapidly as possible. The electronic trip systems instead determine the arrest of the machine train (by acting on the driver) to provide protection against damage to the machinery which could cause situa- tions of danger for the operator. The trip devices present on the compressor and its accesso- ries consist mainly of: - system for detecting vibrations and axial displacement of the rotor; ~ system for detecting temperature and pressure of process gas; ~ system for detecting pressure at the seal vents; ~ system for detecting pressure in the lube oil. The complete list of these devices is given in the "Instrument List" SOM 6602063/3 (571501-4-3001-0223) annexed to this manual All of the electronic safety devices with the function of trip act on the driver to determine the arrest of the entire train in the safest possible manner. Lastly, systems of emergency stopping and manual actuation consisting of pushbuttons which send a stop command to the control system are provided. 10-03-6 1756 P.1d@ GEPS Oil & Gas Nuovo Pignone Safety instructions 39 3.6 RESIDUAL RISKS Introduction The purpose of this section is that of indicating the residual risks of general nature and fur- nishing the warnings necessary to minimize such risks. Other warnings on residual risks of specific types are indicated in the relevant sections of this manual. Failure to respect warnings can cause accidents to operators which may even be fatal. 06-01-E ‘Safety Instruction std. - COCE P12@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3:10 3.6.1 Generic residual risk A DANGER l THE ZONE SURROUNDING THE COMPRESSOR OR ACOUSTIC HOOD (WHEN PRESENT) IS A DANGER ZONE. LIMIT PRESENCES IN THIS ZONE TO THE MINIMUM INDISPENSABLE. PROVIDE ADEQUATE SUPERVISION TO PREVENT ACCESS TO NON- AUTHORIZED PERSONS. A DANGER | ANY WORK ON THE MACHINES AND THE AUXILIARY EQUIPMENT MUST BE CARRIED OUT BY OPERATORS SUITABLY INFORMED OF THE ACTIVI- TIES THEY ARE TO CARRY Ot A DANGER i DO NOT PUT THE COMPRESSOR AND ITS AUXILIARIES IN SERVICE FOR THE FIRST TIME BEFORE ALL OPERATORS HAVE RECEIVED ADEQUATE TRAINING IN SAFETY INSTRUCTIONS, DEVICES AND PROCEDURES. A DANGER i REPLACING PARTS WITH NON-ORIGINAL SPARE PARTS NOT ONLY NUL- LIFIES THE WARRANTY BUT CAN ALSO CREATE DANGEROUS SITUA- TIONS, THE MANUFACTURER DOES NOT ACKNOWLEDGE ANY RESPON- SIBILITY FOR POSSIBLE DAMAGE TO PERSONS AND/OR THINGS DERIV- ING FROM THE UTILIZATION OF NON-ORIGINAL SPARE PARTS. 06-01-E ‘Safety Instruction std. - COCE P.23@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-11 A DANGER DURING OPERATION, ALL PARTS OF THE EQUIPMENT MUST BE IN PER- FECT CONDITION; THE EQUIPMENT MUST NOT BE PUT IN SERVICE IF ANY DEFECTS OR ANOMALIES HAVE BEEN OBSERVED. A DANGER IN GENERAL, OPERATORS MUST UTILIZE THE PERSONAL PROTECTION DEVICES SUITABLE TO THE DANGERS PRESENT IN THE ZONES TO WHICH THEY ACCEDE AND TO THE OPERATIONS TO BE CARRIED OUT. IDENTIFICATION OF THE SPECIFIC PERSONAL PROTECTION DEVICES IS THE RESPONSIBILITY OF THE PLANT MANAGER, ALSO ON THE BASIS OF ‘THE INFORMATION GIVEN IN THIS MANUAL. THE OPERATOR’S CLOTHING MUST BE ADEQUATE TO THE HAZARDS PRESENT, AND IN PARTICULAR MUST BE SUCH AS TO AVOID ANY DAN- GER OF BEING CAUGHT IN THE MACHINERY. GIVEN THE TYPE OF OPERATION OF THE MACHINE AND THE TYPE OF ENVIRONMENT IN WHICH IT OPERATES (PRESENCE OF GAS, HIGH PRES- SURES, ETC.) IT IS EXTREMELY RISKY FOR PERSONNEL TO CARRY OUT OPERATIONS NOT SPECIFIED IN THIS MANUAL (EVEN WITH THE MA- CHINE SWITCHED OFF). FOR SUCH OPERATIONS IT IS ALWAYS NECES- SARY TO CONSULT THE ASSISTANCE SERVICE OF GEPS OIL & GAS NUOVO PIGNONE. 06-01-E ‘Safety Instruction std. - COCE P34@ GEPS Oil & Gas Nuovo Pignone Safety instructions 312 BEFORE WORKING ON THE COMPRESSOR OR ON THE LINES FOR MAIN- TENANCE PROCEDURES, PUT THE MACHINE AND ITS AUXILIARIES OR THE LINE IN SAFE CONDITIONS BY ISOLATING IT FROM ANY SOURCE OF EXTERNAL POWER (ELECTRIC, PNEUMATIC, HYDRAULIC POWER SUP- PLY, ETC. ) AND DISCHARGING ANY SOURCES OF INTERNAL POWER (SUCH AS SPRINGS, PRESSURE VESSELS, CAPACITORS, ETC.). SUITABLY BLOCK EXTERNAL SOURCES OF POWER SO THAT THEY CANNOT BE AC- CIDENTALLY REACTUATED WHILE WORK IS GOING ON. A PROCEDURE PREPARED BY THE PLANT MANAGER MUST BE USED. ONLY OPERATORS AUTHORIZED BY THE PLANT MANAGER CAN CARRY OUT COMMAND AND ADJUSTMENT OPERATIONS ON THE COMPRESSOR AND ITS AUXILIARIES WITH THE MACHINES STOPPED. THIS IS PROHIB- ITED DURING NORMAL OPERATION. ANY ADJUSTMENT AND CONTROL OPERATIONS FOR WHICH IT IS INDIS- PENSABLE TO HAVE THE COMPRESSOR AND ITS AUXILIARIES RUNNING MUST BE REDUCED TO A MINIMUM AND PREVIOUSLY AUTHORIZED BY THE PLANT MANAGER. IT IS PROHIBITED TO MAKE CHANGES IN THE OPERATING PARAMETERS OF THE EQUIPMENT OR THE CALIBRATION OF THE INSTRUMENTS AND FIXTURES: THIS COULD LEAD TO HIGHLY DANGEROUS SITUATIONS. THE INSTALLATION AND FIRST STARTUP OF THE EQUIPMENT MUST BE CONDUCTED UNDER THE SUPERVISION OF NUOVO PIGNONE PERSON- NEL. 06-01-E ‘Safety Instruction std. - COCE P45@ GEPS Oil & Gas Nuovo Pignone Safety instructions 313 A DANGER i ALL CONTROL AND SAFETY DEVICES MUST BE CHECKED, CALIBRATED AND TESTED AT REGULAR INTERVALS. A DANGER | DO NOT CUT OUT NOR REMOVE THE SAFETY DEVICES AND GUARDS IN- STALLED ON THE EQUIPMENT. A DANGER | IN CASE OF LONG PERIODS OF IDLENESS OF THE MACHINES, ADEQUATE PROTECTION AND PRESERVATION OF SAME MUST BE PROVIDED AC- CORDING TO THE INSTRUCTIONS GIVEN IN THE RELEVANT SECTION OF THIS MANUAL. 06-01-E ‘Safety Instruction std. - COCE P56@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-14 3.62 Residual mechanical risk DANGER IT IS PROHIBITED TO START THE EQUIPMENT UNTIL ALL OF THE RE- QUIRED GUARDS HAVE BEEN INSTALLED. FURTHERMORE, IT IS PROHIB- ITED TO REMOVE THEM DURING OPERATION. A DANGER i IT IS PROHIBITED TO USE SELF-CONSTRUCTED EQUIPMENT (SUPPORTS, BRACKETS, FIXTURES, ETC.) WHICH HAS NOT BEEN EXPLICITLY AUTHORIZED BY THE PERTINENT TECHNICAL DEPARTMENT OF GEPS OIL & GAS NUOVO PIGNONE. A DANGER | IN THE COMPRESSOR AND IN SOME AUXILIARY SYSTEMS (LUBE OIL, SEAL OIL, SEAL GAS, COOLING WATER) ARE FLUIDS WHICH ARE HOT (OR COLD) AND/OR UNDER PRESSURE. SPECIAL CAUTION MUST BE ADOPTED IN OPERATING BLEED AND VENT VALVES ON THE SYSTEMS IN QUESTION . PRIOR TO BEGINNING ANY MAINTENANCE PROCEDURE THAT INVOLVES DISASSEMBLY, ENSURE THAT THE INTERNAL FLUID HAS BEEN PROP- ERLY COOLED AND THAT IT IS NOT UNDER PRESSURE. A DANGER DUE TO THE HIGH SPEED OF ROTATION OF THE COMPRESSOR, POSSI- BLE BREAKAGE (ALTHOUGH IMPROBABLE AND ONLY FOR SOME TYPES OF LOW PRESSURE COMPRESSOR) OF AN INTERNAL PART CAN CAUSE THE LEAKAGE OF MATERIAL FROM THE COMPRESSOR CASING WITH POTENTIAL HAZARD TO ANY PERSONS WHO MIGHT BE PRESENT IN THE VICINITY OF THE MACHINE. NEVER REMAIN IN THE VICINITY OF THE MACHINE DURING STARTUP AND AVOID APPROACHING THE MACHINE WHILE IT IS IN OPERATION. 06-01-E ‘Safety Instruction std. - COCE P67@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3.15 A DANGER i IMMEDIATELY CLEAN ANY OIL PRESENT AND RESOLVE THE CAUSE OF SUCH IMMEDIATELY, ALSO TO AVOID THE RISK OF SLIPPING. A DANGER i BEFORE HOISTING ANY EQUIPMENT, VERIFY ON THE HOISTING DRAW- INGS THE HOISTING POSITION AND POINTS OF HOISTING. DO NOT UTILIZE THE HOISTING POINTS RELEVANT TO THE MACHINE ALONE TO LIFT THE WHOLE GROUP OF MACHINE AND BASE PLATE. A DANGER i IN THE PRESENCE OF UNBALANCED LOADS (SUCH AS FOR EXAMPLE COUPLINGS OR OTHER ACCESSORIES) USE ADDITIONAL CABLES TO PREVENT OVERTURNING DURING HOISTING. FAILURE TO OBSERVE THESE PRECAUTIONS CAN CAUSE SEVERE HARM TO PERSONS. HOISTING AND HANDLING OPERATIONS MUST BE CARRIED OUT EXCLUSIVELY BY SPECIALLY TRAINED PERSONNEL. 06-01-8 Safety Instruction std. - COCE P.78@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-16 3.6.3 Residual electrical risks MAINTENANCE OPERATIONS ON ELECTRICAL EQUIPMENT MUST BE CARRIED OUT BY EXPERT, AUTHORIZED PERSONNEL. NOTE THAT IN CIRCUITS WHERE CAPACITORS ARE INSTALLED, THE VOLTAGE MAY REMAIN PRESENT FOR A CERTAIN TIME EVEN AFTER THE POWER SUP- PLY HAS BEEN CUT OFF. A DANGER INSIDE ELECTRIC PANELS AND IN THE VICINITY OF ELECTRICAL DE- VICES MOUNTED ON THE MACHINE AND ITS AUXILIARIES, DANGEROUS. VOLTAGES ARE PRESENT. DO NOT REMOVE THE GUARDS BEFORE HAVING FIRST PUT THE EQUIP- MENT IN SAFE CONDITIONS. REMOUNT THE GUARDS PRIOR TO ENER- GIZING THE EQUIPMENT AGAIN. A DANGER | NEVER WORK ALONE ON ANY ELECTRICAL EQUIPMENT. ENSURE THAT PERSONNEL ASSIGNED TO THIS WORK ARE AWARE OF EMERGENCY FIRST AID PROCEDURES IN CASE OF ELECTROCUTION. A DANGER DO NOT CLIMB ON OR USE AS RESTS ELECTRIC DUCTS, JUNCTION BOXES OR SIMILAR. 06-01-E Safety Instruction std. - COCE P.89@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-17 A DANGER ALWAYS INSTALL GROUND LEADS FOR THE EQUIPMENT AS SPECIFIED BY THE DESIGN. DO NOT REMOVE THESE CONNECTIONS FOR ANY REASON. A DANGER DO NOT USE WATER TO EXTINGUISH FIRES ON LIVE ELECTRICAL EQUIPMENT. THE FIRE EXTINGUISHERS TO BE UTILIZED MUST BE APPROPRIATE TO ‘THE EQUIPMENT AND TO THE TYPE OF FIRE. 06-01-8 Safety Instruction std. -COCE P.9-10 Moo. Men'S 1200@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-18 3.6.4 Residual thermal risks DURING OPERATION SOME PARTS OF THE COMPRESSOR AND OF THE AUXILIARY SYSTEMS REACH HIGH TEMPERATURES. ACCIDENTAL CON- TACT WITH HOT SURFACES CAN CAUSE SEVERE BURNS. BEFORE CARRYING OUT INSPECTION OR MAINTENANCE OPERATIONS, ENSURE THAT THE VARIOUS PARTS ARE SUFFICIENTLY COOL. 0601-6 ‘Safety Instruction std. - COCE P.10-11@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-19 3.6.5 Residual risks generated by noise DURING OPERATION IN THE VICINITY OF THE COMPRESSOR, THE GEAR BOX, THE PROCESS PIPING AND THE ANTI-SURGE VALVES, HIGH NOISE LEVELS ARE PRESENT WHICH CAN CAUSE TEMPORARY OR PERMANENT DAMAGE TO THE HEARING UNLESS ADEQUATE MEANS OF PROTECTION ARE UTILIZED. PERSONNEL WHO MUST WORK FOR ANY REASON, EVEN FOR A BRIEF TIME, IN THE VICINITY OF SUCH EQUIPMENT WHEN THE GROUP IS IN SERVICE MUST WEAR PROTECTIVE DEVICES FOR THE EARS. 0601-8 Safety Instruction std. - COCE P1112@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-20 3.6.6 Residual risks from materials and substances IN THE CASE OF A CARBON DIOXIDE FIRE-FIGHTING SYSTEM, DIS- CHARGE INSIDE OF THE PROTECTED AREA CAUSES SUBSTANTIAL RE- DUCTION IN TEMPERATURE AND IN VISIBILITY AND DRASTIC REDUC- TION IN THE CONCENTRATION OF OXYGEN. THIS CAN RESULT IN AS- PHYXIA FOR ANY PERSONS WHO MAY ACCIDENTALLY REMAIN WITHIN THE AREA IN WHICH THE DISCHARGE TAKES PLACE. BEFORE ACCED- ING TO THE AREA, BLOCK THE AUTOMATIC DISCHARGE SYSTEM AND CLOSE WITH LOCKS THE VALVES ON ALL OF THE DISCHARGE PIPING. AN APPROPRIATE PROCEDURE MUST BE PREPARED BY THE PLANT MANAGER. IN CASE OF WATER-FOG FIRE-FIGHTING SYSTEM, THE DISCHARGE IN- SIDE OF THE PROTECTED AREA CAUSES SUBSTANTIAL DECREASE IN VISIBILITY AND IS HAZARDOUS FOR RESPIRATION. BEFORE ACCEDING TO THE AREA, BLOCK THE AUTOMATIC DISCHARGE SYSTEM AND CLOSE WITH LOCKS THE VALVES ON ALL OF THE DIS- CHARGE PIPING. AN APPROPRIATE PROCEDURE MUST BE PREPARED BY THE PLANT MANAGER. WHEN THE FIRE-FIGHTING SYSTEMS ENTERS OPERATION THE DIS- CHARGE IS ANNOUNCED BY AN ACOUSTIC SIGNAL INSIDE OF AND IN ‘THE VICINITY OF THE PROTECTED AREA. UPON HEARING THIS SIGNAL ANY PERSONS WHO MIGHT BE IN THE AREA MUST LEAVE IT IMMEDIATELY, CLOSING THE DOOR. BEFORE ENTERING THE AREA AFTER ALL OF THE DISCHARGES HAVE TAKEN PLACE, ENSURE THAT THE FIRE HAS BEEN COMPLETELY EX- TINGUISHED AND CANNOT START AGAIN. THEN VENTILATE THE AREA ABUNDANTLY BEFORE ENTERING IT. 06-01-E ‘Safety Instruction std. - COCE P1213, Moo. NoRESML/PF 1200@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-21 A DANGER 0 VENTS, DISCHARGES, DRAINS CAN INVOLVE RISK OF INTOXICATION, FIRE AND EXPLOSION AND MUST BE ADEQUATELY CONVEYED. FOLLOW THE INSTRUCTIONS GIVEN IN THE OPERATIONAL TECHNICAL DOCU- MENTS (P&ID) ANNEXED TO THIS MANUAL. A DANGER i ADEQUATE PROVISIONS MUST BE TAKEN TO AVOID THE ENTRY OF GAS INTO THE COMPRESSOR WHILE THE SEAL SYSTEM IS NOT ACTUATED. A DANGER l DO NOT USE INFLAMMABLE PRODUCTS FOR CLEANING ANY PART OF ‘THE MACHINE. OBSERVE THE PRESCRIPTIONS FOR USE REPORTED IN THE SAFETY CHART FOR THE PRODUCT. VERIFY THE FUNCTION! A DANGER i G OF THE GAS AND FIRE DETECTORS ACCORD- ING TO THE INSTRUCTIONS GIVEN IN THE RELEVANT SECTION OF THIS MANUAL. A DANGER i IN DANGER ZONES IT IS PROHIBITED TO SMOKE, USE FREE FLAME OR DEVICES THAT COULD BE A SOURCE OF IGNITION. 06-01-E ‘Safety Instruction std. - COCE P1313@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-22 37 INFORMATION ON HAZARDS IN CASE OF FAILURE The machine and its auxiliaries are designed according to the "Fail safe" philosophy. In case of failure in the electric, hydraulic or pneumatic system the group is stopped in safe conditions for both the machine and the operators. ‘The control system is also designed according to the "Fail safe” philosophy. Any faults in the control system will be identified by self-diagnostic programs which determine a posi- tioning of the output signals to which safe conditions correspond. Failure due to breakage of the devices containing pressurized and/or dangerous fluids, or to erroneous assembly/disassembly of the components of systems containing pressurized flu- ids, may lead to conditions of danger for the operator, such as the presence of dangerous gases, projection of fluids at high pressure or temperature. For such hazards, refer to the paragraph on residual risks relevant to mechanical hazards and those deriving from materi- als and substances. In case of failure due to breakage of parts of the machinery during operation, the projection of parts is possible (although with minimum probability); for this event refer to the para- ‘graph on residual risks relevant to mechanical hazards. Startup of the machine requires confirmation of the command on the unit control panel (or the DCS), so that the risk of accidental startup is highly improbable. However, in the case of Station remote control, it will be necessary to provide a procedure for notifying station personnel before startup. This procedure will be prepared by the plant manager. 06-01-E ‘Safety Instruction std, - COCE, Pid@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3.23, 3.8 INTENDED USE OF MACHINE The conditions of use intended for the machine and its auxiliaries are given in the relevant data sheet annexed to this manual, Using the machine in different conditions of pressure, temperature, load, speed, can create conditions of damage to the machine and/or danger to the operators. The functioning of the machine in such conditions is to be considered incorrect use of the machine, as is its operation after having cut out or removed any safeguarding device. The properties of the treated gas must have the composition specified in the above- mentioned data sheet. The presence of liquids in the treated gas can generate conditions of damage to the machine and erosion of its inner parts. Hazardous situations can also derive from operating the machine in proximity to its critical speeds which have not been previously approved by the technical department of GEPS Oil & Gas NP (reported in the document "torsional analysis" or "Campbell diagram" annexed to this manual) and/or in conditions of surge (reported in the document "antisurge control diagram" annexed to this manual) since the high stresses on the mechanical elements could lead to breakage with the projection of parts. Modifications made in the machine and its control system, without the prior authorization of GE Oil & Gas Nuovo Pignone, can determine hazardous situations for personnel and/or the machine. GE Oil & Gas Nuovo Pignone cannot be held liable for any consequences deriving from incorrect or non-intended use of the machine and its auxiliaries. ALWAYS VERIFY BOTH THE OPERATING CHARACTERISTICS AND THE SAFETY DEVICES BEFORE STARTING THE COMPRESSOR. ANY DAMAGE TO PERSONS OR THINGS THAT MIGHT RESULT FROM NON-SPECIFIED OR IN ANY CASE NON-REASONABLY FORESEEABLE OP- ERATING CONDITIONS, OR FROM PROCEDURES, INADEQUATE MAINTE- NANCE OR THE EFFECTS OF CORROSION, EROSION, ENCRUSTATION OR GRADUAL DETERIORATION, WILL BE UNDER THE CUSTOMER’S RE- SPONSIBILITY AND AT HIS EXPENSE. 06-01-E ‘Safety Instruction std. - COCE P12@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3204 IT IS PROHIBITED TO USE THE COMPRESSOR FOR COMPRESSING DIF- FERENT TYPES OF GAS OR FOR OPERATING IN AN ATMOSPHERE OTHER ‘THAN THAT OF DESIGN. THE OPERATING PARAMETERS ARE ESTABLISHED AT THE FIRST STARTUP AND CANNOT BE CHANGED FOR ANY REASON WITHOUT THE INTERVENTION OF NUOVO PIGNONE ENGINEERS. 06-01-E Safety Instruction std. - COCE P22 Moo. mrRISMU/ PE 1000@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3.25 39 GENERAL WARNING INFORMATION ‘The following precautions concern the compressor and must be observed during all service procedures. Failure to observe one of these precautions can result in damage or destruction to the ma- chine. ‘The order in which these precautions appear does not imply any order of importance. 1) warning TAKE MAXIMUM CARE TO AVOID IMPACT WHILE HANDLING THE MACHINE AND ITS PARTS. 1 warnine PRIOR TO PUTTING THE MACHINE IN SERVICE, ENSURE THAT THE COVERS OVER INLETS, DISCHARGES AND VENTS HAVE BEEN REMOVED, AND THAT THEY REMAIN UNOBSTRUCTED. 1) warNine ] FOR THE FIRST STARTUP OF THE MACHINE, PLACE A TEMPORARY FILTER ON THE SUCTION PIPING, CLOSE TO THE COMPRESSOR; THIS FILTER CAN BE REMOVED WHEN ALL OF THE PIPING ARE CLEAN. 1 warNina PRIOR TO STARTING THE LUBE OIL SYSTEM IT WILL BE NECESSARY TO PRESSURIZE WITH NITROGEN OR AIR THE THIRD SEAL (WITH CARBON RINGS OR LABYRINTH TYPE) PLACED BETWEEN THE MECHANICAL GAS SEAL AND THE BEARINGS (REFER TO PARAGRAPH RELEVANT TO START- ING OF THE GAS SEAL SYSTEM). 06-01-E ‘Safety Instruction std. - COCE P12@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3-26 { warnina CAREFULLY OBSERVE ALL OF THE INDICATIONS ON THE MONITOR AND THE INSTRUMENTATION PRIOR TO STARTUP AND DURING OPERATION. THE SPEED OF THE MACHINE AND THE PRESSURE AND TEMPERATURE MEASUREMENTS ARE THE BEST INDICATORS OF CORRECT OPERATION OF THE MACHINE. 1 warNinc IN CASE OF STOPPING FOR MALFUNCTION, DO NOT ATTEMPT ANOTHER CLOSE FOR PROTECTION NANCE TO PREVENT THE START BEFORE THE CAUSE HAS BEEN FOUND AND CORRECTED. 1 warninc ALL OF THE DUCTS OPENED DURING MAINTE- ENTRY OF EXTRANEOUS MATERIALS INTO THE SYSTEMS; AVOID USING INSULATING TAPE. AVOID BENDING CABLES; THEM TO BREAK. 1 warnine REPEATED BENDING OF CABLES COULD CAUSE 1 warnina KEEP FIRE-FIGHTING BOXES, COVERS, DOORS, AND PANELS CLOSED, WITH ALL OF THE FASTENERS Si IS NOT REQUIRED. \CREWED TIGHT, WHEN ACCESS FOR INSPECTION 06-01-E Safety Instruction std. - COCE P.23@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3.27 1) warnine WHEN DISCONNECTING ELECTRIC CABLES DO NOT USE TRACTION FORCE ON THEM; DISCONNECT GRASPING ONLY THE CONNECTORS. { warNina ENSURE THAT CHECK VALVES AND CONTROL VALVES ARE INSTALLED AC- CORDING TO THE CORRECT DIRECTION OF FLOW. 1) warning ENSURE THAT ANY MALFUNCTIONING PARTS ARE CUT OUT AND THAT A «DO NOT USE» SIGN IS PLACED ON THE SWITCHES. AVOID IN ANY CASE US- ING THE COMPRESSOR IF ALL OF ITS PARTS AND ACCESSORIES ARE NOT IN PERFECT CONDITION. 1 warnine IF THE COMPRESSOR MUST REMAIN IDLE FOR LONG PERIODS OF TIME, IT MUST BE PRESSURIZED ON THE INSIDE WITH INERT GAS (NITROGEN). ANY DAMAGE CAUSED BY A PERIOD OF IDLENESS DURING WHICH THE PROD- UCT HAS NOT BEEN PUT IN MAINTENANCE CONDITIONS, SUCH AS TO EN- SURE ITS PERFECT PRESERVATION, WILL BE AT THE EXPENSE OF THE CUSTOMER. 06-01-E Safety Instruction std. - COCE P34@ GEPS Oil & Gas Nuovo Pignone Safety instructions 3.28 ALWAYS ENSURE THAT THE FASTENERS (SCREWS, NUTS, ETC.) HAVE BEEN CORRECTLY TIGHTENED TO THE TIGHTENING TORQUES SPECIFIED IN THIS MANUAL WITH A TOLERANCE OF -5% +10%. THE COMPRESSOR ROTOR SHOULD ALWAYS BE CONSIDERED A SINGLE PIECE AND NORMALLY NO PART OF IT MUST BE DISASSEMBLED, EXCEPT FOR THE THRUST COLLAR. IF ANY PART OF THE ROTOR APPEARS DAM- AGED DUE TO CRACKS, SLITS OR REMOVAL OF MATERIAL, IT IS RECOM- MENDED THAT THE NUOVO PIGNONE TECHNICAL SERVICE BE CON- TACTED. 06-01-E ‘Safety Instruction std. - COCE, P44@ GEPS Oil & Gas Nuovo Pignone Operation Section 4 OPERATION Contents Page - FOREWORD 41 - ANTISURGE AND GAS SYSTEM 42 - PRELIMINARY SAFETY CHECK 44 - STOP DEVICES 45 = COMPRESSOR UNIT OPERATION - GENERAL 46 - SEAL GAS SYSTEM PREPARATION, FLUSHING SYSTEM STARTING 47 - LUBE OIL SYSTEM PREPARATION AND STARTING 49 - UNIT START-UP 410 - UNIT SHUT DOWN 412 - INSTRUMENT SETTING 413 - ROUTINE CHECKS 414 = OPERATING OIL PRESSURE AND TEMPERATURE, SEAL GAS PRESSURE 416 1102-8 1756 Pld@ GEPS Oil & Gas Nuovo Pignone Operation 44 OPERATION FOREWORD THE PERSONNEL ENTRUSTED WITH THE INSTALLATION, OPERATION AND MAINTENANCE OF NUOVO PIGNONE PRODUCTS SHALL HAVE THE NECES- SARY TECHNICAL CHARACTERISTICS AND SUITABLE TECHNICAL TRAIN- ING FOR THE TASK IT HAS TO ACCOMPLISH. THESE TECHNICAL CHARACTERISTICS SHALL BE IN COMPLIANCE WITH INTERNATIONAL STANDARD CLASSIFICATION OF OCCUPATIONS, GROUPS 9-61 AND 9-69. ANY DAMAGE, EVEN PARTIAL, ASCRIBABLE TO FAILURE TO COMPLY WITH AFORESAID ESSENTIAL CHARACTERISTICS SHALL BE ATTRIBUTABLE TO THE PURCHASER AND NUOVO PIGNONE WILL BE DISCHARGED OF ANY LI- ABILITY AND INDEMNIFICATION THEREOF. ‘These instructions describe the detailed procedure for the operation of the machine. The instructions are supplied as a guide and do not necessarily include the required ele- ments for every possible condition variation that could take place during operation. There- fore, slightly different procedures may be used to deal with particular conditions. Regardless of the procedure used only qualified and experienced personnel shall be en- trusted with this task. ANY INJURY OR DAMAGE RESULTING FROM OFF DESIGN OR IMPROPER OPERATION, NEGLIGENT PROCEDURE AND MAINTENANCE DEFICIENCY OR EFFECT OF CORROSION, EROSION, DEPOSIT OF SCALE AND WEAR AND TEAR ARE EXCLUDED FROM NUOVO PIGNONE WARRANTY. TOE (07-00-00-S Pid@ GEPS Oil & Gas Nuovo Pignone Operation 42 ANTISURGE AND GAS SYSTEM The system is shown on "Antisurge gas diagram" SOM 09990/1 (571501-4-3001 -01/004) (sheet 22/22), included in the "Drawings" section or volume of this manual. At the end of this para. is shown a simplified dgm. The process gas is compressed from 40.2 Bar a (4020 kPa a) to 90 Bar a (9000 kPa a) by a compression stage utilizing one centrifugal compressor of type BCL S06/N. An antisurge valve (72 FV 19001) is installed in the recycle line. A separator and cooler are provided in the gas discharge line and a strainer in the suction line of the compression stage. Instruments are provided on the suction/discharge lines to take the pressure, the tempera- ture and the gas flow. The capacity at suction of compressor shall always be higher than the capacity at which the pressure and flow pulsation phenomenon begins (surge), as indicated on operation curves. ‘The alternative stresses which the compressor rotor undergoes under such an abnormal op- eration, may seriously damage bearings and seals of compressor. Surging effect occurs when at determined revolutions per minute (R.P.M.) the compressor capacity at suction falls below a certain limit value. In order to avoid surge conditions the compressor unit is equipped with one automatic anti- surge control system that keeps the capacity at suction above the critical value at which surge takes place. If surging problems will occur during start-up or shut-down of the compressor unit, or during mainly changes of compressor unit load, the antisurge system operates recycling a part of the discharge gas line into the suction gas line. The antisurge valve that operates the recycling of the process gas is open or closed by means of air pressure signals becoming, through solenoid valve, from an electric to pneu- matic signal transducer which receives inputs from a flow controller which receives inputs of gas flow temperature and pressure of the suction line and gas pressure of the discharge line. In case of trip the solenoid valve will interrupt the gas pressure to the antisurge valve so that this will be completely open. The “Instrument List" SOM 6602063/3 (571501-4-3001-0223) dwg. included in the "Drawings" section or volume of this manual, shows the control and safety instrumentation supplied by Nuovo Pignone, with proper tags and setting values 10-03-E 1756 P12@ GEPS Oil & Gas Nuovo Pignone Operation 43 ANTISURGE. ‘TO SUCTION ANTISURGE LINE, aaa HEADER RECYCLE INSTRUMENT AIR SUPPLY coe FROM MASTER CONTROLLER PIC 456 FROM SUCTION Snr ‘TO DISCHARGE HEADER Let $e HEADER cootEs DRY INJECTION Gas SEPARATOR ELECTRIC ‘MOTORS Antisurge System Simplified dgm. 102-E 1756@ GEPS Oil & Gas Nuovo Pignone Operation 44 PRELIMINARY SAFETY CHECK Before performing any operation, a general check of safety conditions must be carried out; such inspection must follow instructions given herein after ‘Any actual or potential risk must be removed, before any operation. Preliminary inspection must be carried out as follows : - Learn all special emergency procedures concerning each system. - Note the location and learn the operation of the fire fighting system and of any other emergency or protection appliance, - Note dangerous areas for escape of gases, acid gases, condense collection, drainage line, high voltage, high pressure, other predictable risks. - Ensure the appliance and the adjacent area are in good conditions, and without obstacles and that vent lines are not obstructed. ~ Check if other personnel is operating in the area and if their work is so dangerous to preclude the operation of the compressor. 05-02-E 1674 Pid@ GEPS Oil & Gas Nuovo Pignone Operation 45 STOP DEVICES The appliance is fitted with four types of stop devices: = Work cycle stop device: it is controlled through a PLC for stopping the compressor, and keeping all auxiliary circuits electrically supplied. - Work shift end stop device: it is operated when the appliance must be completely dumped, before a period of inac- tivity. - Emergency stop device: it is operated in emergency conditions, from an emergency control which immediately cuts out electric supply, and keeps software controls operational. Emergency stop can also be activated by pressing the stop pushbutton, - «Trip» stop device: it is automatically activated through the control software each time an anomalous op- ration of the compressor is detected. 05-02-E 1674 PLL Moo. wenisvi/ PF 1280@ GEPS Oil & Gas Nuovo Pignone Operation 46 COMPRESSION UNIT OPERATION GENERAL The instructions given in this section are indicative and are referred to a manual operation of this compressor with the essential references to the driver. The operation instructions of the "Gas Turbine" driving the compressor are given in the proper manual The indicative sequence of the main operations is the following: = Seal gas system preparation and starting ~ Lube oil system preparation and starting ~ Unit gas system preparation = Unit start-up During operations of start-up and shut-down of the compression unit it is necessary refer to the following drawings. - Lube oil dgm. SOM 09990/1 (sheet 8/9) included in the Volume I (571501-4-3001-01/004) Seal gas dgm. SOM 09990/I (sheet 9/10) included in the Volume IL (571501-4-3001-01/004) ~ Instruments list SOM 6602063/3 included in the Volume IL (571501-4-3001-0223) - Antisurge diagram SOM 09990/1 (sheet 22/22) included in the Volume I (571501-4-3001-01/004) Control system functional included in the Gas Turbine manual description SOM 6600365/4 DO NOT ATTEMPT TO OPERATE THE UNIT UNTIL PERSONNEL HAVE A THOROUGH KNOWLEDGE OF THE SAFETY DEVICES AND EMERGENCY OPERATION PROCEDURES AND THE PRE-OPERATION SAFETY AND CON- TROL FEATURES HAVE BEEN CHECKED AND VERIFIED. 10-03-E 1756 Pid@ GEPS Oil & Gas Nuovo Pignone Operation 47 1, SEAL GAS ‘STEM PREPARATION, FLUSHING SYSTEM STARTING. ‘The seal gas system is shown on NP. diagram SOM 0990/1 (571501-4-3001- 01/004) (sheet 9/10) included in Volume Il, section 5, to which we refer. Refer also to simplified dgn. on page 2-21 of this manual. 1.1. Check that the flushing gas (N2) supply for pressurizing the tertiary seals chamber and intermediate chambers is available. 1.2. Check that the isolating valves of the following control valve are open. 72 PCV 19257 Flushing pressure control valve 72 PDV 19220 Pressure differential control valve 1.3. Check that the isolating valves of the seal gas lines to the compressors are open. 1.4, Check that each main seal gas filter (72-F-1908A) and the main fushing gas filter (72-F-1909A)have the isolating valves open and the vent and drain valves closed. 1.5. Check that each stand-by seal gas filter (72-F-1908B) and the stand-by flushing gas filter (72-F-1909B) have the isolating valves and drain valve closed. 1.6. Check that the isolating valve on the primary vent lines are open. 1.7. Check that the isolating valves of pressure gauges, pressure transmitters and pressure differential indicators are open. 1.8. Check the pressure in the lines bearing in mind that the flushing and seal (bal- ancing gas/seal gas) pressure should be as shown in the para. "Oil pressure and temperature - Seal gas pressures" included in this section. 1.9. Check that the flow orifices in the flushing gas lines are fully open 1003-8 1756 P12@ GEPS Oil & Gas Nuovo Pignone Operation 48 1.10. Check that the adjusting flow orifice valves in the primary vent lines are fully open. These valves should be adjusted after first start-up to give a low differential pressure. These valves should then be left in set position. 1.11. Check absence of oil in the compressor flushing chambers tertiary seals open- ing the proper drain valves. ISOLATING VALVES AND DRAIN VALVES TO BE PLUGGED AND BLINDED. 12-01-E 1679-80 P22 Moo. nensvI/ PF 1200@ GEPS Oil & Gas Nuovo Pignone Operation 49 2. LUBE OIL SYSTEM PREPARATION WARNING BEFORE STARTING THE LUBE OIL SYSTEM IT IS NECESSARY TO PRES- SURIZE BY MEANS OF N, THE TERTIARY SEALS CHAMBERS SITUATED BETWEEN "MECHANICAL GAS SEALS" AND "BEARINGS". (SEE PARA. "SEAL GAS SYSTEM PREPARATION, FLUSHING SYSTEM STARTING"). The lube oil system is shown on N.P. diagram SOM 09990/1 (571501-4-3001- 01/004) (sheet 8/9), included in the "Drawings" section or volume of this manual, to which we refer. 2.1. Check that the isolating valves of pressure gauges and pressure transmitters are open. 2.2. Refer to the turbine instruction manual for required adjustments to the main lube oil system prior to start-up. 2.3, Check the normal flow of oil coming out from journal and thrust bearings by means of the flow sight glasses devices. 2.4. Check that the oil temperature is not lower than 20°C - 68°F. 10.03-E 1756 PL@ GEPS Oil & Gas Nuovo Pigrrone Operation 4-10 UNIT START-UP We only supply general information for the compressors). For start-up and operation follow the instructions given in the "Gas Turbine” manual . 1. Open the drain valves of compressor(s) and gas pipings. Check that the isolating valves of gauges, pressure transmitters and so on are open. 3. Flush the compressor unit with inert gas, if the gas being processed makes this neces- sary. 4, Close from upstream to downstream the drain valves of gas pipings and compressor unit 5. Check the pressure and the flushing gas flow into the labyrinth seal chambers (ie. between mechanical seals and bearings). 6. Open slowly the compressor unit filling valve to prevent dangerous variations Of pres- sure. 7. Check absence of any condition of alarm. 8. Open the suction valve, close the filling valve. Make sure that the "Driver" manual in- structions have been observed before starting up the Gas turbine. Start-up the compression unit referring to the "Gas Turbine” manual and open the dis- charge valve. 9. Check differential pressure between seal gas line and balancing gas line. 06-02-E 1745 P12@ GEPS Oil & Gas Nuovo Pignone Operation 441 10, Care must be taken to avoid compressor(s) surge. FOR THE FIRST RUN OF COMPRESSOR(S) FIT A TEMPORARY STRAINER ON THE SUCTION PIPE SECTION CLOSE TO THE COMPRESSOR(S). THIS FILTER SHOULD BE REMOVED ONLY AFTER ASCERTAINING THAT THE PIPES ARE PERFECTLY CLEAN. 05-02-6 1674 P.22@ GEPS Oil & Gas Nuovo Pigrrone Operation 412 UNIT SHUT-DOWN For unit shut-down follow the instructions given in the " Gas Turbine” manual. 1. Care must be taken to avoid compressor(s) surge. 2. Stop the Gas Turbine and close the discharge and suction valves of the compressor. 3. The seal gas will stop to flow after the compressor shut-down. 4, The oil pumps should be stopped only when the oil output temperature in the bearings will become constant 50°C (120°C). 5. Stop the flushing gas pressurizing the tertiary seal chambers (between dry seals and bearings) only after oil pump has been shut-down. IF THE COMPRESSOR(S) IS TO BE SHUT-DOWN FOR A LONG PERIOD THE INSIDE SHOULD BE PRESSURIZED WITH AN INERT GAS (NITROGEN). 102-E 1756 Pid@ GEPS Oil & Gas Nuovo Pignone Operation 4.13 INSTRUMENTS SETTING The set points for the control valves, relief valves and switches should be checked, prior to start-up, as indicated in the "INSTRUMENT LIST" SOM 6602063/3 (571501-4-3001- 0223) included in the "DRAWINGS" volume or section of this manual. Final adjustment of the set points shall be made, if necessary, after initial star-up and op- crating conditions have been reached. 10-03-E 1756 Pad@ GEPS Oil & Gas Nuovo Pignone Operation 414 ROUTINE CHECKS During normal operation To be performed on a regular basis on the running machines. - Temperature in the bearings. ~ Oil temperature in the discharges from bearings. - Oil pressure in the lube oil header. = Oil pressure in the journal and thrust bearings. = Seal gas drop through filters. - Flushing gas drop through filters. = Differential pressure between mechanical gas outer chamber and tertiary flushing cham- bers (E-D chambers) - Differential pressure between seal gas and balance gas. - Seal gas pressure. - Balance gas line pressure. - Flushing pressure downstream the pressure control valve(s). - Pressure in the primary vent lines. - Pressure in the No intermediate chambers. 1201E 1679-80 PLL?@ GEPS Oil & Gas Nuovo Pignone Operation 415 - Pressure through primary vent adjusting flow orifice valves. ~ Oil flow in the discharge lines. = Gas flow in the primary vent lines. - Temperature and pressure of the gas at the suction and discharge of the compressor(s). - Radial vibrations. ~ Rotor axial displacements. - Periodically operate the transfer valve(s) of: seal gas filters. ~ Periodically open the drain valves of the chambers of the tertiary seals. These chambers are between seals and bearings and may contain a small amount of oil which needs to be drained off. - Ete. THE OPERATION DATA NOT AUTOMATICALLY RECORDED BY THE INSTRUMENTS SHALL BE INDICATED IN THE LOG DATA SHEET. ALL DATA RECORDED BY THE INSTRUMENTS OR STATED IN THE LOG SHEET BY THE OPERATOR ARE OF NO USE IF THEY ARE NOT COMPARED WITH THE: DATA PREVIOUSLY READ AND IF THE IMMEDIATE STEPS, WHEN NECESSARY, ARE TAKEN. IMPROVEMENT OF OPERATION RELIABILITY SHOULD BE ACHIEVED BY SPE- CIFIC TRAINING OF THE USER'S PERSONNEL WHO SHOULD ATTEND TRAINING COURSES AT NUOVO PIGNONE'S OR AT THE USER'S SHOP HELD BY NUOVO PIGNONE SPECIALISTS. 1201-E 1679-80 P22@ GEPS Oi! & Gas Nuovo Pignone Operation 4-16 OPERATING OIL PRESSURE AND TEMPERATURE - SEAL GAS PRESSURE @& NOTE THE DATA GIVEN IN THIS TABLE ARE APPROXIMATE. THE CORRECT OIL PRESSURE TO THRUST BEARING IS THAT REQUIRED TO DE- LIVER THE OIL FLOW ADEQUATE FOR THE LUBRICATION AND DISSIPATION OF THE HEAT GENERATED. THE FINAL DATA WILL BE DETERMINED DURING COMMISSIONING. PRELIMINARY OIL PRESSURE FINAL Bar g kPag Lube oil header 1.75 175 Journal bearings 0.91013 | 900 130 Thrust bearing 0.3 100.5 3010 50 OIL TEMPERATURE PRELIMINARY an (Guring normal running) L °C oF Minimum | Bearing oil inlet 35 95 Normal | Bearing oil inlet 35 130 PRELIMINARY SEAL GAS PRESSURE FINAL Bar g kPag Np flushing line (Tertiary seals) 1 100 Seal gas/balancing gas line gas differential 3 300 pressure 11-02-E 1756@ GEPS Oil & Gas Nuovo Pignone Maintenance Section 5 MAINTENANCE Contents Page - FOREWORD 51 - SAFETY DEVICE MAINTENANCE 52 - GENERAL 33 - INSPECTION AND MAINTENANCE LIST 54 - GENERAL RECOMMENDATIONS S14 - PROCEDURE FOR STUD BOLTS TIGHTENING OF CASING 5-16 - INSTRUCTIONS FOR USE OF THE HYDRAULIC EQUIPMENT FOR TIGHTENING CASE NUTS AND BOLTS 5-17 - PROCEDURE FOR TIGHTENING BOLTS AND NUTS FOR ALL THE COMPRESSORS 5-24 - PROCEDURE FOR TIGHTENING TIE RODS AND NUTS 5-25 - JOURNAL BEARING ON END OPPOSITE TO THRUST BEARING 5-26 - JOURNAL BEARING AND THRUST BEARING 5-28 - CHECK OF TILTING PAD BEARING CLEARANCE 5-30 - CHECK OF THRUST BEARING AXIAL CLEARANCE 5-32 - CHECK OF ROTOR AXIAL DISPLACEMENT 5-33 - POSITIONING OF AXIAL POSITION PROBE 5.34 - MECHANICAL GAS SEALS 5-35 05-02-E 1674 P12@ GEPS Oil & Gas Nuovo Pignone Maintenance Section 5 Contents Page - ROTOR, LABYRINTH SEALS AND DIAPHRAGMS 5-36 - TOESTABLISH ROTOR CENTER POSITION RELATIVE TO DIAPHRAGMS 5-45 - LUBE OIL SPECIFICATION - GENERAL 5.47 - OIL PIPINGS - ERECTION - FLUSHING 5-48 - AREAS TO BE CLEANED AND INTERVENTIONS SCHEDULE, 5-50 - PROTECTIVE COMPOUND AND CLEANING SOLVENT 5-52 - PRESERVATION OF THE COMPRESSOR FOR SHIPMENT. 5-58 - PROCEDURE FOR PRESERVATION AND AUXILIARY EQUIPMENT 5-60 - TOOLS - PARTS LIST 5-68 - TOOLS - SKETCHES 5-75 1102-6, 1756 P22@ GEPS Oil & Gas Nuovo Pignone Maintenance 5 MAINTENANCE FOREWORD THE PERSONNEL ENTRUSTED WITH THE INSTALLATION, OPERATION AND MAINTENANCE OF NUOVO PIGNONE PRODUCTS SHALL HAVE THE NECES- SARY TECHNICAL CHARACTERISTICS AND SUITABLE TRAINING FOR THE TASK IT HAS TO ACCOMPLISH. THESE TECHNICAL CHARACTERISTICS SHALL BE IN COMPLIANCE WITH INTERNATIONAL STANDARD CLASSIFICATION OF OCCUPATIONS, GROUPS 9-61 AND 9-69. ANY DAMAGE, EVEN PARTIAL, ASCRIBABLE TO FAILURE TO COMPLY WITH AFORESAID ESSENTIAL CHARACTERISTICS SHALL BE ATTRIBUTABLE TO THE PURCHASER AND NUOVO PIGNONE WILL BE DISCHARGED OF ANY LI- ABILITY AND INDEMNIFICATION THEREOF. ‘These instructions are provided as a guide to establish an inspection planning and inspec- tion procedure. They cover also the assembly and disassembly procedures providing the essential steps in maintenance of components of the machine. ‘The instructions are written assuming that the personnel performing the maintenance is fa- miliar with this type of work, therefore, information provided includes the essentials only. A LOG BOOK SHOULD BE KEPT FOR EACH MACHINE, IN WHICH REASONS FOR MAINTENANCE, WORK PERFORMED, NUMBER OF HOURS AFTER WHICH MAIN- TENANCE WAS REQUIRED, AS WELL AS ANY INSPECTIONS PERFORMED ON THE MACHINE ON SUCH OCCASION SHOULD BE LISTED EVERY TIME SAID MAINTE- NANCES ARE CARRIED OUT. THIS INFORMATION WILL PROVIDE BACKGROUND MATERIAL ON MACHINE PERFORMANCE AND AIDS IN SETTING UP THE MOST APPROPRIATE MAINTE- NANCE PROGRAM POSSIBLE WHETHER OR NOT IT CORRESPONDS TO RECOM- MENDATIONS. TOE (08-00-00-S PL@ GEPS Oil & Gas Nuovo Pig none Maintenance 5-2 SAFETY DEVICE MAINTENANCE, The safety devices installed on the centrifugal compressor or on control boards are pur- chased by Nuovo Pignone suppliers (the list and relevant functions are reported on. Instru- ments List SOM 6602063/3 (571501-4-3001-0223) included in Volume Il). The description, maintenance and operational instructions of such components are imcluded in Auxiliary Appliances - Instrumentation Volumes of present manual; they must be con- sulted for any information concerning above mentioned devices. SCRUPULOUSLY FOLLOW ALL MANUFACTURER INSTRUCTIONS CONCERN- ING THE SAFETY DEVICE, IN ORDER TO PREVENT ANY MALFUNCTIONING DUE TO A WRONG MAINTENANCE. 1003-8 1756 Pil@ GEPS Oil & Gas Nuovo Pignone Maintenance 53 MAINTENANCE INSPECTIONS GENERAL Scheduling of maintenance inspection as indicated herein refers to centrifugal compressors, auxiliaries and instrumentation, The procedures set forth are typical inspection methods covering as wide a range of com- ponents requiring checks as possible. Scheduling times are indicated only as recommendations. It is up to the plant operator him- self to set up a schedule on the basis of his own experience. For this reason, in the “Foreword” we have recommended to keep a log book for each ma- chine. IMPROVEMENT OF MAINTENANCE EFFECTIVENESS SHOULD BE ACHIEVED BY SPECIFIC TRAINING OF THE USER'S PERSONNEL WHO SHOULD ATTEND TRAIN- ING COURSES AT NUOVO PIGNONE'S OR AT USER'S A SHOP HOLD BY NUOVO PIGNONE SPECIALISTS. 11-0LE, (08-01-01-0 PEL@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-4 Inspection and Maintenance List Period Interval o> ° Part (s) Nally, t Purpose of aitla Inspected eye] y x Inspection rlol« x p13 atxufofele TTT ey ays ryif yale éfalajt]eé Siel else ‘A. Centrifugal compressor A1. Journal and thrust x* Check for wear and over- bearings heating. Check rotor axial displace- ment. A2. Rotor X | After three years check for deposits, erosion and corro- sion. A3. Diaphragms X | After three years check for deposits, erosion and corro- sion, Check condition of gas laby- rinth. Replace gaskets. Tore 08-02020 Pia@ GEPS Oil & Gas Nuovo Pignone Maintenance 55 Inspection and Maintenance List Period Interval | ° Part (s) ee ewelety 4 Purpose of cix fe 1 Inspected ole 4 Inspection z]oe| * ‘ rilr{e|a]a ofula]r]e ‘A. Centrifugal compressor ‘A4. Casings-Head flanges X | After three years check for erosion and. corro- Check condition of gas laby- rinth. Replace gaskets. Clean passages in head flange AS. Alignment x* Check TLOL-E (08-02-02-0 P.23@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-6 Inspection and Maintenance List Period Interval 7 WT Part (5) nel eeeleyl A Purpose of f]a]e 1 Inspected eyed u Inspection rio] « ‘ riwtaw |x fy r{x|o]ale t)T/] stare ofufadi}e seis |] sé B. Gearbox B1. Journal and thrust x* Check for wear and over- bearings heating. B2. Gears x* ‘Check for wear. Check tooth-to-tooth con- tact, Check tooth clearance Tore 08-02.000 Pad@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-7 Inspection and Maintenance List Period Interval 7 7m Part (3) e}ule x Purpose of c]a]e : Inspected ole x Inspection elo] * 7 re fetal dy eye] oyele e)t} alata ofmfalale sie] sie y C. Compressor couplings Tooth couplings Cl. Teeth x* Check for centrifugal de- posits, Check tooth-to-tooth contact and wear. C2. Sleeve eal Check axial displacement. C3. Oil nozzles x Check that oil is injected in the right direction. Flexible diaphragm couplings C4, Bolts x Check for loose bolts and nuts. CS. Flex unit center x* Check to see if diaphragms (spacer) are rusted or corroded. Tore 08-02.02-0, P45@ GEPS Oil & Gas Nuovo Pignone Maintenance 58 Inspection and Maintenance List Period Interval v w t |» ° Part (8) Pace Ee : Purpose of cla] e r Inspected syey x Inspection rio « x E | 0 eiwfafy]y a{[xfofele rir] sx]ala ryif rir] e ofm| afi] t sie] s [ely D. Lubrication Oil System D1. Oil properties x Check physical and chemi- cal properties. D2. Main oil reservoir x* Check conditions of paint- ing on walls. x* Check cleanliness of reser- voir bottom whenever reser- voir is drained. D3. Pumps x* Check coupling. x Check cleanliness of suction filter. x* Check pump capacity. X |Check pump intemals after three years. 110LE 08-02.02-0 P56@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-9 Inspection and Maintenance List Period Interval 7 w td]. : Part (9) HBG x Purpose of fale r Inspected oye de " Inspection Flo « 4 ele fufyd yx rie]; ofade SPE} spay sk ret] ry a] s ofafa felt se fe] sl] elt D. Lubrication Oil System D4. Filter x Replace filter cartridges when the pressure drop across the filter exceeds set value. x Replace the cartridge once year regardless of pressure drop. Ba lx Check for smooth easy op- eration of the change over valves. DS. Water cooler x| x Check for smooth, easy op- eration of the change over valves. x* Check water side for depos- its and corrosion. Tore 08-02-0240 P67@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-10 Inspection and Maintenance List Period Interval v | ° Part (s) Pet cele z Purpose of x|t]e clxle r Inspected cas : Inspection eo] « x zt] o eiwlady |v afxufofrle iti; afer] e ste}]s{iyiy¥ D. Lubrication Oil System D6. Air coolers x xt Check proper functioning of ventilation. xX X* Set actuator to check fan pitch angle, x x* Check finned tubes for de- posits and corrosion. D7. Control valves x x Check functioning. Check accessories. X | After three years check inner parts for wear. DB. Safety valves X_ | Check settings. 110FE 08-02.020 P78 Moo. MPAs PF 1200@ GEPS Oil & Gas Nuovo Pignone Maintenance Sl Inspection and Maintenance List Period Interval v wm v |» ° Part (3) aula : Purpose of, ole] x r Inspected fel i Inspection rio|.« x a|[xfolele p]ttxjalda ofulafule sits ivy E. Gas system El. Water coolers xt Check water side for depos- its and corrosion. E2. Air coolers x x* Check proper functioning of ventilation, x x Set actuator to check fan pitch angle, x x* Check finned tubes for de- posits and corrosion. E3. Control valves x x* Check functioning, Check accessories. X |Afier three years check in- ner parts for wear. EA, Safety valves xt Check settings. 10LE 08-02.02.0 P89@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-12 Inspection and Maintenance List Period Interval o |» ° Part (6) Tle] y : Purpose of ie Inspected e] ¥ x Inspection elo] « x r/ 8 a[xi[olel]e Tyi}r}ale ojala] ele stele ds F. Gas seal system FI. Gas filters x Replace filter cartridges when the pressure drop across the filter exceeds set value. x |x Check functioning of the change over valves. x Replace the cartridges once year regardless of pressure drop. F2, Control valves x x Check functioning. Check accessories. X |Affer three years check in- ner parts for wear. F3. Safety valves x* Check settings. Tore 0802020 P30@ GEPS Oil & Gas Nuovo Pignone Maintenance S43 Inspection and Maintenance List Period Interval 7 wT t |. 3 Part (s) riley 4 Purpose of olx]e 1 Inspected a c Y 7 Inspection r{wia]y dy piri x jada rli|rje} se fatale} site les G. Instrumentation Gi. Gauges for pressure, | X x* Calibrate if necessary. temperature. G2. Transmitters, X* Calibrate if necessary. regulator G3. Pressure switches, x x Check alarms. temperature switches, level switches Bc ag Check auxiliary machinery automatic start-up. x x Check shut-down system. G4. Shutdown buttons x x Check operation. IF THE MACHINE IS OPERATING PROPERLY IT IS UP TO THE OPERATOR WHETHER OR NOT INSPECTIONS | MARKED WITH AN ASTERISK (*) SHOULD BE PER- FORMED IMMEDIATELY OR LEFT TO A LATER MORE CONVENIENT DATE. TOE (08-02-02-0 P. 10-10@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-14 GENERAL RECOMMENDATIONS, Itis recommended that a Nuovo Pignone specialist be present when a major disassembly is undertaken. Suitable marked containers should be placed in the machine area for the storage of dis- mantled parts to avoid mechanical damage or loss. Alll special tools shall be checked and made available, prior to starting. All possible replacement parts shall be made available and checked, dimensionally and for damage. Allenergy sources for equipment to be inspected shall be locked off. All piping and equipment openings should be covered during maintenance period. During assembly, carefully follow the assembly drawings and reference numbers stamped on the parts that must be coupled. 1) warninc BEFORE INITIATING MAINTENANCE PROCEDURES, DISCONNECT ALL POWER SOURCES TO THE MACHINE OR ACCESSORIES. FAILURE IN OB- SERVING THESE PRECAUTIONS MAY RESULT IN INJURY TO PERSONNEL. {warning DURING DISASSEMBLY AND ASSEMBLY OPERATIONS OF COMPRESSOR COMPONENTS, HEAVY PARTS MIGHT NEED TO BE REMOVED: EMPLOY SUITABLE LIFTING APPLIANCES IN ORDER TO PREVENT ANY RISK FOR THE PERSONNEL. 05-02-8 1674 P12il jas Nuovo Pignone GEPS Oil & G Maintenance 5-15 DURING MAINTENANCE OPERATIONS, PRODUCTS CONSIDERED FLAMMA- BLE AND HAVE A RELATIVELY LOW ORDER OF TOXICITY, THEY SHOULD BE USED ONLY IN A WELL-VENTILATED AREA THAT IS FREE FROM OPEN FLAMES. AVOID PROLONGED EXPOSURE TO THEIR VAPORS. FAILURE IN OBSERVING THESE PRECAUTIONS MAY RESULT IN INJURY TO PERSONNEL. 05-028 1674 P.22@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-16 PROCEDURE FOR STUD BOLTS TIGHTENING OF CASING VERTICALLY SPLIT CASINGS (BCL - 2BCL - DBCL - PCL) Tightening ‘Smear the stud bolts threads and the mating nuts faces with Molikote, Tighten beginning with four nuts diametrically opposed one another and proceed, subse- quently to tighten the remaining ones in the similar way. TORQUES TABLE Stud bolts ‘Torques nominal diameter mm kgm Nm M24 20 200 M30 40 400 M36x3 80 800 M42x3 130 1300 M 48x3 185 1800 M S6x4 305 3000 M64x4. «——— BCL506/N ———+ 510 «——+5000 M72x4 765 7500 M 80x4 1225 12000 M90x4- 1530 15000 M 100x4 2240 22000 A - ALLOWANCE ON THE TORQUES -5% +10%. B - THE TORQUES SHOWN IN THE TABLE ARE VALID FOR TEMPERATURE ABOVE -101°C 11-02-E 1756 Pril jas Nuovo Pignone GEPS Oil & G. Maintenance 5-17 INSTRUCTIONS FOR USE OF THE HYDRAULIC EQUIPMENT FOR TIGHTENING CASE NUTS AND BOLTS “ENERPAC” OLEODYNAMIC LEVER WRENCHES DRIVEN BY PUMP (PNEUMOHYDRAULIC) 1, PRELIMINARY CHECKS Check the level of the oil in the pump tank. Apply the ring wrench chosen according to the “S” hexagon opening of the nut to be tightened. Connect the flexible tube to the oleodynamic wrench chosen according to the torque wrench setting ENSURE THAT THE QUICK CONNECTIONS ARE WELL ENGAGED AND SCREWED TIGHT. 2. OPERATION With the hydraulic pressure exerted by the operation of the pump, a thrust is created in the cylinder which is transmitted to the ring wrench by means of a system of lev- ers, after securing the adjustable torque arm at a fixed point. ‘The ring wrench turns a 30° angle around the lever axis and thus transmits torque moment to the nut. Within the 30° of rotation torque wrench settings according to the tolerances indicated at point 5 are obtained. The further rotation after 30° may be useful to accelerate the loosening or the first stages of tightening. Once the rotating movement “CYCLE” is terminated, stop the pump, leave the con- trol pedal and move it to the RELEASE (discharge) position, the wrench cylinder will automatically return to the base position. ‘The tool is removed from the nut and re-applied for a further movement until the re- quired tightness is obtained. Subsequent “CYCLES” are carried out until the prede- termined PRESSURE/TORQUE is reached. Always perform a final “CYCLE”. ALWAYS ENSURE THE PERFECT ANCHORING OF THE ADJUSTABLE TORQUE ARM OF THE OLEODYNAMIC WRENCH BEFORE USING THE LATTER. 1LO1E (08-06-02-0 P12 Moo, weRssv¥/ P1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-18 3. USE OF THE EQUIPMENT 34 3.2 Torque wrench setting ‘Without engaging the oleodynamic wrench on the nuts. With the system com- pletely connected and the right power supply, find the required PRESSURE/ TORQUE on the conversion table (diagram) of the oleodynamic wrench. When regulating the torque, it is essential to ensure that the maximum value does not exceed that of the oleodynamic wrench. Once the PRESSURE/TORQUE value is set, the wrench may be positioned on the nuts. This pressure must be regulated on the pump, press the front end of the pedal (marked “PRESSURE”) and keep it pressed. Read crosswise (towards the left) on the pressure gauge up to the correspond- ing pressure. To regulate the pressure, loosen the lock nut on the pressure regulator valve and turn the handle CLOCKWISE to increase the pressure and ANTI- CLOCKWISE to decrease it (see Figure 1). IN DECREASING THE PRESSURE, THE HANDLE MUST BE TURNED TO A LOWER PRESSURE SETTING VALUE THAN THE ONE REQUIRED AND THEN GRADUALLY INCREASED TO THE DESIRED LEVEL. ONCE THE REQUIRED PRESSURE IS STABILIZED, RE-TIGHTEN THE LOCK NUT. BEFORE STARTING TIGHTENING PRESS THE PUMP CONTROL PEDAL AGAIN AND CHECK THAT THE CORRECT PRESSURE HAS BEEN SET. THE HANDLE OF THE CONTROL VALVE MAY BE REMOVED TO PRE- VENT TAMPERING OF THE REGULATED PRESSURE. Application of the oleodynamic tightening wrench Position the ring wrench on the nut and chose an angular position between the 30° and 70° of the working angle of the rotating torque arm. ENSURE THAT THE ADJUSTABLE TORQUE ARM IS PERFECTLY ANCHORED AGAINST A FIXED OBJECT (NUT OR CASING). ‘Temporarily apply pressure to the system to guarantee the correct operation. 11-0F-E (08-06-02-0 P.23@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-19 3.3. Working of the oleodynamic tightening wrench Press on the pneumatic pump control pedal in order to produce a pressure (read on the pressure gauge) corresponding to the torque required. The check on the torque wrench setting will be obtained by examining the correspondence table (diagram) between bar and kgm (bar and Nm) on the basis of the specification of the oleodynamic wrench used. 4, LOOSENING PROCEDURE Position the ring wrench on the nut and set the adjustable torque arm in the loosening position. Press the pneumatic pump pedal (already previously set at 700 bar) and keep it pressed (there will be pressure), as soon as the nut turns the cylinder will extend; once the rotating movement is terminated, stop the pump (see point 2). Repeat the opera- tion until is possible to remove the nut by hand. 5. ACCURACY OF THE TORQUE WRENCH SETTING Oleodynamic wrenches TORQUE WEIGHT eee coe Nm. ACCURACY as YWM 767.45 RCO 11547 640 - 4500 24% 7 YWM 767.100 RCO 11539 1785 - 10100 9 YWM 767.150 RCO 11537 2100 - 14200 £4 5% 15 ‘YWM 767.200 RCO 11608 2860 - 20000 18,5 & NOTE FOR THE TORQUE WRENCH SETTING REFERRED TO THE DIAMETER OF THE STUD BOLT TO BE TIGHTENED SEE THE PARA. “PROCEDURE FOR STUD BOLTS TIGHTENING OF CASING” INCLUDED BEFORE OF THIS PARA. 6. POWER TRANSFORMER UNIT The pneumatic pump can operate with air from 2.8 to 10.3 bar (700 bar with 5.5 bar of air), 1-0L-E (08-06-02-0 P34@ GEPS Oil & Gas Maintenance Nuovo Pignone 5-20 61 Preliminary checks Check the oil level, the pressure and the inlet air flow rate to the unit. For the pump setting see point 3.1. The unit must always be used with the FILTER/LUBRICATOR. MODEL CODE INLET ae PAT-I102N RPO 10329 AIR 2,8 - 10,3 BAR 75 7. CHECKS AND POSSIBLE PROBLEMS Itis advisable to carefully read the instructions and the safety regulations before using the equipment. It is preferable that just one user operates both the oleodynamic wrench and the pump. When tightening the bolts, keep away from the vertical axis; if the bolt breaks, both. the wrench and the bolt are shot along this axis. Before using the wrench with the huts, carry out some cycles and check the efficiency; in this way, in addition, the air will be vented from the tube. When positioning the oleodynamic wrench, arrange the tube so that itis not subject to deformation or stretching. Ensure that the quick joints are assembled correctly. MALFUNCTION DIAGNOSIS SYMPTOM PROBABLE CAUSE REMEDY Lack of pressure 1 = Oillevel too low 1 - Fill the tank 2 - Faulty pressure gauge |2 - Replace 3 - Quick joints not tight-|3 - Tighten the quick joints ened Cylinder that sticks | Air in the circuit Vent the air in the circuit No pressure in the/1 - Incorrect pressure of] 1 - Increase pressure wrench control valve 2 - Faulty pressure control |2 - Replace the valve valve/torque 3 - Inlet air rate too low or}3 - Check pressure and inside air tube too small diameter of tube 4 - Air filter clogged 4 ~ Check and clean 1-01-E 08-06-02-0 Pas@ GEPS Oil & Gas Nuovo Pignone Maintenance 521 8 LIST OF RING WRENCHES OLEODYNAMIC | TORQUE eee ee WRENCH WRENCH ‘CODE SETTING Max. Nm HEXAGON SQUARE “ = CODE CODE 4 > RCO 11598 2 - Rco11549 | 12" - RCO 11584 30 = RCO 11550 32 = Rco1546 | 34" - RCO 11585 36 = ROO 11545 41 = RCO 11551 ROO 11547 4500 46 = RCO 1544 35 = RCO 11543 65 = RCO 11542 70 = RCO83403 75 = RCO 11552 85 = RCO83431 23/16" = _ RCO 83416 36 = RCO 11631 41 = RCO 11632 46 = RCO1163 | 1" = RCO 11386 50 = RCO 11616 35 = Rco1159 | 1.12" - RCO 11587 © = RCO 11600 RCO 11539 10100 65 = RCO 11583 70 + RCO N54) 75 = RCO11591 FORK WRENCH 80 = RCO11540 85 = RCO1133 | 30 - RCO 11592 90. RCO1166 | 50 RCO 11593 60 = - RCO 11594 100 RCO 11599 10s = RCO S414 75 = ROO 11377 80 = RCO1IS78 | Lin" - RCO 11588 RCO 11537 14200 95 = RCO 11582 100 = RCO 11538 105 =_ RCO 11579 30 = RCO 11634 0 = RCO 11609 6s = RCO 11610 RCO 11608 20000 0 = RCoss401 | 1.12" - RCO 11597 80 = RCO 11617 9s = RCO 11606 100 = RCO L611 10s ~ RCOS34I5 120 = RCO 43665 T-OLE 08-06-02-0 P.S6@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-22 9. PRESSURE/TORQUE DIAGRAM -Nm kem--9 20000 —— 18000 —-—}- 16000 +}- + 14000 +—}— : & | £12000 L : 3 - | & [ E S 10000 s Ra Lg S 8000 TAS S, | 4 9 NS 6000 & 4000 a 541 | |_| com | 2000 | | | 0 0 100-200» 300 400 S00 00-700 PRESSURE bar TOLe 08-0602-0, P67i as Nuovo Pignone GEPS Oil & G: Maintenance 5.23 - The items followed by the letter “C” refer to the Part List: “Hydraulic device H.P.” in- cluded in Volume I, Section 3 “Drawing” of this manual. - The item followed by the letter “S” refers to the Parts List: “Tools for assem- bling/disassembling centrifugal compressor supplied with this Job” included in section “Agsembly/Disassembly Tools” of this volume: 4C_- PNEUMOHYDRAULIC PUMP 7C - THERMOPLASTIC TUBE SC - OLEODYNAMIC LEVER WRENCH 1S. - “S” RING WRENCH. AIR REGULATOR ‘VALVE mane (COUNTERNUT Fig.1 TOL 08-06-02-0 P77@ GEPS Oil & Gas Maintenance Nuovo Pigmone 5-24 PROCEDURE FOR TIGHTENING BOLTS AND NUTS FOR THE CENTRIFUGAL COMPRESSOR TORQUES TABLE Stud bolt Torque nominal diameter mm kgm Nm M6 Os 4 M8 1 10 M10 2 20 M12 35 35 M14 5.5 55 M16 9 90 M18 12 120 M20 16 160 M 20x15 17 170 M22 18 180 M24 20 200 M 24x2 2B 230 M27x2 3 330 M30 40 400 M 30x2 45 450 M36 81 800 ‘M 36x3, 81 800 Maz 7 1150 M42x3 122 1200 10.006 1756 Pd@ GEPS Oil & Gas Nuovo Pignone Maintenance 5.25 PROCEDURE FOR TIGHTENING TIE RODS AND NUTS JOURNAL BEARINGS AXIALLY ASSEMBLED SCREWS Centrifugal compressors type: BCL, 2BCL, DBCL and PCL TORQUES TABLE Bearing Torque nominal diameter mm kgm Nm 50 0 90 10 100 110 to 120 18 180 130 31 310 150 to 180 68 620 200 110 1080 05-028 1674 Pid@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-26 JOURNAL BEARING ON END OPPOSITE TO THRUST BEARING (Coupled end) Disassembly A) TO MAKE EASIER THE DISASSEMBLY AND THE ASSEMBLY OF THE BEARING USE THE PROPER TOOLS AS SHOWN ON THIS SECTION "ASSEMBLING - DIS- ASSEMBLING TOOLS". B) IF IT IS NECESSARY TO REMOVE THE COUPLING REMOVE THE COUPLING SPACER AND WITH-DRAW THE HUB ASSEMBLED ON THE END OF THE SHAFT. IN ORDER TO CARRY OUT THIS OPERATION IT IS NECESSARY REFER TO FOLLOWING DOCUMENT INCLUDED IN THE "DRAWINGS" SECTION OR VOLUME DWG. OF "HYDRAULIC DEVICE FOR ASSEMBLING/DISASSEMBLING COUPLINGS". 1. Remove the equipment and instruments installed in the housing cover or in the bearing. BE VERY CAREFUL NOT TO DAMAGE CABLES, PROBES ETC. 2, Remove the top half of the coupling guard and the top half of the end cover (or sup- port). 3. Remove the locking screws of the bearing, or of the locking ring of the bearing, to the casing head. 4, Remove the bolts holding the two halves of the bearing and lift the top half. .. Support the rotor and remove the bottom half of the bearing by rotating it through 180° round the shaft. 6. Disassemble the various parts of the bearing and accurately inspect the internal sur- faces, make sure that there are no splits, scratches, or other damage. Carefully clean pieces individually. Blow through the entrance conduits and the oil drain conduits and clean them, Assembly To reassemble the bearing reverse the procedure outlined for removal. 05.02-E (08-08-01-1.1674 P.L2@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-27 1 warninc MAKE SURE THAT THE COUPLING SURFACES HAVE BEEN CORRECTLY CLEANED BEFORE PROCEEDING TO ASSEMBLY THE VARIOUS PARTS. 1) warninc THE PADS OF THE BEARING MUST BE ASSEMBLED WITH THE BEVELED PORTION IN THE OPPOSITE DIRECTION TO THAT OF THE ROTATION OF THE ROTOR. 05-02-E (08-08-01-1.1674 P.22 Moo mens. 1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-28 JOURNAL BEARING AND THRUST BEARING (Compressor no coupled to the thrust bearing end) Disassembly NOTE TO MAKE EASIER THE DISASSEMBLY AND THE ASSEMBLY OF THE BEARINGS, USE THE PROPER TOOLS AS SHOWN ON THE SECTION “ASSEMBLING - DISAS- SEMBLING TOOLS”. 1, Remove the equipments and instruments installed in the housing cover or in the bear- ings. Be very careful not to damage cables, probes etc. 2, Remove the closing flange and the top half of the cover. 3. Remove the housing holding the outer parts of the thrust bearing and withdraw axially it with the proper bearing elements. 4. Remove the thrust collar. In order to carry out this operation it is necessary refer to following documents included in the “Drawings” volume or section: dwg. of “Rotor” and dwg. of “Hydraulic device for assembling/disassembling thrust collar” 5. Remove the housing holding the inner parts of the thrust bearing and withdraw axially it with proper bearing elements. 6. Remove the bolts locking the bearing to the casing head and withdraw axially it from proper seat. 7. Disassemble the various parts of the bearings. Accurately inspect the internal surfaces ‘make sure that there are no splits, scratches or other damage. Carefully clean pieces individually. Blow through the entrance and oil drains conduits, and clean them. 05-02-E (08-09-07-1.1674 P12@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-29 JOURNAL BEARING AND THRUST BEARING Assembly ~ To reassemble the bearings reverse the procedure outlined for removal. 1 warnina MAKE SURE THAT THE COUPLING SURFACES HAVE BEEN CORRECTLY CLEANED BEFORE PROCEEDING TO ASSEMBLY THE VARIOUS PARTS. 1 warnine THE PADS OF THE BEARING MUST BE ASSEMBLED WITH THE BEVELED PORTION IN THE OPPOSITE DIRECTION TO THAT OF THE ROTATION OF THE ROTOR. FOR THRUST BEARING SEE THE INDICATIONS CONTAINED IN THE MANUFAC- TURER MANUAL INCLUDED IN THE "AUXILIARY EQUIPMENT" VOLUME. 05-02-46 (08-09-07-1.1674 P.22@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-30 CHECK OF TILTING PAD BEARING CLEARANCE (Bearing shell in one piece) For bearing clearances expected refer to “Clearances data sheet” included in the “Drawings” section or volume of this manual. Ll. 12. 13. 14, 15. 1.6. Disassemble, clean and carefully inspect all parts of the bearings for wear and other damages. Clean and check shaft journal for wear and other damages. Measure journal diameter with a four points check taken in the vertical and horizon- tal planes at both the forward and aft edge of the journal. ‘Measure bore of the bearing shell at four positions. Measure each individual pad thickness at the pivot point and ensure that thickness is uniform. Determine the clearance which exists in the bearing assembly subtracting the dimen- sion resulting from the sum of the shaft journal diameter and the thickness of two pads from the bore of the bearing shell. As an alternative to that indicated at the position 1.4,, 1.5., and 1.6., bearing clearance may be measured as follows: a7. 1.8. 19. 1.10. Manufacture a stepped mandrel whose smaller diameter is journal diameter plus minimum desired clearance and the larger diameter is journal diameter plus maxi- mum desired clearance, Slip the bearing over the smaller diameter of the mandrel. Ensure that the bearing rotates. Try to slide the bearing over the larger diameter of the mandrel. Determine if clearance is within tolerance by the resistance offered by the bearing to rotation, 01-908 (08-10-01-1 PLT@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-31 CHECK OF TILTING PAD BEARING CLEARANCE (Bearing shell in two halves) For bearing clearances expected refer to “Clearances data sheet” included in the “Drawings” section or volume of this manual. Ll. 12. 13. 14, 15. 16. Disassemble, clean and carefully inspect all parts of the bearings for wear and other damages. Clean and check shaft journal for wear and other damages. ‘Measure journal diameter with a four points check taken in the vertical and horizon- tal planes at both the forward and aft edge of the journal. Clamp the two shell halves of each bearing with the joint faces together and meas- ure bore of the shell at four positions. ‘Measure each individual pad thickness at the pivot point and ensure that thickness is uniform. Determine the clearance which exists in the bearing assembly subtracting the dimen- sion resulting from the sum of the shaft journal diameter and the thickness of two pads from the bore of the bearing shell. As an alternative to what indicated at the position 1.4, 1.5., and 1.6. bearing clearance may be measured as follows: 73 18. 1.9, 1.10. Manufacture a stepped mandrel whose smaller diameter is journal diameter plus minimum desired clearance and the larger diameter is journal diameter plus maxi- mum desired clearance, Clamp the two shell halves of each bearing with the joint faces together. Slip the bearing over the smaller diameter of the mandrel. Ensure that the bearing rotates. Try to slide the bearing over the larger diameter of the mandrel. . Determine if clearance is within tolerance by the resistance offered by the bearing to rotation. *02.00E 08-10-01-2 Pld@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-32 CHECK OF THRUST BEARING AXIAL CLEARANCE For thrust bearing clearance excepted refer to "Clearances data sheet" included in the "Drawings" section or volume of this manual. ‘The thrust bearing clearance is the actual distance that the rotor will travel between shoes in axial direction. ‘The check is to be carried out as follows: a) Attach a dial indicator to compressor casing, preferably at the thrust bearing end of the compressor, with the plunger depressed one-half, contacting the end of the rotor. b) Apply force enough to the opposite end of the shaft to move it to the end of its travel. ©) Set dial indicator to read zero. ) Move the rotor as far as possible towards the other end. ¢) The amount read on the dial indicator is the thrust bearing clearance. 01-90 (08-10-03-0 Pld Moo NeRSMU P1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-33 CHECK OF ROTOR AXIAL DISPLACEMENT WHEN THRUST BEARING IS REMOVED ‘The rotor total displacement within casing is the distance that the rotor will travel from one extreme to the other in an axial direction with the thrust bearing removed, For determining the rotor total displacement observe the following: a) Remove the inboard and outboard shoe assembly. b) Attach a dial indicator to compressor casing, preferably at the thrust bearing end of the compressor, with the plunger, depressed one-half, containing the end of the rotor. ©) Move the rotor axially in one direction until it contacts the stationary parts of the casing (or diaphragms). 4) Set the dial indicator to read zero. ©) Move the rotor in the opposite direction to the end of its travel. f) The amount read on the dial indicator is the rotor total displacement. g) _ Install the inboard shoe assembly and move the rotor until the thrust collar is hard up against the shoes. h) Set the dial indicator to read zero. i) Move the rotor in the opposite direction until it stops. }) The amount read on the dial indicator is the rotor axial displacement in one direction. m) The rotor axial displacement is to be recorded and compared with values indicated in the machine assembly drawing included in the "Drawings" volume or section of this manual. OFA 08-10-04-0 Pld@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-34 POSITIONING OF AXIAL POSITION PROBE ‘The axial position probe shall be set so that, when the rotor is in the center of its thrust float, zero reading is obtained on the monitor. After the check of the thrust bearing clearance force the rotor against the inboard shoes as- sembly, zero the dial indicator and adjust the probe gap until an indication of one half thrust bearing clearance is obtained on the axial position monitor in (-) direction. ‘The adjustment of the probe gap shall be done in accordance with the instruction of the monitoring system manufacturer included in the "Instrumentation" Volume. Move the rotor as far as possible towards the other end. A rotor bump check should indicate a travel, corresponding to the thrust bearing clearance, on the dial indicator and the axial position monitor. ‘The dial indicator should now read the thrust bearing clearance. ‘The axial position monitor should read one half of the thrust bearing clearance in (+) di- rection. 1185-E (08-12-01-0 Pld@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-35 MECHANICAL GAS SEALS ‘The mechanical gas seals are supplied by JOHN CRANE UK LTD. ‘The assembly drawings and instructions of mechanical gas seals are included in the "Com- pressor Drawings and Part List" Volume or Section of this manual. ‘The drawing of special device and the instructions for assembling and disassembling of dry mechanical seals are included in the "Compressor Drawings and Parts List" Volume or Section "Special Devices for Assembling/Disassembling" of this manual. ‘The instructions supplied by JOHN CRANE UK LTD for the Mechanical Seals are in- cluded in the "Auxiliary Equipments" Volume of this manual. BEFORE BEGINNING THE MECHANICAL GAS SEALS DISASSEMBLY IT IS NECES- SARY TO REMOVE THE JOURNAL BEARINGS AND THE THRUST BEARING WITH ITS COLLAR IN ACCORDANCE WITH THE INSTRUCTIONS GIVEN IN THE RELE- VANT PARAGRAPHS IT IS MOREOVER ESSENTIAL TO REMOVE THE COUPLING SPACER AND DISASSEMBLE THE COUPLING HUB INSTALLED ON THE SHAFT END(). JOHN CRANE DRY GAS SEALS ARE DIMENSIONALLY INTERCHANGEABLE WITH A PROTOTYPE FLOWSERVE DRY GAS SEAL WHICH WAS SUPPLIED TO TCO. PLEASE CONTACT ENGINEERING BEFORE CONSIDERING ANY INTERCHANGE BETWEEN JOHN CRANE AND FLOWSERVE SEALS. SOME SEAL SYSTEM CHANGES WOULD BE REQUIRED TO COMPLETE SUCH AN INTERCHANGE. 11-02-E 1756 Pld Moo. meRIsvU P1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-36 ROTOR, LABYRINTH SEALS AND DIAPHRAGMS BCL - 2BCL - DBCL 1 Disassembly In order to check the compressor internal components, the rotor/diaphragm bundle should be extracted from the casing. For this purpose remove first the compressor head flange on thrust bearing side, and then the rotor/diaphragm bundle. If the unit consists of two or more compressor mounted in tandem, the compressor coupled on both ends should be removed from their base. Use the following procedure: 1.1. Remove all piping which may cause trouble during disassembling of the casing head flange (thrust bearing side). If interstage drains or gas connections are used remove the sleeves screwed in the diaphragms. important to clear the bundle disassembly/assembly. 1.2, Remove the coupling guard and coupling spacer. THE COUPLING FLANGE BOLTS ARE GAUGED AND THERE-FORE THEY CAN BE FOUND WITH DIFFICULTY. THEREFORE PAY AT- TENTION THEY DO NOT FALL IN THE LUBOIL DRAIN HEADER. TO THIS PURPOSE, PUT TEMPORARILY, A RAG OR PLATE ON THE OIL DRAIN HOLE OF COUPLING. 1.3. Remove both end covers. 1.4. Remove the coupling hub(s) from the coupling(s) end of the shaft, 15. Remove the thrust bearing and the journal bearings, complying with the fore- going chapters. 1LOLE 08-14-11-1 P19 Moo NPRSMU Re 1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-37 16. 47. 1.8. 19. 1.10. All. 1.12, 1.13. 114. Remove the oil seals or the mechanical gas seals (if any) following the in- structions described in the proper chapter. Remove the nuts from the reference studs of the casing head flange, thrust bearing side, and screw on them the guide pins, supplied with the standard as- sembling tools. Remove all stud bolts nuts. Install jack screw in head flange and tighten evenly to force head flange out of casing. Adjust hoisting equipment, draw out the head flange and lower it carefully to floor resting it on wooden blocks. Remove rotor/diaphragm bundle positioning key. Withdraw rotor/diaphragm bundle assembly as indicated in the dwg. 'Ass/disass. rotor/diaphragm bundle" included in the "Drawings" section or volume. Lower bundle to floor resting it on wooden blocks. Remove union bolts and dowels from bundle split line. Adjust hoisting equipment and carefully raise upper half and lower it do suit- able supports. Prepare two hardwood supports having the same height and a wide enough base. Make two "V" notches where the rotor will rest for the installation in the Journal bearing zone, Protect these two "V" notches with lead or other soft material. ‘Wrap rope slings or plastic covered wire slings around shaft at each end (see the sketch in the following page). Carefully lift the rotor in good balance, ‘guiding it by hand, to avoid damaging the labyrinths. Lower the rotor carefully to the hardwood supports. FOR THE WEIGHTS OF ROTOR AND BUNDLE REFER TO DWG. "MACHINERY AND FOUNDATIONS" OR "INSTALLATION" INCLUDED IN THE "DRAWINGS" SECTION OR VOLUME. 1-0LE 08-14-11-1 P29@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-38 LIFTING THE ROTOR (typical sketch) SLING - SEAL JOURNAL Sa BEARING JOURNAL ~ GEEDET|/ ~~~ I-Ie - - KEEP THE ROTOR IN GOOD BALANCE, GUIDING IT BY HAND, TO AVOID DAM- AGING LABYRINTHS, AT LIFTING OR LOWERING IT. - BE CAREFUL THAT SLINGS DO NOT BEAR ANY LOADS AGAINST IMPELLERS. 1-0L-E 08-14-11-1 P.39@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-39 2. Rotor and diaphragms cleaning and inspection All internal parts of the centrifugal compressor can now be cleaned and inspected as follows: - Dirt tenaciously adheres to the impellers and diaphragms. ‘Treat these parts first with proper thinner such as naphtha, trichloroethylene etc., then remove it by wire brushes of different size so as to clean internal parts such as the channels of impellers and diffusers. Owing to the toxicity and flammability of some thinners, it is advisable to perform these operations outdoors or in suffi- ciently ventilated places. - Rusty parts, if any, of the rotor shall be treated with deoxidizers, such as "FOS- FORUST"; when wide areas are involved, the parts shall be immersed in a bath, in the other cases the deoxidizer shalll be applied by brush or sprayed. - After the cleaning, cover the parts with protective oil. Should the parts have to be left outdoors, even if under roof, cover them with waterproof cloth against sand, rain, humidity. ~ Itis a good practice not to remove the diaphragms unless they are damaged. THE ROTOR SHALL BE CONSIDERED AS A SINGLE PIECE AND NO PART SHALL BE REMOVED EXCEPT FOR THE THRUST COLLAR SHOULD ANY ROTOR PART BE DAMAGED OWING TO CRACKS, SPLITS OR MATERIAL REMOVAL, THE ROTOR COMPLETELY AS- SEMBLED SHOULD BE SHIPPED TO NUOVO PIGNONE FOR THE NECESSARY REPAIRS AND BALANCING. ~ Verify the impeller condition, particularly the internal channels and check if there are corrosion signs. = Check that the thrust bearing and the rotor zones where the bearings and the seals, work have no scoring. Eliminate the scoring only by means of an abrasive, very fine grain stone. 11-01E 08-14-11-1 P49@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-40 3. Check of labyrinth seal clearances 3.1. Preparation a) Place lower half diaphragm assembly horizontally on a saddle-shaped sup- port, b) Level lower half assembly with a precision level and lock it to the support with brackets, ©) Assemble the two half rings for rotor centering on diaphragms bundle, sup- plied by assembling and disassembling tools for this job, in place of laby- rinths at both ends of the half bundle. Position the rotor on half bundle and let the rotor supported by the two half rings. 4) Position axially the rotor making the impeller outlet channel center coincide with the nozzle inlet channel center. 3.2. Side clearances a) Gauge, by means of feeler gauges, the labyrinth seal side clearances. b) Two values (one for each side) are taken for each labyrinth and added to each other. ‘The results is then compared with the relevant value on the diametral clear- ance table. CLEARANCES SHOWN ON TABLE ARE DIAMETRAL THAT IS TOTAL. 3.3. Vertical clearances a) Remove the rotor from the lower half diaphragm assembly. b) Some pieces of lead wire shall be arranged transversally in the bottom of the lower half-rings of labyrinth seals. Fix the wires with vaseline. 1-0LE 08-1411-1 P59 Moo NeRISMI PF 1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-41 ©) Place now the rotor in the original position, paying attention it is cen- tered. DO NOT LET THE ROTOR SLIDE AXIALLY, OTHER WISE THE LEAD WIRES GET DAMAGED. 4) Place, on the rotor top, in the zones of the labyrinth seals of the upper half- assembly, some pieces of lead wires as indicated at point b).. ) Install upper half diaphragm assembly on lower half. Install split-line cap- screws and tighten. f) Then remove the split-line cap-screws and lift the upper half assembly. g) Remove the rotor. ) Remove the lead wires that now are shaped as the free space between the labyrinth seal and the relevant rotor part. i) Measure by a micrometer screw gauge the flattenings made by the labyrinth seals on the lead wires. ) Now add the values of upper and lower clearances of the same labyrinth and compare the result with the value indicated in the diametral clearance table for each labyrinth seal ring. The seals, whose clearance complies with the established value but have the blades slightly rounded or dented, can be re- stored by a tool of the same type as those used for the lathe having the pro- file like that included between two seal blades. SHOULD THE VALUES TAKEN BE HIGHER THEN ALLOWED CLEARANCES (FOR THE COMPRESSOR IN NORMAL OPERATION), REPLACE THE LABY- RINTH SEALS PROCEEDING AS INDICATED IN THE FOLLOWING PARA. 1-0LE 08-14-11-1 P.69@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-42 4, Replacement of labyrinth seals Usually the labyrinth seal rings are supplied in two halves (in four sections these of bigger compressor) and with the clearances already established, therefore no adjust- ment is required. However it is advisable to always check the clearance again. To remove and then replace the labyrinth seal rings act as follows: 4.1. With a hammer or a brass bar (or of another equivalent soft metal) whose sec- tion is smaller than that of the half-ring, beat on one of two sides of such a ring to let it rotate and therefore come out. First beats shall be light to avoid de- forming the half-ring and make the extraction difficult. 4.2. Inthe event, after the first beats, the half-ring does not begin to slide, put in its housing some penetrating oil and let it soak for some hours. DO NOT FORCE, BY ANY TOOL, THE SEAL RING HOUSING SHOUL- DER, PARTICULARLY ON THE CENTER LINE. 4.3. The half-ring removed, clean the housing carefully by thinners and scrapers and blow air in, 4.4. Introduce the new half-ring in the relevant housing. The half-ring is so shaped that no positioning mistake is allowed. SHOULD THE HALF-RING NOT FIT WELL, DO NOT FORCE IT. IN THESE CASES IT IS ADVISABLE TO REMOVE AND ADJUST IT WHERE THERE ARE CLEAR FORCING TRACES. 4.5. Should the half-ring not fit owing to its different bending in respect of its housing, rest it upside-down on a plane and beat slightly on the top to increase the relevant bending radius, To reduce the bending radius it will be necessary to beat on one end. 1L0VE 08-14-11-1 P79@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-43 4.6. The labyrinth seal half-rings just replaced shall be marked with the same num- bers as those removed and therefore as those of the half-casing (or half dia- phragm assembly). THE HALF-RINGS ASSEMBLED ON THE UPPER HALF PART ARE FIXED ON THE CENTER LINE THROUGH SCREWS TIGHTENED ON THE RELEVANT HALF-DIAPHRAGMS; THEREFORE THE HALF-RINGS TO BE REPLACED SHALL BE MILLED ON THE CENTER LINE DURING THE ASSEMBLING OP- ERATION, SO THAT THEY HAVE THE SAME SPOT-FACING AS THOSE RE- MOVED (MARK ON THE NEW HALF-RINGS THE SAME NUMBER OF THOSE REMOVED). 1LOVE 08-14-11-1 P.8d Woo. NeRISML/P. 1900@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-44 5. Assembly It is made performing the operations of disassembly but in the opposite order. In particular take the following measures: 5.1. 5.2. 5.3. 5.4, 5.5. 5.6. 5.7. 5.8. 5.9. Blow carefully air into all parts to be assembled. When the machine is about to put into operation, remove the protective oil from the rotor. Replace correctly the dowel pins of the two halves of diaphragms bundle. Po- sition the rotor in the lower half bundle. Reassemble the upper half bundle. Before fitting the rotor/diaphragm bundle into the casing clean the internal sur- face of the casing and the external surface of the diaphragms, Replace the "O" rings if they are damaged. To fit the bundle make use of the suitable equipment refer to "assembly/disass. rotor/diaphragm bundle” dwg. included in the "Drawings" section or volume of this manual. A positioning key assures the orientation of the bundle in the casing, this must be inserted in the proper seat after the fitting of the bundle. The seat of the key is machined between the bottom of the bundle and the cor- respondent inner surface of the casing on the thrust bearing side. (Refer to “Compressor assembly drawing” included in the "Drawings" section or volume of this manual). Insure that the shims, especially those for the thrust bearing, are correctly fitted. Check that all parts are thoroughly clean and lubricated. When assembling the coupling guard, be sure that no foreign matter has re- mained in the oil drain hole and that the oil inflow tube to the coupling is prop- erly assembled, paying attention that the outlet holes are towards the coupling teeth. THE CASING HEAD FLANGE LOCKING BOLTS SHOULD BE TIGHTENED TO A TORQUE VALUE SHOWN IN TABLE ON PARA. "PROCEDURE FOR STUD BOLTS TIGHTENING OF CASINGS" INCLUDED IN THIS SECTION. 1L-OL-E 08-14-11-1 P99@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-45 HOW TO ESTABLISH THE CENTERING POSITION RELATIVE TO DIA- PHRAGMS OF BCL, 2BCL AND DBCL ROTORS The relative position of the thrust collar and the thrust bearing assembly determine the ax- ial position of the rotor within the diaphragms, This position is adjusted with thickness rings located on either side of the thrust bearing as- sembly. If it is necessary to change a rotor or/and diaphragm bundle, then the correct center position must be established. Use the following procedure: 1. Check that the lower diaphragm half is completely assembled and horizontal. 2. Carefully lower the rotor, guiding it by hand, into lower diaphragm half and set it on labyrinth halves. The rotor should be axially positioned to obtain optimum impeller- diffuser passage alignment. 3. Measure distance between shaft end and No-Drive face of bundle. Take two values, 0,05 mm., 180° apart and record the mean value. 4, Assemble the diaphragms-rotor bundle and fitting it into the casing. ‘The Drive End head flange is already installed. 5. Set rotor to center position using dimension established in step 3 above. Measure + 0.05 mm distance from shaft end to face of head flange on Drive End and record the value. 6. Install none Drive End head flange. Using value taken in step 5 above, set rotor to center position. Measure, + 0.05 mm., the distance from the shaft end to the face of the none Drive End head flange and record the value. 7. Install oil or gas seals, install journal bearings and thrust bearing use existing thickness rings. from 02-85-E. 08-15-11-0 PL? to 0991-8 00.4906 28@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-46 8. Force rotor against outboard thrust assembly. Measure the distance, + 0.05 mm., be- ‘tween shaft end and head flange face on none Drive End. Compare this value with that taken in step 6 above. When rotor is against outboard thrust assembly, it should be in the center position, * 0.1 mm. If it is not the outboard thickness ring must be adjusted. This will alter thrust bearing clearance, therefore ad- justment of the inboard thickness ring may be required. Thickness rings must be surface ground. Do not shim, If additional thickness is re- quired, grind new rings from blanks, "from 02-85-E 08-15-11-0 to 09-9141@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-47 GENERAL - LUBE OIL SPECIFICATION, The lube oil of the compressors is supplied by the oil console of the Gas Turbine that drives the compressor. Therefore see the Gas Turbine manual where oil physical characteristics and periodic checks are written. 05-02-E 1674 Pd@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-48 OI PIPING Erection - Flushing 1. Erection All components of the oil system which are fabricated and assembled in NP’s work- shop are cleaned and protected from rust and contaminants before transportation to site. It is recommended that the components be inspected after receipt to determine their condition and integrity of protection. If any contamination is disclosed the components should be cleaned and reprotected. Components of the system which are fabricated at erection site should be cleaned and protected from rust and contamination before erection. Flushing Even if the best care has been taken in fabricating and erecting the oil system to ‘maintain the cleanliness, some contamination will unavoidably be introduced into the oil system, therefore an oil flush must be performed before start up to keep the con- tamination to an absolute minimum. Prior to charging the system with flushing oil it is recommended to check the state of cleanliness of the oil inspecting all accessible areas. If rust and dirt is found it should be manually removed. To flush you should use a hot oil and make pipe jumper to by pass the machine bearings, seals, couplings and other accessory devices. If it is not practical to flush the feed lines on the site, they are to be removed from place, thoroughly cleaned, sealed and stored for all the flushing period. ‘Temporary stainless steel screens of 100 mesh or finer, backed up by perforated steel plates, should be installed to the downstream side of the jumpers for collecting dirt that will be freed during the flushing. ‘The amount of dirt, plotted against flushing time will give an indication of the state of cleanliness of the system. *06-91-E (06-02-02-0 P12@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-49 Gate shut off valves may be installed at outlet from jumpers so ensuring a higher flushing velocity by sequential isolation of each line. The charge of the oil for flushing the system, normally selected to be of the same type and characteristics as that prescribed for normal operation, should be enough to maintain lube oil pumps submerged during operation. ‘The success of the operation depends mainly on the capability of the oil pumps to provide a flow rate larger than normal and thus a high velocity within the lines. Throughout the flushing, the oil in the system should be heated and run at a tem- perature of approx 75°C (165 °F). A thermal shock of the system, obtained allowing the oil temperature to drop tempo- rarily to approx 50°C (120°F), may be found effective for loosening adherent parti- cles which are not readily removed by a continuous flow of hot oil. The dislodgment of particles that may have adhered to the piping surfaces should be accelerated by vibrating or hammering the oil lines. Cleaning of the system should be assisted keeping in operation the oil separator. Throughout the flushing the oil separator, filter elements and screens should be serv- iced as needed. Flushing should be continued until inspection discloses a definitive reduction in size and number of particles collected in the separators, filter elements and screens. When flushing is completed, heating of the oil should be discontinued and circulation continued until the temperature drops to approx 50°C (120°F) at cooler outlet. ‘Then the oil pump and separator are to be stopped and the flushing oil removed from the system opening the lines at lowest points. Reservoir and filter body should be inspected and all traces of residual contamination removed. ‘Temporary screens, jumpers and blanks are then to be removed from the system, new filter elements installed and pipe spools reinstated, Finally the reservoir is to be topped up to maximum operating level with a new charge of system operating oil to be introduced through screen filter or oil purifier. *0691E (06-02-02.0 P.22@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-50 AREAS TO BE CLEANED AND INTERVENTIONS SCHEDULE ‘The appliance dealt with in present manual does not produce any residues which might soil the appliance or the surrounding areas. ‘A monthly cleaning for removing dust or aggressive substances deposited on the appliance should be carried out, according to the installation site. Special care must be taken while cleaning control boards, relevant indicators and the dis- play instruments installed on panels, even in the areas nearby the appliance and the boards, in order to prevent sliding and fires. The following figure shows the main areas requiring a periodic cleaning. 05-02-E 1674 P12 Moo. NeRISVL/ PF 1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-51 A 3 Be as st —$_irst ~ a ee ia a Fig. 7.1 - Main areas requiring periodic cleaning Troe 1756 P22@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-52 PROTECTIVE COMPOUND AND CLEANING SOLVENT TECTYL 506 Application Tectyl 506 is an anti-corrosion agent used for protecting machine parts exposed to corro- sion, ic. shafts, couplings, tools and other devices, as well as machined castings and forg- ings. Anti-corrosion protection is particularly important for parts which are to be sent overseas and to tropical regions, and for the storage of parts outdoors. Proprieties Marketed as Light-brown liquid solvent carrier Thinner White spirit Yeld 12 to 17 mflitre, depending on the nature of the surface (shape, coarseness and porosity of the surface) Specific gravity 0.9 kg/dm* Dying period 1 to 2 hours at ambient temperature; agent then becomes waxy and dry to the touch Temperature constancy -40 to + 100°C Duration of protection Up to 2 years, depending on the thickness of the film and on the wear and exposure to which the part is subjected Transparency ‘The inscription on metal parts remains legible Tectyl does not affect the hands even after long contact, but they should be washed with ordinary cleansing pasta and warm water. 10LE 3-03-30-01-220 P12@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-53 Application of anti-corrosion agent Clean and dry the surface to be protected, carefully removing fingerprints and grease. Tec- tyl should not be heated, but applied at ambient temperature. ‘Method Brushing of application: Spraying Dipping Brushing Apply Tectyl uniformly with a clean, soft paintbrush, It is not absolutely necessary to apply several coats. In the surface is coarse, paint Tectyl well into the pores and furrows. Coat all bare parts properly. Spraying For small quantities, the Lichtenberg spray gun Type LM 54n is suitable and for larger quantities, the Valvoline spray set. Which can be connected direct to the drum. Dipping ‘Small parts can be protected by dipping them in Tectyl. THE THICKNESS OF THE COAT SHOULD BE AS UNIFORM AS POSSIBLE IN THE CASE OF PARTS TO BE STORED OUTDOORS OR SHIPPED BY SEA. THE DRIED TECTYL COAT IS NOT IMMUNE TO BLOWS OR SCRATCHES. ATTENTION SHOULD BE PAID TO THIS POINT WHEN HANDLING OR TRANSPORTING PARTS. Flammability Soften with paraffin for 3 minutes and wipe off with a rag. Volatile solvents (petrol, tri- chlorethylene) are less suitable for this purpose, since they evaporate too quickly. Due attention should be paid to the flammability of thinners and solvents, 1OLE 3-03-30-01-220 P23 Moo measur 1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-54 DO NOT SMOKE OR HOLD A NAKED FLAME NEAR TO FLAMMABLE SOL- VENTS AND THINNERS. OBSERVE FIRE REGULATIONS. Manufacturer Valvoline Ol-Gesellschaft m. b. H., 2000 Hamburg 36. Neur Wall 75, Federal Republic of Germany. MOLYKOTE PASTE G General Molykote Paste G is used for reducing friction between metallic surface subjected to high pressures and temperatures. The joining together of parts when erecting machines often results in one metal part rub- bing against another, e.g. when reaming drilled holes, drawing in retaining bolts, and driv- ing in wedges, etc. In braking waterwheel generators excessive friction may also occur between the brake ring of the rotor and the brake linings; this can be reduced by applying Molykote Paste G to the brake linings, ‘Treating machine parts with Molykote Paste G leads to the formation of a durable surface film which protects them against wear even when they are subject to heavy stresses: it also prevents rubbing, seizing, and metal-to-metal-contact. Molykote Paste G is used to finish friction surfaces. I. e. it should be rubbed on to form a thin lubricating film. DO NOT MIX MOLYKOTE PASTE G WITH OIL OR GREASE. Properties Molykote Paste G is highly stable chemically, hinders corrosion, is highly resistant to aging and does not resinify. ‘Temperature range: -25 to + 450°C with unimpeded exposure to air . It is a concentrated paste of pure, natural molybdenum disulphide combined with a high- grade paraffin mineral oil. 1-OLE 3-03-30-01-220 P34@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-55 Application Do not use an excessive amount of Molykote Paste G as with grease or oil lubricants, but apply it thinly and uniformly. Clean the metallic surfaces. Remove excess lubricants with trichlorethylene or a similar agent. Then rub a thin layer of paste vigorously into the metallic surfaces in all directions using a leather glove, stiff paintbrush or Moltopren (synthetic) sponge. Molykote Paste G can be applied to parts immediately before joining them if need be. Manufacturer Molykote KG, Kraus, Kuhn-Weiss & Co., 8000 Munchen 19, Anuifstrasse 71, Federal Republic of Germany. TRICHLORETHYLENE General Trichlorethylene is also marked under such names as trilene, ethylene-trichloride, Triol, Triolin, Vestrol, Benzonol, Petrazinol, Westrosol etc. PERCHLORETHYLENE (ALSO TETRACHLORETYLENE OR PERAWIN) IS A SOLVENT SIMILAR TO TRICHLORETYLENE BUT IS LESS DANGEROUS. HOWEVER, THE SAME PRECAUTIONARY MEASURES SHOULD BE TAKEN. Application Trichlorethylene is used chiefly for cleaning and removing grease from machine parts. PARTS TREATED WITH TRICHLORETHYLENE TEND TO CORRODE AND SHOULD THEREFORE BE GREASED IMMEDIATELY AFTER BEING CLEANED. WOE 3-03-30-01-220 P45@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-56 Properties Trichlorethylene is non-flammable but its vapours can be harmful if inhaled. Precautionary measures Never leave heated trichlorethylene in open containers without taking measures to see that the vapour condensers or is drawn off. Small quantities of cold trichlorethylene in containers without condensing or suction fa- cilities can be used on building sites (both indoors and outdoors). IT IS ABSOLUTELY IMPERATIVE THAT VAPOURS BE EFFECTIVELY DRAWN OFF FROM PITS AND SHAFTS SINCE - BEING FOUR AND A HALF TIMES AS HEAVY AS AIR - THEY TEND TO ACCUMULATE AT THE BOTTOM. IF NECES- SARY, SUITABLE BREATHING APPARATUS (RESPIRATORS, GAS MASKS ETC.) SHOULD BE MADE AVAILABLE. MAKE SURE THAT TRICHLORETHYLENE VAPOURS DO NOT PENETRATE INTO OTHER ROOMS WHERE WORK IS BEING CARRIED OUT. DO NOT SHUT OFF THE SUCTION EQUIPMENT OR REMOVE THE BREATH- ING APPARATUS WHILE THERE IS STILL A STRONG SMELL OF SOLVENT. WEAR PROTECTIVE GOGGLES IF THERE IS A DANGER OF TRI- CHLORETHYLENE SPLASHING. Procedure Only brushes or cloths should be used for cleaning parts with trichlorethylene. Never expose trichlorethylene to high temperature (over 110°C, perchloretylene over 150°C, dampness, radiation with bright light and contact with red-hot parts, otherwise there is a danger of decomposition into hydrochloric acid and the formation of the highly toxic phosgene. Explosive decomposition is possible in the presence of light alloy chips, dust or powder. Trichlorethylene should not be kept in transparent containers. 11-01-E 3-03-30-01-220 P56@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-57 Health protection Avoid alcohol and nicotine. Alcohol and nicotine aggravate the harmful effects of tri- chlorethylene. Take good and regular care of the skin. Before working with trichlorethylene, rub a suitable nongreasy protective ointment into the hands, followed by a greasy skin cream. DO NOT WASH SOILED HANDS WITH TRICHLORETHYLENE. irst aid for trichlorethylene poison cases Bring persons suffering from trichlorethylene poisoning at once into a well ventilated room, remove clothing from upper part of body, wrap in blankets and call a doctor. Do not try to force liquids down in the case of person who have lost consciousness. Carefully rub the flats of the hands and soles of the feet. In the case of persons who have already stopped breathing, apply artificial respiration by hand, with oxygen equipment or, best of all, by the mouth-to-mouth or mouth-to-nose method. Flush out any trichlorethylene splashed into the eyes with a 2 percent solution of sodium bicarbonate or with plenty of tap water. 1-01-E 3-03-30-01-220 P.66@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-58 PRESERVATION OF THE CENTRIFUGAL COMPRESSORS FOR SHIP- MENT After testing at the factory, centrifugal compressors are inspected, cleaned, thoroughly dried and internally protected before reassembly. The following protective measures are taken: 1 ‘Compressors internal components are coated with protective oil AGIP ALISMA 32 PV. (At this point the dry mechanical seals should not be assembled to the unit, see NOTE 3). Optimal protection with ALISMA 32 PV is dependent on the level of insulation that can be achieved between machine interior and external environment. This condition is obtained by closing all connections with seal plugs fixed with protection covers and blank flanges where contemplated. 2. The bearings and oil seals are protected with protective oil FUCHS ANTICORIT 3 applied in quantity sufficient to cover all surfaces. Protective oil shall not be removed prior to compressor operation. 3. Flange facings are coated with protective oil FUCHS ANTICORIT 2006 and fitted with metal blanks with gaskets. For further precaution, blank flanges are taped around the circumferences, in order to ensure weather tight sealing. 4, Other casing and bearing housing connections are sealed off with metal caps securely taped around the circumference. 5. Allexternal surfaces that are subject to rusting are coated with protective oil FUCHS ANTICORIT 2006. 6. The inside surfaces of oil piping and reservoirs are wetted with oil AGIP ALISMA 32PV, which is soluble in normal lubricating oil. All flanges and connections are sealed off with metal blanks and caps securely taped around the circumference. 06-0248 10-02-02.0 P10@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-59 SINCE MATERIAL PROTECTION IS SUBJECT TO MANY VARIABLES, EACH CUS- TOMER MUST CONSIDER INDIVIDUAL CIRCUMSTANCES AND TAKE ADDITIONAL MEASURES WHERE NECESSARY. IT IS THEREFORE RECOMMENDED TO CHECK THE INTEGRITY OF THE PROTEC- TION UPON MACHINES DELIVERY ON SITE. & NOTE2 d IF COMPRESSOR IS EMPLOYED FOR OXYGEN, OR OTHER APPLICATIONS WHERE OIL FREE OPERATION IS REQUIRED, SPECIAL INSTRUCTIONS ON PROTECTION ARE TO BE FOLLOWED. & NOTES THE DRY MECHANICAL SEALS SHOULD BE PROTECTED ACCORDING TO THE MANUFACTURER'S PRESCRIPTIONS. HOWEVER NO TYPE OF PROTECTIVE OIL OR GREASE MUST BE UTILIZED. AS IT WOULD DAMAGE THE SEALINGS SUR- FACES WHICH SHALL REMAIN DRY AND CLEAN. 06-02-E 10-02-02-0 P2410@ GEPS Oil & Gas Nuovo Pignone . Maintenance 5-60 PRESERVATION PROCEDURES FOR CENTRIFUGAL COMPRESSOR AND AUXILIARY EQUIPMENT General The protection applied by the manufacturer (N-P.) assures a 6-month preservation. After that period, protections must be renewed for further 6 months, by following the instructions given by N.P. personnel who will have to be called for the inspection. Materials must be stored indoors or under roofing. Original protections must be preserved as long as possible, since air and humidity might reduce the efficacy of protections on machinery inner components and auxilia- ries, thus causing rust formation on metallic surfaces. Before the compressor is put into operation, preserving oil shall completely be drained through the valves in the bottom. Once protection covers have been removed from main nozzles, the machine must be connected to plant piping quickly since, during that phase, any prolonged exposure of inner components to air might cause rust formation on metallic surfaces. Once the compressor has been connected to plant piping, the “Compressor ~ Piping” assembly must be insulated by means of blank flanges and seal gaskets. Where avail- able, slightly pressurize (10 mm H,O) with dry nitrogen. Rotate the compressor of 90° once a month. If the compressor has to remain in “READY TO START” mode for a prolonged pe- riod (stop phases between startings > 1 month), the following procedures must be performed: ‘© Keep process gas in slight overpressure (10 mm HO) with respect to ambient pressure. Before starting the unit, remove any condensate from the drains located on compressor lower sides; ¢ Flow oil once a week; 06-02-E 10-02-02.0 P.310 Moo NPAISMU PE 100@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-61 © Start the compression train at the minimum load for at least one hour twice a month, Ensure it is possible to cool process gas. Delivery temperature must not exceed 150°C, Since protection is subject to many variables, the instructions furnished serve as a guide and do not necessarily cover all possible abnormal conditions to which the equipment might be exposed. Therefore each customer must consider individual cir- cumstances and take additional protective measures. ANY DAMAGE DUE TO LONG INACTIVITY PERIODS DURING WHICH THE PRODUCT IS NOT ADEQUATELY PROTECTED AND PRESERVED SHALL BE CHARGED TO THE CUSTOMER. In case of long periods of inactivity (normally > 6 months, to be agreed with NP site representative depending upon specific environmental conditions),, the entire ma- chine must be disassembled and casings, diaphragms, rotor surfaces must be in- spected, cleaned, dried and protected as described herein after. 2. Compressor 2.1 Disassemble the compressor, in order to inspect, clean and thoroughly dry all parts, 2.2 Coat the inside casing, diaphragms, and rotor surfaces with protective oil (e.g. AGIP ALISMA 32 PV). This will later be removed during recommissioning by the gas (NOTE 2). 2.3 Reassemble the internal components and close the casing. 06-02-E 10-02-02-0 P.4-10@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-62 2.4 Coat bearings with protective oil (e.g. FUCHS ANTICORIT 3), which must not necessarily be removed prior to unit operation. 2.5 Protect dry mechanical seals as for manufacturer's instructions. 2.6 Reassemble seal rings and bearings. 2.7 Place one or more bags of dehydrator inside the casing adjacent to the inlet and outlet flanges to ease removal. The flanges shall be labelled: "dehydrator in- side” to assure that all bags are removed prior to unit operation. 2.8 Coat flange facing with protective oil (e.g. FUCHS ANTICORIT 2006) and fit a metal blank fitted with gasket. Tape the blank flange around the circumference, as an added precaution, in or- der to ensure a weather tight seal. 2.9 Tightly seal off other casing and bearing housing connections with metal caps securely taped around the circumference, 2.10 Apply protective oil FUCHS ANTICORIT 2006 to all external surfaces subject to rusting. 2.11 Turn the rotor 90° at least once a month. 3. Oill system 3.1 Remove water and solids from the oil by centrifugal separator. 3.2 Manually rotate the oil pump shafts to assure pump internals are wetted with oil (e.g. AGIP ALISMA 32 PV). 3.3. Energize the electric motor driven oil pump and flow the oil at least one hour per week through total system by passing the machines. 3.4 Apply protective oil FUCHS ANTICORIT 2006 to all external machined sur- faces of the oil system components. 3.5 Lubricate with oil (e.g. AGIP ALISMA 32 PV) the inner surfaces of all piping removed from the system, to allow by-passing of the machine, coat flange fac- ings with protective oil FUCHS ANTICORIT 2006 and fit a metal blank fitted with gasket. 06-028 10-02-02-0 P50 Moo wenisvu/er. 1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-63 4. Water cooler 4.1 Cooler water boxes must be drained, cleaned and wetted with oil (e.g. AGIP ALISMA 32 PV). 4.2. Place one or more bags of dehydrator inside the water box. Flanges are to be sealed and labelled “dehydrator inside", to assure that all bags are removed prior to unit operation. 5. Controls and instrumentation 5.1 Before draining, insulate instruments by shutting relevant block valves. 5.2 Apply protective oil (e.g. FUCHS ANTICORIT 2006) to all external surfaces subject to rusting. 5.3. Whenever possible, place instruments in a moisture vapour proof bag contain- ing dehydrator. 6, Additional operations When it is known for sure that the unit will not be recommissioned for several years, the maintenance personnel has to decide whether the following operations have to be performed, by considering environmental conditions, viability of conducting period inspections and the time required for restoring the machine to service. 6.1 Machine 6.1.1 If turbines, compressors, motors, pumps (except an oil pump driven by electric motor) and relevant instruments are installed outdoors, beside the protective measures indicated above, they must be removed and stored indoors in a controlled dry place. 6.1.2 Otherwise, once machine inner components have been disassembled and protected, store the rotor vertically in an airtight container suitable for nitrogen pressurization at 10 mm of water. 06-02-E 10.02-02.0 P.6-10@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-64 62 Oilsystem 6.2.1 Open all drain lines at the lowest points, allow oil to drain. Remove oil from the system and clean the reservoir. 6.2.2 Partially fill the reservoir with oil (e.g. AGIP ALISMA 32 PV). 6.2.3 Lubricate with oil (e.g. AGIP ALISMA 32 PV) the inner surfaces of all piping removed from the system, in order to allow machines removal, coat flange facing with protective oil FUCHS ANTICORIT 2006 and fit metal blank fitted of gasket. 6.2.4 Run lube oil pump just enough to flow oil throughout the system. 6.2.5 Run lube oil weekly. & Nore1 IF COMPRESSOR IS EMPLOYED FOR OXYGEN, OR OTHER APPLICATIONS WHERE OIL FREE OPERATION IS REQUIRED, SPECIAL INSTRUCTIONS ON PROTECTION ARE TO BE FOLLOWED. & NoTe2 DON'T USE EXCESS OF PROTECTIVE OIL COATING OF THE INTERNAL AND EXTERNAL COMPONENTS IN ORDER TO AVOID CONTAMINATION OF DRY MECHANICAL SEALS. 06-02-E 10-02-02.0 P.7-10@ GEPS Oil & Gas Maintenance Nuovo Pignone 5-65 CHARACTERISTICS OF RECOMMENDED PROTECTIVE OIL FUCHS ANTICORIT 2006 Physical and chemical characteristics Aspect Odour Flash point Solubility with water Miscibility Evaporation speed Viscosity at 25°C Stability and reactivity Conditions to avoid Materials to avoid Dangerous substances after decomposition Stabilizers Exothermic reactions Substance aspect variation Decomposition upon contact with water Degradation and formation of instable products Even beige Light 40°C Insoluble Oil solvents Negligible (n-butyl acetate = 1) 2000-6000 cP high temperatures strong oxidizing agents not mentioned not required; stable product at ambi- cent temperature not mentioned a slight colour variation in time does not impair product characteristics and efficiency. not mentioned. not mentioned 06-02-E 10-02-02.0 P.810@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-66 AGIP ALISMA 32 PV OIL This is protective oil in steam phase, containing products that, volatilized, reach the metal surfaces to be protected and remain strongly absorbed on them. Itis particularly suitable for the protection of metal surfaces over the free oil surface and of those that are not wet with oil. The protection is obtained very quickly; circuits or metal components containers must be sealed, in order to prevent any protective steam leakage and humidity. ‘Treatment and preservation temperature must not be high. - Specific gravity at 15°C (60°F) Kgl 0.870 max = Viscosity at 20°C °E 10 (75 St) ~ Viscosity at 30°C °B 258.1 (19/21 cSt) = Viscosity at 100°C °E 14 (cSt) = Viscosity index 95 min, = Open cup flash point cc 210 min. - Pour point Cy -10 max. - Rust ASTM D 665 (a and b) passes - Corrosion on Cu ASTM D130 1 - Hot plate reflux rust test passes = Cyclic rust test passes - Thermal stability test at 55°C (130°F) and 93°C (200°F) passes - Hydraulic stability test passes 06-028 10-02-02.0 P.9-10@ GEPS Oil & Gas Maintenance FUCHS ANTICORIT 3 OIL (Supplier: FUCHS LUBRIFICANTI S.r.1. - NOVATE MILANO) Nuovo Pignone 5-67 Rust inhibitory protective paraffin oil, with anticorrosive and water-repellent additives. Tris particularly suitable for protecting metal surfaces, rough or finish machined, Itis compatible with lubricating oil. It may be applied by using a sprayer, brush or by immersion. Its protective film is removable with petroleum solvents. ~ Specific gravity at 15°C (60°F) Kgil. 0.86 = Viscosity at 50°C °E 2 (11.8 St) - Open cup flash point ASTM D92 °c 197 - Pour point ASTM D 97 °c -40 - Dry residue % 100 ~ Film thickness (immersion) mm/1000. 7.7 ~ Coating capacity mi 130 06-026 10-02-02.0 P.10-10@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-68 Parts List: SSO 0668239 GENERAL LIST OF THE ASSEMBLING/DISASSEMBLING HYDRAULIC DEVICES H.P. FOR CENTRIFUGAL COMPRESSOR TYPE: BCL 506/N POS NAME AND USE N.P.CODE QTY 10 HYDRAULIC DEVICE SSO 0646505 i for coupling 6110 20 HYDRAULIC DEVICE SSO 0644808 1 for collar 610 1/2" 30 HYDRAULIC DEVICE SSO 0644904 1 ACCESSORIES H.P. 40 REDUCTION SSO 0667122 1 50 HYDRAULIC DEVICE SSO 0644935 1 for BCL 60 HYDRAULIC DEVICE SSO 0645532 1 for diaphragm bundle assy./ disassy. THE PARTS LIST AND THE ASSEMBLY DRAWINGS, WITH INSTRUCTIONS FOR USE, OF THESE DEVICES ARE INCLUDED IN THE SECTION OR VOLUME "DRAWINGS AND PARTS LIST" OF THIS MANUAL. 1102-8 1756 Pit@ GEPS Oil & Gas Maintenance Nuovo Pignone 5-69 Parts List: SSO 0668280 GENERAL LIST OF THE ASSEMBLING/DISASSEMBLING TOOLS CENTRIFUGAL COMPRESSOR TYPE: BCL 506/N POS NAME AND US P.CODE Qty 10 ASSEMBLING TOOLS SsO 0660115 1 for general use for all compressors 20 ASSEMBLING TOOLS SSO 0660408 1 for BCL SOO/N 30 ASSEMBLING TOOLS SSO 06682791 for BCL 506/N supplied with this job 40 ROTOR LOCKING DEVICE SSO 0667229* 1 30 TOOLS SSO 0667264* 1 for safety plate of collar nut 60 HYDRAULIC DEVICE SSO 0647695* 1 COMPONENTS for rotor/diaphragm bundle assyldisassy 70 HYDRAULIC DEVICE SSO 0660039" 1 for gas seal assy./disassy. 80 TOOLS SSO 0650017* 1 for safety plate of seal gas nut 1-02E 1736 Pl?@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-70 Parts List: SSO.0668280 GENERAL LIST OF THE ASSEMBLING/DISASSEMBLING TOOLS CENTRIFUGAL COMPRESSOR TYPE: BCL 506/N CP NOTE1 d THE SIMPLIFIED DRAWINGS OF THE TOOLS FOR GENERAL USE ARE INCLUDED IN THE FOLLOWING PAGES OF THIS SECTION. & NoTE2 THE ASTERISK (*) IN THE MARGIN OF N.P. CODE (PARTS LIST) INDICATE "SPE- CIAL DEVICE". THE PARTS LIST AND THE ASSEMBLY DRAWINGS ARE INCLUDED IN THE SEC- TION "SPECIAL DEVICES FOR ASSEMBLING/DISASSEMBLING" OF THE VOLUME DRAWINGS AND "PARTS LIST" OF THIS MANUAL. 102 1756 P22@ GEPS Oil & Gas Maintenance Nuovo Pignone S71 ASSEMBLING/DISASSEMBLING TOOLS FOR GENERAL USE Parts List: SSO 0660115 FOR ALL CENTR. COMPRESSORS NAME USE Tools case General NI N.2 _ N.3 a Double wrenches General 55 mm - 60 mm 0 Simple wrenches General 65mm : 75 mm " Dynamometric wrench General Dynamometric wrench General Eye bolts Lifting (General) Dia. 8 " Dia. 10 7 Polygonal wrench S=24 mm Ass./disass. probes Polygonal wrench S=12 mm Ass/disass, probes Carrier For tools, "Seeger" pliers Ass. ring wrench on oleodynamic wrench N.P. CODE sos 757 RCO 43337 RCO 43338 RCO 43339 ITN 78019 MBC 12334 ITN 78013 MBC 12054 MBC 12058 RCO 11555 RCO 11523 TIN 33105 FHD = 01008 FHD 01010 FHD 01012 FHD 01016 FHD 01020 FHD 01024 FHD 01030 FHD 01136 RCP 11204 RCP 11205 RRO 52045 SOS 71368 MBP 07680 QTY RRRRR RRA 11-02-E 1756 Pld@ GEPS Oil & Gas Maintenance Nuovo Pignone 5-72 Parts List: SSO 0660408 ASSEMBLING/DISASSEMBLING TOOLS FOR ALL CENTRIFUGAL COMPRESSOR TYPE BCL 500/N POS NAME AND USE N.P.CODE Q.TY 10 WRENCH S=95 SOS 63263 1 for stud bolts O64 tightening RCO 11554 20 GUIDE PIN ITW 22201 2 for head flange assy./disassy. REP 07422 30 SCREW ITN 32215 3 for head flange detaching GSA 202400450 40 PULLER @20 ITN 78050 3 REP 07757 50 PULLER @12 ITN 78050 3 REP 07755 60 PULLER @8 ITN 78050 2 REP 07753 65 PULLER @6 ITN 78050 2 REP 05166 70 PULLER @5 ITN 78050 2 REP 05163 15 PULLER 016 ITN 78050 2 REP 07750 80 PULLER 912 ITN 78050 2 REP 07749 90 PULLER @8 ITN 78050 2 REP 07747 11-02E 1756 P12@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-73 Parts List: SSO 0660408 ASSEMBLING/DISASSEMBLING TOOLS FOR ALL CENTRIFUGAL COMPRESSOR TYPE BCL 500/N NAME AND USE .P.CODE, Qqy 95 PULLER 06 ITN 78050 2 REP 05162 96 PULLER @5 ITN 78050 2 REP 05159 100 WRENCH 3 1/8" RCP 43616 1 for roller adjustment of rotor/diaphragm bundle device 110 BRACKET rw 22211 2 for head flange lifting SWQ 37078 THE PULLERS AT POS. 40 TO 96 SERVE FOR REMOVAL/INTRODUCTION OF JOURNAL BEARINGS, THRUST BEARINGS LABYRINTH SEALS AND SO AND SO ON. 102E 1756 P22@ GEPS Oil & Gas Maintenance Nuovo Pignone 5-74 POS 10 30 50 70 110 150 Parts List: SSO 0668279 ASSEMBLING/DISASSEMBLING TOOLS FOR CENTRIFUGAL COMPRESSORS BCL 506/N SUPPLIED WITH THIS JOB NAME AND USE WRENCH for collar nut "SEEGER" PLIER for end seal "seeger" ring PIN for lifting compressor ADAPTER for rotor locking device HALF RING for rotor centering on diaphragm bundle GUIDE PILLAR for journal bearing assy./disassy GUIDE PILLAR for flange thrust bearing side assy/disassy WRENCH WRENCH EYEBOLTS N.P.CODE SOS RCQ SOs MBP Tw RPQ SOS SWP SWS SSP SSP RCP RCP ITN 65165 44873 71368 07675 22206 03851 74885 45587 22203 41599 22207 40238 22207 40260 11207 11206 33205 01148 QTY 11-02-E Moo. MPRSULPE. 1200 “1756 PL@ GEPS Oil & Gas Maintenance Nuovo Pignone 5-75 N.1 TOOLS CASE CONTENTS DESCRIPTION (VARIOUS ASSORTMENT) COMPLETE CASE: N.P.CODE SOS 75764 RCO 43337 NAME SKETCH SIZE NP. CODE TEN _78005 1 | Hexagonal (allen) wrench 3 |MBC 11284 1 " nos 4 |MBC 11286 1 " moos 5 |MBC 11288 1 : ee 6 | MBC 11290 1 ¢ = 2 8 MBC 11292 1 " " " 10 MBC 11294 1 a og 12 |MBC 11295 1 " 7 7 14 MBC 11296 1 " " " 17 MBC 11297 1 is eee 19 |MBC 11298 1 ee 3/16" | MBC 11326 7 a " : 4" MBC 11328 1 a 5 5/16" | MBC 11329 1 y oD 3/8" | MBC 11330 1 a ee 9/16" | MBC 11333 ITN _78007/A 1 | Bush wrench 1/2"-10 {MBC 10003 1 yee 1/2"-11 {MBC 10004 a 1/2"-12 {MBC 10005 tee 1/2"-13 {MBC 10006 joo 1/2"-14_ |MBC 10007 1 " V/2"-17 MBC 10010 1 1/2"-19 MBC 10012 ITN_78007 1 | Extension 1/2"-125 |MBC 10097 1 o 1/2"-250 | MBC 10629 RC_09172/4 1 [Increasing union @P wee RCO 09172 07948 11-12-09-1 P.l2@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-76 N.1 TOOLS CASE CONTENTS DESCRIPTION (VARIOUS ASSORTMENT) Qr1y NAME SKETCH SIZE | NP. CODE RC_43653/4 1 Ratchet wrench pees 1?" Mf {Rc0 43653 SOS 64169/4 1 |Hexagonal male wrench with square female connection 12"-5 RCQ 12307 1 eg . 12"-6 RCQ 12308 1 a y 12°-8 RCQ 12309 1 a " eS 12"-10 — |RCQ 12310 il es " V/2"-10L_}RCQ 12311 1 "oo " 12"-14 | RCQ 12312 SOS 64505/4 1 | Hexagonal extension 12x100 | RCP 44859 1 " " 17x100 | RCP 44853 1 " " 19x100 | RCP 44854 1 " Y 22x100 [RCP 44855 1 " " 27x100 | RCP 44856 1 " " 32x100 | RCP 44857 1 . Q 36x100 | RCP 44858 GENERAL USE O794E 11-12-09-1 P.23@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-77 N.2 TOOLS CASE CONTENTS DESCRIPTION (BUSH WRENCHES) COMPLETE CASE: N.P. CODE SOS 75764 " ‘ 3/4"-41 {MBC 10136 " HL: 3/4°-46 | MBC 10138 7 1"-50 MBC 10258 " " 1"-55 MBC 10260 7 7 1"-60 MBC 10262 "oe 1°65 |MBC 10263 RCO 43338 ry NAME SKETCH SIZE | NP. CODE ITN_78007/A Bush wrench 3/4"-22 |MBC 10121 noon 3/4"-24 {MBC 10123 a 3/4"-27 {MBC 10126 " MBC 10129 o MBC 10130 " MBC 10133 ITN_78007 1 | Extension 3/4"-200 | MBC 10205 1 7 1 ee MBC 10227 ITN_78007 1 "T" wrench iF iv [Mpc 1061s RC _09176/4 1 Reduction ae ‘ RCO 43348 1 Y ital RCO09176 GENERAL USE 07-948 11-12-09-1 P34 Woo. NeRESML/PE 1200@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-78 N.3 TOOLS CASE CONTENTS DESCRIPTION (DOUBLE WRENCHES) COMPLETE CASE: N.P.CODE SOS 75764 RCO 43339 QTY NAME SKETCH SIZE NP. CODE ITN_78019 1 Double wrench 7x8 MBC 12248 1 oo 10x11 | MBC 12255 1 yy 12x13 |MBC 12261 1 uy 14x17 | MBC 12268 1 uo 19x22 | MBC 12284 1 og 24x27 [MBC 12297 1 22 30x32 | MBC 12311 1 aa 36x41 | MBC 12319 1 o. 2 46x50 | MBC 12330 j———=¢ SOS 71270/4 1 | Double wrench : AS | 1/2".9/16" |RCO 11204 1 | Combination wrench 7 MBC 11122 1 . " 8 MBC 11123 1 . . 10 |MBC 11125 1 . " 11 |MBC 11126 1 12. |MBC 11127 1 13° |MBC 11128 1 o 17 |MBC 11132 1 . o C 19 |MBC 11134 1 1 1 1 1 22 {MBC 11136 " " 24 |MBC 11138 " " 27 |MBC 11141 z a 716" |MBC 11173 ” " 9/16" |MBC 11175 1 Double ended open jaw 30x32 [MBC 12311 1 a . 36x41 [MBC 12319 1 " " 46x50_ [MBC 12330 GENERAL USE 09-02. 11-12-09-1 P45@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-79 CHIAVI DOPPIE DOUBLE ENDED WRENCHES CLES DOUBLES (DE BENARDE) DOPPELSCHLUSSEL ITN 78019 GENERAL USE 0794-8 11-12-09-1 P56@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-80 (DYNAMOMETER) WRENCH - for: bolt tightening CHIAVE (DINAMOMETRICA) - per: serraggio prigionieri RCO 11555 RCO 11523 GENERAL USE 07-94-8 11-12-09-1 P.6-7@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-81 (t GOLFARI = per: servono per sollevare i component del compressore EYEBOLTS - for: these serve for the compressor com- ponent lifting OEILLETS FILETES - ils servent pour le levage des éléments du compresseur OSENSCHRAUBEN - zum: dienen zum Heben der Kompres- soren-bestandteile ITN 33105, GENERAL USE 07-.94-E 11-12-09-1 PTB@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-82 CHIAVE POLIGONALE - per: serve per il montaggio e smontaggio sonde POLYGONAL WRENCH - for: it serves for the probe assembling and dis- assembling RCO 11204 ——— | | O——— > | \, CHIAVE POLIGONALE serve per il montaggio e smontaggio sonde POLYGONAL WRENCH - it serves for the probe assembling and dis- assembling RCO 11205 GENERAL USE 7-94, 11-12-0941 P89@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-83 PINZE PER ANELLI SEEGER uso: serve per —montaggio/smontaggio chiave ad anello su chiave oleodi- namica PLIERS FOR SEEGER RING use: it serves for assembly/disassembly ring wrench on oleodynamic wrench SOS 71368 GENERAL USE wee 113091 P.9-10@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-84 CARRELLO PER ATTREZZI CARRIER FOR TOOLS CHARIOT A OUTILS WERZEUGWAGEN RRO 52045 GENERAL USE 05-02-E 1674 P. 10-10@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-85 HANDLE PUMP. REGULATOR VALVE PRESSURE GAUGE FEMALE COUPLING FEMALE COUPLING preps HYDRAULIC DEVICE - use : for casing bolt tightening, ass./disass. coupling, collar and diaphragm bundle SOS 77224 GENERAL USE 07-98-E 1449.50 Pt@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-86 CHIAVE OLEODINAMICA. - per: serraggio bulloneria cassa OLEODINAMIC WRENCH - for: casing bolt tightening CLE OLEODYNAMIQUE = pour: serrage boulonnerie corps OLDYNAM. SCHLUSSEL - zum: — Gehausebolzenanziehen RCO 11547 RCO 11539 RCO 11537 RCO 11595 RCO 11608 GENERAL USE 11-958 1308 Pld@ GEPS Oil & Gas Maintenance Nuovo Pignone 5-87 CHIAVE AD ANELLO BOX-TYPE (RING) WRENCH CLE A SIX PANS SECHSKANTRIGSHLUSSEL CHIAVE AD ANELLO- BOX-END WRENCH CLE A ECROUS CARRES VIERKANTRINGSCHLUSSEL CHIAVE A FORCHETTA FORK WRENCH CLE A FOURCHE MAULSCHLUSSEL SOS 63263 BCL USO: Per dadi esagonali USE: For hexagonal nuts USO: Per dadi quadri USE: For square nuts 1195-6 1308 Pid@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-88 CANDELA DIGUIDA =~ use: serve per il montaggio/smontaggio della flan- gia di testata GUIDE PIN use: it serves for the casing head (flange) as- sembling/disassembling GUIDE DE MONTAGE = -_—emploi:_ elle sert pour le montage/démontage de la bride de téte FUEHGRUNGSSTIFT —- _gebrauch: dient zum Auf- und Abmontierend des Kopf- flansches Iw 22201 BCL 0792-8 “1116 P.it@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-89 JACK SCREW - use: — it serves for detaching casing head VITE DI SPINTA - uso: serve per distacco flangia di testata ITN 32210 ITN 32215 BCL 09.95-E 1290 P.Ld@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-90 ESTRATTORE = uso: serve per estrazione/introduzione cuscini portanti, anelli di tenuta, ecc. PULLER - use: it serves for the removal/introduction of the jour- nal bearings, seal rings, etc. ITN 78050 BCL 3928 1080 Pid@ GEPS Oil & Gas Nuovo Pignone Maintenance 5.91 CHIAVE = uso: serve per l'aggiustaggio del rullino dell'attrezzatu- ra del pacco diaframmi WRENCH = use: it serves for roller adjustment of diaphragm bun- dle device RCP 43616 BCL 05-93-E 1165 Pid@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-92 FO - CHIAVE A SETTORE - per : bloccaggio dado ralla ad apertura variabile - HOOK (WRENCH) SPANNER: - for locking of thrust collar adjustable type ring nut - CLEF A CROCHET A - pour blocage écrou de frette & overture variable - HAKENSCHLUESSEL MIT - zum : Einspannen de Schei- benschraubenmutter SOS 65165 BCL 1195 1308 Pr@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-93 GUIDE PILLAR - for: assembling/disassembling thrust bearing flange and journal bearings COLONNINA DI GUIDA - per: montaggio/smontaggio flangia cuscino reggi- spinta e cuscini portanti ITW 22207 BCL 05-93-8 1165 P.t-d@ GEPS Oil & Gas Nuovo Pignone Maintenance 5-94 PERNO DI SOLLEVAMENTO - uso: _ serve per il sollevamento compressore cen- trifugo LIFTING PIN - use: it serves for lifting centrifugal compressor ITW 22206 BCL 05-938 “1165 Prd