Emerson VSG, VSSG User Manual
VSG/VSSG compressor unit
Installation, operation & maintenance manual
VSG/VSSG Standard Vilter Warranty Statement
Seller warrants all new single screw gas compression units and bareshaft single screw compressors
manufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a period
of (a) eighteen (18) months from the date of shipment or (b) twelve (12) months from the date of
installation at the end user’s location, whichever occurs fi rst.
If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product
shall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation
and Buyer’s exclusive remedy hereunder and shall be conditioned upon (a) Seller’s receiving written notice
of any alleged defect within ten (10) days after its discovery, (b) payment in full of all amounts owed by
Buyer to Seller and (c) at Seller’s option, Buyer shall have delivered such products to Seller, all expenses
prepaid to its factory. Expenses incurred by Buyer in repairing or replacing any defective product
(including, without limitation, labor, lost refrigerant or gas and freight costs) will not be allowed except by
written permission of Seller. Further, Seller shall not be liable for any other direct, indirect, consequential,
incidental, or special damages arising out of a breach of warranty.
This warranty is only applicable to products properly maintained and used according to Seller’s
instructions. This warranty does not apply (i) to ordinary wear and tear, damage caused by corrosion,
misuse, overloading, neglect, improper use or operation (including, without limitation, operation beyond
rated capacity), substitution of parts not approved by Seller, accident or alteration, as determined by Seller
or (ii) if the product is operated on a gas with an H2S level above 100 PPM. In addition, Seller does not
warrant that any equipment and features meet the requirements of any local, state or federal laws or
regulations. Products supplied by Seller hereunder which are manufactured by someone else are not
warranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products
that Seller may have from the original manufacturer. Labor and expenses for repair are not covered by
warranty.
THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND
WARRANTIES, EXPRESS OR IMPLIED, AND SELLER EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Any description of the products, whether in writing or made orally by Seller or Seller’s agents,
specifi cations, samples, models, bulletins, drawings, diagrams, engineering sheets or similar materials used
in connection with Buyer’s order are for the sole purpose of identifying the products and shall not be
construed as an express warranty. Any suggestions by Seller or Seller’s agents regarding use, application or
suitability of the products shall not be construed as an express warranty unless confi rmed to be such in
writing by Seller.
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
i
Important Message
READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.
The following instructions have been prepared to assist in installation, operation and removal of Vilter Single Screw
Compressors. Following these instructions will result in a long life of the compressor with satisfactor y operation.
The entire manual should be reviewed before attempting to install, operate, service or repair the compressor.
A compressor is a positive displacement machine. It is designed to compress gas. The compressor must
not be subjected to liquid carry over. Care must be exercised in properly designing and maintaining the
system to prevent conditions that could lead to liquid carry over. Vilter Manufacturing is not responsible
for the system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing cannot
warrant equipment damaged by improperly protected or operating systems.
Vilter screw compressor components are thoroughly inspected at the factory. However, damage can occur
in shipment. For this reason, the equipment should be thoroughly inspected upon arrival. Any damage
noted should be reported immediately to the Transportation Company. This way, an authorized agent
can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with
no serious or costly delays. At the same time, the local Vilter representative or the home office should be
notified of any claim made.
All inquires should include the Vilter sales order number, compressor serial and model number. These can be
found on the compressor name plate on the compressor.
All requests for information, services or parts should be directed to:
Vilter Manufacturing LLC
Customer Service Department
P.O. Box 8904
5555 South Packard Ave
Cudahy, WI 53110-8904 USA
Telephone: 1-414-744-0111
Fax:1-414-744-3483
e-mail: info.vilter@emerson.com
Equipment Identification Numbers:
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________
ii
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Table of Contents
Section Title Section Number
VSG/VSSG Standard Vilter Warranty Statement ..................................................................................... i
Important Message................................................................................................................................ii
Section 1 • General Information
How To Use This Manual .........................................................................................................................1-1
Gas Compressor Unit Model Designations ..............................................................................................1-2
System Unit Identification .....................................................................................................................1-3
Compressor Unit Component Identification ........................................................................................... 1-4
Piping & Identification Component Tags ................................................................................................. 1-7
Symbols and Identification .....................................................................................................................1-8
Section 2 • Theory of Operation
Gas Flow ................................................................................................................................................2-1
Oil Life and Oil Flow ................................................................................................................................2-1
Oil Pressure Regulating ..........................................................................................................................2-2
Control System ......................................................................................................................................2-2
RTDs and Pressure Transducers .............................................................................................................. 2-2
Section 3 • Installation
Delivery Inspection ................................................................................................................................3-1
Rigging and Lifting ................................................................................................................................. 3-1
Short Term Storage Recommendations ..................................................................................................3-2
Long Term Storage Recommendations ...................................................................................................3-2
Compressor Motor .....................................................................................................................3-2
Air Cooled Oil Coolers ................................................................................................................ 3-3
Compressor Unit Inspections Prior to Stoarge or Installation .................................................................. 3-3
Recommended Onsite Tools .................................................................................................................. 3-3
Long Term Storage Log ..........................................................................................................................3-4
Foundation ............................................................................................................................................3-5
Piping ..................................................................................................................................................3-10
Header Piping and Drains ...........................................................................................................3-10
Remote Air Cooled Oil Cooler Piping ..........................................................................................3-10
General Installation Guideline for Multiple Air Coolers Installed in a Common Area ................................ 3-12
Free Flow ...................................................................................................................................3-12
One Fan Diameter ...................................................................................................................... 3-12
Intake Velocity ...........................................................................................................................3-12
Hot Air Recirculation ..................................................................................................................3-14
Pressure Testing ..................................................................................................................................... 3-16
Initial Oil Charging .................................................................................................................................3-16
Using Non-Vilter Oils .................................................................................................................. 3-16
Unit Oil Charging and Priming .................................................................................................... 3-16
Priming Oil Cooler (Shell and Tube)and Piping............................................................................3-16
Priming Compressor and Oil Filters ............................................................................................ 3-18
Priming Remote Oil Cooler and Piping (Initial Oil Charging) ........................................................3-20
Priming Compressor and Oil Filters ............................................................................................ 3-21
Pre Start-Up ...........................................................................................................................................3-22
Start-Up .................................................................................................................................................3-24
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
TOC - 1
Table of Contents
Section Title Section Number
Section 4 • Operation
Oil Inspection ........................................................................................................................................4-1
Dual Oil Filters........................................................................................................................................4-1
Control System Calibration ....................................................................................................................4-2
Starting, Stopping and Restarting the Compressor ................................................................................4-2
Calibrate Slide Valve Actualors ...............................................................................................................4-2
Oil Temperature Control Valve (Oil Mixing Valve) Operation ...................................................................4-7
Manual Override ........................................................................................................................4-8
Purging with Dry Nitrogen ..................................................................................................................... 4-9
Purging with Dry Gas .............................................................................................................................4-11
Coalescing Oil Return Line Setup ............................................................................................................ 4-14
Section 5 • Maintenance/Service
Maintenance and Service Schedule ........................................................................................................ 5-1
Maintaining Proper Operation ................................................................................................................5-2
Compressor Unit Isolation for Maintenance/Service ...............................................................................5-3
Compressor Unit Leak Check ..................................................................................................................5-3
Oil System Components ......................................................................................................................... 5-4
Oil Sampling...............................................................................................................................5-4
Oil Charging ...............................................................................................................................5-5
Oil Draining ................................................................................................................................5-6
Oil Filter Replacement ................................................................................................................5-6
Coalescing Oil Filter Replacment ................................................................................................. 5-8
Oil Pump Strainer .......................................................................................................................5-9
Drive Coupling (Form-Flex BPU) Installation ...........................................................................................5-10
Drive Center Member (Form-Flex BPU) Installation and Alignment .........................................................5-11
Drive Coupling (Form-Flex BPU) Removal ............................................................................................... 5-13
Drive Coupling (Type C Sure-Flex) Replacement ..................................................................................... 5-13
Compressor Replacement ...................................................................................................................... 5-14
Compressor Bearing Float Inspections ...................................................................................................5-16
Gate Rotor Float and Gate Rotor Bearing Float Inspection .......................................................................5-17
Gate Rotor and Support Clearance ......................................................................................................... 5-19
Gate Rotor Assembly Replacement (All VSG & VSSG Compressors Except VSG 301-701 Compressors) .... 5-21
Gate Rotor Assembly Replacement (VSG 301-701 Compressors ONLY) ...................................................5-24
Gate Rotor Disassembly .........................................................................................................................5-26
Gate Rotor Blade Removal/Installation ....................................................................................... 5-26
Gate Rotor Thrust Bearing Removal/Installation .........................................................................5-27
Gate Rotor Roller Bearing Removal/Installation ........................................................................... 5-27
Slide Valve Actuator Assembly Replacement .......................................................................................... 5-28
Command Shaft Assembly Replacement ................................................................................................5-29
Command Shaft Seal Replacement .........................................................................................................5-29
Section 6 • Troubleshooting
Table 6-1. Slide Valve Actuator Troubleshooting Guide ........................................................................... 6-1
Table 6-2. Slide Valve Actuator LED Blink Codes ......................................................................................6-3
Table 6-3. Troubleshooting Guide - General Problems & Solutions ..........................................................6-5
TOC - 2
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
List of Tables and Figures
Section Title Section Number
Section 7 • Warranty and Parts
Warranty Claim Processing .................................................................................................................... 7-1
On Site Service Support ......................................................................................................................... 7-1
Remanufactured Bare Shaft Compressors Process ..................................................................................7-2
Explanation of Rebuild Levels .....................................................................................................7-2
Bare Shaft Compressor Description ............................................................................................7-2
Appendices
Appendix A Torque Specifications ......................................................................................................A
Appendix B Motor (Compressor) General Storage Instructions .......................................................... B
Appendix C Oil Analysis Report .......................................................................................................... C
Appendix D Recommended Header Piping ........................................................................................D
Appendix E Recommended Remote Air Cooled Oil Cooler Piping .......................................................E
Table/Figure Section Number
Tables
Table 3-1. Long Term Storage Compressor Hardware .............................................................................3-2
Table 3-2. Maximum Allowable Flange Loads ......................................................................................... 3-11
Table 4-1. Command Shaft Rotation Specifi cations ................................................................................4-6
Table 5-1. Maintenance/Service Schedule ..............................................................................................5-1
Table 5-2. Oil Filter Elements and Compressor Models ............................................................................5-6
Table 5-3. Shaft and Hub Distances ........................................................................................................5-10
Table 5-4. Hub Clamp Bolt and Set Screw Torque Specifi cations ............................................................. 5-12
Table 5-5. Disc Pack Installation Torque Specifi cations ...........................................................................5-12
Table 5-6. Clamping Bolts and Set Screw Torque Specifi cations..............................................................5-14
Table 5-7. Maximum Bearing Float (Compressor Shaft) ..........................................................................5-17
Table 5-8. Gate Rotor Float .....................................................................................................................5-18
Table 5-9. Gate Rotor Tool Sets ...............................................................................................................5-21
Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 2) ...............................................................6-1
Table 6-2. Slide Valve Actuator LED Blink Codes* (1 of 2) ........................................................................6-3
Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3) ..............................................6-5
Figures
Figure 1-1. Gas Compressor Unit Model Designation .............................................................................1-2
Figure 1-2. Gas Compressor Unit Components .......................................................................................1-4
Figure 2-1. Gas Compressor Unit P&ID ...................................................................................................2-1
Figure 3-1. Rigging and Lifting Points .....................................................................................................3-1
Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View ................................................3-5
Figure 3-3. Concrete Pad with Compressor Unit Dimensions - Front View ...............................................3-6
Figure 3-4. Interior Foundation Isolation ................................................................................................ 3-6
Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View ................................................3-7
Figure 3-6. Housekeeping Pad Dimension Detail - Top View ...................................................................3-9
Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers ............................................3-9
Figure 3-8. Concrete Pad Housekeeping Detail .......................................................................................3-10
Figure 3-9. Maximum Allowable Flange Loads ........................................................................................3-11
Figure 3-10. Installation of Coolers - One Fan Diameter Next to Building ................................................ 3-12
Figure 3-11. Leg Height ..........................................................................................................................3-13
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
TOC - 3
List of Tables and Figures
Table/Figure Section Number
Figure 3-12. Installation of Coolers - Next to Buildling ............................................................................3-13
Figure 3-13. Discharge Elevation of Coolers ............................................................................................ 3-15
Figure 3-14. Cooler Placement and Spacing ............................................................................................ 3-15
Figure 3-15. Oil Operating Levels ...........................................................................................................3-17
Figure 3-16. Suction Oil Charging Valve, Oil Cooler Drain and Oil Filter Shut-Off Valves ...........................3-17
Figure 3-17. Priming Oil Cooler (Shell & Tube) and Piping .......................................................................3-18
Figure 3-18. Priming Compressor (with Shell & Tube Oil Cooler) and Piping ............................................ 3-19
Figure 3-19. Priming Remote Oil Cooler and Piping ................................................................................3-20
Figure 3-20. Priming Compressor and Oil Filters ..................................................................................... 3-21
Figure 4-1. Oil Operatiing Levels ............................................................................................................. 4-1
Figure 4-2. Actuator Assembly ............................................................................................................... 4-3
Figure 4-3. Menu Screen and Slide Calibraiton Button (Compact Logix PLC) ...........................................4-4
Figure 4-4. Slide Valve Calibraiton Screen (Compact Logix PLC) .............................................................. 4-5
Figure 4-5. Photo-chopper .....................................................................................................................4-5
Figure 4-6. Oil Temperature Control Valve (Oil Mixing Valve) .................................................................. 4-8
Figure 4-7. PLC Main Screen ................................................................................................................... 4-9
Figure 4-8. Suction Bypass Valve and Equalizing Solenoid ....................................................................... 4-10
Figure 4-9. Suction Oil Charging Valve and Discharge Bleed Valve .......................................................... 4-10
Figure 4-10. Customer Purge Line .......................................................................................................... 4-11
Figure 4-11. PLC Main Screen ................................................................................................................. 4-12
Figure 4-12. Suction Bypass Valve and Equalizing Solenoid ..................................................................... 4-13
Figure 4-13. Suction Oil Charging Valve .................................................................................................4-13
Figure 4-14. Coalescing Oil Return Line .................................................................................................. 4-14
Figure 5-1. Suction Bypass Valve (Manual) Location (1 of 2) .................................................................... 5-2
Figure 5-1. Suction Bypass Valve (Equalizing Solenoid) Location (2 of 2) .................................................5-3
Figure 5-2. Oil Analysis Kit ...................................................................................................................... 5-4
Figure 5-3. Suction Oil Charging, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves ............................5-5
Figure 5-4. Oil Filter Assemblies (Single and Dual) ..................................................................................5-6
Figure 5-5. Oil Filter Drain, Vent and Shut-Off Valves .............................................................................. 5-7
Figure 5-6. Oil Separator Manhole Cover and Coalescing Filter Assembly ................................................5-8
Figure 5-7. Oil Pump Strainer and Drain Valve ........................................................................................ 5-9
Figure 5-8. Hub Distance (Axial Spacing) ................................................................................................5-11
Figure 5-9. Angular Alignment and Parallel Offset ..................................................................................5-12
FIgure 5-10. Compressor Replacement and Hardware Assembly (Models 2401-3001 Shown) ................5-15
FIgure 5-11. Bearing Axial Float Inspection (Compressor) .......................................................................5-16
FIgure 5-12. Bearing Radial Float Inspection (Compressor) .....................................................................5-17
FIgure 5-13. Gate Rotor Float ................................................................................................................. 5-17
FIgure 5-14. Gate Rotor Bearing Float ..................................................................................................... 5-18
FIgure 5-15. Gate Rotor and Support Clearance - Minimum Clearances .................................................. 5-19
FIgure 5-16. Gate Rotor and Support Clearance - Measuring ................................................................... 5-20
FIgure 5-17. Gate Rotor Assembly Removal and Tools ............................................................................5-22
FIgure 5-18. Gate Rotor Assembly Removal ............................................................................................5-22
FIgure 5-19. Gate Rotor Assembly and Tools ...........................................................................................5-23
FIgure 5-20. Gate Rotor and Shelf Clearance ........................................................................................... 5-23
FIgure 5-21. Gate Rotor Assembly Breakdown ........................................................................................5-24
FIgure 5-22. Gate Rotor Thrust Bearing .................................................................................................. 5-25
FIgure 5-23. Gate Rotor and Shelf Clearance ........................................................................................... 5-25
FIgure 5-24. Gate Rotor Blade Assembly .................................................................................................5-26
FIgure 5-25. Gate Rotor Blade Installation .............................................................................................. 5-26
FIgure 5-26. Gate Rotor Thrust Bearing .................................................................................................. 5-27
FIgure 5-27. Thrust Bearing Installation .................................................................................................. 5-27
FIgure 5-28. Roller Bearing Assembly ..................................................................................................... 5-28
FIgure 5-29. Command Shaft Seal ..........................................................................................................5-29
FIgure 5-30. Command Shaft Seal Installation ........................................................................................5-30
TOC - 4
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 1 • General Information
How To Use This Manual
This manual contains instructions for gas compressor
units. It has been divided into eight sections:
Section 1: General Information
Section 2: Theory of Operation
Section 3: Installation
Section 4: Operation
Section 5: Maintenance & Service
Section 6: Troubleshooting
Section 7: Warranty and Parts
Appendices
It is highly recommended that the manual be reviewed
prior to servicing system parts.
Figures and tables are included to illustrate key concepts.
Safety precautions are shown throughout the manual.
They are defi ned as the following:
NOTICE - Notice statements are shown when there are
important information that shall be followed. Not following such notices may result in void of warranty, serious fi nes, serious injury and/or death.
WARNING - Warning statements are shown when there
are hazardous situations, if not avoided, will result in serious injury and/or death.
CAUTION - Caution statements are shown when there
are potentially hazardous situations, if not avoided, will
result in damage to equipment.
NOTE - Notes are shown when there are addtional information pertaining to the instructions explained.
Additional installation, operation and maintenance instructions can be found in the associated software manual and bareshaft compressor manual.
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
1 – 1
Section 1 • General Information
Gas Compressor Unit Model Designations
The compressor unit model designation can be found on the nameplate. For nameplate location, see Component
Identifi cation on section page 1-4.
VSG-601-VVR-L-HP-VFD-36H-NEC-ST-WTR
1234567 8 9 10
Figure 1-1. Gas Compressor Unit Model Designation
1. Compressor Model
VSG = Vilter Single Screw Compressor
VSSG = Vilter Single Screw Compressor
(Compressor models 291, 341, 451 & 601 -
these are 240mm diameter rotors with
counter clockwise rotation)
VRSG = Vilter Twin Screw
2. Size
CFM - Nominal CFM displacement of the compressor at
3600 rpm
3. Slide Arrangement
VVR = Variable Volume Ratio; Parallex™
4. Gas Compressed
L = Landfi ll Gas
D = Digester Service Site Application
N = Natural Gas (Primarily Methane)
G = Other Gas Type
5. Application
HP = High Stage with Oil Pump
HN = High Stage no Oil Pump
7. Separator Type
16 = 16 inch diameter 36 = 36 inch diameter
20 = 20 inch diameter 42 = 42 inch diameter
24 = 24 inch diameter 48 = 48 inch diameter
30 = 30 inch diameter 54 = 54 inch diameter
H = Horizontal V = Vertical
SH = Special Horizontal SV = Special Vertical
8. Economizer
NEC = No Economizer, Economizer Ports Plugged
HEC = Holes drilled in Economizer Plug for Oil
or Unloading
9. Oil Cooler
PLT = Plate
ST = Shell and Tube
REM = Remote
10. Oil Cooling Medium
REF = Refrigerant
WTR = Water
GL = Glycol
AIR = Air
6. Driver
VFD = Variable Frequency Drive
EMD = Electric Motor Drive
ENG = Engine Drive
1 – 2
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 1 • General Information
System Unit Identifi cation
To keep defi nitions of units simple and consistent, Vilter has defi ned the following three:
• Bare Shaft Compressor
• Compressor Unit
• Package Unit
Bare Shaft Compressor
A bare shaft compressor is just the compressor with no coupling and motor nor foundation.
Compressor Unit
A compressor unit consists of the bare shaft compressor with the coupling, motor, oil separator, frame, micro-controller system and oil system. A compressor unit typically a single screw compressor unit, is not mounted on a structural
steel base.
Package Unit
A package unit is a complete system mounted on a structural steel base with interconnecting piping.
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
1 – 3
Section 1 • General Information
Compressor Unit Component Identifi cation
Each gas compressor unit may differ, but below are typical components that can be found on each unit.
1 - Motor
2 - Coupling
3 - Suction Strainer
4 - Suction Check Valve
5a - Suction Stop Valve
5b - Suction Stop Butterfl y Valve
(Typically Shipped Loose)
6 - Compressor
7 - Discharge Pipe
8 - PLC Panel
1
9 - Block & Bleed Assembly
10 - Oil Pump
11 - Oil Heater
12 - Oil Separator
13 - Oil Temperature Control Valve
(Oil Mixing Valve)
14 - Oil Pump Strainer
15 - Oil Sight Glass
16 - Oil Filter
(Optional Dual Oil Filters Shown)
23 4 5a
17 - Discharge Connection
18 - Oil Separator Inspection Port
19 - Thermal/Acoustic Oil Separator
Blanket
(Optional Per Application)
20 - Nameplate
21 - Heat Trace Insulation
(Optional Per Application)
22 - Frame
23 - Oil Cooler (Shell and Tube Heat
Exchanger)
5b
16
17
Figure 1-2. Gas Compressor Unit Components (1 of 3)
6
7
8
9
1112141511
1013
1 – 4
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 1 • General Information
20
34
22
14
18
19
17
2021
23
Figure 1-2. Gas Compressor Unit Components (2 of 3)
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
1 – 5
Section 1 • General Information
Component Identifi cation (Continued)
24 - RTD (Oil Filter Outlet)
25 - Pressure Transducer (Oil Injection
Temperature)
26 - Volume Slide Valve Actuator
27 - RTD (Discharge)
24
28 - RTD (Suction)
29 - Capacity Slide Valve Actuator
30 - Pressure Transducers
(Discharge, Oil Filter Inlet and
Outlet)
25 27 28
26
31 - Block & Bleed Assembly
32 - Remote Oil Cooler (Finned Fan
Heat Exchanger)
33 - RTD (Oil Separator)
29
30
31
1 – 6
33
32
Figure 1-2. Gas Compressor Unit Components (3 of 3)
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
OUTLET
INLET
Section 1 • General Information
Piping & Identifi cation Component Tags
Use this list to identify components shown in the Piping & Identifi cation Diagram.
A Atmosphere
AN Anode - Sacrifi cial
AV Angle Valve
BFV Butterfl y Valve
BDV Automatic Blowdown
Valve
BV Ball Valve
C Compressor
CPL Coupling
CRR Cooling Refrigerant Liquid
Return
CRS Cooling Refrigerant Liquid
Supply
CS Carbon Steel or Cold Side
CV Check Valve
CWR Cooling Water Return
CWS Cooling Water Supply
D Drive Motor or Drain
E Heat Exchanger
EQ Equalizing Line
F Fan
FC Fail Closed or Flow
Controller
FG Flow Switch Indicator or
Glass
FI Flow Indicator
FIT Flow Indicating
Transmitter
FO Fail Open
FSI Flow Sight Indicator
FT Flow Transmitter (Blind)
FV Flow Control Valve
(Pneumatic Actuator)
GLV Globe Valve
GTV Gate Valve
HS Hand Switch or Hot Side
HEV Hand Expansion Valve
HV Hand Valve
IA Instrument Air
II Current Indicator
IT Current Transmitter
JB Electrical Terminal Box or
Junction Box
LC Level Control
LE Level Probe
LI Level Indicator or Gauge
LIT Liquid Level Indicating
Transmitter
LO Lube Oil or Lock Open
LP Local Panel
LSH Level Switch High
LSHH Level Switch Shutdown
High High
LSL Level Switch Low
LSLL Level Switch Shutdown
Low Low
LV Level Control Valve -
Pneumatic Actuator
MCC Motor Control Center or
Motor Starter
MV Motor Operated Valve
MGV Manifold Gauge Valve
MI Moisture Indicator
N Nitrogen
NC Normally Closed
NO Normally Open
NV Needle Valve
P Pump or Process
PDI Differential Pressure
Indicator - Gauge
PDIT Differential Pressure
Indicating Transmitter
PDSH Differential Pressure
Switch High
PDSHH Differential Pressure
Switch Shutdown High
High
PDSL Differential Pressure
Switch Low
PDSLL Differential Pressure
Switch Shutdown Low
Low
PDT Differential Pressure
Transmitter - Blind
PDV Differential Pressure
Control Valve - Pneumatic
Actuator
PI Pressure Indicator or
Gauge
PIT Pressure Indicating
Transmitter
PSH Pressure Switch High
PSHH Pressure Switch
Shutdown High High
PSL Pressure Switch Low
PSLL Pressure Switch
Shutdown Low Low
PSV Pressure Safety Relief
Valve
PT Pressure Transmitter
- Blind
PV Pressure Control Valve
QE Heater Element -
Immersion Heater
R Refrigerant
RD Rupture Disc
SDV Automatic Shut-off Valve
SG Sight Glass
SS Stainless Steel or Heat
Exchanger Shell Side
STR Strainer
SV Safety Relief or Slide Valve
SW Selector Switch
TE Temperature Element -
RTD or Thermocouple
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
1 – 7
Section 1 • General Information
TI Temperature Indicator or
Thermometer
TIT Temperature Indicator
Transmitter
TRV Transfer Valve - 3-way or
6-way Valve
TS Heat Exchanger Tube Side
TSH Temperature Switch High
TSHH Temperature Switch
Shutdown High High
TTSL Temperature Switch Low
TSLL Temperature Switch
Shutdown Low Low
TT Temperature Transmitter
- Blind
TV Temperature Control
Valve
Symbols and Identifi cations
TW Thermowell
V Vent
VG Gauge Valve
VTRI Venturi
VLV Stop Valve
XV Solenoid Valve
YE Vibration Probe
YSH Vibration Switch High
YSHH Vibration Switch
Shutdown High High
YT Vibration Transmitter
YU Vibration Monitoring
System
YZE Axial Proximitor Probe -
Axial Displacement
YZT Axial proximitor
Transmitter - Axial
Displacement
YZU Axial Proximitor
Monitoring System
ZE Position Element
- Positioner
ZI Position Indicator
ZIT Position Indicating
Transmitter
ZT Position Transmitter
- Blind
Use this list to identify components shown in the Piping & Identifi cation Diagram.
3-Way Valve
Angle Valve
Globe Valve
Gate Valve
Butterfl y Valve
Ball Valve
Schrader Valve
Pressure Safety Relief
Valve
Spring-Closing Drain
Valve
Block & Bleed Manifold
S
Solenoid Valve
S
3-Way Solenoid Valve
Needle Valve
Suction Strainer
M
Motorized Valve
T
3-Way Thermostatic Valve
Hand Expansion Valve
Restriction Orifi ce
Rupture Disc
Inlet Pressure Regulating
Valve
Outlet Pressure
Regulating Valve
Differential Pressure
Regulating Valve
Pneumatic Actuator
Control Valve Fail Close
Pneumatic Actuator
Control Valve Open
Diaphragm
Pressure-Balanced
Vilter Venturi Injector
Nozzle
Flange Set
Pipe Reducer
TW
Thermowell
Drive Coupling
C
Insulation Not by Vilter
V
Insulation by Vilter
Vibration Absorber
QE
Heater
Heat Trace
1 – 8
Check Valve
Strainer
Diaphragm Actuator
Diaphragm
Low Side Float Valve
Spring-Opposed
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 1 • General Information
High Side Float Valve
Steady-Mount
Bulb & Capillary
Horizontal Tank/Drum
Positive Displacement
Vessel
Pump
Control Panel, Normally
Accessible to Operator
Programmable Logic
Control, Local Control
Panel, Normally
Accessible to Operator
Pneumatic Signal
Thermostatic Expansion
Valve
Pilot Light (Color Inside)
G
MW
Man-Way Cover
BY VILTER BY OTHERS
Scope of Supply
SV
E1
Economizer Regulator
Compressor
Motor
Heat Exchanger
Fan
Vertical Tank/Drum Vessel
Centrifugal Pump
Rotary Pump
Filter
Plate & Frame Heat
Exchanger
Discrete Instrument, Field
Mounted
Discrete Instrument,
Remote, Mount, Normally
Accessible to Operator
Discrete Instrument, Local
Rack Mounted, Normally
Accessible to Operator
Shared Display/Control,
Field Mounted
Shared Display/Control,
DCS or Remote Control
Panel Normally Accessible
to Operator
Shared Display/Control,
Local Control Panel
Normally Accessible to
Operator
Programmable Logic
Control, Field Mounted
Programmable Logic
Control, DCS or Remote
XXXXX
Capillary Tube
Electrical Signal
Internal System Link
(Software or Data Link)
Mechanical Link
LLLLL
Hydraulic Signal
EQUIPMENT TYPE
V100
SERIES NUMBER
Equipment Number
Identifi cation
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
1 – 9
1 – 10 / Blank
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 2 • Theory of Operation
1 2 3 4
SUCTION GAS
1/4” OIL CHARGING
BLEED
MOTOR
15
FILTER
DRAIN
FILTER
DRAIN
OPTIONAL DUAL OIL FILTERS
BLEED
TE
COMPRESSOR
BLEED
TE
STANDARD SINGLE
OIL FILTER
FILTER
12
BLEED
DRAIN
10
14
5
6
DISCHARGE
CHECK
STOP VALVE
VALVE
TE
1/4”
13
OIL SEPARATOR
11
M
DRAIN
TE
MOTOR
PUMP
100#
7
FG
1
8
OIL COOLER
VENT
9
OPTIONAL REMOTE AIR COOLED OIL COOLER
Figure 2-1. Gas Compressor Unit P&ID
The gas and oil systems work in unison, but each one
will be explained separately. Reference Figure 3 - Gas
Compressor Unit P&ID for gas and oil fl ow descriptions.
Gas Flow
The gas compression process begins as processed gas
enters the suction inlet (1). The processed gas fl ows
through a stop valve (2), check valve (3) then through
a suction line strainer (4) to the compressor (14). The
processed gas is then pressurized through the compressor and discharged as high pressure gas vapor into the
oil separator (13). In the oil separator, the oil is then
separated from the discharged gas vapor by impingement separation. The high pressure gas fl ows out to
OIL
DRAIN
STANDARD WATER COOLED OIL COOLER
DRAIN
the aftercooler and scrubber for cooling while the oil is
pumped or syphoned back to the compressor.
Moreover, check valves (3) and (6) are provided between
the oil separator to prevent gas vapor or liquid from fl ow-
ing back to the compressor during shutdown periods.
An equalizing line is also installed between the high
pressure side (oil separator) and low pressure side (suc-
tion) to allow .
Oil Life and Oil Flow
The life of the oil is directly affected by the quality of the
gas. Proper separation of any liquids must be accomplished to prevent droplets of liquid at the compressor
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
2 – 1
Section 2 • Theory of Operation
suction. The discharge temperature of the compressor
must be kept a minimum of 30°F (or 17°C) above the discharge gas dew point to prevent the condensing of liquids in the oil separator. The oil separator shell and legs
must be insulated when the gas stream has a high probability of having condensables.
Oil in the gas compressor unit serves three primary purposes. They are compressor lubrication, sealing clearances between moving parts, and heat removal resulting from heat of compression and friction. Initially, oil
fl ow is driven by a mechanical gear pump (7). Once the
system reaches design conditions, the oil pump is shut
off and oil fl ow is maintained by differential pressure in
the gas system.
As the oil is separated from the gas in the oil separator,
it is pumped or syphoned through an oil cooler (9), then
fi ltered through a single (11) or dual oil fi lters (15) and
back to the injection port of the compressor (14). The
standard oil cooler is a shell and tube water cooled heat
exchanger (9). The other option is to air cool oil remotely
through a fi nned fan heat exchanger (8).
Furthermore, to collect oil from the coalescing side of
the oil separator (12), a line is installed between the oil
separator and the compressor. By opening the shut-off
valve (6), this will allow oil dripping off the coalescing fi l-
ters to be fed back to the compressor. In addition, the oil
cooler (8 or 9) is piped in parallel to the oil temperature
control valve (oil mixing vlave) (10), which acts as a bypass valve.
On units with a full-time oil pump, oil pressure is regulated by the oil pressure regulator (12). It controls upstream pressure to the compressor bearings and should
be adjusted to hold the oil pressure at 20 psig above suction pressure. Excess oil not required for bearing lubrication is passed through the regulator and back into the oil
separator (13).
This is a continuous cycle.
RTDs and Pressure Transducers
Resistance Thermometers (RTDs) and pressure transducers are instruments used to measure temperatures
and pressures at specifi c locations on the gas compressor
unit, see Figure 1-2. Gas Compressor Unit Components.
RTDs are typically mounted on the suction pipe, discharge pipe, oil separator and oil fi lter outlet pipe.
Pressure transducers are typically mounted on the block
and bleed assembly and directly on the suction pipe. The
pressure transducers measure suction pressure, inlet
and outlet oil pressure, and oil separator pressure.
Control System
The gas compressor unit is controlled by a Programmable
Logic Controller (PLC) panel. This PLC panel’s main function is to control the gas compression system from the
data that it receives from the sensors around the unit.
Refer to Compact Logix PLC manual (35391CL) for additional information.
2 – 2
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 3 • Installation
Delivery Inspection
All equipment supplied by Vilter are thoroughly inspected at the factory. However, damage can occur in shipment. For this reason, the units should be thoroughly
inspected upon arrival, prior to off-loading. Any damage noted should be photographed and reported immediately to the transportation company. This way, an
authorized agent can examine the unit, determine the
extent of damage and take necessary steps to rectify the
claim with no serious or costly delays. At the same time,
the local Vilter representative or the home offi ce should
be notifi ed of any claims made within ten (10) days after
its discovery. Refer to long term storage for additional
recommendations.
Rigging and Lifting of Compressor
Unit
WARNING
When rigging and lifting a compressor unit, use proper
lifting device capable of lifting and maneuvering the
weight and size of the compressor unit. Use only
qualifi ed personnel and additional personnel and
lifting equipment (i.e. spreader bar) as required.
Failure to comply may result in death, serious injury
and/or damage to equipment.
Only qualifi ed personnel shall operate rigging and lift-
ing equipment. Ensure that the lifting device is capable
of lifting the weight of the compressor unit, refer to the
supplied Vilter General Assembly (GA) drawing.
To lift the compressor unit, use lifting points on compressor unit frame to attach the lifting device, see Figure
3-1. There are a few points to consider prior to moving
the unit:
• Ensure that the weight is evenly distributed amongst
the lifting device (i.e. lifting chains and spreader bar)
prior to lifting.
• Ensure that the lifting device is not obstructed by any
parts of the compressor unit to prevent damage to
components.
• Use additional personnel as needed to spot and aid in
maneuvering the compressor unit.
• Ensure there is plenty of space to maneuver the compressor unit and a clear path to its location.
Lifting Point
Use lifting chains/straps and spreader bar. Evenly
distribute weight. Keep lifting chains and spreader
bar clear of components to prevent damage.
Figure 3-1. Rigging and Lifting Points
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
3 – 1
Section 3 • Installation
Long Term Storage Recommendations
The procedure described is a general recommendation
for long term storage (over one month of no operation)
of Vilter compressor units. It is the responsibility of the
installation fi rm and end user to address any unusual
conditions. Use the supplied long term storage log sheet
to help with record keeping, see section page 3-3.
Warranty of the system remains in effect as described at
the beginning of this manual, section page i.
The following are recommendations regarding long
term storage:
• If the unit is designed for indoor duty, it must be
stored in a heated building.
• If the unit is designed for outdoor duty and is to be
stored outdoors, a canvas tarp is recommended
for protection until installation. Adequate drainage
should be provided. Place wood blocks under the
base skid so that water does not collect inside the
base perimeter or low spots in the tarp.
• All compressor stop valves are to be closed to isolate
the compressor from the remainder of the system.
All other valves, except those venting to atmosphere,
are to be open. The unit is shipped with dry nitrogen
holding charge of approximately 5 psi above atmospheric pressure. It is essential that the nitrogen holding charge be maintained.
• The nitrogen or clean dry gas holding charge in the
system and compressor are to be monitored on a
regular basis for leakage. If not already installed, it is
required that a gauge is to be added to help monitor the nitrogen holding charge pressure. If a drop in
pressure occurs, the source of leakage must be found
and corrected. The system must be evacuated and
recharged with dry nitrogen to maintain the package
integrity.
• Cover all bare metal surfaces (coupling, fl ange faces,
etc.) with rust inhibitor.
• Desiccant is to be placed in the control panel. If the
panel is equipped with a space heater, it is to be energized. Use an approved electrical spray-on corrosion
inhibitor for panel components (relays, switches,
etc.)
• All pneumatic controllers and valves (Fisher, Taylor,
etc.) are to be covered with plastic bags and sealed
with desiccant bags inside.
COMPRESSOR MOTOR
The following are general recommendations. Refer to
specifi c motor manufacturer instructions for storage
recommendations.
• Remove the condensation drain plugs from those
units equipped with them and insert silica-gel into
the openings. Insert one-half pound bags of silicagel (or other desiccant material) into the air inlets and
outlets of drip-proof type motors.
NOTE
Bags must remain visible and tagged, so they will be
noticed and removed when the unit is prepared for
service.
• Cover the motor completely to exclude dirt, dust,
moisture, and other foreign materials.
• If the motor can be moved, it is suggested that the
entire motor be encased in a strong, transparent plastic bag. Before sealing this bag, a moisture indicator
should be attached to the side of the motor and several bags of silica-gel desiccant be placed inside the
bag around the motor. When the moisture indicator
shows that the desiccant has lost its effectiveness, replace desiccants.
• Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10°F
above the ambient temperature.
• Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate fl at
spots on the bearing surfaces. For motors utilizing
anti-friction bearings, the shaft should be rotated
once every 30 days by hand at 30 RPM for 15 seconds
in each direction. Bearings should also be re-lubricated at 2-year intervals using the grease specifi ed on
the motor lubrication nameplate.
• If the compressor unit is installed, wired and charged
with oil, open all oil line valves and run the oil pump
for 10 seconds prior to rotating the compressor shaft.
Continue running the oil pump while the compressor
shaft is being turned to help lubricate the surfaces of
the shaft seal.
For additional storage information, refer to Appendices.
3 – 2
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 3 • Installation
AIR COOLED OIL COOLERS
The following are general recommendations. Refer to
specifi c air cooled oil cooler manufacturer instructions
for storage recommendations.
• If the coolers are to be stored or not operated for an
extended period of time, the fan motors may ingress
moisture if they are not protected or operated regularly. In severe cases, the moisture will reduce the insulation level of the windings or cause rusting of the
bearings necessitating removal for repairs at a motor
repair facility. This is a common problem with large
generating installations when the coolers are often
ready but commissioning of the main turbine-generator is delayed for several months.
• The simplest remedy for installed coolers is to operate the fan motors for a few hours every week during the downtime period until regular operation
resumes. The fan motors on stored coolers must be
protected from the elements by covering them with
waterproof tarps.
Compressor Unit Inspections Prior to
Storage or Installation
The compressor unit must be inspected prior to installation since components could have come loose and/or
damaged during shipment or moving.
• Check for loose bolts, particularly the compressor
and motor mounting nuts.
• Check for bent or damaged components. The compressor unit should have also been inspected prior to
off-loading, see Delivery Inspection.
• Check that the nitrogen pressure is still holding pressure. The pressure gauge is located at the discharge
bleed valve on the block and bleed assembly. Any
leaks must be fi xed and the system purged and re-
charged with dry nitrogen.
Recommended Onsite Tools
The tools recommended to have on site are important
for troubleshooting, inspections and compressor unit
operation. Besides general mechanic tools, these tools
are recommended:
• Oil Pump (maximum of 2-3 GPM with motor approved for Division 1 or Division 2 and with ability to
overcome suction pressure)
• Infrared Heat Gun
• Torque Wrenches (with ranges from 0 to 600 ft-lbs)
• Sockets and wrenches up to 2-1/2” (63.5 mm)
• Voltmeter
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
3 – 3
Section 3 • Installation
LONG TERM STORAGE LOG
Date: _______________________________
Name: _______________________________ Intial:_______________
Company:
Vilter Order No. _____________________________________________
Compressor Serial Number: ________________________________________________________
Was Compressor Shaft Rotated? _______YES _______ NO HOW OFTEN? __________
Was Air Cooled Oil Cooler Rotated? _______YES _______ NO HOW OFTEN? __________
Was Compressor Motor Rotated? _______YES _______ NO HOW OFTEN? __________
Was Compressor Motor Lubricated? _______YES _______ NO HOW OFTEN? __________
What was the Nitrogen pressure? _______PSIG
Was it necessary to recharge with Nitrogen? ________YES _______NO
If unit needed recharging, was the leak found? ________YES _______NO
Please briefly explain nature of leak:
Is compressor stored in a building that is heated and insulated to prevent condensation of moisture and freezing of Equipment?
___________YES _________NO
Are all machined surfaces exposed to atmosphere coated with a light grease to prevent rusting (compressor shaft)?
__________YES _________NO
Compressor has been placed in operation as of: DATE ______________
3 – 4
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 3 • Installation
Foundation
Vilter Single Screw compressor units are low vibration machines. Under most conditions, no elaborate
foundation is necessary. However a sound foundation
maintains motor alignment and proper elevation, and
is therefore required. Provided are recommendations
for the foundation and anchoring of the compressor
unit. The Vilter foundation supports the entire operating
weight of the unit and is suitable for years of continuous
duty. Included are specifi cations for concrete, rebar, ag-
gregate, anchors and grout.
Considerations Prior to Starting
Consult professionals, such as building inspectors,
structural engineers, geotechnical engineers and/or
construction contractors prior to starting. Below are a
few points to consider:
Site Characteristics:
• Soil information
• Site drainage
• Wind data
• Seismic zone
• Ingress and egress
• Power and power lines
Site Layout:
• Plant elevations, grading, drainage and erosion
• Accessibility to compressors for service
• Location of surrounding buildings
• Property lines and roadways
• Power
• Fire safety
Safety:
NOTE
Always check with a safety engineer before proceeding.
• Arranging equipment with adequate access space for
safe operation and maintenance
• Wherever possible, arrange equipment to be served
by crane. If not feasible, consider other handling
methods
• Make all valves and devices safely accessible
• Use special bright primary color schemes to differentiate service lines
• Lightening protection for outdoor installations
• Relief valve venting
Foundation Materials
Materials needed to build the foundation are forms,
concrete, sand, rebar, wire, grout, anchor bolts, expansion board and shims. A set of concrete forms will
need to be acquired; generally, these can be rented or
constructed from dimensional lumber. There should
be enough 4,000 psi concrete with one inch aggregate
to build the foundation. Also, there should be enough
sand to provide a base of compacted sand four inches
thick for the foundation to rest on, see Figure 1 - Concrete Pad with Compressor Unit Dimensions - Side
View. The rebar required is ASTM 615, grade 60, sizes
#4 and #6. Wires will also be needed to tie the rebar
together. The recommended grout is Masterfl ow 648CP
high performance non-shirk grout to provide at least
a 1” thick pad under each foot. The recommended anchors are 5/8” Diameter HILTI HAS SS threaded rod for
outdoor installations or HAS-E rods for indoor installations. Anchor bolts shall have a fi ve inch projection and
12-3/8” embedment. The required adhesive is HIT-ICE/
HIT/HY 150 anchoring system. There should be enough
one inch expansion boards to go around the perimeter
of the foundation. Finally there should be enough shim
stock and extra anchor bolt nuts to level the compressor unit.
Building the Foundation
Use the Vilter General Arrangement (GA) and foundation drawings to help secure a building permit and
foundation construction. The Vilter GA drawing will
have the necessary dimensions required to determine
the overall foundation size and where to locate the
compressor unit on the foundation. It will also show the
dimensions required to form up the housekeeping piers
that the compressor unit rests on. The Vilter foundation
drawing lists the necessary information to construct a
suitable foundation. It includes the rebar requirements
and locations. It also shows anchor bolt locations,
grouting and the concrete specifi cations. Using the
Vilter GA drawing, Vilter foundation drawing and the
information from site characteristics, site layout and
safety studies will provide enough data to allow building the foundation to proceed.
The foundation is to be cast and permanently exposed
against the earth. Therefore, if constructing on an existing fl oor, typically indoors, the fl oor will need to be bro-
ken up to get to the earth. If starting from undisturbed
soil, it must be also be prepared accordingly. In either
case, these are some check points to consider:
• Check the depth of your frost line to ensure
the foundation extends below it
• Ensure the foundation rests entirely on natural rock
or entirely on solid earth, but never on a combination
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
3 – 5
Section 3 • Installation
of both
• Check the ability of the soil to carry the load
• Check wet season and dry season soil characteristics
for static loading limits and elasticity
• Check local codes for Seismic Design requirements
For examples of foundation diagrams, see to Figure 3-2
and Figure 3-3.
G.A.
trolled level and a surface texture etched in place. Leave
the concrete to cure for at least 28 days.
Compressor Unit Installation
Once the foundation has cured, the compressor unit
can be placed on the foundation, see Figure 3-5 and
Figure 3-6. With the appropriate material handling
equipment, lift the compressor unit by locations shown
on the Vilter GA drawing and slowly place it on the
G.A.
COMPRESSOR UNIT
CENTER LINE OF
GAS COMPRESSION
SYSTEM
1'-0"
6"
EL. TOP OF
GRADE
3" CLR. 2" CLR.
# 6 @ 12"
EACH WAY
TOP & BOTTOM
2" (TYP.)
2" (TYP.)
Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View
NOTE
In Figures 3-3 and 3-8, the recommended
housekeeping height of 6” is to allow maintenance/
service of the oil strainer and oil pump.
Once the site has been excavated and prepared, place
four inches of sand down on the bed where the foundation will rest. The sand must be compacted before placing the forms and rebar. After the sand is compacted,
use the Vilter GA drawing to construct the forms for
the foundation. With forms in place, install expansion
boards on the inside of the forms, for example, see
Figure 3-4. Next, place your rebar in the forms as per the
Vilter foundation drawing. When all rebars are in place
the concrete can be poured. The concrete must then be
4" COMPACTED
SAND
EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL
WITH CLSM OR NON-FROST SUSCEPTIBLE FILL
foundation housekeeping piers. As per the Vilter GA
drawing, ensure the compressor unit is correctly placed
on the foundation. Once placed, use the spherical washers directly under the compressor as the surface to level
the compressor unit, see Figure 3-7. Place shims under
the feet of the compressor unit, as needed, until it is
leveled, see Figure 3-8. Select the correct drill bit and
drill thru the anchor bolt hole in the mounting feet of
the compressor unit to the depth called for on the Vilter
foundation drawing. Finally using the HILTI instructions,
put your anchor bolts in place and wait for them to cure.
Then place the nuts on the anchor bolts to fi nger tight
and prepare to grout.
3 – 6
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 3 • Installation
Leveling and Grouting
The unit should be level in all directions. Wet the
concrete pad according to the grout manufacturer’s
directions. Mix a suffi cient amount of grout. The grout
must be an expanding grout rather than shrinking to
provide a tighter bond. Follow the manufacturer’s
COMPRESSOR UNIT
EL. TOP OF
GRADE
6"
recommendations for setting, precautions, mixing, and
grout placement, fi nishing and curing. The grout must
be worked under all areas of the feet with no bubbles or
voids. If the grout is settled with a slight outside slope,
oil and water can run off of the base. Once the grout has
cured, torque the anchor bolts as per HILTI instructions.
G.A.
G.A.
CENTER LINE OF
GAS COMPRESSION
SYSTEM
# 6 @ 12"
EACH WAY
TOP & BOTTOM
EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL
WITH CLSM OR NON-FROST SUSCEPTIBLE FILL
Figure 3-3. Concrete Pad with Compressor Unit Dimensions - Front View
ISOLATION JOINT,
1" MINIMUM
COMPRESSOR UNIT
CHAMFER EDGE
THICKNESS
FOUNDATION
6”
CONCRETE
SLAB IN
BUILDING
Figure 3-4. Interior Foundation Isolation
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
3 – 7
Section 3 • Installation
Additional Information
Codes and Standards
Vilter followed the following codes and standards when
designing your foundation:
• ACI
• ASTM
• ASCE 7
• IBC 2006
Operation and Performance
The foundation was designed for:
• Outside environment severe exposure
• Ambient temperature -10 degrees F to 105 degrees F
• Unit weight 20,000 lbs
• RPM 3600
• Soil bearing capacity 1,500 lbs/sq.ft.
• Wind speed 120 MPH
• Exposure factor D
• Wind importance factor 1.15
• Concrete poured on and permanently cast against
the earth
General Design Requirements
The compressor foundation is designed to:
• Maintain the compressor in alignment and at proper
elevation.
• Minimize vibration and prevents its transmission to
other structures
• Provide a permanently rigid support
• Provide suffi cient depth to dampen vibrations.
10'-0"
5'-0"
OVER ALL G.A. LENGTH + 4'-0"
CENTER LINE GAS
COMPRESSION
SYSTEM
3 – 8
Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 3 • Installation
1" (TYP.)
G.A.
G.A.
G.A.G.A.
(2) - # 4
CLOSED TIES
CENTER LINE
G.A. + 2"
G.A.
G.A.
(5) - # 6 VERT.
WITH STD. 90° HOOK
AT BOTTOM EACH
FAC E
5/8" DIA. HILTI HAS SS THREADED ROD
(HAS-E RODS ARE ACCEPTABLE FOR INTERIOR
INSTALLATIONS) INSTALLED USING
HIT-ICE/HIT-HY 150 ADHESIVE ANCHORING
SYSTEM.
(5" PROJECTION, 12 3/8" EMBEDMENT.)
HOLES TO BE INSTALLED WITH HAMMER DRILL.
DO NOT DIAMOND CORE.
Figure 3-6. Housekeeping Pad Dimension Detail - Top View
(TYP.)
COMPRESSOR UNIT
LEVEL
HOUSEKEEPING PADS
SPHERICAL
WASHERS
Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
3 – 9
Section 3 • Installation
70+6.')
010Ä5*4+0-
'21:;)4176
4'%1//'0&'&
(14
*175'-''2+0)
%10%4'6'
$#5'
Figure 3-8. Concrete Pad Housekeeping Detail
Piping
The ideal load applied to fl anges of the compressor unit
is zero. However, it’s not practical to expect that no loads
will be applied to unit connections. Thermal, dead, live,
wind & seismic loads must be considered and even tolerated. Well supported external piping connected to the
compressor will still result in some loads applying forces
and moments in three axes to unit fl anges.
The most important issue is the motor-compressor misalignment caused by external forces (F in lbf) and moments (M in ft-lbf) imposed by plant piping. In Figure
3-9 and Table 3-2, are the maximum allowable forces
and moments that can be applied to compressor fl anges
when the compressor is mounted on an oil separator.
It must be noted that it is necessary to check for compressor shaft movement when the job is complete. In
no case shall the attached piping be allowed to cause
more than 0.002” movement at the compressor shaft.
If more than 0.002” movement is detected the piping
must be adjusted to reduce the compressor shaft movement to less than 0.002”. For example, the compressor
shaft should not move more than 0.002” when piping is
removed or connected to the compressor.
IMPORTANT – piping elements shall be supported per
the requirements of ASME B31.5 / B31.3 as applicable.
See guidelines below, particularly with concern to minimizing loads on check valves.
3 – 10
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
*1.&&190076
9#5*'4
/+0
Header Piping and Drains
Header drains should also be installed to allow drainage
of liquids from the discharge and suction headers. See
Appendices for Recommended Header Piping.
.'8'.+0)076
#0%*14$1.6
CAUTION
Accumulated liquid in the suction header can damage
the compressor if not drained. Always drain headers
(suction and discharge headers) prior to start-ups.
Failure to comply may result in damage to equipment.
Remote Air Cooled Oil Cooler Piping
If equipped with a remote air cooled oil cooler, it is important that the piping be installed correctly to and from
the compressor unit and remote air cooled oil cooler.
See Appendices for Recommended Air Cooled Oil Cooler
Piping.
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