1.04.002 Compressor Shaft Seal Replacement (LeRoi)

This Policy is completed waiting on Field Service, Engineering & Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for removing and replacing the Shaft Seal on LeRoi Rotary Screw Compressors. This applies to all Flogistix rotary screw compressor packages equipped with the LeRoi Rotary Screw Compressors.

Procedure

This procedure applies to all units that are in currently in service in the field, at a repair shop, and in storage yards. Flogistix Service Technicians will perform the procedure of removing and installing the Shaft Seal the LeRoi model Rotary Screw Compressors as outlined in this procedure

Before any work is performed a JSA must be completed according to Flogistix procedure along with any customer requirements before any work is started.

Before any work is performed on the compressor make sure all pressure has been relieved from compressor and process piping on skid. Proper LOTO procedure must be done on compressor unit. A drain pan or other means of collecting compressor oil from compressor will be required when the seal or seal housing is removed from compressor.

Removal of Compressor Shaft Seal

1. Remove the Seal Housing,/Seal Retainer and Seal Assembly. See figure 1

• 1. Figure 1

1. Discard old Seal parts (No parts from old seal should be reused with the new seal assembly)

2. Carefully remove the old Seal Face from the Seal Retainer. Inspect Seal Retainer for any damage around where the Seal Face was seated. Check for any scratches or nicks in Seal Retainer from removing Seal Face.

Installation of Compressor Shaft Seal

1. Clean the Seal Housing/Retainer and Seal Housing. See figure 2 When cleaning inspect the oil fitting and the orifice that is inside of the Seal Retainer to make certain the orifice is clean and no debris may be restricting the orifice.

• 1. Figure 2

1. To protect the exposed shaft bearings from Dirt, dampen a lint free rag with clean compressor oil and insert the rag into the bearing retainer cavity.

2. Inspect the surface of the shaft for nicks and burrs. If found remove them by using a fine file or stone. See figure 3 Remove any sharp edges from tapers or chamfers on the shaft.

• 1. Figure 3

1. On the shaft area, where the seal is to be located, polish the shaft using a number 100 grit silicon carbide emery cloth. Wrap a strip of emery cloth around the shaft. Grasp the emery cloth and use a rotary motion, use four 180 degree movements with a hand motion for a total of two revolutions to polish the shaft. See figure 4

• 2. Figure 4

1. Carefully remove the damped rag from the bearing retainer cavity with a wiping motion.

2. Dampen a lint free rag with a non-hydrocarbon solvent (spray parts cleaner) and remove any remaining dirt from the shaft. Make certain the shaft is oil and dirt free. Warning: Some Solvents may be toxic when when inhaled. Always use in a well ventilated area

3. Carefully remove the new seal from the wrapping, check for any damage, and wipe clean.

4. Lubricate the o-ring on the new Seal Face with P-80 Rubber Lubricant Emulsion, Take care to not touch polished seal area on Seal Face.

5. Make sure the polished/lapped side of the Seal Face is facing outward (away from the Seal Retainer) and place the Seal Face in the Seal Retainer. Take care that the Seal Face does not fall out of the Seal Retainer when handling.

6. Protect the polished side of the Seal Face by using the paste board seal protector furnished with the seal assembly and push the Seal Face insert into the Seal Retainer until it bottoms out in the counter bore. See figure 5

• 1. Figure 5

1. DO NOT TOUCH the polished face of the Seal insert with your fingers, rags ect.

2. Apply a film of P-80 on the gas end shaft and on the inside diameter of the flexible section of the seal assembly. See figure 6

• 1. Figure 6

1. To make certain that the flexible section of the seal adheres to the shaft in the correct location, it is necessary to complete the rest of the remaining assembly steps once started.

2. Make certain all parts and supplies (gasket, sealer,ect) are available before beginning final assembly

3. Lubricate the polished ring section of the seal assembly with clean compressor oil. Do Not Use other types of oil or grease only use the type compressor oil being used in the compressor

4. Without touching the polished area of the seal ring, install the seal assembly (spring, ect) on the shaft. See figure 7 Making sure the the seal ring works back and forth on the shaft without binding up

• 1. Figure 7

1. Install gasket or Sealer(if applicable) on the Seal Retainer

2. Immediately install the Seal Retainer on the gas end and attaching capscrews to the Bearing Retainer mating surface. Tighten all capsrews securely. See figure 8

• 1. Figure 8

1. NOTE: The 108mm input and fan shaft, Non-geared 127mm input and 245mm Seal Retainers do not have a locating pilot or dowels. For these applications install the capscrews hand tight. Then using a feeler gauge or shim stock, carefully check around the shaft and inside of retainer to insure that the Seal Retainer is centered. Adjust position as necessary to center. Tighten all Seal Retainer capscrews securely.

2. After installation is complete allow the seal to sit without rotating the shaft for approximately 30 minutes.

After compressor has been restarted.

Anytime a seal has been replaced refer to policy 1.4.9 Compressor Shaft Seal pressure test before allowing compressor unit to run unattended. 1.4.9 Compressor Shaft Seal pressure test

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the following requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all model LeRoi Rotary Screw compressor units and are applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees should be aware that units could contain flammable and toxic gasses. Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids, rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes. Environmental spill of compressor oil and possible production fluids

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure. Four Gas Monitor, which is outlined in the Flogistix EHSS Manual, PPE Section 8, Procedure 8.3 This procedure applies to all units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification as required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools

Spills and Disposal

All spills shall be handled immediately according to MSDS recommendations and the employee's level of training

Flogistix Service Technicians performing task will properly dispose of any waste liquids or solids. Disposal of any fluids or solid waste will be disposed of properly according to Flogistix policy. Disposal of any fluids will be done at an approved or designed waste location. Disposal of solid waste from a compressor shaft seal change such as, oily rags, ETC, will be disposed of according to the local regulations regarding the disposal of oil soaked rags.

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• MSDS Online System

• Emergency and First Aid procedures

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing Compressor Shaft Seal Replacement shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out(LOTO) items to properly perform LOTO procedure according to Flogistix policy

• Basic Hand Tools to include metric sizes

• Drain Pan

• Oil absorbent Pads

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: