1.04.003 Compressor Shaft Seal pressure test

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

Purpose

The purpose of this procedure is to establish the minimum requirements for pressure testing the compressor shaft seal after replacing the shaft seal. The procedure outlines the pressure test requirements for the seal after returning the unit to service for verification that the seal will not leak at maximum working pressure of the compressor. This applies to all Flogistix rotory screw and liquid ring compressor packages.

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 checking the compressor shaft seal to make sure the shaft seal will will not leak when the compressor is operated at or near the working pressure of the compressor. This procedure will be required after any compressor shaft seal has been replaced once the compressor is put into service.

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

Anytime a compressor shaft seal is replaced, the following must be completed.

After replacing a compressor shaft seal, restart the unit and return to service under normal operating conditions for that location.

Once the compressor achieves normal operating discharge pressure, the compressor shall be shut down while at the normal discharge pressure.

If there are no leaks from the newly replaced seal at normal operating conditions, the compressor shall be restarted and the discharge pressure shall be increased. Manually increase the discharge pressure to slightly less than the Maximum Working Pressure of the package. This may be the Maximum Working Pressure of the vessels on the unit or the compressor, whichever is less. Limiting horsepower of the engine or electric motor may not allow the compressor to achieve Maximum Operating Pressure. If limited on horsepower then the discharge pressure would need to be run up to the highest discharge pressure allowed due to horsepower. In this case, the inlet suction pressure should be decreased to allow the compressor to achieve elevated discharge pressure.

Some customer locations may prohibit high discharge pressure due to pipeline or other equipment limitations. In this case, the discharge pressure shall be increased up to a discharge pressure limit that is dictated by the customer. If running the discharge pressure greater than the normal discharge pressure shutdown set point, the shutdown set point must be temporaritly raised. Determine the overall maximum discharge pressure limit for the site and establish a shutdown setpoint for that pressure. Manually increase pressure and allow the system shutdown to act, faulting the unit on high discharge pressure. The seal will then be subjected to the highest possible operating pressure for static testing.

Once the compressor has been shutdown at the elevated discharge pressure, the compressor needs to be left shut down for a minimum of 10 minutes to verify the seal continues to hold without leaking. If the compressor shaft seal holds at the elevated pressures, the shutdown setpoint can be returned to the previous setting and the artificial backpressure shall be slowly released to the normal operating conditions of the location.

If the compressor shaft seal holds at the lower normal operating pressure but leaks at the higher elevated discharge pressures, the compressor Can Not be allowed to continue to run or operate.

When relieving pressure from the unit, always blown down at a slow rate to prevent foaming or loss of the compressor oil before attempting to restart the compressor package.

During this Seal testing procedure if the unit has a LOGIX panel or has auto start capability then the auto start feature must be Disabled during the seal test procedure.

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 follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all 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 waste oil and 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 according to the local regulations regarding the disposal of used oil filters and 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 Oil Filter Change 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

• Drain Pan

• Means of waste oil evacuation either by Sage or a pump system on service truck, or by containers to dispose of waste oil.

• Oil absorbent Pads

Approvals:

Field Service approved by:

Date:

Engineering approved by:

EHSS approved by:

Date: