1.04.004 LeRoi HG10 & HG12 Versatrol Operator (Poppet) Removal-Installation and Torque

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

Purpose

The purpose of this procedure is to establish the minimum requirements for removing the Versatrol Operators and studs from LeRoi HG12 (127mm) and HG10/HGF10 (108mm) compressors and stud inspection, replacement and torquing procedure. This applies to all Flogistix rotary screw compressor packages equipped with the LeRoi model HG10 & HG12 compressor.

The LeRoi Technical Service Bulletin (TSB) is included at the bottom of this Flogistix procedure labeled TSB1701 Versatrol Operator Stud/Rebuild/Replacement/Torquing Procedure Technical Service Bulletin ECN 49032.

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 installing the Versatrol Operator and insuring the proper torque of the Versatrol Operator studs and nuts on the LeRoi HG10 & HG12 model compressors. This torque procedure will be required after the re-installation of any Versatrol Operator on a LeRoi HG10 & HG12 model compressor as outlined in this procedure. Versatrol Operator may also be referred to as a Poppet 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 Versatrol Operator is removed from compressor.

Removal of Versatrol Operator (Poppet)

1. Remove the 1" tubing from the top of the Poppet assembly.

2. Remove the 1/4" control tubing from the Poppet assembly.

3. The Poppet assembly is now ready for removal. Use a wrench to loosen and remove the two 9/16" headed 5/16" nuts from studs on the end of the Poppet. (Some cases the stud may try to come out when removing the nut. If the stud unscrews from the compressor housing with the nut, it is OK.)

4. The Poppet should be able to be removed by sliding the Poppet away from the compressor housing on the studs. Compressor oil will likely drain out of the compressor housing once the Poppet is removed from the housing.

5. The Poppet can now be rebuilt if necessary.

6. Check for any corrosion of the Poppet studs, if corrosion seems to be present, the studs must be replaced. If replacing the studs due to corrosion or damaged threads, stud removal pliers can be used if the studs are not to be used again. If the studs are going to be reused stud removal pliers Are Not Allowed to be used to remove the studs.

7. If the studs are to be reused the next process must be used to remove the studs. The studs can be removed by using two 5/16' nuts threaded onto the free end of the stud with full engagement of both nuts. Using two wrenches hold the inner nut stationary with a wrench and tighten the outer nut with a wrench against it until it touches with slight resistance. Use a wrench on the inner nut and turn the stud counterclockwise to remove the studs.

Installation of Versatrol Operator (Poppet)

1. With the Poppet studs removed from the compressor housing the threads in the stud holes need to be chased. Use a 5/16"-18 thread bottom hole tap and run the tap all the way to the bottom of the threads.

2. If installing new studs check that each new stud easily threads into the gas end housing also check the outer threads using the 5/16"- 18 thread nut to make sure the nut goes on the threads freely.

3. If reusing the studs, the studs will need to cleaned and the threads on both ends of the stud will need to be cleaned and checked with a 5/16"-18 thread die. After cleaning the threads check that each stud easily threads into the gas end housing.

4. Remove the studs from the gas end housing and apply Loctite 242 (Blue) to the threads and make sure threads are completely coating the threads.

5. Insert the studs by hand until the studs bottom out in the bottom of the gas end housing making sure that there are still threads showing on each stud.

6. Using two 5/16" nuts threaded onto the free end of the stud with full engagement of both nuts. Using two wrenches hold the inner nut stationary with one wrench and tighten the other nut with a wrench against it until it touches with slight resistance.

7. Remove the wrenches and use a torque wrench on the outer nut to finalized the stud insertion by torquing the stud to 5 ft-lbs (60 in-lbs).

8. Then remove the nuts on the stud by reversing the nut installation process.

9. The gas end housing is now ready for the Poppet to be installed. It is recommended if reinstalling a used Poppet to replace all seals and o-rings on the Poppet before it is reinstalled.

10. Install the assembled Poppet on both studs and slide the Poppet all the way into the gas end housing.

11. Apply Loctite 242 (Blue) completely coating the outer threads on each stud.

12. Run the nuts on so the assembly is evenly pressed against the gas end.

13. Using a torque wrench and torque each nut to 30 in-lbs.

14. Then reset the torque wrench and torque each nut to 60 in-lbs.

15. For the final torque reset the torque wrench and torque each nut to 96 in-lbs.

16. Be sure to check to check each nut twice at 96 in-lbs torque

17. NOTE: Each stud must be torqued to the same value, un-equal torquing can lead to premature failure.

18. Remove excess Loctite and allow to set per Loctite instructions before operating.

19. Reconnect all process tubing going to Poppet.

After compressor has be restarted.

Anytime a Versatrol Operator (Poppet) is replaced, the following must be completed. After replacing a Versatrol Operator (Poppet), 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 Versatrol Operator (Poppet) 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 temporarily raised. Determine the overall maximum discharge pressure limit for the site and establish a shutdown set-point for that pressure. Manually increase pressure and allow the system shutdown to act, faulting the unit on high discharge pressure. The Versatrol Operator (Poppet) 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 Versatrol Operator (Poppet) and any tubing connecting the Versatrol Operator continues to hold without leaking. If the compressor Versatrol Operator holds at the elevated pressures, the shutdown set-point can be returned to the previous setting and the artificial back-pressure shall be slowly released to the normal operating conditions of the location. If the compressor Versatrol Operator and connecting tubing 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.

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 HG12 model LeRoi 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 poppet change such as, oily rags, ETC, will be disposed 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 Versatrol/Poppet Removal and Installation 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

• Oil absorbent Pads

• Torque wrench capable of torque in inch pounds up 96 in-lbs. Torque wrench must be with a valid CALIBRATION certificate. The certificate should support 4% tolerance on CW rotation for indicated values when compared to actual torque Torque wrenches must be calibrated once a year or every 5000 uses whichever comes first. The recommended calibration standard is ASME B107.14-Current.

  • B107.14‐Current.

• a small tube or bottle of Loctite 242 (Blue)

Approvals

Field Service approved by:

Date:

Engineering approved by: Aaron Baker

Date: April 26, 2017

EHSS approved by:

Date: