1.04.005 LeRoi compressor Poppet disassembly and assembly

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

Purpose

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

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, rebuilding and installing the rebuilt Versatrol Operator on the LeRoi HG10 & HG12 model compressors 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. For Removal and Installation of the Versatrol Operator or Poppet, refer to Flogistix procedure 1.4.4 Poppet removal and installation and torque 1.4.4 LeRoi HG10 & HG12 Versatrol Operator (Poppet) Removal-Installation and Torque

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

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

4. 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. (In some cases, the stud may come out when removing the nut. If the stud unscrews from the compressor housing with the nut, it is OK.)

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

6. The Poppet can now be rebuilt if necessary.

7. 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 for removal of the studs.

8. 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.

Disassembly of Versatrol Operator (Poppet)

1. With the Poppet removed from the compressor, use the flat blade of a small screw driver to remove the Red Indicator from the Indicator Pin.

1. Remove the Cylinder Cap from the Cylinder

1. Use a 19mm wrench to remove the Indicator Housing from the Cylinder Cap

1. Use a small pick to remove the o-ring next to the threads on the outside of the Indicator Housing

1. There are two o-rings inside the Indicator Housing on each end that must be removed.

• 2. Remove the O-ring from the outer end of the cylinder that seals between the Cylinder and the Cylinder Cap

1. Remove the O-ring from the inner end of the cylinder that seals between the Poppet Cylinder and the Compressor Housing.

• 2. Remove the O-ring from inside the Poppet Cylinder that is in the center of the Poppet Cylinder bore.

1. Use a 19mm wrench to remove the Indicator Support from the Piston.

1. Use a small pick to remove the Piston Seals from the Poppet Piston.

1. The Poppet is now completely disassembled. Clean all parts of the Poppet that were disassembled in the previous steps.

2. Installation of new Piston Seal on the Piston: Make sure that the piston Seals are clean and the Piston groves are clean on the Piston. The Piston Seals have a grove all the way around the seal on one side.

• 1. The other side of the Piston Seal is solid and does not have a grove around the seal.

1. Install the Piston Seal with the Groove side of the Piston Seal facing outward in both groves. The smooth side of the Piston Seals should be facing each other when installed on the Piston.

2. After Piston Seals are installed on Piston, reinstall the Indicator Support into the Piston. The Indicator support does not have a torque value. Tighten the indicator Support in the Piston with a snug fit using the 19mm wrench.

3. Lubricate the Piston Seals with Molykote 111, or the same type compressor oil that is being used in the compressor

4. Install the Piston into the Cylinder by sliding the Piston in the cylinder bore

1. With Piston installed in Cylinder apply mild pressure to Piston and by using a small pick go around and work each Piston Seal to help get Piston Seal edge started in Cylinder bore.

2. Once Piston is full installed in Cylinder, it should look like the photo below.

1. Install the two new O-rings inside the Indicator Housing and then install the new O-ring over the threads on the Indicator Housing.

2. Install the Indicator Housing in the Cylinder Cap.

1. 1. Install Cylinder Cap. Red Indicator must remain off of Indicator Pin when cap is installed. It may take a small amount of pressure to push the Indicator Pin over the new o-rings in the Indicator Housing. Align the Cylinder Cap's 1/4" tubing connection on same side of the Poppet as the 1" tubing connection on the Cylinder.

• 1. Align 1/4" tubing connection with the 1" tubing connection on the Cylinder as shown below.

• 1. Install Red indicator on the end of Indicator Pin by pushing the Red indicator on with the flat blade of a screw driver, then install the Indicator Shield hand tight.

• 1. The Poppet assembly is now assembled and ready for installation on the compressor

Installation of Versatrol Operator (Poppet)

1. For Removal and Installation of the Versatrol Operator or Poppet refer to Flogistix procedure 1.4.4 Poppet removal and installation and torque 1.4.4 LeRoi HG10 & HG12 Versatrol Operator (Poppet) Removal-Installation and Torque

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, increase the discharge pressure to the highest discharge pressure achievable within the horsepower limit. 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 Must 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 HG10 and HG12 model LeRoi compressor units equipped with Versatrol/Poppet operators 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)

• 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 disassembly and assembly shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• 19mm wrench

• Small mechanics pick

• Drain Pan

• Oil absorbent Pads

  • a small tube of Molykote 111 lubricant or compressor oil type that is being used on compressor that Poppet was removed from.

Approvals

Field Service approved by:

Date:

Engineering approved by: Aaron Baker

Date: 5/11/2017

EHSS approved by:

Date: