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This Policy is under development.
Purpose
Purpose
The purpose of this procedure is to establish the understanding of the proper loading sequence of LeRoi Compressors equipped with poppets. Poppets are sometimes referenced as Versatrol, Econotrol, Lift Valve or Load Valves. It is important to understand the correct loading sequence and unloading sequence of the LeRoi poppets. This applies to all Flogistix rotary screw compressor packages equipped with the LeRoi model compressors that have poppets..
Procedure
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 verifying and or diagnosing the proper load sequence of the poppet valves.
Before any work is performed a JSA must be completed according to Flogistix procedure along with any customer requirements before any work is started.
All poppets when fully un-loaded will have the stem with the red indicator of the poppet all the way out and the red indicator will be farther from the compressor housing.
All poppets when fully loaded will have the stem with the red indicator of the poppet all the way in and the red indicator will be closer toward the compressor housing.
LeRoi HG12 model compressors:
The lift valves on the LeRoi HG12 model are located in side of the stator housing (cylinder housing) opposite of each other. see example below
On the HG12 (127mm) model Two poppet design on older Flogistix units there was one solenoid control valve that controlled both Poppets.
On newer FX units there are two solenoid control valves to control the poppets. Each solenoid control valve operates each poppet independently.
On the HG12 (127mm) model Two poppet design, either poppet valve can be named valve #1 or valve #2 in the LOGIX panel for Auto Loading or Unloading.
On the HG12 (127mm) model there is not a preference or correct sequence of which poppet valve needs to be opened or closed first.
LeRoi HG17, HG20, HG24, HG30 compressors:
The lift valves on the LeRoi HG17, HG20, HG24, HG30 have a four (4) poppet design.
All four models are similar to the photo example below.
It is important that the correct sequence is used in how the poppets are loaded and then unloaded.
Using the incorrect loading or unloading sequence may cause various issues such as low gas volume output, excessive use of horsepower required, or excess load during warm up.
On the HG17, HG20, HG24, Hg30 model compressors the poppets are numbered. It is important to under stand how they are numbered for loading and unloading purposes.
Facing the side of the compressor looking at the poppets, the input shaft needs to be on the left and the discharge housing on the right.
Facing the poppets as mentioned.
#1 Poppet will be the top left
#2 Poppet will be the bottom left
#3 Poppet will be the top right
#4 Poppet will be the bottom right
Loading Poppets:
When loading the #4 poppet should load first. Depending on the pulse duration set in the LOGIX panel it may take multiple pulses to fully load each poppet. Once fully loaded the next poppet should start to load if the conditions set in the LOGIX panel are calling for additional loading.
The next poppet to load will be #3 poppet, If the LOGIX panel is still requiring additional loading the next poppet will start to load.
The next poppet to load will be #2 poppet, If the LOGIX panel is still requiring additional loading the next poppet will start to load.
The next and final poppet to load will be #1 poppet, Once the #1 poppet is loaded, all other poppets (#2, #3, #4) should still be fully loaded.
Correct loading sequence of the poppets will always be #4 poppet first, then #3 poppet, next is #2 poppet, then the final is #1 poppet
UnLoading Poppets:
When Unloading the #1 poppet should unload first. Depending on the pulse duration set in the LOGIX panel it may take multiple pulses to fully unload each poppet. Once fully unloaded the next poppet should start to unload if the conditions set in the LOGIX panel are calling for additional unloading.
The next poppet to unload will be #2 poppet, If the LOGIX panel is still requiring additional unloading the next poppet will start to unload.
The next poppet to unload will be #3 poppet, If the LOGIX panel is still requiring additional unloading the next poppet will start to unload.
The next and final poppet to unload will be #4 poppet, Once the #4 poppet is unloaded, all other poppets (#3, #2, #1) should still be fully unloaded.
Correct unloading sequence of the poppets will always be #1 poppet first, then #2 poppet, next is #3 poppet, then the final is #4 poppet
Responsibilities
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
Scope
This procedure applies to all LeRoi compressors equipped with Versatrol/Poppet operators and are applicable to all Flogistix employees, contractors, and temporary employees.
Hazards
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
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
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
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:
Date:
EHSS approved by:
Date:
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