1.06.002 Scavenge Line Adjustment

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

Purpose

The purpose of this procedure is to establish the minimum requirements for properly adjusting the scavenge line as laid out in this procedure. A properly adjusted scavenge line will optimize the efficency of the coalescing/receiver element and will help to eliminate the recirculating of any unneccessay gas through the scavenge line back into the inlet gas stream.

Procedure

This procedure applies to all rotary screw compressor units that are in currently in service and running in the field, running on the Test Loop, or running at a repair shop. Flogistix Service Technicians will perform the proper adjustment and any diagnostics as required when making adjustments to the scavenge line needle valve on a Flogistix compressor package. This procedure is to be used as a guide to the proper adjustment and diagnosis of the scavenge line needle valve.

Before any work is performed a JSA needs to be done according to Flogistix procedure along with any Customer requirements before any work is started.

Before any work is performed other than the adjustment to the scavenge needle valve all Safety precautions and LOTO must be in-place according to Flogistix policy for the unit type.

Initial adjustment of the scavenge line needle valve needs to be done properly. Any time the operating conditions change when discharge pressures or flow rate changes the scavenge line needle valve will need to be adjusted.

** Before adjusting the scavenge needle valve it needs to be determined if the needle valve may have a faulty adjustment stop. The adjustment stop prevents the needle valve stem from being rotated all the way out of the needle valve housing. Possibility of Personal injury, release of high pressure gas or fluids, or fluid spill may occur if valve stem is rotated out of neelde valve housing while under pressure. Reference Needle Valve Adjustment procedure.1.6.1 Needle Valve Adjustment

• 1. To properly adjust the scavenge line needle valve the compressor unit needs to be running at the desired operating conditions that the compressor will normally be operating at. It is important that the compressor oil operating temperature and RPM be at operating conditions, the inlet and discharge pressures need to be at the average pressures that the unit will be running at.

  2. When unit is running at normal operating conditions the proper adjustment of the scavenge line needle valvecan be done, the needle valve needs to be opened all the way to the open position to evacuate all oil that may be in the receiver element. Leave the needle valve in the full open position for a few minutes to verify that all oil has been evacuated from the receiver element. There should be none or very little oil going through the inline sightglass once the oil has be evacuated out of the receiver element

  3. After the oil has been purged, start closing the needle valve until a small film of oil can be seen in the sightglass. It should look like rain on your windshield as you’re going down the highway. As seen in the Video below:

• 1. Once scavenge line needle valve is adjusted properly the locking set screw on the side of the needle valve needs to be tightened to prevent needle valve bonnet from moving. (See Photo 1)

Photo 1

If the scavenge line needle valve is closed too much, any oil that has penetrated the reciever element will build up in the bottom of the receiver element and will not be returned back into the system. Oil in the reciever element that is not returned back into the compressor oil system via the scavenge line oil could be reintroduced into the gas stream leaving the reciever element and would then not be recoverable.

If the needle valve is open too much, unnecessary gas will be returned back in to the inlet gas stream, reducing compressor capacity.

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 requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all compressors equipped with an adjustable Needle Valve and are applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of release of pressure from the Needle Valve if the the valve stem factory stop is faulted, allowing the valve stem to be rotated past the factory set stop.

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 production fluids.

Safety

All Personal Protective Equipment (PPE) for 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, or at a service shop.

Insure Flogistix personnel have proper safety certification or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to any Customers safety practices.

Proper use of required tools if replacing Needle Valve

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

• 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 procedure to replace defective Needle Valve shall be required to have the listed tools to perform job tasks:

• No tools required for adjustment of needle valve only

• No Lock Out Tag Out is required for adjustment of needle valve, LOTO is required for needle valve replacement according to Flogistix policy

• Basic Hand Tools if needle valve is being replaced.

Approvals:

Field Service approved by:

Date:

Engineering approved by:

EHSS approved by:

Date: