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This Policy is Under Development. If you have any questions please contact your Lead/Supervisor or Area Manager.
Purpose
Purpose
The purpose of this trouble-shooting guide is to assist you in diagnosing a high discharge temperature fault on an electric driven screw type compressor.
Procedure
Procedure
This procedure applies to all electric driven screw type compressor skid units that are currently in service in the field, at a repair shop, and in storage yards.
Before any work is performed a JSA must be completed in accordance to Flogistix procedures along with any customer requirements
Trouble shooting a High Discharge Temperature fault:
Step 1: To begin diagnosing a high discharge temperature fault the first step is to trend out the temperature using the trending page located in settings or via Flux if available. Look for erratic spikes in temperature or open loop reading of 32000. Erratic or Open Loop readings can be caused by loose wiring being vibrated during operation or a faulty thermocouple. It is important to use a heat gun to verify temperatures at the port for discharge temperature reading.
If this did not correct the high discharge temperature fault, continue to step two.
Step 2: Compressor oil plays a vital part in heat transfer on screw type compressors. Checking the compressor oil level and condition along with filter differential will be the next step. The differential pressure is the difference of pressure between injection and discharge. If there is an excessive amount of differential pressure present this would indicate that the compressor oil filters need to be changed. Next, you will need to check the oil level. The oil level should be visible in middle sight glass on the discharge vessel while the compressor is operating. If the compressor skid is blown down the level should be visible up to 3/4 of the discharge vessel. After confirming oil level, a viscosity check will be the next step to confirm good condition. Please see the link listed below for instructions on checking compressor oil viscosity.
Page: 1.05.001 Minimum Viscosity Limits for Poly Glycol Synthetic Screw Compressor Oil
If this did not correct the high discharge temperature fault, continue to step three.
Step 3: Check cooling fan operation. Verify that the cooling fan drive is operating in remote if it has its own drive. After verifying this status return to the skid and verify fan is operating at desired temperature. To check this, you can login as mechanic and continue to the settings page. Locate the cooling fan control page and change the desired temperature for the fan to turn on lower than the actual reading at the time. Watch the fan operation all the way to full speed. If the fan is not working, there are a few things it could be. Check the command wire on TB2, #3. Verify there is ground signal reading when the fan is being commanded to run. If there is not a ground signal being produced, check for a positive signal instead. If there is a positive signal being produced on TB2, #3 the PLC will most likely need replacement. If you are getting the correct ground signal to that terminal the problem could be at the VFD or contactor. Please consult with your area lead/supervisor on next steps.
If this did not correct the high discharge temperature fault, continue to step four.
Step 4: Check thermostat operation. Most screw type compressor packages will be utilizing a 230-degree thermostat. (a device that automatically regulates temperature, or that activates a device when the temperature reaches a certain point.) Allow the temperature to rise to operating conditions before checking thermostat operation. Please refer to the link below for thermostat operation diagnosis.
1.11.004 FX Screw Compressor Oil Piping
If this did not correct the high discharge temperature fault, continue to step five.
Step 5: Continue diagnosing by checking for restrictions in the oil injection system. Possibilities could include clogged cooler tubes, clogged piping, clogged injection orifices, etc. Oil restrictions are easily found using a temperature gun. Major temperature drops can indicate a restriction of oil.
If this did not correct the high discharge temperature fault, continue to step six.
Step 6: Compressor operating conditions. The compressor could be operating above rated conditions. If the compressor is under a load that it is not rated for it will cause higher temperatures. Understanding inlet/outlet pressures are important for this diagnosis. Please consult with your lead/supervisor on operating conditions of the compressor you are working on.
If this did not correct the high discharge temperature fault, continue to step seven.
Step 7: Compressor condition. The compressor has internal factors that could effect discharge temperature. Check temperatures on the bearings and record the difference. If there is a major difference in temperature this could indicate a failing compressor.
If issues continue after using this diagnostic sheet, contact your area lead/supervisor for further instruction.
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 following requirements outlined in this procedure and ask for assistance
Scope
Scope
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 this 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 of 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)
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 Preventative Maintenance 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
Temperature Gun
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 viscosity gauge
Approvals
Field Service Revised by: Bryton Reedy - Training and Operations Support Manager
Date: 11/13/2024
Field Service approved by:
Date:
Engineering approved by:
Date:
EHSS approved by:
Date:
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