@ GEPS Oil & Gas Nuovo Pignone INSTRUCTION , OPERATION A MAINTENANCE MANUAL CENTRIFUGAL COMPRESSOR TYPE: SRL252 Volume T11- Tomo A Auxiliary Equipment & Instrumentation NUOVO PIGNONE JOB N.P. SERIAL NUMBER CUSTOMER SERVICE PLANT LOCATION PLANT OR UNIT PLANT LOCATION MANUFACTURER 115.9017 10-K-4011 TECHNIP ITALY FOR PETROVIETNAM FUEL GAS BOOSTER INDUSTRIAL ZONE BA-RIA VUNG TAU - VIETNAM PHU MY FERTILIZER PLANT KHARG ISLAND ‘® Nuovo Pignone Via F. Matteucci, 2 50127 Florence - Italy Telephone (055) 423211 Telefax (055) 4232800 05.04-E 115.9017 Pill@ GEPS Oil & Gas Nuovo Pignone MANUAL VOLUME I Tamo A INP. Job: 1159017 Auslary Equipment & instrumentation (R151, TECHNIP ITALY FOR PETROVIETNAM - VIETNAM) 05.04-E 115.9017@ GEPS Oil & Gas Nuovo Pignone i INSTRUCTIONS MANUAL Status and description of the revisions Shao direvisione | Data | Eseguito | Controllato | Approvato Descrizione della revisione Revision Status | Date | Prepared | Checked | Approved Description of the revisions First Issue | 05/04 | GDS. - ISSUE V © 2001 Nuovo Pignone S.p.A., tutti diritiriservati NUOVO PIGNONE PROPRIETARY INFORMATION Questo documenta inlude informazion’ confidenzal¢ oi propreta f Nuovo Pignone e non pud essere rprodto, copato, ‘0 forto a terza parte senza il preventvo consenso scria di Nuovo Pignone. 1 destinatariaccettano dl prendere agn ragionevole precauziono por proteggers tal formation de uso non aulorzzato 0 ‘alia loro divwigazione. 2001 Nuovo Pignone S.p.A., all rights reserved NUOVO PIGNONE PROPRIETARY INFORMATION “This document includes proprietary and confidential information of Nuovo Pignone and may not be reproduced, copied, or furnished to third parties without he prior writen consent of Nuowo Pignone. Recipient agrees to take reasonable stops fo protect such information rom unauthorized use or disclosure. 05-048 115.9017 Pid@ GEPS Oil & Gas Nuovo Pignone After Sales Service Introduction 10 Nuovo Pignone after-sales service ‘Nuovo Pignone organization is structured in such a way as to guarantee a comprehensive and effective after-sales service for its machinery. Here is briefly described the organization of the company, based on its experience as a manufacturer and on a continuos effort to meet customers needs. Being aware of the importance of maintenance in all operational activities, Nuovo Pignone deals with its various aspects from the design stage, through: ~ the use of design criteria that enhance maintainability, ~ the continuos research of innovative solutions to improve availability, -the selection of components and advanced technologies to enhance equipment maintenance, - the inspection procedures and topics, to be used in connection with a detailed schedule of maintenance operations, =the choice of the spare parts to be kept in stock, optimizing investment cost vs plant downtime. In late years Nuovo Pignone after-sales service has also been brought up-to-date to guarantee the best support to its customers. In more details: - worldwide, where Nuovo Pignone has been operating for tens of years, the structure consists of a service network which is the natural expansion of the "Customer Service Division" in Florence. There are localized Service Units and authorized Service Shops at strategic points of the world, to cover areas where plants with Nuovo Pignone machinery are located. ~in Florence, ( Headquarters) specialized depts. which are active from the receipt of the enquiry, to the issue of the offer and, in case of an order, to the management of all activities connected with the job, up to its completion. ‘This organization, available for all customers, ensures a qualified interface to refer to for any requirements in connection with operation/maintenance of machinery. The names and address for localized Service Units and authorized Service Shops are available at GE POWER SYSTEM WEB SITE (URL: htp//www.gepower.com) selecting from its home page the following choices: Business sites/GE Nuovo Pignone/Sales Organization (complete URL: hutpvliwww.gepower.com/geoilandgas/oil_gasbrands/nuovo_pignone/sales_org.html) In the section “Service” of this page are available the names and addresses of localized Service Units divided into geographical areas. In the above indicated web site, in the section “New Units” are available the names and addresses of the Branch Offices Abroad divided into geographical areas. 05-048 ‘Afier Sales Service PLL@ GEPS Oil & Gas Nuovo Pignone stor Sales Service Nuovo Pignone has been managing for many years special after sales "Support Packages”. These packages typically include: - diagnostic analysis of machines in operation - consultancy in scheduling maintenance based on operational requirements = field maintenance - refurbishing of worn components - original spare parts supplies - technical expertise in updating machines Product engineering departments are staffed with experts in analysing machinery operating data, who provide users with technical consulting services aimed at optimizing use of equipment. The entire service organization guarantees users get the most suitable maintenance to restore original design conditions and the total information relevant to all technological innovations introduced in Nuovo Pignone’s products as applicable to the installed machinery. Full flexibility allows us to adapt each maintenance contract upon User's needs.Service Apreements in force today, range from "On call” basis to "Global Service” 05.046 ‘Afer-Sales Service Pld@ GEPS Oil & Gas Nuovo Pignone Volume Index VOLUME INDEX ‘The complete instructions of the compressor unit are subdivided as follows: - COMPRESSOR INSTRUCTIONS Volume I = COMPRESSOR DRAWINGS AND PARTS LIST Volume Il ~ AUXILIARY EQUIPMENT & INSTRUMENTATION Volume IIL Tomo A Tomo B = CONTROL PANEL, ‘Volume IV ~ ANTISURGE CONTROL AND PERFORMANCE CONTROLLER Volume V Tomo A Tomo B - BENTLY NEVADA Volume VI 05-04-E, 115.9017 PLL Woo eRe. 1200@ GEPS Oil & Gas Nuovo Pignone Volume TT JOB 115.9017 VOLUME INDEX Auxiliary equipment A Instrumentation B@ GEPS Oil & Gas Nuovo Pignone ». JOB: 115.9017 AUXILIARY EQUI (MAIN INDEX) COSTRUTTOR DESCRIPTION Pos. JOHN CRANE MECHANICAL SEAL GAS L KINGSBURY JOURNAL BEARING 2 FLENDER GEARBOX 3 EL.cCO SEAL GAS PANEL 4 CONTROL PANEL ANTISURGE CONTROL AND SEE PERFORMANCE CONTROLLER VOL.VI CON-PRO TOSCANA PNEUMATIC ACTUATOR 7 KOP-FLEX COUPLING BETWEEN GEAR MOTOR AND 6 GEAR ICET LUBE OIL SKID 7 O08 1159017 Pid@ GEPS Oil & Gas Nuovo Pignone Vol.IIT N.P. JOB: 115.9017 AUXILIARY EQUIPMENT (MAIN INDEX) DESCRIPTION AND a NP.CODE MANUFACTURER ITEM | MAN.INSTRUC. SEC. RTO9421590 _ | MECHANICAL GAS SEAL INSTR” T (SOS 7246036) | TYPE: T28AT 1OM-0250 JOHN CRANE /28AT,28XP,28EXP | DwG: SOs 72460361 sos 2991689/2 |RTO 9421591 | MECHANICAL GAS SEAL INSTR. 1 |(SOS 7246037/1) |TYPE: T28AT {10M-0250 | JOHN CRANE 28AT.28XP,28EXP DWG: SOS 7246037/1 SOS 2991690/2 RCO 37427 JOURNAL BEARING THRUST INSTR. 2 SIDE KINGSBURY TYPE: T5080-032/2D DwG.: KINGSBURY SOS 7246169/1 RCO 37428 JOURNAL BEARING OPP. INSTR 2 THRUST SIDE KINGSBURY TYPE: T3080-032/2D DwG.: KINGSBURY SOS 724616911 RRO 2114677 |GEARBOX INSTR. 3 TYPE: TRS0SX 29543 FLENDER wa: Sos 7246092/2 'SOS 7246080/1 'SOS 7246079/1 | 05.04-E 115.9017 P12@ GEPS Oil & Gas Nuovo Pignone Vol JOB: 115.9017 AUXILIARY EQUIPMENT (MAIN INDEX) > DESCRIPTION AND : a NP.CODE, Sennen ITEM | MAN.INSTRUC. SEC. QO 5000074 | SEAL GAS PANEL. 4 EL.CO | DWG SOS 8179513/1 SOS 7245135/1 SOS 724513614 /SOS 72451373 [SOs 9965032/3 DSE 10183/4 QO 5000075. | CONTROL PANEL INSTR. SEE VOL SAF SAF. | NHC [ANTISURGE CONTROL AND INSTR: | 8101700004. | PERFORMANCE CONTROLLER ccc CC. RVO 54069 | PNEUMATIC ACTUATOR INSTR. 5 TYPE: PDI2s CON-PRO |CON-PRO TOSCANA TOSCANA RGO 9997986 | COUPLING BETWEEN INSTR: 6 ELECTRIC MOTOR AND GEAR FORM 16-616 TYPE: RRM KOP-FLEX 2GD00 LUBE OIL SKID INSTR. 7 - ICET ICET 05-008 115.9017 P22John Crane (atnCrane/ Engineered Sealing Systems Installation, Operation and ~ Maintenance Instructions for Type 28 Gas Seals Used in Turbo-Machinery Applications This applies to the following John Crane seals: Type 28 AT’s Type 28 XP's 4 3 ingham Avene, Slough SLI ALU England, UK Printed copies are uncontrolled documents ‘This seal may only be installed, commissioned and maintained by an authorized plant machinery specialist, paying close attention to these instructions and all other relevant regulations. Failure to do this relieves the ‘manufacturer from any liability or warranties. IC Ref N*: ]OM-0250-ver-1.2Installation, Operation and Maintenance (oinGrang! Page 2 of 11 Instruetions CONTENTS 1 INTRODUCTION TO THE JOHN CRANE TYPE 28 GAS SEAL wnneninnnnsnnnd 2. DECLARATION OF INCORPORATON... 3. SAFETY 3.1 WARNING SYMBOLS. 3.2. SAFETY INSTRUCTIONS .. 4. SEAL PREPARATION. 4.1 EXERCISING THE SEAl 4.2 COMPRESSOR PREPARATION. 4.3. FITTING THE SEALs 4.4 REMOVAL OF SEALS... 4.5 REPLACEMENT OF TOLERANCE RINGS.. 4.6 SHIPPING OF THE SEAL CARTRIDG! 5. COMMISSIONING PROCEDURE... snes SA Static Test 5.2 DYNAMIC TEST... 6_COMPRESSOR OPERATION AND MAINTENANCE WITH DRY GAS SEALS. 7_STORAGE OF SEALS APPENDIX I. PRINCIPLE OF OPERATION... APPENDIX Il, RETURNING SEALS TO JOHN CRANI APPENDIX III. INSTALLATION DRAWINGS ~ ATTACHED. ‘ohn Crane, 361-366 Buckingham Avenas, Slog, SL. 4L.U, Englund, UK JC Ref. N° TOM-0250-ver-1.2Installation, Operation and Maintenance (loinCrene) Page 3 of 11 Instructions 1, INTRODUCTION TO THE JOHN CRANE TYPE 28 GAS SEAL These instructions describe the Gas Seal's preparation for fitting, operation in, and removal from the compressor. Seal cartridge disassembly, is not covered, asthe complet cartridge should be retumed to John Crane if refurbishment is required ‘The seals are robust in operation, However incorrect handling or assembly fiting can easily damage them. Its therefore recommended that the seals are fited by a John Crane tained and approved Technician, If there are any Gas Seal problems that need an urgent response from John Crane EAA, there is a Hotline "Number 44 (0)1753 224400 (answer phone out of hours). Emergency line 4 hours + 44 (0)7889 653846. 2. DECLARATION OF INCORPORATON EC, MACHINERY DIRECTIVE (98/37/EC AND ITS AMENDMENTS) DECLARATION OF INCOI N SECTION 1,0 ~ MACH TONS ‘Type 28 Series Dry Running Gas Seal ‘SECTION 2.0 APPLICABLE STANDARDS BS EN 292 Parts 1 and 2 SECTION 3.0 INSTALLATION, OPERATION AND MAINTENANCE MANUAL “The document of which this declaration isa par. DECLARATION ION 4, We John Crane UK Ltd, declare that the product described in Section 1.0 above, is intended to be incorporated into machinery or assembled with machinery to constitute relevant machinery as covered by the Machinery Directive and in compliance to other applicable directives, e.g. the ATEX Directive (94/9/EO), ‘The component assembly covered by this declaration must be incorporated in accordance with the pplication guidance supplied by the vendor and the specified conditions in the contract of supply. It must be installed in accordance with its appropriate Installation, Operation and Maintenance Manual described in Section 3.0 above. It must not be put into service until the relevant machinery into which it is to be ‘incorporated bas also been declared in conformity with the provisions of the Machinery Directive, For and on behalf of John Crane ohn Crane. 361-366 Buekinghamn Avenue, Slough, SLI ALU, England, UK, IC Ref. N°: 10M-0250-ver-1.2Page 4 of 11 Installation, Operation and Maintenance Instructions tae! 3. SAFETY The safery notes refer to the arrangement supplied. They can never be exclusive, and must be used in ‘conjunction with the relevant safety regulations for the machine, auxiliary equipment, plant and sealed ‘Aid. 3.1 Warning Symbols ‘The following symbols are used in this instruction ‘manual to highlight information of particular importance! prevent personal injury or extensive A damage, [ATTENTION Speval instructions or information to avoid damage tothe seal or its surroundings. Danger ‘Mandatory instructions designed to Information for easy installation and cfficient operation. Note: 3.2. Safety Instructions A | Any working practice that compromises safety is to be avoided. [ATTENTION] Atal stages in work relating tothe seal reference must be made to the installation drawing. The relevant seal drawings are attached in the last appendix of this document In the event of an operating problem the machinery must be switched off immediately and made safe! Problems must be solved promptly. A slight leakage will occur during normal seal operation. In case of a wom or defective seal the leakage will increase. The leakage may be hazardous or toxic, and a safe collection system is required. Hot surfaces have to be protected against accidental contact. In order to avoid unforeseen hazards do not make [unauthorised changes to the gas to be sealed, the specified duty, or the seal parts, Follow the local relevant guidelines forthe safe and environmentally friendly disposal of assembly lubricants, supplied fluids and scrapped [components. |Compounds containing PTFE, fluorocarbons and perfluoroelastomers should never be burned as the fumes and residues are highly toxic. I this occurs protective gloves must be worn as hydrofluoric acid may be present, As a general safeguard, protective gloves should be worn if handling failed seal pars John Crane 361-366 Buckingham Avene, Slough, SL1 4LU, England, UK, JC Ref. N°: 1OM-0250-ver-1.2Page 5 of 11 Installation, Operation and Maintenance Instructions 4. SEAL PREPARATION If seal cartridge installation or compressor commissioning (first start-up) takes place later than 24 months after shipment from John Crane, the seals must be inspected by a John Crane trained and approved Techni Seal fiting and removal tools are not supplied by John Crane. John Crane use Rocol anti-scize compound for shafUshaft sleeve assembly lubrication (Alternatives such as Molycate MAY be used). This ‘compound should be applied sparingly, and only at the seal sleevelcompressor shaft interface. Silicone ‘grease is used for lubricating stator interface 'O’ rings. This too must be applied sparingly. [ATTENTION] Silicon grease must not be used on sleeve shaft 0" rings. [Excess grease and compound must be removed, and care taken to prevent ingress of these lubricants into the sealing area during cartridge installation. The suitability of altemative lubricants should be ‘confirmed with John Crane. UNDER NO CIRCUMSTANCE MUST SILICONE COMPOUND BE USED FOR SHAFT/SHAFT SLEEVE ASSEMBLY LUBRICATION OTHERWISE SHAFT SLEEVE GALLING CAN RESULT. ©) Remove any locking serew locking inner and cuter setting rings 4) Rotate the seal stator relative to the seal rotor by ‘one complete turn. If this is not possible, there is problem within the seal cartridge and John Crane should be contacted. ‘TO CHECK FOR FREE AXIAL MOVEMENT 4a) Support the main sleeve as shown below. 'b) Remove the setting rings as explained above ©) Apply even hand pressure t0 the seal stator (as indicated in Figure 1) such that the seal is slowly ‘compressed into itself FIRMLY SUPPORTED SURFACE Figure I 4) When fully compressed slowly release the pressure, ‘The following fext assumes that the compressor is ready to accept the Dry Gas Seal, and that the required fiting/extracton tools are availabe. 4.1 Exercising the Seal Prior to seal installation itis recommended that the seal cartridge is exercised to check for free axial and rotational movement. ‘TO CHECK FOR FREE ROTATI MOVEMENT 4) Position the seal cartridge on a firmly supported ‘surface with the setting ings uppermost 'b) Loosen off all the setting ring caphead screws by ‘two complete turns [ATTENTION] ‘Use minimum pressure necessary to avoid the risk ‘of impact damage when maximum movement limitis reached ) Repeat steps (b) and (c) three times. If itis not possible to compress the seal or it fails to return 1 it's original position when hand pressure is released, there is a potential problem within the seal cartridge and John Crane EAA should be contacted. £8) Refit the setting rings. Note: ‘With large or heavy seals the weight of the Satie parts may overcome the spring force, which may prevent the static parts ftom retwming to their original position. John Crane 3461-366 Buckingham Avene, Slough, SL1 ALU, England, UK IC Ref. N° 1OM-0250-ver-1.2