QSGTL CMT RE Repair Report

ABNORMAL NOISE FROM STAGE 2 CYLINDER AND 4000 Hrs PM

Causes/Reasons:

Reported abnormal noise from stage # 2 / Opportunity based 4000 Hrs Preventive Maintenance

Scope of work:

 Ensure isolation for the compressor and accessories.

 Replacement of suction and discharge valve for all stages.
 Removing all pistons assembly for rider and piston rings inspection.
 Replacing the piston and rider rings for the piston if required.
 Inspection of all stuffing boxes, oil scrapper rings replacement.
 Replacing stage 1&2 clearance pocket valves.
 Cleaning of all compartments, valves pockets and cylinder end covers.
 Measuring piston rod deflection/ run out/Cross head sliding clearance.
 Measuring S2, S1 and H1 clearances for piston and rider rings.
 Reconnect pistons assembly with cross heads.
 Cylinder end covers box up.
 Confirming lube oil flow and closing the inspection covers.

Epoch of job done: June 9th, 2012-June 18th, 2012

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 QSGTL CMT RE Repair Report
Dismantling activities:-

 All instrument tubing and thermo couples removed by instrumentation.

 All inspection windows opened.
 Piston rod run out checked and recorded in stage1, stage3.
 Cross head clearance checked and recorded in all stages.
 Visual inspection for stuffing boxes and intermediate compartments done.
 Suction /discharge valves removed for all stages.
Note: grating removed for 2nd stage discharge valves removal) .
Note: fabricated special tool for 3rd stage discharge valves used successfully)
 Cylinder head cover removed by utilizing jack bolt M12.
Note: 2nd stage cylinder end cover removed by barring device (wooden pieces between
cross head and piston rod and moving the piston by barring device to push the cover) as
end cover was stuck due to sludge between end covers.
 Cross head to piston rod disconnected using special hydraulic tool (820 bars).
 Pistons assembly pulled out using crane and lifting tackles. (Remove the hand rails to have
more space for piston removal).
 Oil scrapper assembly removed and sent to CWS for refurbishment.

Findings: –

 2nd stage suction two valves found completely broken.

 Intermediate compartment found full of oil.(Oil need to be drained weekly once as per
reliability)
 Suction valves for 1st stage found rusty.
 Liquid traces found in the valve pockets and cylinders.
 Circlip for two suction valves for 1st stage and And 3rd stage, crank4 found broken.
 Liquid traces found in the cylinders.
 Solid deposits found in some valve pockets.
 Sludge found on 2nd stage piston.
 S2 /cross head clearances/piston rod run out found within limit as per the attached QA/QC
report.
 Indication of dry friction between cylinder liner and piston in 1st stage.
 Stage 3 ,crank4 lube oil supply lines from lubricator to cylinder liners were choked.

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 QSGTL CMT RE Repair Report

2nd stage suction. Liquid Broken Rust in 1st stage

Valve damage traces circlip valve pocket

Lube oil in the intermediate 1st stage suction Liquid traces in 1st
compartment valve rust stage

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 QSGTL CMT RE Repair Report

Sludge deposits in 2nd 2nd stage Suction valve Sludge on the piston
stage clearance pocket damage 2nd stage

2nd stage discharge valve

st
1 stage piston and liner sludge deposits

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 QSGTL CMT RE Repair Report
Inspection and Assembling: –

 After removing the old piston rings /rider rings and cleaning, new sets were installed in the
grooves and all the clearances checked and recorded as per attached QA/QC report.

 Cylinder liners cleaned and all dimensions checked and recorded as per attached QA/QC
report.

 All the oil scrapper assembly inspected. 1st Stage, 2nd stage and 3rd stage crank 2 replaced
by new rings in CWS. Stage 3 crank 4 only cleaned and same rings installed.

 Oil scrapper assembly installed in cylinders.

 Inserted the piston assembly in the cylinder with the help of mounting strip (for closing-in
the piston rings) and ensured the piston rings are staggered at 1800 in horizontal condition
(ring gaps not to pass through the valve ports)
Note: Ensure anti rotation pins for rider rings are not at bottom.

 All the stages piston rod coupler assembled with the help of special hydraulic tool at 820
bar pressure and lock nut tightened and secured with split pin.

 Cross head to piston rod nut bolts were tightened (with spacer plate) to 1000 N-m and lock
plate for securing the bolts.
Note: lock plates should be ordered to be replaced in the next planned PM (not available in
WH).

 All the stages piston to cylinder liner clearance (S2) measured and recorded as per the
attached QA/QC report. (Reject if <0.3 mm).

Protect eye bolts Protect cross head bed Mounting strips for
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holes for covers during removing hydraulic piston/rider rings
nut and flange
 QSGTL CMT RE Repair Report

 Cross head clearance measured and recorded for all cylinders.

 Cylinder head end cover cleaned and mounted back and bolts tightened to the
recommended torque values with new O-ring for all stages.

 1st and 2nd stages clearance pocket valves replaced with new valves, metallic gaskets and O-
rings.

 All suction valves replaced with new valves and valve covers tightened to the recommended
torque value (as below recommended torque values table).

 11 of 12 discharge valves replaced with new valves and valve covers tightened to the
recommended torque value as given in the table.

 Old discharge valve re-used after cleaning in 3rd stage crank#4.

Note: - Fabricated special tools for discharge valves used successfully. It makes valve
installation easier and more safety.
Note: - Marking required for all valve glands to avoid using in the wrong valve pocket and
wrong assembly.

 All the stages piston rod run out checked by fixing one dial indicator vertically and another
one horizontally near rod drop probe and the readings recorded as per attached QA/QC
report.

Rods run out checking@ rod Thermo-Couples installation

drop probe compartment

 Rod drop probe gap voltage setting done by keeping piston assembly at BDC (instrument
+condition monitoring).

 Lube oil pump started to confirm oil flow and all inspection windows closed.
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 QSGTL CMT RE Repair Report

Fabricated tool for discharge Cylinder before fixing cover

Follow recommended
valve of 3rd stage torque values
3rd stage

RECOMMENDED TORQUE VALUES:-

1 1st stage suction /Discharge valves-460 NM

2 1st stage cylinder end cover- 1865 NM
3 2nd stage suction /discharge valves-400 NM
4 2nd stage cylinder end cover -635 NM
5 3rd stage suction /Discharge valves -690 NM
6 3rd stage cylinder end cover -1360 NM
7 Cross head topiston hydraulic nut -820 Bar.
8 Crosshead to piston flange -1000 NM.

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 QSGTL CMT RE Repair Report
Spare parts required:-

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 QSGTL CMT RE Repair Report

(QA/QC) Dimensions and Clearances Reports

Cylinder Liner bore Piston Dim.report Piston Rod Piston Rod Dim. Piston Top Clearance
Dim.Report 1 Report 2

Lessons learned:-
 Before starting that job confirm spading and gas testing.
 Valve glands should be marked to avoid confusion during assembly.
 Separate permit required for grating and hand rail removal to take out the pistons from
cylinders for stage1&stage2.
 Manual handling is a routine task in this job, so in TBT it required to mention manual
handling hazards.
 Different disciplines activities (inst.,RE,Scaffolding,AM)should be co-ordinate to avoid
Interfaces.
 People working under direct sun light in summer time without shading or cooling fan.
 Scaffolding team should be at site all the time.
 During opening 1st valve cover keep yourself away from the valve as you can to avoid any
trapped gases (H2S clip gave alarm during 1st stage valve cover removal).
 More scaffolding racks required to keep our tools and escape sets for work party.
 Good communication making the job more easier (Two IS mobile phone at site).
 Good management for spare parts required specially with changing scope of work.
 Team work behavior is a core reason for high quality and safety work (we did that).
 Review and read PTSW documents before starting the job.
 Protect the end covers eye bolt holes from weather condition (water/sand) for future jobs,
cover them or fill them with grease.
 Keep a wooden piece on the cross head bed during removing hydraulic nut and flange to
protect the CH bed in case of nut or flange falling.
 Lubricator pumps should be inspected regularly to insure Piston to Liner lubrication.

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