Revisione 6000h KB001C

g Nuovo Pignone S.p.A.
Nuovo Pignone
RECIPROCATING COMPRESSOR
FIELD
SERVICES
SERVICE REPORT
RECO/SER 0000
Service SHEET. 2 of 2
Via F. MATTEUCCI, 2
N.P. REF.:
50100 Firenze (Italy)
REC. /CO Tel. +39 055 423211
type.: Serial N° :
Telefax. +39 055 4232800 PLANT REF.:
By: Telex. 571320
Service date:
N° A B C D PHASE SERVICE PERIOD

INSPECTED FROM: 23/08/2010
ITEMS Y N TO: 28/08/2010
FORM N°
CUSTOMER:
32 * Hydraulic
ENI Tunisia test of prefabricated pipes SITE ADDRESS: OUED ZAR Tunisia RECO/ser 0032
33
PHONE N°: * Visual check certificate FAX N°: TELEX: RECO/ser 0033
PURCHASER
34 ORDER:
* Leak test on process gas system & primary N.P. JOB: ORIGINAL N.P. JOB:RECO/ser 0034
MACHINE TYPE:connections
Gemini E 604 SERIAL N°: 65F107 ITEM: 360 KB 001 C
STARTS:
35 * Loop check RUNNING HOURS: 6104 RECO/ser 0035
TYPE OF SERVICE: Medium Overhaul
36
SERVICE Ispection
BY: *Pietrini and test report
Luca SIGNATURE: RECO/ser 0036
PEOPLE MET ON SITE:
NAME
37 * Instrument calibration COMPANY TITLE RECO/ser 0037
Rami
38 Rached * Punch list ENI Tunisia Site Manager RECO/ser 0038
SERVICE SCOPE: EMERGENCY: [ ] SCHEDULED: [ X]
STANDSTILL: [ ]
MACHINE STATUS AT SITE ARRIVAL:
RUNNING: [ X ]
MEDIUM OVERHAUL: [ X ]
TYPE OF SERVICE: MAJOR OVERHAUL: [ ]
WITHOUT MACHINE OPENING: [ ]
STANDSTILL: [ ]
MACHINE STATUS AT SITE DEPARTURE:
RUNNING: [ ]
COMPLETED: [ X ]
SERVICE HAS TO BE CONSIDERED:
SUSPENDED: [ ]
INFORMATION: [ ]
CUSTOMER IS WAITING:
MATERIAL: [ ]
NO: [ ]
ENCLOSED REPAIR DATA FORMS:
YES: [ X ] N°
NOTE: A= 4.000 Hrs Overh. B= 8.000 Hrs Overh. C= Major Overh. D= Installation
CUSTOMER COMMENTS ( IF ANY ):
gNuovo Pignone INSPECTION AND TEST REPORT RECO/SER 0036
Serial N°: 65F107 Type: Gemini: E604 Item: KB001C Date: 28/08/2010
SCHEDULE
Involved Witness Review
Day 6
Nuovo Pignone Expected
Time
Client
Contractor Days 5
Performed
Third party Time
ITEM DESCRIPTION OF INSPECTION / TEST
KB001C In data odierna é terminata la manutenzione programmata delle 12000 ore.

Le operazioni effettuate sono quelle prescritte da Nuovo Pignone ed includono:
Attività svolte sul compressore Gemini:
1) Smontaggio pistone – testa a croce.

2) Ispezione camicie e controllo dimensionale.
3) Ispezione pattini testa a croce.
4) Controllo dimensionale asta pistone.
5) Smontaggio Slitte linee 2 e 4.
6) Sostituzione anelli tenuta pistone.
7) Sostituzione anelli pacchi premistoppa.
8) Sostituzione anelli tenuta coperchio separazione.
9) Smontaggio slitte da Incastellatura linee 1e 3.
10) Controllo tolleranze pattini testa a croce.
11) Controllo tolleranze tra pistone e cilindro.
12) Regolazione spazi nocivi.
13) Sostituzione valvole aspirazione e mandata.
14) Controllo serraggio incastellatura.
15) Controllo e serraggio supporti cilindri.
16) Ispezione e calibrazione pompa lubrificazione cilindri.
17) Sostituzione olio incastellatura e filtri.
18) Riassiemaggio tutte le Parti,
Vedere note pagina seguente:
End User Client Nuovo Pignone Third Party
Date/Signature: Date/Signature: Date/Signature:

Date/Signature: 28/08/2010
Pietrini Luca
SCHEDULE
Day 6
Time
Client
Contractor Days 5
Performed
Third party Time
ITEM DESCRIPTION OF INSPECTION
KB001C
REMARKS :
Foto smontaggio slitte per montaggio nuove su linee 2 e 4.
Foto smontaggio slitte per inserimento pasta siliconica su linee 1 e3.

Pietrini Luca
SCHEDULE
Day 6
Time
Client
Contractor Days 5
Performed
Third party Time
KB001C
REMARKS :
Foto delle 4 facce incastellatura.
Nella faccia accoppiamento, linea n°2 si è verificato la rottura di n° 1 tirante.

Pietrini Luca
SCHEDULE
Day 6
Time
Client
Contractor Days 5
Performed
Third party Time
KB001C
REMARKS :
Cilindi Nuovi presentano accoppiamento da 6" 900RF anzichè da 6" 600RF come necessario per montaggio
polmoni Aspirazione e Mandata. Per essere utilizzati devono essere modificati.

Date/Signature:28/08/2010
Pietrini Luca
SCHEDULE
Day 6
Time
Client
Contractor Days 5
Performed
Third party Time
KB001C
REMARKS :
Le Valvole di Mandata nuove sono state modificate per poter eseguire un corretto
montaggio.
SEGUE 4/8

Pietrini Luca
g Nuovo Pignone GENERAL INFORMATION RECO/SER 0001
SCOPE of WORK: Warranty [ ] Post Warranty [ ]
4.000 Hrs. Overh. [ ] 8.000 Hrs. Overh. [ ] Medium Overh. [ X ]
P= Scheduled [ X ] S= Emergency Service [ ]
RECIPROCATING COMPRESSOR
Type: Gemini Serial N°: E 604
Job: Item: 360 KB 001 C
CUSTOMER: ENI Tunisia
SITE: Oud Zar Tunisia
N.P. Job: Date: 28/08/2010
SERVICE TYPE of GAS

0701 Ammonia 0200 Air
0101 Ammonia Syntesis 0850 Ammonia
0810 Carbon Dioxide 1200 Charge Gas
0901 Air 1400 Carbon Dioxide
0530 Ethylene 1900 CO2 + NH3
0250 Gas Lift 2400 Ethylene
0205 Gas Recompression 3200 H2 + HC
0204 Gas Storage 3800 HC + H2S
0467 Hydrogen 2900 Hydrogen
0562 M.T.B.E. 4000 Methane
0462 L.P.G. 4600 N2
0469 Make Up X 5200 Natural Gas X
0130 Methanol Syntesis 5400 NH3
0203 Gas Pipeline 5800 O2
0241 Reinjection 6200 Propane
0400 Refineries
0468 Recycle
0441 F.C.C.
0821 Steam Compression ITEM COMPOSITION
0150 Syngas Type Job N° Serial N°
0160 Urea Syntesis Reciprocating Comp. E 604
0402 Vacum Distllation Motor Waukesha P9390GL
0170 Waste Gas
0770 Refrigerating
g Nuovo Pignone CYLINDER LINER RECO/SER 0008
Serial N°:Gemini E 604 Job N°: Drw. N°: Date: 28/08/2010
CYLINDER LINE n°: 1
Cylinder Liner Type: Free [ ] Shrinked [ X ]
Liner Nominal Diameter: mm 241,3
1 2 3
X
A B C D
Checked Cylinder Liner Serial N°: 89C2183 Replaced Cylinder Liner Serial N°:
Cylinder Liner Checked Cylinder Liner Replaced

Cyl. Liner CHECK DIAMITER Cyl. Liner CHECK DIAMITER
dimensional dimensional
A B C D A B C D
control area control area
1 242,15 242,20 242,20 242,15 1
2 242,15 242,20 242,20 242,20 2
3 242,15 242,15 242,15 242,15 3
Values express in mm Values express in mm
GEOMETRICAL CHECK Allow.ce Found Negative Allowance during Assembly: mm

Max. Wear (M)
Relative Wear (R)
Ovalization (P) X Value: mm
Lapping Yes [ ] No [ ]
EVENT 1 2 3 4 5 6
6700 Wear
4850 Scoring
1300 Damage
6000 Deposits
2700 Seizure
1100 Corrosion
1450 Deformation
1850 Erosion
0025 Overheating
P.S. Tick with X the items and relative EVENTS.

Line n°1 is the nearest to coupling side ( first on the right for SHMB )
Cylinder Liner Type: Free [ ] Shrinked [ X ]
1 2 3
X
A B C D

A B C D A B C D
1 242,20 242,20 242,20 242,20 1
2 242,20 242,20 242,20 242,20 2
3 242,20 242,20 242,20 242,20 3

Max. Wear (M)
Relative Wear (R)
EVENT 1 2 3 4 5 6
6700 Wear
4850 Scoring
1300 Damage
6000 Deposits
2700 Seizure
1100 Corrosion
1450 Deformation
1850 Erosion
0025 Overheating

Cylinder Liner Type: Free [ ] Shrinked [X]
1 2 3
X
A B C D

A B C D A B C D
1 242,15 242,15 242,15 242,15 1
2 242,20 242,15 242,15 242,15 2
3 242,15 242,15 242,15 242,15 3

Max. Wear (M)
Relative Wear (R)
EVENT 1 2 3 4 5 6
6700 Wear
4850 Scoring
1300 Damage
6000 Deposits
2700 Seizure
1100 Corrosion
1450 Deformation
1850 Erosion
0025 Overheating

Cylinder Liner Type: Free [ ] Shrinked [ X]
1 2 3
X
A B C D

A B C D A B C D
1 242,20 242,20 242,20 242,20 1
2 242,15 242,20 242,20 242,15 2
3 242,20 242,20 242,20 242,20 3

Max. Wear (M)
Relative Wear (R)
EVENT 1 2 3 4 5 6
6700 Wear
4850 Scoring
1300 Damage
6000 Deposits
2700 Seizure
1100 Corrosion
1450 Deformation
1850 Erosion
0025 Overheating

g Nuovo Pignone PISTON ROD RECO/SER 0006
L3 (Intermediate Paking)
L2 (LP)
L1 (HP)
V
L4 (Partition Cover/Scraper Oil) Control Area True Diam.
L1 85mm
L2 250mm
Nominal Diam. mm.:57,20 True Diam. mm.: L3 350mm
LINE 1 2 3 4 5 6
L1 V 57,18 57,18 57,18 57,18
O 57,18 57,18 57,18 57,18
L2 V 57,19 57,19 57,19 57,19
O 57,19 57,19 57,19 57,19
L3 V 57,19 57,19 57,19 57,19
O 57,18 57,18 57,18 57,18
L4 V 57,18 57,18 57,18 57,18
O 57,18 57,18 57,18 57,18
LINE 1 Replaced [ Y ] [ N ] LINE 4 Replaced [ Y ] [N]x

Chk. Piston Rod s.n.: Chk. Piston Rod s.n.:
New Piston Rod s.n.: New Piston Rod s.n.:
LINE 2 Replaced [ Y ] [ N ] x LINE 5 Replaced [ Y ] [N]
LINE 3 Replaced [ Y ] [ N ] x LINE 6 Replaced [ Y ] [N
NOTE:
A) Check the True diameter on the indicated control Area before to check the relative measure
B) Show the following distances : L1, L2, L3 and L4.
EVENT
1 2 3 4 5 6
6700 Wear
4850 Scoring
1300 Damage
2700 Seizure
1100 Corrosion
1450 Deformation
6000 Deposit
1850 Erosion
0025 Overheating

g Nuovo Pignone PISTON RIDER RING
PISTON RING RECO/SER 0007
T A C D N B
L R
TA TC
B
Piston Position related to the 4245 Piston Rider Ring 2465 Piston Rider Ring
Liner on Forward Position
LIN T B L R Teflon [X] Teflon []
1 2.50 2.20 2.40 2,40 Bronze [ ] Bronze [ ]
2 2.50 2.20 2.40 2,40 White Metal [ ] Cast Iron [ ]
3 2.50 2.20 2,40 2.40 Other [ ]
4 2.50 2.20 2,40 2.40
5 REPLACED REPLACED
6 Yes [ X ] No [ ] Yes [ ] No [ ]
CLEARANCE CHECKED
Line Piston Rider Ring Piston Ring
A TA B TB C TC D TD E TE F TF G TG H TH I TI L TL
1 0,20 2,2 0,20 2,2 0,20 2,2 0,20 2,2
2 0,20 0 0,20 0 0,20 2,2 0,20 2,2
3 0,20 2,2 0,20 2,2 0,20 2,2 0,20 2,2
4 0,20 0 0,20 0 0,20 2,2 0,20 2,2
5
6
NOTE:
aa) Show cat total measure with piston rider ring or piston ring in two half.
bb) Piston rider ring and piston ring position is given by progressive number starting from piston rod opposit
side.
EVENT Rr Rr Pr Pr Pr Pr Pr Pr
1 2 3 4 5 6 7 8
6700 Wear
4850 Scoring
1300 Damage
6000 Deposits

g Nuovo Pignone PISTON END CLEARANCE
PISTON ROD TORQUING TO CROSS HEAD RECO/SER 0009
Serial N°: E 604 Job N°: Drw. N°: Date: 28/08/2010
Valore di Spallamento albero a manovella rilevato: 1,30 mm.
FORWARD BACKWARD
END STROK PISTON CLEARANCE (mm)
LINE 1 2 3 4 5 6
FORWARD Specificat. 2,0-2,3 2,0-2,3 2,0-2,3 2,0-2,3
Checked 2,1 2,1 2,1 2,1
BACKWARD Specificat. 1,0-1,5 1,0-1,5 1,0-1,5 1,0-1,5
Checked 1,30 1,30 1,30 1,30
PISTON ROD TORQUING TO CROSSHEAD
LINE 1 2 3 4 5 6
Hydr. Tightening (Barg) - - - -
Wrench Tightening x x x x
g Nuovo Pignone PRESSURE PAKING SEALS RECO/SER 0004
STUFFING BOX DETAILS
G
X
A B
Picture n° 1 Picture n° 2
Picture n° 3 Picture n° 4
L CHECKED CLEARANCES (mm) SIDE VIEW A -B

I Pict. Pict.n° Pict.n° Pict. Pict. Pict. Pict. Pict. Pict.n°
N n°. 1 . 2 . 2 n°. 2 n°. 2 n°. 4 n°. n°. .
E Mat. Mat. Mat. Mat. Mat. Mat. Mat. Mat. Mat.
1 new0 0,05 new 0,15 new 0,15 new 0,15 new 0,15 new 0,35
2 new 0,15 new 0,15 new 0,15 new 0,15 new 0,15 new 0,35
5
6
EVENT
1 2 3 4 5 6 NOTE: If the pressure packing seals are more than 6
6700 Wear use another sheet.
4850 Scoring
1300 Damage
2700 Seizure
1100 Corrosion
1450 Deformation
6000 Deposit
1850 Erosion
0025 Overheating
g Nuovo Pignone PARTITION COVER RECO/SER 0011
OIL SIDE
G 1 tenuta G2 G3
olio tenuta tenuta
gas gas
OIL SIDE VIEW

L CHECKED CLEARANCES (mm)
I
N G 1 G 2 G3 G G G G G G
E Mat. Mat. Mat. Mat. Mat. Mat. Mat. Mat. Mat.
1 0,05 0,10 0,10
2 0,05 0,10 0,10
3 0,05 0,10 0,10
4 0,05 0,10 0,10
5
6
EVENT
1 2 3 4 5 6
6700 Wear
4850 Scoring
1300 Damage
2700 Seizure
1100 Corrosion
1450 Deformation
6000 Deposit
1850 Erosion
0025 Overheating
g Nuovo Pignone CROSSHEAD CLEARANCE RECO/SER 0018
Service SMALL END BUSH AXIAL CLEARANCE SHEET. 1 of 1
Serial N°:Gemini E 604 Job N°: Drw. N°: Date:28/08/2010
G
B F
A C
VALUE EXPRESSED IN MM
CYLINDER POSITION 1 2 3 4 5 6
A 0,45 0,45 0,45 0,45
CHECK
CLEARANCE G B 0,45 0,45 0,45 0,45
C 0,45 0,45 0,45 0,45
NOMINAL CLEARANCE MIN. 0,45 MAX ADMIS.

MAX 0,55 CLEARANCE
TAC N° 1 FLYWHEEL SIDE
SIDE CLEARANCE OF ROD "F"

WEBS
N° 1 2 3 4 5 6
NOTE:
CLEARANCE TAKEN ON:
A) IN BOARD
B) HALF STROKE
C) OUT BOARD
Line 1 is the nearest to coupling side (first on the right for SHMB)
g Nuovo Pignone REPLACED PART LIST RECO/SER 0025
REPLACED COMPONENTS
DESCRIPTION CODE N.P. ITEM CODE Q.TY REMARKS
Ring Packing KB 001C 10-PS-7521 4
Ring Packing 10-PS-6058 16

"
"
"
O-Ring 272-PS-2988 4
"
O-Ring 216-PS-2988 16
"
O-Ring A22 - 21007 4
"
Piston ring 2055-100067 16
"
Filter oil Balduin B99 4
"
O-ring end cyl. 448-PS-2987 4
"
CapSrew 488-PS-182 36
"
Suction valve 2-01-50478 8
"
Discharge valve 2-01-50479 8
"
Filter oil Balduin BT251 2
"
Crosshead Guide " 1-102506 2
O-ring " 450-3019 4
Gasket door " 1-026114 8
Capscrew " 124-PS-182 40
"
"
"
"
"
"
"
REMARKS: INSPECTED BY: Pietrini Luca

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Revisione 6000h KB001C

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g Nuovo Pignone S.p.A.

N° A B C D PHASE SERVICE PERIOD

SERVICE SCOPE: EMERGENCY: [ ] SCHEDULED: [ X]

TYPE OF SERVICE: MAJOR OVERHAUL: [ ]

WITHOUT MACHINE OPENING: [ ]

ITEM DESCRIPTION OF INSPECTION / TEST

KB001C In data odierna é terminata la manutenzione programmata delle 12000 ore.

1) Smontaggio pistone – testa a croce.

Vedere note pagina seguente:

End User Client Nuovo Pignone Third Party

Date/Signature: Date/Signature: Date/Signature:

ITEM DESCRIPTION OF INSPECTION

End User Client Nuovo Pignone Third Party

Date/Signature: Date/Signature: Date/Signature:

ITEM DESCRIPTION OF INSPECTION

End User Client Nuovo Pignone Third Party

Date/Signature: Date/Signature: Date/Signature:

ITEM DESCRIPTION OF INSPECTION

End User Client Nuovo Pignone Third Party

Date/Signature: Date/Signature: Date/Signature:

ITEM DESCRIPTION OF INSPECTION

End User Client Nuovo Pignone Third Party

Date/Signature: Date/Signature: Date/Signature:

SCOPE of WORK: Warranty [ ] Post Warranty [ ]

4.000 Hrs. Overh. [ ] 8.000 Hrs. Overh. [ ] Medium Overh. [ X ]

P= Scheduled [ X ] S= Emergency Service [ ]

Type: Gemini Serial N°: E 604

Job: Item: 360 KB 001 C

CUSTOMER: ENI Tunisia

SITE: Oud Zar Tunisia

N.P. Job: Date: 28/08/2010

SERVICE TYPE of GAS

CYLINDER LINE n°: 1

Cylinder Liner Type: Free [ ] Shrinked [ X ]

Liner Nominal Diameter: mm 241,3

Cylinder Liner Checked Cylinder Liner Replaced

GEOMETRICAL CHECK Allow.ce Found Negative Allowance during Assembly: mm

P.S. Tick with X the items and relative EVENTS.

CYLINDER LINE n°: 2

Cylinder Liner Type: Free [ ] Shrinked [ X ]

Liner Nominal Diameter: mm 241,3

Cylinder Liner Checked Cylinder Liner Replaced

GEOMETRICAL CHECK Allow.ce Found Negative Allowance during Assembly: mm

P.S. Tick with X the items and relative EVENTS.

CYLINDER LINE n°: 3

Cylinder Liner Type: Free [ ] Shrinked [X]

Liner Nominal Diameter: mm 241,3

Cylinder Liner Checked Cylinder Liner Replaced

GEOMETRICAL CHECK Allow.ce Found Negative Allowance during Assembly: mm

P.S. Tick with X the items and relative EVENTS.

CYLINDER LINE n°: 4

Cylinder Liner Type: Free [ ] Shrinked [ X]

Liner Nominal Diameter: mm 241,3

Cylinder Liner Checked Cylinder Liner Replaced

GEOMETRICAL CHECK Allow.ce Found Negative Allowance during Assembly: mm

P.S. Tick with X the items and relative EVENTS.

L4 (Partition Cover/Scraper Oil) Control Area True Diam.

LINE 1 Replaced [ Y ] [ N ] LINE 4 Replaced [ Y ] [N]x

P.S. Tick with X the items and relative EVENTS.

P.S. Tick with X the items and relative EVENTS.

Valore di Spallamento albero a manovella rilevato: 1,30 mm.

END STROK PISTON CLEARANCE (mm)

PISTON ROD TORQUING TO CROSSHEAD