DISASSEMBLY DISASSEMBLY. - Aux. piping removal - Instrument work such as probes removal, RTD connector removal, etc. - Rotor shipping lock

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1 DIS - Aux. piping removal - Instrument work such as probes removal, RTD connector removal, etc. - Rotor shipping lock - Coupling lock nut removal. Special tool: Face spanner (Figure 7) - Coupling hub depth measurement - Coupling hub removal Special tool: Hydraulic installation kit (Figure 1) DESIGN Piston Pressure = 496bar Hub Pressure = 186.9Mpa or 1869bar ACTUAL Piston Pressure = Hub Pressure = PAGE 1 DIS DE - Upper bearing housing removal. - Shaft end seal clearance check: DESIGN (radial) = mm - Journal bearing clearance check DESIGN (diametral) = mm - Journal bearing removal - Lower bearing housing removal Special tool: Jacking studs (Figure 5) Special tool: Guide rod (Figure 8) - Barrier seal removal is in following sequence: - Remove Item#38 (socket cap screw) - Remove Item#37 (thrust split ring) - Remove Item#34 (socket cap screw) - Assemble barrier seal installation plate Special tool: T83 Installation plate PAGE 2

2 DIS - Barrier seal removal (continue): Special tool: Gas seal fixture - Remove barrier seal - DGS removal is in following sequence: - DGS depth = - DGS removal is in following sequence; - Remove Item#31 (o-ring) - Remove Item#30 (thrust split ring) - Assemble DGS installation plate Special tool: T28 Installation plate Special tool: Gas seal fixture - Remove DGS - Buffer labyrinth seal depth check = - Buffer labyrinth seal clearance check: DESIGN (diametral) = mm - Buffer labyrinth seal removal PAGE 3 DIS NDE - End cover removal - Upper bearing housing removal - Thrust bearing removal - Thrust disk locknut removal Special tool: Adjustable face spanner (Figure 6) - Thrust disk lockwasher removal. - Thrust collar removal Special tool: Thrust disk pusher (Figure 3) DESIGN (Piston Pressure = 620bar) Thrust Disk Pressure = 75.8Mpa or 773bar Special tool: Pressure relief valve, etc. (Figure 4) - Journal bearing clearance check DESIGN (diametral) = mm - Journal bearing removal - Lower bearing housing removal Special tool: Jacking studs (Figure 5) PAGE 4

3 DIS Special tool: Guide rod (Figure 8) - Barrier seal removal is in following sequence: - Remove Item#38 (socket cap screw) - Remove Item#37 (thrust split ring) - Remove Item#34 (socket cap screw) - Assemble barrier seal installation plate Special tool: T83 Installation plate Special tool: Gas seal fixture - Remove barrier seal - Set up dial gauge on DE for axial movement - DGS removal is in following sequence: - DGS depth = - Remove Item#31 (o-ring) - Remove Item#30 (thrust split ring) - Assemble DGS installation plate Special tool: T28 Installation plate Special tool: Gas seal fixture PAGE 5 DIS - DGS removal is in following sequence (continue): - Remove DGS - Buffer labyrinth seal depth check = - Buffer labyrinth seal clearance check: DESIGN (diametral) = mm - Buffer labyrinth seal removal PAGE 6

4 DIS - Compressor stud bolts removal NOTE: Reaction torquing device is not recommended such as hydro-torque - Release splitline pull up - Jack in endwall of a min. of 3mm clearance - Installation of dummy seal - Tighten the fixture tabs into the 2nd annulus of the seal housing - Adjust the endwall position axially until the fixture tabs can be tightened into the shaft annulus - Removal of top endwall jack bolt x2 - Installation of casing guide rods x2 - Top casing removal - Top balance piston seal removal - Balance piston seal clearance check DESIGN (radial) = mm - Impeller seal clearance check 1st Stg DESIGN (radial) = mm 1st Stg PAGE 7 DIS - Impeller seal clearance check (continue) 2nd Stg DESIGN (radial) = mm 2nd Stg PAGE 8 4th Stg DESIGN (radial) = mm 4th Stg 5th Stg DESIGN (radial) = mm 5th Stg 7th Stg DESIGN (radial) = mm 7th Stg 8th Stg DESIGN (radial) = mm 8th Stg - Shaft seal clearance check 2nd Stg DESIGN (radial) = mm 2nd Stg

5 DIS - Shaft seal clearance check (continue) 3rd Stg DESIGN (radial) = mm 3rd Stg 5th Stg DESIGN (radial) = mm 5th Stg PAGE 9 6th Stg DESIGN (radial) = mm 6th Stg 8th Stg DESIGN (radial) = mm 8th Stg - Removal of bottom endwall jack bolt x2 - Removal of splitline pull up x2 - Assemble hoist rings onto both endwalls (Figure 9) - Rotor removal, along with endwalls - Lower diaphgrams removal CLEANING - Lower casing cleaning - Lower diaphragms cleaning - DE bearing housing cleaning - NDE bearing housing cleaning - Rotor cleaning - DE endwall cleaning - NDE endwall cleaning - DE endwall blow out - NDE endwall blow out - DE DGS cleaning (NOT UNDER ELLIOTT SV SUPERVISION) - NDE DGS cleaning (NOT UNDER ELLIOTT SV SUPERVISION) PAGE 10 - Transfer all necessary spare parts to Oxygen Plant - DE journal bearing PT check - NDE journal bearing PT check - Outboard thrust bearing PT check - Inboard thrust bearing PT check

6 - Lower diaphragms installation - Diaphragms butt check DESIGN = ±0.05MM ACTUAL LEFT RIGHT STAGE#1 STAGE#2 STAGE#3 STAGE#4 STAGE#5 STAGE#6 STAGE#7 STAGE#8 DISCHARGE VOLUTE PAGE 11 - Diffuser width check DESIGN ACTUAL STAGE#1-#2 STAGE#2-#3 STAGE#4-#5 STAGE#5-#6 STAGE#7-#8 STAGE#8-DV - Replace enwall o-rings (P/N=P700D506 x4) - Assemble hoist rings onto both endwalls (Figure 9) - Rotor installation, along with endwalls - Rotor centering - Dummy seal removal (NDE) - Installation of bottom endwall jack bolts x2 - Installation of splitline pull up x2 - Jack out of endwalls (DE& NDE) - Balance piston seal clearance check DESIGN (radial) = mm PAGE 12

7 - Impeller seal clearance check 1st Stg DESIGN (radial) = mm 1st Stg PAGE 13 2nd Stg DESIGN (radial) = mm 2nd Stg 4th Stg DESIGN (radial) = mm 4th Stg 5th Stg DESIGN (radial) = mm 5th Stg 7th Stg DESIGN (radial) = mm 7th Stg 8th Stg DESIGN (radial) = mm 8th Stg - Shaft seal clearance check 2nd Stg DESIGN (radial) = mm 2nd Stg PAGE 14 3rd Stg DESIGN (radial) = mm 3rd Stg 5th Stg DESIGN (radial) = mm 5th Stg 6th Stg DESIGN (radial) = mm 6th Stg 8th Stg DESIGN (radial) = mm 8th Stg - Lower bearing housing assembly (DE) - Journal bearing assembly (DE)

8 - Lower bearing housing assembly (NDE) - Thrust bearing assembly - Journal bearing assembly (NDE) - Thrust float check. Adjust if necessary DESIGN = mm - Thrust bearing disassembly - Journal bearing clearance check. DESIGN (diametral) = mm ACTUAL (NDE) = ACTUAL (DE) = - Journal bearing disassembly (NDE) - Lower bearing housing disassembly (NDE) - Journal bearing disassembly (DE) - Lower bearing housing disassembly (DE) - Jack in of endwalls (approx. 3mm) - Use splitline pull up to hold endwalls perpendicularly. - Installation of casing guide rods x2 - Replace all sealing strips - Reverse casing stud bolts stoppers to inverted 'U' PAGE 15 - Compressor stud bolts installation - Hand tight casing stud bolt nuts - Reverse back casing stud bolts stoppers to 'U' - Apply Silastic on compressor split surface - Top casing installation - Installation of top endwall jack bolt x2 - Jack both endwalls outward until in contact with casing - Compressor stud bolts torquing in sequence PRE-TORQUE = 508.4Nm ANGLE OF TURN = 189 EFFECTIVE TORQUE = Nm - Buffer labyrinth seal installation using fixture/jig - Buffer labyrinth seal depth check (NDE) = - Buffer labyrinth seal depth check (DE) = - Buffer labyrinth seal clearance check: DESIGN (diametral) = mm ACTUAL (NDE) = ACTUAL (DE) = PAGE 16

9 NDE - Dry gas seal mechanical distance check DESIGN = 39.62±0.76mm - Exercising dry gas seal - O-rings replacement; if necessary - Installation plate assembly - DGS length measurement; from the inside face to the installation plate surface - Measure the same distance from buffer labyrinth seal and mark on the housing - Draw center line from anti-rotational pin on the shaft - Draw center line on the dry gas seal - Check full rotor lift = - Rotor lock on DE - Setup dial gauge on DE - DGS assembly is in following sequence: - Assemble DGS onto mounting fixture, with bevel nuts on top & bottom (For centering purpose) - Install guide rods to the endwall - Rotor centering PAGE 17 - DGS assembly is in following sequence (continue): - Install DGS - Stop jacking when the marking is reached. PRE- DISTANCE = POST- DISTANCE = - Disassemble installation plate - Install Item#30 (thrust split ring) - Install Item#31 (o-ring) - Barrier seal assembly is in following sequence: - Assemble barrier seal installation plate Special tool: T83 Installation plate Special tool: Gas seal fixture - Install barrier seal - Disassemble installation plate - Install Item#34 (socket cap screw) - Install Item#37 (thrust split ring) - Install Item#38 (socket cap screw) PAGE 18

10 - Apply Silastic RTV to lower bearing housing - Lower bearing housing installation Special tool: Guide rod (Figure 8) - Journal bearing installation - Install thrust disk key - Install inner oil seal ring - Install adapter to thrust disk (MAKE SURE IT DOES NOT GO THROUGH) Special tool: Pressure relief valve, etc. (Figure 4) - O-ring replacement for thrust disk (P/N: ) - Backup ring replacement for thrust disk (P/N: ) - Thrust collar installation Special tool: Thrust disk pusher (Figure 3) DESIGN Thrust Disk Pressure = 75.8Mpa or 773bar Piston Pressure = 620bar ACTUAL Thrust Disk Pressure = Piston Pressure = - Thrust disk lockwasher installation. PAGE 19 - Thrust disk locknut assembly Special tool: Adjustable face spanner (Figure 6) - Thrust bearing installation - Thrust bearing cover installation - Arrange all cables - Apply Silastic RTV to upper bearing housing - Upper bearing housing installation - Apply Silastic RTV to end cover - End cover installation PAGE 20

11 DE - Dry gas seal mechanical distance check DESIGN = 39.62±0.76mm - Exercising dry gas seal - O-rings replacement; if necessary - Installation plate assembly - DGS length measurement; from the inside face to the installation plate surface - Measure the same distance from buffer labyrinth seal and mark on the housing - Draw center line from anti-rotational pin on the shaft - Draw center line on the dry gas seal - Check full rotor lift = - Rotor lock on DE - Setup dial gauge on DE - DGS assembly is in following sequence: - Assemble DGS onto mounting fixture, with bevel nuts on top & bottom (For centering purpose) - Install guide rods to the endwall - Rotor centering PAGE 21 - DGS assembly is in following sequence (continue): - Install DGS - Stop jacking when the marking is reached. PRE- DISTANCE = POST- DISTANCE = - Disassemble installation plate - Install Item#30 (thrust split ring) - Install Item#31 (o-ring) - Barrier seal assembly is in following sequence: - Assemble barrier seal installation plate Special tool: T83 Installation plate Special tool: Gas seal fixture - Install barrier seal - Disassemble installation plate - Install Item#34 (socket cap screw) - Install Item#37 (thrust split ring) - Install Item#38 (socket cap screw) PAGE 22

12 - Apply Silastic RTV to lower bearing housing - Lower bearing housing installation Special tool: Guide rod (Figure 8) - Journal bearing installation - Arrange all cables - Coupling hub contact check - ACTUAL CONTACT AREA = % - O-ring replacement for coupling hub (P/N: ) - Backup ring replacement for coupling hub (P/N: ) - Coupling hub installation Special tool: Hydraulic installation kit (Figure 1) DESIGN Piston Pressure = 496bar Hub Pressure = 186.9Mpa or 1869bar ACTUAL Piston Pressure = Hub Pressure = - Coupling hub depth measurement DESIGN PULL UP = mm ACTUAL PULL UP = PAGE 23 - Apply Silastic RTV to upper bearing housing - Upper bearing housing installation - Apply Silastic RTV to end cover - End cover installation PAGE 24 - Shipping lock installation - Shipping lock removal after compressor moved to the site - Coupling lock nut installation Special tool: Face spanner (Figure 7)