IL 5 - 10 Ed.

: 21/11/2007
SLIDE VALVE INSPECTION/REPLACEMENTS Page 1 of 8
Prepared: Released Language: Revision: File No.:
A. Wernsing / 2007-11-21 R. Ferretti / 2007-11-22 en - IL 5-10_-_en.DOC

Document Type: Work Instruction

Product-Range: Gas compressor
Product: GHH Rand
Scope of Application: 05 Commissioning

SLIDE VALVE INSPECTION/REPLACEMENT

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without
express authority is strictly forbidden. © ENERPROJECT 2008
 IL 5 - 10 Ed.: 21/11/2007
SLIDE VALVE INPSECTION/REPLACEMENTS Page 2 of 8

1. TABLE of CONTENT
1. TABLE of CONTENT ....................................................................................................... 2
2. GENERAL DESCRIPTION ............................................................................................... 3
2.1. Purpose ...................................................................................................................................................... 3
2.2. Validity ........................................................................................................................................................ 3
2.3. Conditions .................................................................................................................................................. 3
2.4. General ....................................................................................................................................................... 3
2.5. Introduction ............................................................................................................................................... 4
2.6. Acceptance ................................................................................................................................................ 4
2.7. Expressions ............................................................................................................................................... 4
3. WORK TO BE CARRIED OUT ......................................................................................... 5
3.1. Criteria for Repair ...................................................................................................................................... 5
3.1.1 Piston seal of piston flange: ................................................................................................................................... 5
3.2. Dismantling ................................................................................................................................................ 5
3.2.1 Removal of piston seal from piston flange: ........................................................................................................... 5
3.3. Assembly ................................................................................................................................................... 8
4. TIGHTENING TORQUES FOR SCREW AND NUTS ....................................................... 8

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without
express authority is strictly forbidden. © ENERPROJECT 2008
 IL 5 - 10 Ed.: 21/11/2007
SLIDE VALVE INPSECTION/REPLACEMENTS Page 3 of 8

2. GENERAL DESCRIPTION

2.1. Purpose

This procedure is a general guide for the responsible commissioning engineer to adhere
while commissioning GHH compressors.

2.2. Validity

The procedure is applicable to GHH compressors.

The adjustments and the operation must be in accordance with the manufacturer's
instructions and data.

2.3. Conditions

The user of this procedure should be knowledgeable in commissioning aspects of gas

compressors.

2.4. General

¾ Apart from technicians authorized by the manufacturer, repair work on the screwcompressor
may only be undertaken by skilled operating personnel or qualified technicians in compliance
with these safety instructions.
¾ Before commencing any repair work the screw compressor unit must be put out of operation
according to the operating instructions, all refrigerant removed and the unit depressurized.
¾ Preparations for maintenance work on the compressor are to be undertaken in such a manner
that it is only necessary for the machine to be open for a short period.
¾ The sealing and locking devices which have become accessible must be renewed.
¾ Utmost cleanliness during assembly is absolutely essential for continued trouble-free
operation.
¾ After maintenance and repair work has been carried out, the parts must be cleaned with an
organically degreasing agent and treated with the refrigerating machinery lube oil of the same
brand used in the plant.
¾ Instructions for prolonged shutdown periods:
¾ When the compressor is shut down for a long period of time (longer than one week), the
following is recommended:
ƒ Close the shut-off valves on the suction and the discharge side of the screw-compressor
unit.
ƒ Turn the coupling of the compressor by one eighth of a shaft turn every four weeks.
¾ When the compressor is to be stored separately, it must be filled with dry nitrogen after it has
been evacuated (0.5 bar excess pressure).

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without
express authority is strictly forbidden. © ENERPROJECT 2008
 IL 5 - 10 Ed.: 21/11/2007
SLIDE VALVE INPSECTION/REPLACEMENTS Page 4 of 8

2.5. Introduction

The screw-compressor can remain connected to the unit during the maintenance and repair
operations described here since subassemblies are only partially disassembled.
Repair of the compressor when completely disassembled requires specific technological
prerequisites and is therefore not described here.
We recommend the operator of the compressor to ensure that maintenance and repair work is
carried out according to the time schedules specified.
Take a look at tightening torques defined in the table in (Table 1).

2.6. Acceptance

¾ Acceptance shall be in accordance with the tolerances and requirements of the applicable
drawings, specifications, codes and standards.

¾ Any results outside the established tolerances shall be reported as a non-conformance and be
the subject of a disposition by the appropriate project authorities.

2.7. Expressions

¾ The expression General Flow Diagram and P&ID (Piping and Instrumentation Diagram) are
synonymous. In this procedure the term P&ID is always used.

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without
express authority is strictly forbidden. © ENERPROJECT 2008
 IL 5 - 10 Ed.: 21/11/2007
SLIDE VALVE INPSECTION/REPLACEMENTS Page 5 of 8

3. WORK TO BE CARRIED OUT

3.1. Criteria for Repair

In case of problems with the capacity control device / Vi adjusting device assembly, first
check if the oil supply system the compressor (solenoid valves, filters) is operating correctly.
If it does, repair will be necessary if the following criteria apply:

3.1.1 Piston seal of piston flange:

¾ The primary slide does not move towards its partial load position.
¾ Under manual setting, the primary slide moves spontaneously towards its full load position.

3.2. Dismantling

3.2.1 Removal of piston seal from piston flange:

a) Set the slide to its maximum position.

b) Drain oil from suction casing through screwed drain plug.
c) Loosen screws to remove the cover.(see picture 1 and 2)

Picture 1. Removal of cover

Picture 2.
d) Loosen the locking nut with a special tool. (see picture 3 and 4)

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express authority is strictly forbidden. © ENERPROJECT 2008
 IL 5 - 10 Ed.: 21/11/2007
SLIDE VALVE INPSECTION/REPLACEMENTS Page 6 of 8

Picture 3. Removal of locking nut

Picture 4. Special tool for removing locking nut

e) After the locking nut is been removed, screw to bolts in the locking plate and pull it
out of the cylinder
f) Loosen screws to remove the main cover.(see picture 5)

Picture 5. Loose the bolt from the main cover

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express authority is strictly forbidden. © ENERPROJECT 2008
 IL 5 - 10 Ed.: 21/11/2007
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g) Slide the cover slowly backwards. Till the piston is completely out of the casing (see
picture 6 and 7)

Picture 6. Removal of cover

Picture 7. Cover
h) Slowly pull by hand the slide out of the cylinder (see picture 8)

Picture 8. Removal of slide

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express authority is strictly forbidden. © ENERPROJECT 2008
 IL 5 - 10 Ed.: 21/11/2007
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i) Check the internal for any dirt and / or oxidation.

The inner parts must be cleaned with an organically degreasing agent and treated
with the refrigerating machinery lube oil of the same brand used in the compressor.
Oxidation should be removed with soft grounding paper made wet with oil

3.3. Assembly

a) Re-install the slide piston and push it completely to the back

b) Re-install the main caver and tight the bolts with the torque given in Table 1
c) Push the locking plate back into the cylinder and lock it with the locking nut
d) Re-install the cover and tight the bolt with the torque given in Table 1

4. TIGHTENING TORQUES FOR SCREW AND NUTS

Part component/ subassembly Tightening Torques (Nm)
Type
Screw Cover for shaft seal 60+20 150+20 150+20 150+20 150+20 250+20
Screw Cover for capacity control 60+20 150+20 150+20 150+20 150+20 250+20
Grooved
Piston rod capacity control 100+20 100+20 100+20 100+20 100+20 100+20
nut
Clamping
Position sensor 3+1 3+1 3+1 3+1 3+1 3+1
screw
Screw Cover plate (axial bearings) 150+20 150+20 150+20 150+20 150+20
Grooved
Axial bearings male rotor 400+100 500+100 500+100 1000+100 1500+100 1600+100
nut
Grooved
Axial bearings female rotor 400+100 400+100 500+100 600+100 1100+100 1200+100
nut
Male rotor 40+10 70+10 70+10 70+10 120+20 120+20
Clamping plate
Screw
axial bearings Female rotor 40+10 40+10 70+10 70+10 120+20 120+20

Table 1. Tightening Torques

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without
express authority is strictly forbidden. © ENERPROJECT 2008