Overhauling of LABYCompressor

Model No: 4D300B-3W_1; Sr. No: 1014

Tag: 33-KR-301
Day

Sl. No.
Activity

1 Stop the compressor and purge the compressor with nitrogen.

2 Electrical isolation (LOTO) of main motor and AOP motor.
3 Blinding of process lines and utility lines.
4 Removal of instruments like Temperature probes, Vibration probes etc.
Removal of firefighting lines and other lines above compressor to get access for using EOT crane to remove
5
pistons and cylinders.
6 Cleaning of compressor outer surface
7 Opening of all side covers of the compressor
Removal of all connecting lines including jacket water lines, leak gas line, purge gas line, vent gas line and
8
tubing’s connecting suction valve unloaders etc.

9 Draining of the lube oil from crank case.

10 Recording of crank shaft web deflection for all the webs.

11 Removal of suction and discharge valves of all stages.

12 Recording piston TDC (Top Dead Center) and BDC (Bottom Dead Center) clearances for all cylinders.

13 Opening of cylinder end covers and checking of radial clearance of labyrinths with the cylinder.
Inspection of suction valve un-loaders for proper functioning. If required servicing of un-loaders to be carried
14
out.
15 Removal of piston rod lock nuts and pulling out piston assemblies one by one.
16 Cleaning of piston assemblies.
17 Visual inspection and dimensional inspection of piston rods and pistons.

18 Recording of piston pre-tension and required to do rework, if necessary.

19 Removal of gas packing leak gas line and guide bearing cooling water line. Hydrotest of cooling water lines.

Removal of rod packing elements, scrapper rings. Cleaning and inspection of the rings. New packing
20
elements and scrapper rings shall be installed during assembly if required.

21 Recording of connecting rod big end bearing clearances and cross head pin bush bearing clearances.

Removal of Connecting Rod big end bearings one by one, cleaning, inspection, dimensional checks and to
22 carryout NDT. After inspection of the bearings, same bearings shall be assembled if found fit for reuse or
else new bearings shall be installed.
Cleaning, inspection, dimensional checks and to carryout NDT of crosshead pin bearings and crosshead
23 pins one by one. After inspection, same pins and bearings shall be assembled if found fit for reuse or else
new pins and bearings shall be installed.

Cleaning, inspection, dimensional checks and to carryout NDT of guide bearings one by one. After
24
inspection, same bearings shall be used if found fit for reuse or else new bearings shall be installed.

Removal of crank shaft main bearing one by one, cleaning, inspection, dimensional checks and to carryout
25 NDT. After inspection of the bearings, same bearings shall be assembled if found fit for reuse or else new
bearings shall be installed.

Carryout Non-Destructive Tests (NDT) as per the Annexure-1 provided. After inspection and NDT checks,
26
same piston rods shall be reused if found fit for re use or else new piston rods shall be installed.

27 Cleaning of all cylinders.

28 Recording of cylinder bore dimensions for all cylinders.
29 Removal and cleaning of gas suction strainer.
 Cleaning of compressor crank case internal. Removal and cleaning of suction strainers of Main oil pump
30
(MOP) and Auxiliary lube oil pump (AOP). Re-install the strainers after cleaning.
31 Check coupling condition of Main oil pump. Use new coupling if required. Install MOP.
32 Installation of rod packing elements, scrapper rings.
33 Installation of gas packing leak gas line and guide bearing cooling water lines.
34 Assembly of Piston rods one by one.
35 Recording of TDC and BDC clearance after piston assembly.
36 Recording of radial clearances of piston labyrinths with cylinders.
37 Recording of crank shaft web deflection for all webs.
38 Removal and cleaning if Raschig filters (if applicable)
39 Fixing back the removed pipes of cooling water, leak gas, purge gas and vent gas.
Charging the cooling water and checking for any leaks inside the compressor. If any leak is observed, same
40
shall be arrested.
41 De-couple the motor. Remove flywheel. Replace shaft seal. Re-install flywheel.
42 Measure alignment and correct if required. Couple main motor.
43 Final cleaning of compressor crankcase.
44 Filling of fresh lube oil into the crank case.
45 Install bearing temperature probes and compressor vibration probes.
46 Fixing back all side covers of different compartment of the compressor.
47 Remove LOTO of main motor and AOP motor.
48 Carry out No Load Mechanical Run Test (NLMRT) of compressor.
49 Installation of suction and discharge valves.
50 Fixing back the removed tubing connections of the valves.
51 Carryout “running in of piston” if piston skirt is replaced.
52 Inspection of valve chambers after running-in
53 Leakage checking of the compressor with nitrogen. If any leakage is found, same shall be arrested.

Trial run of the compressor with process gas at 50% and 100% loads and to record all operating data
54
including the vibration readings.
Analysis of the machine parameters and process parameters to review the pre post overhaul healthiness of
55
the compressor.

Need to check cooling water flow for gas cooler and gas temperature to be record in various conditions as
mentioned below:
56 1. When the CW return valve for gas cooler fully open Gas temperature is ____?&Cooling water Flow___?
2. When the CW return valve for gas cooler throttle or crack open Gas temperature shall be as per data
sheet what is the Cooling water Flow___? *to measure the CW flow OPaL to arrange necessary instruments

Verify the site condition for implementation of BC solution to avoid low gas temperature outlet of gas cooler.
57
*required to refer BC offer for the solution

58 Handing over the machine for operations for continuous run.

Note:
1. Above mention days are tentative. It may change based on availability of Work Permit, EOT crane, Scafoldings, Workshop facilities, Sp
2. All spares to be arranged at site according to the spares list.
3. This schedule have been prepared considering 24 hours / Day
4. All special tools should be available at site.
5. 04 nos Flood light and 06 nos Hand lamp to be provided at site.
6. Approx. 40 litre Cleaning agent like acetone or naphtha or equivalent to be provided at site.
7. Compressor surrounding area should be free for use.
8. Wooden Planks to be provided at site for resting accessories.
9. Rubber sheet or old gasket sheet to be provided.
10. Removal, installation and calibration of instruments to be done by customer in parallel to other activities.
ng of LABYCompressor

300B-3W_1; Sr. No: 101494;

Tag: 33-KR-301
Day 0

Day 1

Day 2

Day 3

Day 4

Day 5

Day 6

Day 7

Day 8
Remarks

To be completed before site

handover to BCIN engineer.
Scafolding to be prepared arround
the compressor.

Client to ensure proper disposal of

drained oil.

Unloader servicing depends on

availability of spares

Client to provide workshop facility in

case of re-work

Client to arrange hydrotest.

In case of bearing replacement,

Client to arrange hydraulic press for
bearing removal and liquide N2 / Dry
Ice for bearing installation
 Client instrumentation team

Clent

Sufficient flow of nitrogen is required

for running-in

OPaL MOC related to check point

foldings, Workshop facilities, Special tools and Spares.

es.
 CR3 Manpower Required

Manpower Day Shift Night Shift

MWF 2 2
Fitter 2 2
Rigger 4 8
Helper 3 4
Forman 1 1
 Overhauling of LABYCompr

Model No: 4K165-1C_1

Sr. No: 101493; Tag: 33-KR

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Note:
1. Above mention days are tentative. It may change based on availability of Work Permit, EOT crane, Scafoldings, Workshop
2. All spares to be arranged at site according to the spares list.
3. This schedule have been prepared considering 24 hours / Day
4. All special tools should be available at site.
5. 04 nos Flood light and 06 nos Hand lamp to be provided at site.
6. Approx. 40 litre Cleaning agent like acetone or naphtha or equivalent to be provided at site.
7. Compressor surrounding area should be free for use.
8. Wooden Planks to be provided at site for resting accessories.
9. Rubber sheet or old gasket sheet to be provided.
 Overhauling of LABYCompressor

Model No: 4K165-1C_1;

Sr. No: 101493; Tag: 33-KR-241

Day
Activity

Stop the compressor and purge the compressor with nitrogen.

Electrical isolation (LOTO) of main motor and AOP motor.

Blinding of process lines and utility lines.

Removal of instruments like Temperature probes, Vibration probes etc.

Removal of firefighting lines and other lines above compressor to get access for using EOT crane
to remove pistons and cylinders.

Cleaning of compressor outer surface

Opening of all side covers of the compressor

Removal of all connecting lines including jacket water lines, leak gas line, purge gas line, vent gas line and
tubing’s connecting suction valve unloaders etc.

Measure and record the Flow orifices ID installed to Purge inlet, Packing leak to suction line

Draining of the lube oil from crank case. *Send the lube oil for oil sample analysis test

Recording of crank shaft web deflection for all the webs.

Removal of suction and discharge valves of all stages. *Need to install click poppet design valves,
Check for availability

Recording piston TDC (Top Dead Center) and BDC (Bottom Dead Center) clearances for all cylinders.

Opening of cylinder end covers and checking of radial clearance of labyrinths with the cylinder.

Inspection of suction valve un-loaders for proper functioning. If required servicing of un-loaders to be carried
out.

Removal of piston rod lock nuts and pulling out piston assemblies one by one.
Cleaning of piston assemblies.

Visual inspection and dimensional inspection of piston rods and pistons.

Recording of piston pre-tension (if required) and required to do machining, if necessary.

Hydrotest of cooling water lines.

Removal of rod packing elements, scrapper rings. Cleaning and inspection of the rings. New
packing elements and scrapper rings shall be installed during assembly if required.

Recording of connecting rod big end bearing clearances and cross head pin bush bearing clearances.

Recording of all main bearing clearances.

Carryout Non-Destructive Tests (NDT) as per the Annexure-1 provided. After inspection and NDT checks,
same piston rods shall be reused if found fit for re use or else new piston rods shall be installed.

Cleaning of all cylinders.

Recording of cylinder bore dimensions for all cylinders (in case of major wear).

Removal and cleaning of gas suction strainer.

Cleaning & inspection of rasching filter assembly, ensure NRV direction as open to distance piece and
remove the NRV internal spring.

Cleaning of compressor crank case internal. Removal and cleaning of suction strainers of Main oil pump
(MOP) and Auxiliary lube oil pump (AOP). Re-install the strainers after cleaning.

Check coupling condition of Main oil pump. Use new coupling if required. Install MOP.

Installation of rod packing elements, scrapper rings.

Installation of gas packing leak gas line and guide bearing cooling watre lines.

Assembly of Piston rods one by one.

Recording of TDC and BDC clearance after piston assembly.

Recording of radial clearances of piston labyrinths with cylinders.

Recording of crank shaft web deflection for all webs.

 Removal and cleaning if Raschig filters (if applicable)

Fixing back the removed pipes of cooling water, leak gas, purge gas and vent gas.

Charging the cooling water and checking for any leaks inside the compressor. If any leak is observed, same
shall be arrested.

In case of shaft seal leakage, De-couple the motor. Remove flywheel. Replace shaft seal. Re-install flywheel.

Measure aligment and correct if required. Couple main motor.

Check provision for installation of TCV in lube oil skid. Opal to plan to estimate work plan for TCV execution
in next opportunity

Final cleaning of compressor crankcase.

Filling of fresh lube oil into the crank case.

Install bearing temperature probes and compressor vibration probes.

Fixing back all side covers of different compartment of the compressor.

Remove LOTO of main motor and AOP motor.

Carry out No Load Mechanical Run Test (NLMRT) of compressor.

Installation of suction and discharge valves.

Fixing back the removed tubing connections of the valves.

Carryout “running in of piston” if piston skirt is replaced.

Leakage checking of the compressor with nitrogen. If any leakage is found, same shall be arrested.

Trial run of the compressor with process gas at 50% and 100% loads and to record all operating
data including the vibration readings.

Analysis of the machine parameters and process parameters to review the pre post overhaul healthiness of
the compressor.

Handing over the machine for operations for continuous run.

Note:
1. Above mention days are tentative. It may change based on availability of Work Permit, EOT crane, Scafoldings, Workshop facilities
2. All spares to be arranged at site according to the spares list.
3. This schedule have been prepared considering 24 hours / Day
4. All special tools should be available at site.
5. 04 nos Flood light and 06 nos Hand lamp to be provided at site.
6. Approx. 40 litre Cleaning agent like acetone or naphtha or equivalent to be provided at site.
7. Compressor surrounding area should be free for use.
8. Wooden Planks to be provided at site for resting accessories.
9. Rubber sheet or old gasket sheet to be provided.
 of LABYCompressor

No: 4K165-1C_1;
493; Tag: 33-KR-241

Remarks
Day 0

Day 1

Day 2

Day 3

Day 4

Day 5
To be completed before site
handover to BCIN engineer.
Scafolding to be prepared arround
the compressor.

Client to ensure proper disposal of

drained oil.

Unloader servicing depends on

availability of spares
Client to provide workshop facility
in case of machining

Client to arrange hydrotest.

Client to provide NDT test

 It requires additional 6 - 8 hours

Client instrumentation team

Clent

Sufficient flow of nitrogen is

required for running-in

oldings, Workshop facilities, Special tools and Spares.

 CR3 Manpower Required

Manpower Day Shift Night Shift

MWF 3 3

Fitter 8 6

Rigger 8 6

Helper 6 6

Forman 1 1