Overhauling a centrifugal compressor, particularly the BCL type, involves a detailed and systematic process to ensure the compressor is restored to optimal operating condition. Below is a general procedure for a complete overhaul of a centrifugal compressor. Note that this is a high-level overview, and specific steps may vary depending on the manufacturer's guidelines, the compressor's condition, and operational history.
1. Preparation*
Shutdown and Isolation
Safely shut down the compressor and isolate it from the system. Lock out and tag out (LOTO) all energy sources.
Draining and Purging*
Drain all process fluids (oil, gas, etc.) and purge the system to remove any hazardous or flammable materials.
Documentation Review
Review the compressor's maintenance history, operational data, and manufacturer's manuals.
Tool and Equipment Preparation
Ensure all necessary tools, lifting equipment, and replacement parts are available.
2. Disassembly*
External Components Removal
Remove couplings, guards, and auxiliary systems (lube oil system, seal gas system, etc.)
Disconnect instrumentation and electrical connections.
Casing Disassembly
Remove the entire casing
Rotor Removal
Carefully lift the rotor assembly out of the casing using proper lifting equipment.
Seal and Bearing Removal
Remove dry gas seals, labyrinth seals, and bearings.
3. Inspection and Cleaning*
Component Inspection
Inspect impellers, diffusers, diaphragms, and casing for erosion, corrosion, or cracks.
Check shaft alignment, runout, and balance.
Inspect all bolts, fasteners, and gaskets.
Cleaning
Clean all components using appropriate solvents or cleaning agents.
Remove any deposits, scale, or debris.
Non-Destructive Testing (NDT)
Perform NDT, UT, MPI
4. Repair and Replacement*
Component Repair
Repair or refurbish damaged components.
Rotor Balancing
Rebalance the rotor if necessary to ensure smooth operation.
5. Reassembly*
Bearing and Seal Installation
Install new or refurbished bearings and seals according to manufacturer specifications.
Rotor Installation
Carefully lower the rotor back into the casing, ensuring proper alignment.
6. Alignment and Testing*
Coupling Alignment
Align the compressor shaft with the driver.
Leak Testing
Perform leak tests on the casing and seals to ensure integrity.
Run-In and Vibration Testing
Conduct a run-in test at low speed to check for vibration, temperature, and noise.
7. Final Checks and Commissioning
System Checks
Verify all systems are functioning correctly.
8. Startup and Monitoring*
Gradual Startup
Start the compressor gradually, monitoring for any abnormalities.
Performance Monitoring
Continuously monitor vibration, temperature, pressure, and flow during initial operation.
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