Centrifugal Compressors

Maintenance Policy

Electronically approved draw. GE NuovoPignone DT-'N'

MAINTENANCE INTERVALS AND PROCEDURES

TITLE DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy 1
ETO00001
REVISION DESCRIPTION: APPROVED Turini G.
Rev. security code DATE SECURITY CODE
CHECKED Ermini M.
15/10/12 N
EXECUTED PD-SY
SCALE REPLACES/DERIVED FROM 1st ISSUE ORIGINAL JOB SIZE LANGUAGE
/ SOS2418251 10/10/12 4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 1 of 41
 INDEX
1. Overview

1.1. Preventive maintenance 3

1.2. Scheduled maintenance 3

1.3. Auxiliary systems maintenance 5

2. BCL Compressors

2.1 Minor Inspection BCL 6

2.2 Major Inspection BCL 9

3. MCL Compressors

3.1 Minor Inspection MCL 12

3.2 Major Inspection MCL 15

4. PCL Compressors

4.1 Minor Inspection PCL 18

4.2 Major Inspection PCL 21

5. SRL Compressors

5.1 Minor Inspection SRL Overhung 24

5.2 Minor Inspection SRL Integrally Geared 28

5.3 Major Inspection SRL Overhung 32

5.4 Major Inspection SRL Integrally Geared 35

6. Compressor Auxiliary Systems

6.1 Mechanical auxiliary systems 38

6.2 Electrical auxiliary systems 39

6.3 Control auxiliary systems 39

1. Overview
TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 2 of 41
 Operation of a centrifugal compressor, like any other rotating machine, must include a
maintenance program for repair and/or replacement of parts needed to ensure maximum
availability and reliability of the unit.

Maintenance operations are classified and described in the present document.

1.1. Preventive maintenance

• Running Inspection
Consists in logging the main running parameters during startup and while the unit is in service. Subsequent analysis of recorded data allows to assess
the general conditions of the unit and the auxiliary systems.

• Standby Inspection
Is conducted when the unit is out of operation due to plant requirements and therefore does not
interfere with availability but increases reliability.

May consist in changing filters, checking the lube oil level, checking and regulating instrumentation,
etc.

1.2. Scheduled maintenance

Scheduled maintenance is performed when machines are out of service, since the unit has to be partially
disassembled in order to allow inspection of internal components. The extent of the disassembly depends on
the type of inspection. Inspections start from the most critical zone and continue to cover the whole
machine.

Maintenance operations to be carried out for minor and major inspections are detailed in the
following paragraphs 2. to 5.

All the operations listed in the present procedure shall be carried out with maximum care and in
strict accordance to procedures (internal and international standards, instruction manuals and
other available documentation). In particular the operations highlighted in text are the most critical
according to potential EHS (Environment, Safety and Health) risks.

1.2.1. Scheduled maintenance frequency

The required frequency of scheduled maintenance and the list of maintenance operations are
variable, depending on compressor features and application.

The general criteria to select the frequency of minor and major inspections in function of
compressor and service type are listed below, and refer to a compressor operating in normal
conditions. In case of anomalies observed in compressor operating parameters (such as
TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 3 of 41
 vibrations, gas pressure and temperature at compressor inlet/discharge, journal and thrust
bearing temperature/pressure, DGS system pressures and flows etc.) or in other parts of the
plant that may influence the compressor, the suggested intervals shall be consequently reduced.
In particular the inspections shall occur more frequently if the composition and the cleanliness of
the process gas and/or seal gas are altered with respect to nominal conditions, even for transient
periods.

Compressor for LNG and Pipeline application

if the driver is a Gas Turbine:

‐ the minor inspection is carried out at the same time of the gas turbine hot gas path inspection

‐ the major inspection is carried out at the same time of the gas turbine major inspection.

for other driver type:

‐ the major inspection is carried out after not more than 50,000 hours

Compressor for Process application (Air, CO2, Urea Plant, Ethylene / Charge Gas, Refinery...)

The major inspection of the compressor shall be carried out during the scheduled maintenance
intervals of the plant, generally determined by catalyst maintenance (typically 4‐5 years). In any
case the major inspection of the compressor shall occur after no more than 50,000 hours of
operation.

Compressor for Reinjection, Sour /Acid Gas, Blast Furnace Plant application

if the driver is a Gas Turbine:

‐ the minor inspection is carried out at the same time of the gas turbine hot gas path inspection

‐ the major inspection is carried out at the same time of the gas turbine major inspection, and in
any case after no more than 50,000 hours of operation.

for other driver type:

‐ the minor inspection is carried out after 24,000 hours of operation

‐ the major inspection is carried out after 48,000 hours of operation

A major inspection may be required after a shorter time than those indicated above, depending
TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 4 of 41
 on the efficiency of the equipments upstream of the compressor(s) and on other possible needs
or problems of the plant.

SRL Compressors

if the process gas is Polyethylene / Polypropylene:

‐ the minor inspection is carried out after 12,000 hours of operation

‐ the major inspection is carried out after 24,000 hours of operation

for other cases:

‐ the minor inspection is carried out after 24,000 hours of operation

‐ the major inspection is carried out after 48,000 hours of operation

1.3. Auxiliary systems maintenance

Maintenance of auxiliary systems follows a separate inspection schedule which can be found in
the machine documentation.

As a general rule, the main auxiliary systems are inspected during major inspections.

2. BCL Compressors
2.1. Minor Inspection

This inspection consists in the check of the two compressor ends. It is carried out by
disassembling the bearings and the mechanical seals, verifying their conditions and providing
replacement if they appear damaged.
This inspection also includes the disassembly and check of the coupling(s).

PRELIMINARY OPERATIONS

2.1.1. Operations to be done before disassembly

1. Check the presence of leaks on compressor at interfaces between casing and head flange(s), by
TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 5 of 41
 means of bubble test or gas detector. If a leakage is detected, the head flange shall be
disassembled (see point 2.1.4.7) and the leakage eliminated by restoring the sealing between
casing and flange.
2. Analyze the main operating data and service programming data
3. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system
2.1.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover
3. Removal of coupling spacer
4. Removal of coupling hub
5. Alignment check

2.1.3. Parts to be inspected

1. Coupling spacer

OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

2.1.4. Disassembly

1. Disconnection and removal of instrumentation

2. Removal of piping
3. Removal of bearings covers
4. Removal of bearings
5. Removal of thrust collar
6. Removal of dry gas seals / oil seals
(7.)Removal of suction and/or discharge head flange: to be performed if the check done at step
2.1.1.1 highlights a gas leakage between head flange and casing.

2.1.5. Cleaning and inspection

The operations to be carried out are listed in table below.

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 6 of 41
 Oil Seals Inspection
JB and TB Pad Change
Oil Seals O-Rings / Gaskets Change
Instrumentation Inspection
Piping Inspection
DGS Inspection
JB and TB Pad Change
DGS O-Rings / Gaskets Change
Instrumentation Inspection
Piping Inspection

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.

2.1.6. Re‐assembly

(1.) Reassembly of head flange(s), if removed at step 2.1.4.7

2. Installation of dry gas seals / oil seals

3. Installation of thrust collar

4. Installation of bearings

5. Installation of bearings covers

6. Installation of piping
7. Installation and connection of instrumentation

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

2.1.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)
2. Installation of coupling spacer
3. Installation of coupling cover
4. Installation of acoustic enclosure (under shed with an overhead crane)

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 7 of 41
 2.1.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks
3. Start the unit and check the main operating parameters

2.2. Major Inspection

This inspection includes all the activities performed for the minor inspection, and in addition the
examination of all the rotating internal and stationary components of the compressor.

It reuires the removal of the end flanges, the removal and opening of the diaphragm bundle and
the removal of the rotor.

PRELIMINARY OPERATIONS

2.2.1. Operations to be done before disassembly

1. Analyze the main operating data and service programming data

2. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

2.2.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

2.2.3. Parts to be inspected

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 8 of 41
 1. Coupling spacer

OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

2.2.4. Disassembly

1. Disconnection and removal of instrumentation

2. Removal of piping

3. Removal of bearings covers

4. Removal of bearings

5. Removal of thrust collar

6. Removal of dry gas seals / oil seals
7. Removal of suction head flange

8. Removal of bundle

9. Bundle opening

10. Removal of the rotor

11. Removal of discharge head flange (not applicable for bell casing design)

2.2.5. Cleaning and inspection

The operations to be carried out are listed in table below.

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 9 of 41
 Oil Seals Change
JB and TB Pad Change
O-Rings / Gaskets Change*
Rotor Inspection
Oil Seals Bushes Change
Bundle Inspection
Labyrinth Seals Inspection**
Instrumentation Inspection
Piping Inspection
DGS Change
JB and TB Pad Change
O-Rings / Gaskets Change*
Rotor Inspection
DGS
Bundle Inspection
Labyrinth Seals Inspection**
Instrumentation Inspection
Piping Inspection

* Including those installed on head flange(s)

** Replace "Inspection" with "Change" if compressor discharge pressure is higher than 200 bar‐a

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.

2.2.6. Re‐assembly

1. Installation of discharge head flange (not applicable for bell casing design)
2. Installation of rotor inside bundle and clearance check
3. Bundle closing
4. Installation of bundle inside casing
5. Installation of suction head flange
6. Installation of dry gas seals / oil seals
7. Installation of thrust collar
8. Installation of bearings
9. Installation of bearing cover
10. Installation of piping
11. Installation and connection of instrumentation

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 10 of 41
 OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

2.2.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)

2. Alignment check
3. Installation of coupling spacer

4. Installation of coupling cover

5. Installation of acoustic enclosure (under shed with an overhead crane)

2.2.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks, by means of
bubble test or gas detector

3. Start the unit and check the main operating parameters

3. MCL Compressors

3.1. Minor Inspection

This inspection consists in the check of the two compressor ends. It is carried out by
disassembling the bearings and the mechanical seals, verifying their conditions and providing
replacement if they appear damaged.
This inspection also includes the disassembly and check of the coupling(s).

PRELIMINARY OPERATIONS

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 11 of 41
 3.1.1. Operations to be done before disassembly

1. Check the presence of leaks on compressor at interface between casing parts, by means of
bubble test or gas detector. If a leakage is detected, the compressor shall be opened (see point
3.1.4.7) and the leakage eliminated by restoring the sealing between casing parts.

2. Analyze the main operating data and service programming data

3. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

3.1.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

3.1.3. Parts to be inspected

1. Coupling spacer

OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

3.1.4. Disassembly

1. Disconnection and removal of instrumentation

2. Removal of piping

3. Removal of bearings covers

4. Removal of bearings

5. Removal of thrust collar

6. Removal of dry gas seals / oil seals

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 12 of 41
 (7.) Removal of top half casing: to be performed if the check done at step 3.1.1.1 highlights a gas
leakage between head flange and casing.

3.1.5. Cleaning and inspection

The operations to be carried out are listed in table below.

Oil Seals Inspection
JB and TB Pad Change
Oil Seals O-Rings / Gaskets Change
Instrumentation Inspection
Piping Inspection
DGS Inspection
JB and TB Pad Change
DGS O-Rings / Gaskets Change
Instrumentation Inspection
Piping Inspection

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.
3.1.6. Re‐assembly

(1.)If compressor has been opened at step 3.1.4.7: clean the contact surfaces between casing top and
bottom half, apply sealing paste and then close the casing.
2. Installation of dry gas seals / oil seals

3. Installation of thrust collar

4. Installation of bearings

5. Installation of bearings covers

6. Installation of piping
7. Installation and connection of instrumentation

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 13 of 41
 3.1.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)
2. Installation of coupling spacer

3. Installation of coupling cover

4. Installation of acoustic enclosure (under shed with an overhead crane)

3.1.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks

3. Start the unit and check the main operating parameters

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 14 of 41
 3.2. Major Inspection

This inspection includes all the activities performed for the minor inspection, and in addition the
examination of all the rotating internal and stationary components of the compressor.

It requires the removal of the top half casing and the removal of the rotor.

PRELIMINARY OPERATIONS

3.2.1. Operations to be done before disassembly

1. Analyze the main operating data and service programming data

2. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

3.2.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

3.2.3. Parts to be inspected

1. Coupling spacer

OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

3.2.4. Disassembly

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 15 of 41
 1. Disconnection and removal of instrumentation
2. Removal of piping

3. Removal of bearings covers

4. Removal of bearings

5. Removal of thrust collar

6. Removal of dry gas seals / oil seals
7. Removal of top half casing

8. Removal of the rotor

3.2.5. Cleaning and inspection

The operations to be carried out are listed in table below.

Oil Seals Change

JB and TB Pad Change
O-Rings / Gaskets Change
Rotor Inspection
Oil Seals Bushes Change
Bundle Inspection
Labyrinth Seals Inspection
Instrumentation Inspection
Piping Inspection
DGS Change
JB and TB Pad Change
O-Rings / Gaskets Change
Rotor Inspection
DGS
Bundle Inspection
Labyrinth Seals Inspection
Instrumentation Inspection
Piping Inspection

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 16 of 41
 3.2.6. Re‐assembly

1. Installation of rotor and clearance check

2. Installation of the top half casing: clean the contact surfaces between casing top and bottom
half, apply sealing paste and then close the casing
3. Installation of dry gas seals / oil seals
4. Installation of thrust collar
5. Installation of bearing
6. Installation of bearing cover
7. Installation of piping
8. Installation and connection of instrumentation

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

3.2.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)

2. Alignment check

3. Installation of coupling spacer

4. Installation of coupling cover

5. Installation of acoustic enclosure (under shed with an overhead crane)

3.2.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks, by means of
bubble test or gas detector

3. Start the unit and check the main operating parameters

4. PCL Compressors
4.1. Minor Inspection

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 17 of 41
 This inspection consists in the check of the two compressor ends. It is carried out by
disassembling the bearings and the mechanical seals, verifying their conditions and providing
replacement if they appear damaged.
This inspection also includes the disassembly and check of the coupling(s).

PRELIMINARY OPERATIONS
4.1.1. Operations to be done before disassembly

1. Check the presence of leaks on compressor at interfaces between casing and head flange(s), by
means of bubble test or gas detector. If a leakage is detected, the head flange shall be
disassembled (see point 4.1.4.7) and the leakage eliminated by restoring the sealing between
casing and flange.

2. Analyze the main operating data and service programming data

3. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

4.1.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

4.1.3. Parts to be inspected

1. Coupling spacer

OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

4.1.4. Disassembly

1. Disconnection and removal of instrumentation

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 18 of 41
 2. Removal of piping

3. Removal of bearings covers

4. Removal of bearings

5. Removal of thrust collar

6. Removal of dry gas seals / oil seals

(7.) Removal of head flange: to be performed if the check done at step 4.1.1.1 highlights a gas
leakage between head flange and casing.

4.1.5. Cleaning and inspection

The operations to be carried out are listed in table below.

Oil Seals Inspection

JB and TB Pad Change
Oil Seals O-Rings / Gaskets Change
Instrumentation Inspection
Piping Inspection
DGS Inspection
JB and TB Pad Change
DGS O-Rings / Gaskets Change
Instrumentation Inspection
Piping Inspection

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.
4.1.6. Re‐assembly

(1.) Reassembly of head flange(s), if removed at step 4.1.4.7

2. Installation of dry gas seals / oil seals

3. Installation of thrust collar

4. Installation of bearings

5. Installation of bearings covers

6. Installation of piping
TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 19 of 41
 7. Installation and connection of instrumentation

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

4.1.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)

2. Installation of coupling spacer

3. Installation of coupling cover

4. Installation of acoustic enclosure (under shed with an overhead crane)

4.1.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks, by means of
bubble test or gas detector

3. Start the unit and check the main operating parameters

4.2. Major Inspection

This inspection includes all the activities performed for the minor inspection, and in addition the
examination of all the rotating internal and stationary components of the compressor.

It reuires the removal of the end flanges, the removal and opening of the diaphragm bundle and
the removal of the rotor.

PRELIMINARY OPERATIONS

4.2.1. Operations to be done before disassembly

1. Analyze the main operating data and service programming data

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 20 of 41
 2. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

4.2.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

4.2.3. Parts to be inspected

1. Coupling spacer

OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

4.2.4. Disassembly

1. Disconnection and removal of instrumentation

2. Removal of piping

3. Removal of bearings covers

4. Removal of bearings

5. Removal of thrust collar

6. Removal of dry gas seals / oil seals
7. Removal of suction head flange

8. Removal of bundle

9. Bundle opening

10. Removal of the rotor

11. Removal of discharge head flange (not applicable for bell casing design)

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 21 of 41
 4.2.5. Cleaning and inspection

The operations to be carried out are listed in table below.

Oil Seals Change

JB and TB Pad Change
O-Rings / Gaskets Change*
Rotor Inspection
Oil Seals Bushes Change
Bundle Inspection
Labyrinth Seals Inspection
Instrumentation Inspection
Piping Inspection
DGS Change
JB and TB Pad Change
O-Rings / Gaskets Change*
Rotor Inspection
DGS
Bundle Inspection
Labyrinth Seals Inspection
Instrumentation Inspection
Piping Inspection

* including those installed on head flange(s)

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.

4.2.6. Re‐assembly

1. Installation of discharge head flange (not applicable for bell casing design)
2. Installation of rotor inside bundle and clearance check

3. Bundle closing

4. Installation of bundle inside casing

5. Installation of suction head flange

TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 22 of 41
 6. Installation of dry gas seals / oil seals

7. Installation of thrust collar

8. Installation of bearings

9. Installation of bearing cover

10. Installation of piping

11. Installation and connection of instrumentation

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

4.2.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)

2. Alignment check
3. Installation of coupling spacer

4. Installation of coupling cover

5. Installation of acoustic enclosure (under shed with an overhead crane)

4.2.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks, by means of
bubble test or gas detector

3. Start the unit and check the main operating parameters

5. SRL Compressors

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 23 of 41
 5.1. Minor Inspection ‐ Overhung SRL Compressors

This inspection consists in the check of the two compressor ends. It is carried out by
disassembling the bearings and the mechanical seal, and verifying the conditions of bearings,
mechanical seal, external labyrinth seal, thrust collar and gear teeth. Components that appear
damaged shall be replaced.
Gear teeth control can be performed by checking the contact surface with the use of blue of
Prussia.

PRELIMINARY OPERATIONS

5.1.1. Operations to be done before disassembly

1. Check the presence of leaks on compressor at interface between casing parts, by means of
bubble test or gas detector. If a leakage is detected, the compressor shall be opened (see point
5.1.4.7) and the leakage eliminated by restoring the sealing between casing parts.

2. Analyze the main operating data and service programming data

3. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

5.1.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

5.1.3. Parts to be inspected

1. Coupling spacer
TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 24 of 41
 OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

5.1.4. Disassembly

1. Disconnection and removal of instrumentation

2. Removal of piping

3. Removal of bearings covers

4. Removal of bearings

5. Removal of thrust collar

6. Removal of dry gas seals / oil seals

(7.) Casing opening: to be performed if the check done at step 5.1.1.1 highlights a gas leakage
between head flange and casing.

5.1.5. Cleaning and inspection

The operations to be carried out are listed in table at next page.

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.

5.1.6. Re‐assembly

(1.) Reassembly of casing, if opened at step 2.1.4.7 or for polypropylene / polyethylene

removal.
2. Installation of dry gas seals / oil seals

3. Installation of thrust collar

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 25 of 41
 4. Installation of bearings

5. Installation of bearings covers

6. Installation of piping
7. Installation and connection of instrumentation

Polyethylene /
Clean Gas
Polypropylene
Labyrinths inspection
JB and TB Pad Inspection
O-Rings / Gaskets Change
IGV Inspection (Correct
blades movement and
Oil Seals
sleeves and bushes
inspection)
Thrust Collar Inspection
Instrumentation Inspection
Piping Inspection
DGS Inspection DGS Inspection
JB and TB Pad Inspection JB and TB Pad Inspection
O-Rings / Gaskets Change O-Rings / Gaskets Change
IGV Inspection (Correct IGV Inspection (Correct
blades movement and blades movement and
sleeves and bushes sleeves and bushes
DGS inspection) inspection)
Thrust Collar Inspection Thrust Collar Inspection
Instrumentation Inspection Instrumentation Inspection
Checking of Polypropylene
/ Polyethylene presence
inside CC and Removal *
Piping Inspection Piping Inspection

* the compressor will be inspected from suction end. If polypropylene / polyethylene is present, the
compressor shall be opened and the deposit shall be removed.

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

5.1.7. Re‐assembly of parts outside the centrifugal compressor

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 26 of 41
 1. Installation of coupling hub, to be done according to official procedure (see CC instruction
manual)
2. Installation of coupling spacer

3. Installation of coupling cover

4. Installation of acoustic enclosure (under shed with an overhead crane)

5.1.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks

3. Start the unit and check the main operating parameters

5.2. Minor Inspection ‐ Integrally Geared Compressors (IGC)

This inspection consists in the check of the two compressor ends. It is carried out by
disassembling the bearings and the mechanical seal, and verifying the conditions of bearings,
mechanical seal, external labyrinth seal, thrust collar and gear teeth. Components that appear
damaged shall be replaced.
Gear teeth control can be performed by checking the contact surface with the use of blue of
Prussia.

PRELIMINARY OPERATIONS

5.2.1. Operations to be done before disassembly

1. Check the presence of leaks on compressor at interface between casing parts, by means of
bubble test or gas detector. If a leakage is detected, the compressor shall be opened (see point
TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 27 of 41
 5.1.4.7) and the leakage eliminated by restoring the sealing between casing parts.

2. Analyze the main operating data and service programming data

3. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

5.2.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

5.2.3. Parts to be inspected

1. Coupling spacer

OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

5.2.4. Disassembly

1. Disconnection and removal of instrumentation

2. Removal of top half gear casing

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 28 of 41
 3. Removal of suction piping

4. Removal of bearings cover (if present)

5. Removal of bearings

6. Removal of dry gas seals / oil seals

(7.) Compressor casing opening: to be performed if the check done at step 5.2.1.1 highlights a gas
leakage between head flange and casing.

5.2.5. Cleaning and inspection

The operations to be carried out are listed in table at next page.

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.

5.2.6. Re‐assembly

(1.) Reassembly of casing, if opened at step 5.2.4.7 or for polypropylene / polyethylene

removal.
2. Installation of dry gas seals / oil seals

3. Installation of bearings

4. Installation of bearings cover (if present)

5. Installation of top half gear casing

6. Installation of piping
7. Installation and connection of instrumentation

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 29 of 41
 Polyethylene /
Clean Gas
Polypropylene
Labyrinths inspection
JB and TB Pad Inspection
O-Rings / Gaskets Change
IGV Inspection (Correct
blades movement and
Oil Seals
sleeves and bushes
inspection)
HSS Thrust Collar Inspection
Instrumentation Inspection
Piping Inspection
DGS Inspection DGS Inspection
JB and TB Pad Inspection JB and TB Pad Inspection
O-Rings / Gaskets Change O-Rings / Gaskets Change
IGV Inspection (Correct IGV Inspection (Correct
blades movement and blades movement and
sleeves and bushes sleeves and bushes
DGS inspection) inspection)
HSS Thrust Collar Inspection HSS Thrust Collar Inspection
Instrumentation Inspection Instrumentation Inspection
Checking of Polypropylene
/ Polyethylene presence
inside CC and Removal *
Piping Inspection Piping Inspection

* the compressor will be inspected from suction end. If polypropylene / polyethylene is present, the
compressor shall be opened and the deposit shall be removed.

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

5.2.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 30 of 41
 2. Installation of coupling spacer

3. Installation of coupling cover

4. Installation of acoustic enclosure (under shed with an overhead crane)

5.2.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks

3. Start the unit and check the main operating parameters

1.1

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 31 of 41
 5.3. Major Inspection ‐ Overhung SRL Compressors

This inspection includes all the activities performed for the minor inspection, and in addition the
check of impellers and suction diaphragm. In particular the condition of the abradable layer shall
be checked.

PRELIMINARY OPERATIONS

5.3.1. Operations to be done before disassembly

1. Check the presence of leaks on compressor at interface between casing parts, by means of
bubble test or gas detector. If a leakage is detected, the compressor shall be opened (see point
5.1.4.7) and the leakage eliminated by restoring the sealing between casing parts.

2. Analyze the main operating data and service programming data

3. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

5.3.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

5.3.3. Parts to be inspected

1. Coupling spacer
TITLE: DOCUMENT CODE REVISION
Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 32 of 41
 OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

5.3.4. Disassembly

1. Disconnection and removal of instrumentation

2. Removal of piping

3. Removal of bearings covers

4. Removal of bearings

5. Removal of thrust collar

6. Removal of dry gas seals / oil seals

7. Casing opening
8. Removal of the rotor

5.3.5. Cleaning and inspection

The operations to be carried out are listed in table below.

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 33 of 41
 Polyethylene /
Clean Gas
Polypropylene
Labyrinths Change
JB and TB Pad* Change
O-Rings / Gaskets Change**
Rotor Inspection
IGV Inspection, Replacement
Oil Seals
of Bushes, Sleeves and O-
Rings
Thrust Collar Inspection
Instrumentation Inspection
Piping Inspection
DGS Change DGS Change
JB and TB Pad* Change JB and TB Pad* Change
O-Rings / Gaskets Change** O-Rings / Gaskets Change**
IGV Inspection, Replacement IGV Inspection, Replacement
of Bushes, Sleeves and O- of Bushes, Sleeves and O-
Rings Rings
Thrust Collar Inspection Thrust Collar Inspection
Instrumentation Inspection Instrumentation Inspection
DGS
Checking of Polypropylene
/ Polyethylene presence
inside CC and Removal *
Piping Inspection Piping Inspection
Check of Teeth Contact Check of Teeth Contact
Rotor Inspection Rotor Inspection

Removal of PP or PE deposit

* or bearing, in case of fixed geometry

** including those on casing

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.

5.3.6. Re‐assembly

1. Installation of rotor inside casing and clearance check

2. Reassembly of casing
3. Installation of dry gas seals / oil seals

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 34 of 41
 4. Installation of thrust collar

5. Installation of bearings

6. Installation of bearings covers

7. Installation of piping
8. Installation and connection of instrumentation

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

5.3.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)
2. Installation of coupling spacer

3. Installation of coupling cover

4. Installation of acoustic enclosure (under shed with an overhead crane)

5.3.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks

3. Start the unit and check the main operating parameters

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 35 of 41
 5.4. Major Inspection ‐ Integrally Geared Compressors (IGC)

This inspection includes all the activities performed for the minor inspection, and in addition the
check of impellers and suction diaphragm. In particular the condition of the abradable layer shall
be checked.

PRELIMINARY OPERATIONS

5.4.1. Operations to be done before disassembly

1. Check the presence of leaks on compressor at interface between casing parts, by means of
bubble test or gas detector. If a leakage is detected, the compressor shall be opened (see point
5.1.4.7) and the leakage eliminated by restoring the sealing between casing parts.

2. Analyze the main operating data and service programming data

3. Tag‐out: deactivate the fire protection system ‐ tag‐out electric power system ‐ deactivate the
control system

5.4.2. Disassembly of parts outside the centrifugal compressor

1. Removal of acoustic enclosure (under shed with an overhead crane)

2. Removal of coupling cover

3. Removal of coupling spacer

4. Removal of coupling hub

5. Alignment check

5.4.3. Parts to be inspected

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 36 of 41
 1. Coupling spacer

OPERATIONS ON THE CENTRIFUGAL COMPRESSOR

5.4.4. Disassembly

1. Disconnection and removal of instrumentation

2. Removal of top half gear casing

3. Removal of suction piping

4. Removal of bearings cover (if present)

5. Removal of bearings

6. Removal of dry gas seals / oil seals

7. Compressor casing opening

5.4.5. Cleaning and inspection

The operations to be carried out are listed in table below.

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 37 of 41
 Polyethylene /
Clean Gas
Polypropylene
Labyrinths Change
JB and TB Pad* Change
O-Rings / Gaskets Change**
Rotor Inspection
IGV Inspection, Replacement
Oil Seals
of Bushes, Sleeves and O-
Rings
HSS Thrust Collar Inspection
Instrumentation Inspection
Piping Inspection
DGS Change DGS Change
JB and TB Pad* Change JB and TB Pad* Change
O-Rings / Gaskets Change** O-Rings / Gaskets Change**
IGV Inspection, Replacement IGV Inspection, Replacement
of Bushes, Sleeves and O- of Bushes, Sleeves and O-
Rings Rings
HSS Thrust Collar Inspection HSS Thrust Collar Inspection
Instrumentation Inspection Instrumentation Inspection
DGS
Checking of Polypropylene
/ Polyethylene presence
inside CC and Removal *
Piping Inspection Piping Inspection
Check of Teeth Contact Check of Teeth Contact
Rotor Inspection Rotor Inspection

Removal of PP or PE deposit

* or bearing, in case of fixed geometry

** including those on casing

If during the inspection activity one or more components are found damaged (not including
normal wearing due to operation), it is appropriate to perform a Root Cause Analysis in order to
develop possible corrections for procedures or plant operability.
All wear parts whose clearances are found outside the allowable range shall be replaced, even
when not specified in the above table.

5.4.6. Re‐assembly

1. Installation of rotor inside casing and clearance check

2. Reassembly of casing
3. Installation of dry gas seals / oil seals

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 38 of 41
 4. Installation of bearings
5. Installation of bearings cover (if present)

6. Installation of top half gear casing

7. Installation of piping
8. Installation and connection of instrumentation

OPERATIONS SUBSEQUENT TO COMPRESSOR REASSEMBLY

5.4.7. Re‐assembly of parts outside the centrifugal compressor

1. Installation of coupling hub, to be done according to official procedure (see CC instruction

manual)
2. Installation of coupling spacer

3. Installation of coupling cover

4. Installation of acoustic enclosure (under shed with an overhead crane)

5.4.8. Restart operations

1. Reactivate electric, control systems

2. Check operation of instrumentation ‐ check piping and compressor for gas leaks

3. Start the unit and check the main operating parameters

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 39 of 41
 6. Compressor Auxiliary Systems

INSPECTION AND MAINTENANCE OF MECHANICAL, ELECTRICAL AND CONTROL AUXILIARY

SYSTEMS TO BE PERFORMED PARALLEL WITH MAJOR INSPECTION ON THE COMPRESSOR

6.1. Mechanical Auxiliary System

6.1.1. Lube oil system inspection

‐ inspection of the main pump

‐ inspection of the stand‐by pump

‐ inspection of the emergency pump

‐ replacement of filters

‐ inspection of heat exchangers ‐ (coolers)

‐ inspection of regulating valve

- inspection of relief valve

- inspection of electric motor
- inspection of heater

6.1.2. Dry gas seal system inspection

‐ replacement of gas filters

6.1.3. Anti‐surge system inspection

‐ inspection of anti‐surge valve

‐ inspection of control devices

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 40 of 41
 6.1.4. Ventilation system inspection

‐ inspection of fans

‐ inspection of dampers

6.2. Electrical auxiliary systems

6.2.1. Inspection of MCC panels

‐ examination of contacts

6.2.2. Inspection of direct current system

‐ inspection of battery system

6.2.3. Inspection of electric motors

‐ examination of windings

‐ replacement of bearings

6.3. Control auxiliary systems

‐ field instrumentation calibration

‐ control panel calibration

‐ operating sequences check

TITLE: DOCUMENT CODE REVISION

Centrifugal Compressors Maintenance Policy
ETO00001 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
Rev. security code N
ORIGINAL JOB SIZE LANGUAGE
4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. . ALL RIGHTS RESERVED. 41 of 41