The document provides instructions for observing the disassembly of a gas boost compressor as part of an overhaul familiarization program. The FSR is to observe and have initialed 16 key steps in the disassembly process, including determining identifying information, inspecting exterior components, observing removal of bearing capsules and seals, removing the end cap and bundle, disassembling internal stages, and inspecting individual components. The goal is for the FSR to gain insight into the overhaul process and components not normally accessible during field work.
The document provides instructions for observing the disassembly of a gas boost compressor as part of an overhaul familiarization program. The FSR is to observe and have initialed 16 key steps in the disassembly process, including determining identifying information, inspecting exterior components, observing removal of bearing capsules and seals, removing the end cap and bundle, disassembling internal stages, and inspecting individual components. The goal is for the FSR to gain insight into the overhaul process and components not normally accessible during field work.
The document provides instructions for observing the disassembly of a gas boost compressor as part of an overhaul familiarization program. The FSR is to observe and have initialed 16 key steps in the disassembly process, including determining identifying information, inspecting exterior components, observing removal of bearing capsules and seals, removing the end cap and bundle, disassembling internal stages, and inspecting individual components. The goal is for the FSR to gain insight into the overhaul process and components not normally accessible during field work.
The document provides instructions for observing the disassembly of a gas boost compressor as part of an overhaul familiarization program. The FSR is to observe and have initialed 16 key steps in the disassembly process, including determining identifying information, inspecting exterior components, observing removal of bearing capsules and seals, removing the end cap and bundle, disassembling internal stages, and inspecting individual components. The goal is for the FSR to gain insight into the overhaul process and components not normally accessible during field work.
Instructions and General Guidelines Instructions for the FSR
Prior to participating in the observation portion of the program, ensure that you are familiar with the basic layout and construction of a gas boost compressor. Key compressor components have been described in Module Two, Lessons One and Two. If you have not already done so, take the time to review the materials covered in these lessons.
To complete this observation task, observe the disassembly of a Gas Boost
Compressor. It is expected this will take about 6 to 8 hours to complete.
The FSR will need to:
Print the Observation Checklist.
Complete page one of the checklist, taking care that all details are filled in. Have the Overhaul Technician initial each of the key observation points noted on the checklist. Return the completed Observation Checklist to the Technical Training Department.
Instructions for the Overhaul Technician
The goal of the Overhaul Observation and Familiarization program is to provide the FSR an insight into the processes involved in overhauling a gas boost compressor. The overhaul environment provides the opportunity for the FSR to observe and inspect critical compressor components that are typically not accessible in the “field” environment.
In order for the FSR to complete the Observation Tasks it is necessary they witness the steps involved in the disassembly of the gas boost compressor. This document is designed as a job aid to assist the FSR observe the key aspects of the overhaul process. You will be asked to initial some or all of the key observation tasks.
Please note this program is observation only. By initialing the observation task in the spaces provided, you will verify that the FSR has observed the steps involved in the task.
Example: Initial Here • Determine the model number, serial number, and staging of the ____________ compressor. This information is generally available on the compressor nameplate and typically fixed to the compressor casing. Observation Guide
1. Determine the model number, serial number, and staging of the
_____________ compressor. This information is generally available on the compressor nameplate and typically fixed to the compressor casing.
_____________ 2. If possible, determine the reason for overhaul of the compressor, restage, or repair.
_____________ 3. Visually inspect the exterior of the compressor case, bearing capsules, and inside the suction and discharge ports to identify any irregularities.
_____________ 4. For a wet seal compressor, observe the removal of the suction and discharge bearing capsules and carbon seals. It may be necessary to return to the capsules at a later time to observe their disassembly.
_____________ 5. For a dry seal equipped compressor, observe the removal of the radial bearing, thrust bearing, buffer air seals, and dry gas seals.
_____________ 6. Observe the removal of the end cap. Note, in the workshop, the end cap or end bell is typically removed from the compressor with the compressor in a horizontal position. In the case of a field overhaul, this is not always achievable. Special tooling is used in field situations to counter the center of gravity of the end caps and allow for horizontal removal.
_____________ 7. Observe the order in which the end caps are removed. Typically are the compressor bundle is removed from the discharge end. However this is not always the case. Observation Guide (continued)
_____________ 8. Observe the removal of the compressor bundle from the body of the compressor.
_____________ 9. In the case of generation 1 compressors (C165,C166,C167,C168,
C165H,C168H, C284,C304,C306,C307,C505j), the internal stage components were built in-place within the compressor body. Observe removal of the individual stage components from the compressor body.
_____________ 10. Observe de-stretching of the rotor center bolt using the hydraulic jacking tool.
_____________ 11. Observe disassembly of the bundle into its stage components: stator diaphragms and impellers. Note the various impeller tips. Impeller tips directly affect the head and flow characteristics of the compressor. Impellers with wide tips are high flow head impellers. Refer to Module Two, Lesson One for further explanations.
12. If not already complete, observe the removal of the suction end cap from _____________ the compressor body. Note the seal used between the end cap and casing. Determine if it differs from the discharge end seal.
_____________ 13. Observe the separating of the stators from the diaphragms. Note the vane angles of the various diaphragms. The diaphragm vane angle directly affects the flow capacity of the compressor. Again, refer to Module Two, Lesson One for further explanations Observation Guide (continued)
_____________ 14. Various compressor components will now be subjected to a series of
inspections. Observe the inspection process applied to each component. Refer to Lesson One, Step Three for NDT inspection practices.
_____________ 15. During the inspection process, note any NDT techniques applied and note all measurements taken.
_____________ 16. Ensure that all observation points have been initialed. Complete the check sheet by signing in the space provided on page one. Observation Notes Observation Notes (continued)
