Centrifugal Compressor overhauling

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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