MM-CHK-IMS-090 Rev 00 (15/12/2016)

Maintenance Checklist
Maintenance
Overhauling of Integral Gear compressor Department
(NP CO2 compressor)

1. Safety
1.1 Ensure lube oil circulation is stopped and isolated Yes / No
1.2 Ensure power supply to motor is isolated & tagged Yes / No
1.3 Ensure Casing is fully depressurized & purged Yes / No
1.4 Ensure Valid PTW is taken and available on job Yes / No
1.5 Ensure that all requirements of JSA have been fulfilled Yes / No
1.6 All workers are validated by HSE for safety awareness Yes / No

2. Coupling
2.1 Check free axial/radial movement of coupling Free / Tight
2.2 Inspect coupling and fill Coupling inspection Checklist
2.3 Check tightness of coupling bolts prior to removal Loose / Tight
2.4 Check match marking of coupling parts before removal
2.5 Measure and record coupling hub draw
2.6 Visually inspect coupling hubs, bolts, spacer and sleeves OK / Damage
2.7 DPT of coupling hubs, sleeves and bolts Pass / Fail
2.8 Check tightening torque of cap screws (3/8 - 24) 50.2 N.m
2.9 Check tightening of lock nuts (1/2 - 20) {Factory set value} 130 N.m

Notes:

3. Alignment (As found)

Parameter Recommended Actual
3.1 Alignment method used Rim and face Rim and face / Reverse dial / Laser
3.2 Ambient temperature 20C
3.3 Spacer free length 17.51(419.354mm)
3.4 Distance b/w spacer and adapter 0.73 (18.542mm)
3.5 Distance b/w shaft ends (DBSE) 20 (508.0mm)
3.6 Dial needle on Compressor coupling
3.7 Driver machine relative to driven Higher (0.051mm/C)

As found alignment reading Tolerance (R): +0.1

3.8 R A
(HP - GB) Tolerance (A): +0.05

Notes:

Important Note: Actions marked with Asterisk sign (*) are hold points and must be signed by supervisor, engineer or VSM Page 1 of 6
 MM-CHK-IMS-090 Rev 00 (15/12/2016)

Maintenance Checklist
Maintenance
Overhauling of Integral Gear compressor Department
(NP CO2 compressor)

4. Lube oil and seal systems

4.1 Ensure marking / securing of all lube oil connections Yes / No
4.2 Ensure marking / securing of all dry gas seal connections Yes / No
4.3 Inspect lube oil filter element and its housing Yes / No
4.4 Inspect seal gas filter element and its housing Yes / No
4.5 Inspect mist eliminator element and its housing Yes / No
4.6 Inspect and clean lube oil strainers Yes / No
4.7 Remove and inspect thermostatic valve OK / Faulty

Notes:

5. Inlet Guide Vanes and Shrouds

5.1 Remove and inspect inlet expansion joint OK / Crack
5.2 Check condition of actuator rod ends of IGVs OK / Seize
5.3 Inspect and perform DPT on all levers & links of IGVs OK / Cracks
5.4 Check all bearings / bushes of IGVs OK / Seize
5.5 Confirm free movement of all IGVs Free / Hard
5.6 Witness stroke testing of pneumatic actuator Yes / No
5.7 Check tightness of all bolts on IGVs Tight / Loose
5.8 Remove and visually inspect both stage shrouds Yes / No
5.9 Replace O-rings and seals of both shrouds Yes / No

Notes:

6A. Core Unit Assembly

7.1 Confirm all V&T probes are disconnected & secured Yes / No
6.2 Confirm end caps and DE oil seal are removed Yes / No
6.3 Check condition of all split joint bolts OK / Damage
6.4 Check condition of gearbox top cover OK / Corroded
6.5 Oil holes in casing are secured to prevent contamination Yes / No
6.6 Ensure securing of all probe areas and journal areas Yes / No
6.7 Check and record axial float of all three rotors Yes / No
6.8 Ensure arrangements in place to prevent rotors tipping Yes / No

6B. STAGE - I, ROTOR ASSEMBLY

6.9 Check for any looseness of bearing housing bolts Loose / Tight
6.10 Ensure impeller side bearing is removed first Yes / No
6.11 * Ensure proper marking of all bearing parts Witness
6.12 Check journal bearings and fill Journal bearing checklist Yes / No

Important Note: Actions marked with Asterisk sign (*) are hold points and must be signed by supervisor, engineer or VSM Page 2 of 6
 MM-CHK-IMS-090 Rev 00 (15/12/2016)

Maintenance Checklist
Maintenance
Overhauling of Integral Gear compressor Department
(NP CO2 compressor)

6.13 Check condition of bearing oil seal OK / Damage

6.14 Check thrust bearing and fill Thrust bearing checklist Yes / No
6.15 Inspect gas seal faces for wear, rubbing or scale OK / Damage
6.16 Inspect impeller for any scale, burrs, cracks etc OK / Damage
6.17 Inspect vibration probes area for any discontinuities OK / Scratched
6.18 Inspect shaft journal area for any abnormalities OK / Scratched
6.19 Inspect gear teeth and perform DPT OK / Crack
6.20 Inspect labyrinth seal for rubbing or bent teeth OK / Damage
6.21 Check magnetism of rotor and demagnetize if needed
6.22 Record rotor number
Dimensional Checks
Design As Found Final
Sr Parameters Witness
(mm) (mm) (mm)
6.23 * Axial clearance at impeller back 3.81 (min)
6.24 * Radial clearance at impeller tip 1.9 (min)
6.25 * Radial bearing clearance (Wheel side) 0.086 - 0.124
6.26 Shaft journal area OD (Wheel side)
6.27 * Radial bearing clearance (Drive side) 0.076 - 0.114
6.28 Shaft journal area OD (Drive side)
6.29 Backlash with bull gear
6.30 * Axial Clearance (with thrust bearing) 0.203 - 0.305
6.31 Thickness of thrust liner shims
6.32 Axial clearance (w/o thrust bearing)
6.33 Housing pre-load / crush (Wheel Side)
6.34 Oil seal clearance (Wheel side)
6C. STAGE - II, ROTOR ASSEMBLY
6.35 Check for any looseness of bearing housing bolts Loose / Tight
6.36 Ensure impeller side bearing is removed first Yes / No
6.37 * Ensure proper marking of all bearing parts Yes / No Witness
6.38 Check journal bearing and fill Journal bearing checklist Yes / No
6.39 Check condition of bearing oil seal OK / Damage
6.40 Check thrust bearing and fill Thrust bearing checklist Yes / No
6.41 Inspect gas seal faces for wear, rubbing or scale OK / Damage
6.42 Inspect impeller for any scale, burrs, cracks etc OK / Damage
6.43 Inspect vibration probes area for any discontinuities OK / Scratched
6.44 Inspect shaft journal area for any abnormalities OK / Scratched
6.45 Inspect gear teeth and perform DPT OK / Crack
6.46 Inspect labyrinth seal for rubbing or bent teeth OK / Damage
6.47 Check magnetism of rotor and demagnetize if needed
6.48 Record rotor number
Dimensional Checks
Design As Found Final
Sr Parameters Witness
(mm) (mm) (mm)
6.49 * Axial clearance at impeller back 2.54 (min)

Important Note: Actions marked with Asterisk sign (*) are hold points and must be signed by supervisor, engineer or VSM Page 3 of 6
 MM-CHK-IMS-090 Rev 00 (15/12/2016)

Maintenance Checklist
Maintenance
Overhauling of Integral Gear compressor Department
(NP CO2 compressor)

6.50 * Radial clearance at impeller tip 1.27 (min)

6.51 * Radial bearing clearance (Wheel side) 0.091 - 0.129
6.52 Shaft journal area OD (Wheel side)
6.53 * Radial bearing clearance (Drive side) 0.084 - 0.122
6.54 Shaft journal area OD (Drive side)
6.55 Backlash with bull gear
6.56 * Axial Clearance (with thrust bearing) 0.203 - 0.305
6.57 Thickness of thrust liner shims
6.58 Axial clearance (w/o thrust bearing)
6.59 Housing pre-load / crush (Wheel Side)
6.60 Oil seal clearance (Wheel side)
6D. BULL GEAR ROTOR
6.61 Check looseness of all housing bolts Loose / Tight
6.62 Ensure protection tape is installed on probe areas Yes / No
6.63 * Ensure proper marking of all bearing parts Yes / No Witness
6.64 Check radial bearings and fill Journal bearing checklist Yes / No
6.65 Oil drain lines are secured to prevent contamination Yes / No
6.66 Check condition and clearance of splash ring seal OK / Damage
6.67 Inspect shaft journal area for any abnormalities OK / Scratched
6.68 Inspect gear teeth and perform DPT OK / Crack
Dimensional Check
Design As Found Final
Sr Parameters Witness
(mm) (mm) (mm)
6.69 * Radial bearing clearance (Wheel side) 0.064 - 0.145
6.70 Shaft journal area OD (Wheel side)
6.71 * Radial bearing clearance (Drive side) 0.064 - 0.145
6.72 Shaft journal area OD (Drive side)
6.73 Backlash with bull gear
6.74 * Axial Clearance (with thrust bearing) 0.635 - 1.27
6.75 Thickness of thrust liner shims
6.76 Axial clearance (w/o thrust bearing)
6.77 Housing pre-load / crush (Wheel Side)
6.78 Oil seal clearance (Wheel side)
Notes:

7. Assembly
7.1 Verify cleaning of both rotor Yes / No
7.2 Verify cleaning of shrouds Yes / No
7.3 Ensure all elastomers have been replaced Yes / No
7.4 * Ensure no foreign object inside gear case Yes / No Witness
Important Note: Actions marked with Asterisk sign (*) are hold points and must be signed by supervisor, engineer or VSM Page 4 of 6
 MM-CHK-IMS-090 Rev 00 (15/12/2016)

Maintenance Checklist
Maintenance
Overhauling of Integral Gear compressor Department
(NP CO2 compressor)

7.5 Ensure both rotors centered and gap voltage adjusted Yes / No
7.6 * Final dimensional check and record in 6A/6B/6C Yes / No Witness
7.7 * Ensure RTDs are properly connected to pads Yes / No Witness
7.8 * Ensure all V&T probes have been installed properly Yes / No Witness
7.9 Verify cleaning of upper casing Yes / No
7.10 Verify match marks before assembly Yes / No
7.11 Tightening sequence of gear-case bolts is followed Yes / No
7.12 Torquing of all casing bolts to required value Yes / No
7.13 Verify tightening of all lube oil connections Yes / No Witness
7.14 Verify tightening of all seal gas connections Yes / No
7.15 * Ensure no oil leakages from coupling guards Yes / No Witness
7.16 Verify area housekeeping Yes / No

Notes:

8. Alignment (Final)
Parameter Recommended Actual
8.1 Alignment method used Rim and face Rim and face / Reverse dial / Laser
8.2 Ambient temperature 20C
8.3 Spacer free length 17.51(419.354mm)
8.4 Distance b/w spacer and adapter 0.73 (18.542mm)
8.5 Distance b/w shaft ends (DBSE) 20 (508.0mm)
8.6 Dial needle on Compressor coupling
8.7 Driver machine relative to driven Higher (0.051mm/C)

As found alignment reading Tolerance (R): +0.1

8.8 R A
(HP - GB) Tolerance (A): +0.05

Notes:

9. Attachments
9.1 Coupling inspection checklist attached MM-CHK-IMS-071 Yes / No

9.2 Stage 1 rotor Journal bearing inspection checklist attached MM-CHK-IMS-072 Yes / No

9.3 Stage 2 rotor Journal bearing inspection checklist attached MM-CHK-IMS-072 Yes / No

9.4 Bull gear Journal bearing inspection checklist attached MM-CHK-IMS-072 Yes / No

Important Note: Actions marked with Asterisk sign (*) are hold points and must be signed by supervisor, engineer or VSM Page 5 of 6
 MM-CHK-IMS-090 Rev 00 (15/12/2016)

Maintenance Checklist
Maintenance
Overhauling of Integral Gear compressor Department
(NP CO2 compressor)

10. Spare parts replaced

Item Description Qty Item Description Qty Item Description Qty

11. Remarks
Major Observations, Special repairs, Recommendations for future etc

12. Verification
Job date: Team:
Filled by Reviewed by Approved by

Important Note: Actions marked with Asterisk sign (*) are hold points and must be signed by supervisor, engineer or VSM Page 6 of 6