Htdrocom Operation and Safety 4.01
Htdrocom Operation and Safety 4.01
Edition 4.01
2 Abbreviations Used............................................................................................3
2 Abbreviations Used
Actuator Device for suction valve control
CIU Compressor Interface Unit
CCM Compressor Condition Monitoring
DCS Distributed control system
EPS External Power Supply, 48VDC for Actuators and Fast-TIMs
Fast-TIM Transmitter Interface Module: Decentral data acquisition
device for fast and slow signals
DCS Distributed control system
GIM General Interface Module
HSS HydroCOM Service Software
HU Hydraulic Unit
IA Isolation Amplifier
IPS Internal Power Supply
PLC Programmable logic controller
SIM Stage Interface Module
TDC Top Dead Center
Bus Data line connecting all actuators and Fast-TIMs of one
stage
PA Equipotential bonding
PE Protective earth
TDC Top Dead Center
Safety Instructions
Danger of injury to person
Function instruction
Notes to avoid damage to the unit
EX protection instruction
Notes for EX protection rules
EEx-e is applied to the connection box and the construction of the solenoid.
Exception: The connection box for CSA and FM Div. 1 is EEx-d
The electric housing of the Fast-TIM is built in protection class EEx-d. The
connection box for power supply and field bus connection is designed as per
EEx-e. The connection box for connecting the transmitters is supplied as per
EEx-i.
Japan: Ex de IIB + H2 T4
General Description: General function - Certificates and approvals - Explosion protection
HydroCOM complies with the EMC regulations and the safety regulations for
low voltage devices.
General Description: General function - Certificates and approvals - Electromagnetic Compatibility (EMC)
All components and devices are only certified for correct and intended
applications. If using components and devices for other purposes then
warranty expires immediately.
Assembly and Installation Manual: Assembly and installation instructions for HydroCOM
The compressor must not be operated with other gases than specified at the
time of placing the order. If the compressor shall be operated with other
gases written approval has to be obtained from HOERBIGER.
General Description: General function - Certificates and approvals - Explosion protection
Caution: During operation (or when the suction plenum of the compressor is
under pressure) the valve housing must not be separated from the seal
housing!
Assembly and Installation Manual: System components – Actuators - Installation
Assembly and Installation Manual: Oil leakage, flare and seal gas lines - Flare gas lines standard
Note: It has to be ensured that the compression area and flare gas area are
kept free of explosive gas mixtures when operating the compressor plant.
The operation of the Hydraulic unit driving motor with a frequency converter
is inadmissible!!
Hydraulics Unit HydroCOM-HU Maintenance Instructions: General operating instructions for hydraulic units – Operation – Oil pressure
The Oil temperature - “Hi-Alarm” should be used as a warning signal for the
operator. An immediate failure or malfunction of the HydroCOM is not
expected, however the maintenance group should be informed, to solve the
problem of the unintentional temperature increase.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: General operating instructions for hydraulic units – Operation – Oil temperature
The oil level in the tank of the hydraulic unit will be monitored by a level
switch. This switch has to be used according to ATEX-standards. These
standards prescribe to switch off the pump if the level in the tank is too low.
To avoid unintentional shutdowns of the HydroCOM system HOERBIGER
recommends to check the oil level visually.
Please check daily the visual blocking indicators at the oil filters. Additional
information is contained in the operations instruction of the hydraulic unit. At
least one filter cartridge should be on stock for an eventual exchange.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: Inspection and maintenance - Routine Inspections - Check of the Blocking Indicators at the Oil Filters
During a daily round and especially in case the oil level decreases the pipes
to the compressor at the hydraulic unit should be checked.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: Inspection and maintenance - Routine Inspections - Visual Leakage Check at the Hydraulic Unit and the Pipes
The hydraulic oil together with the high pressure filter and the return filter
should be exchanged at latest every 16,000 service hours or every 2 years.
During this service, the oil / air cooler has to be cleaned and the coupling
engine – oil pump has to be checked for possible wear.
The hydraulic unit should be cleaned completely and tested for performance
every 32,000 service hours or 5 years.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: Inspection and maintenance - Routine maintenance of the Hydraulic Unit
Hydraulics Unit HydroCOM-HU Maintenance Instructions: Inspection and maintenance – General maintenance - Cooler
Hydraulics Unit HydroCOM-HU Maintenance Instructions: Inspection and maintenance – General maintenance - Fan cowl from the drive motor
• If the wear of the gear rim amounts more than 2mm the gear rim has to
be replaced
Hydraulics Unit HydroCOM-HU Maintenance Instructions: Inspection and maintenance – General maintenance - Clutch type 001
Remark: All service work requires the compressor being switching off and
depressurised. Further on the whole HydroCOM unit has to be switched off.
With dangerous and explosive gases the unit has to be purged with Nitrogen
as well. Please combine the service work with the scheduled maintenance.
The HOERBIGER service companies will gladly assist for installation work.
Assembly and Installation Manual: Assembly and installation instructions for HydroCOM
Hits onto parts of the actuator or other housing parts with metallic (e.g.
corroded) parts are not acceptable.
Assembly and Installation Manual: Assembly and installation instructions for HydroCOM
Assembly and Installation Manual: Assembly and installation instructions for HydroCOM
Note: On delivery diaphragm cylinders are filled with 2barg. Only the ones
installed in the pressure lines are to be filled with nitrogen. The correct
pressure is specified in the hydraulic data sheet (part of the customer
documentation).
Filling of the diaphragm cylinders can be done only with the HYDAC-filling
equipment.
All operations at the motor and at the hydraulic unit have to be performed
taking into account „safety first“.
• Please make sure to disengage the power pack before you perform your
work.
Caution: When working on the hydraulic unit, make sure that the piping
system is not under pressure. Additionally the hydraulic unit must be
switched off.
Assembly and Installation Manual: Hydraulic lines & fittings - General specifications
The hydraulic unit can be used within the zone 1, 2, 21 and 22. The unit is
designed for the gas and dust Ex- range of the equipment group II in the
equipment category 2.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: General description – Design and Components
For the actuators it is necessary to use mineral based hydraulic oil with a
viscosity of 10cSt to 15cSt at a temperature of 40°C (equal to ISO-VG 10 or
ISO-VG 15) and ignition temperature of ≥ 185°C.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: General description – Design and Components
The hydraulic unit should operate with a temperature of 70°C. When the oil
temperature reached 80°C, the hydraulic unit must be switched off.
The oil level switch must be connected in accordance with the operating
manual by the manufacturer electrically.
If the oil level reached the switching point from the oil level switch, the
hydraulic unit must be switched off. Level disconnection in the safety circuit
of the driving motor.
With a pressure decrease of 30bar, the power unit must be switched off .
Pressure disconnection in the safety circuit of the driving motor.
The drive motor which is selected and installed by the customer, must be
correspond the explosion protection requirement. The customer is
responsible to full fill the explosion protection requirements.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: Assembly and Installation instructions – Connecting of electrical equipment – Drive motor
The aggregate must be grounded over the ground terminal (earth clip) which
is installed on the tank cover.
For security reasons don't loosen any connections or devices while the
system is pressurized. Before hand, the pressure has to be reduced, the
pumps have to be switched off, and the accumulators have to be relieved.
Make sure everything is absolutely clean before working, because dirt can
cause major damage to hydraulic systems.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: General operating instructions for hydraulic units - Notes
• Check the position of the shut-off ball valves and change if necessary
• Open the bypass valve for depressurising the hydraulic unit (horizontal
position of lever = bypass open)
• Does the direction of rotation of the drive motor correspond to the given
direction of rotation of the pump? Start for a short moment and confirm.
• Close the bypass valve. Increase set values of pressure relief valve up
to the required value. Fix the locknut. Should no pressure build up: stop
motor, and proceed, as is described under point no suction of the pump.
Hydraulics Unit HydroCOM-HU Maintenance Instructions: General operating instructions for hydraulic units – Start up – Trial run
Note: The ventilation holes must be protected from water splashes by the
covers supplied. They must not be closed, as they are an element of the Ex-
protection.
Assembly and Installation Manual: System components – Actuators – Japanese Cable Glands
The devices are built in protection degree IP55 and must be protected
additionally when used in more severe environment (e.g. when
hoseproofness is required or when pollution higher than degree 2 occurs).
Assembly and Installation Manual: System components – Measuring Module TIM – Installation
All terminal parts are located in the EEx e terminal compartment. Opening of
the Ex d compartment is not required. Wiring work is only allowed while the
Fast-TIM is not powered.
Only the cable glands that are certified for this application must be used for
this application (EEx e).
Wiring has to be supported externally, therefore cable glands without
tension-compensation are permitted.
Not used cable glands must closed with the supplied certified plugs (EEx e).
Assembly and Installation Manual: System components – Measuring Module TIM – Connections
Assembly and Installation Manual: System components – Measuring Module TIM – Technical Data
6.5 CIU
Assembly and Installation Manual: System components – EPS (External Power Supply) – Installation
Note: Two dry contacts or two 0/24VDC signals can be connected to the
isolation amplifier. It is not possible to mix dry contacts and 0/24VDC signals
on the same isolation amplifier!
Assembly and Installation Manual: Wiring – Wiring for Isolation Amplifier IA - Wiring of IA to CIU and DCS
Warning: If the wrong file is downloaded to the CIU the compressor may trip
and the equipment be damaged.
Service & Configuration Software: Service – Set Parameters Download Configuration to CIU