Storage in struction

1. G eneral inform ation

Storage and shipping instructions

for Z-com pressors, stages and elem ents
SELLER DOCUMENT REVIEW
Printed M a tter Nu m ber

2946 0066 02

Applic able to

Z-compressors

Prelim ina ry Operations

2 Revise & Resubmit. Work make proceed 4 Review not required. Work may proceed

Safe ty Ins tru ctions

General

Document Status: 4

Perso ns Re quired

Sp ecial Tools

C onsum able s

Roto-Z oil

Permission to proceed does not constitute acceptance or approval of design detail, calculations,
analysis, test methods, or materials developed or selected by SELLER, and does not relieve
SELLER from full compliance with contractual obligation.

1 work may proceed

Subject to incorporation of change

3 Revise & Resubmit. Work may NOT proceed

5 Cancelled / Supersede

Review Name: RAL

Date: 4/5/2013

Discipline: EM - Mechanical

Document Type Code: V1A

Job#

25635

VP#

25635-220-V1A-MCS0-00074

Subm002

Equip# 0393-CPC-0015;0393-CPC-0016;0393-CPC-0017;0393-CPC-0018;0393-CPC-0044;

Program# NA;
Job#

VP#

SEQ#

Equip#

2. Docum ent overview

This document describes the following:
1.

General information ...................................................................................................................................................... 1

2.

Document overview ...................................................................................................................................................... 1

3.

Safety first .................................................................................................................................................................... 2

4.

Introduction .................................................................................................................................................................. 3

5.

Shipping precautions, ex factory .................................................................................................................................. 3

5.1.

Com pressor units ..................................................................................................................................................... 3

5.2.

Stages ..................................................................................................................................................................... 3

5.3.

Frequency converters of the ZR-VSD's ................................................................................................................... 4

6.

Inspection after shipment ............................................................................................................................................. 5

6.1.

Inspecting com pressor units .................................................................................................................................... 5

6.2.

General comm ents .................................................................................................................................................. 5

7.

Precautions before storage .......................................................................................................................................... 6

7.1.

Com pressor units ex factory .................................................................................................................................... 6

7.2.

Com pressor units stored after operation .................................................................................................................. 7

7.3.

Com pressor stages .................................................................................................................................................. 8

7.4.

Frequency converters .............................................................................................................................................. 9

8.

Instructions for equipment in transit ........................................................................................................................... 10

8.1.

Com pressor units ................................................................................................................................................... 10

8.2.

Stages ................................................................................................................................................................... 10

8.3.

Frequency converters ............................................................................................................................................ 10

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3. Safet y firs t

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4. In tr o d u c t io n
This service bulletin explains how to take care of equipm ent in storage and/or in transit. These instructions apply during the
entire period of storage, up to the point of delivery to the end user. The present information relates to the Z-range of Oil-free
compressors. It also relates to the relevant com pressor elements or stages delivered as spare parts.

5. Sh ip p in g p r ec au tio n s , ex f ac t o r y
Special procedures are followed in Airpower when packaging equipment. Their aim is to prevent corrosion during shipment.
These procedures apply to all compressor units and compressor stages.

5.1.

C om pressor units

All compressor units are test-run with Roto-Z oil, a film of which rem ains behind on shafts, gears and bearings.
Five silica gel bags, tied together, are placed inside the housing of the intercooler water separator of ZR compressors.
The purpose of this is to absorb any traces of moisture. The compartments are closed off airtight using the original flange
of the machine.
NOTE:

One of the strings of the bags is made to stick out of the flange and a sticker is glued to the flange in order to draw your attention
to the presence of the silica gel bags.

The vent holes are closed off with m oisture repellent adhesive tape.
Unpainted surfaces are covered with a layer of highly adhesive grease.
Gauges, switches and other instruments, not built into a cubicle or cabinet, are covered externally with a protective layer
of wax.
Panel doors (except for the cubicle door) are secured with a locking plate on one of the hinges and a clamp on the
bottom frame.
The complete compressor unit is enclosed in a plastic cover and placed on a pallet or in a crate. Lifting m arks are
painted on the crates.

5.2.

Stag es

ZR compressor stages are test-run using Roto-Z oil. A protective oil film remains behind on the drive components.
The tim ing gears of the stages are covered with a layer of highly adhesive grease.
Air inlet cham bers are provided with pleated VCI-paper (Volatile Corrosion Inhibitor) or silica gel bags and closed-off with
m oisture repellent adhesive tape.
All oil inlet and vent orifices and the cooling medium in- and outlets are closed off with a plastic plug, a cap, or water
repellent adhesive tape.
Drain plugs are removed and delivered loose with the elem ent.
The drive shaft and the outer surface of the bearings at the drive side are covered with highly adhesive grease and
wrapped with moisture repellent paper held in place with adhesive tape.
A protective coating of grease is applied to all threaded holes.
The flange which m ates the compressor gear case is covered with adhesive masking tape.
Compressor stages are placed in containers fitted with special supports designed to keep the contents in place.

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5.3.

Fr eq u en c y c o n v ert er s o f t h e ZR-VSD' s
On ly ap p li cab le fo r VSD u n its!

Since the control cubicle (the cubicle containing the frequency converter) contains a lot of electronic devices, this
compartm ent of the compressor has to be kept as dry as possible. Therefore, VCI-paper (Volatile Corrosion Inhibitor) is
placed inside the converter compartm ent ex factory. By doing this, the converter will be protected against a possible high
hum idity.
During transport, the relative humidity may not exceed 95%, because this can damage the electronic parts inside the
converter. In addition, the tem perature is limited. During transport, the perm issible ambient and cooling-medium
temperature is set at -25C to 70C (-13F to 158F ).

Once implem ented, these precautions will protect the compressor stage for a period of at least one year. The precautions
remain valid providing there has been no rough handling during transport, and that the equipm ent has not been subjected to
unfavourable am bient conditions (excessive humidity, heat or cold).
It is imperative to inspect each com pressor, stage, or element imm ediately upon arrival. Check the shipping documents to
determine how long the unit has been underway since leaving Atlas Copco Airpower.

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6. In s p ec tio n aft er s h ip m en t
Always inspect the equipm ent immediately after shipm ent. Verify the m ode of transport as well as the length of tim e that the
equipment has been underway. The purpose of such an interim inspection is to ensure that the equipment will reach its final
destination in perfect condition.
Never forward a compressor unit or stage to a custom er without first having inspected it properly.
A brief inspection entails checking the crate or container for dam age. Check that no moisture has penetrated the packaging
material and that the contents have not moved inside the box or container.
If you encounter transport damage, subm it a damage claim imm ediately - directly with the carrier. Also send a copy of the
damage claim report to Atlas Copco Airpower, Supply Department (ASC). Do this without delay.

6.1.

In s p ec tin g c o m p res s o r u n it s

1.

Dism ount the top part and the sides of the crate. Take the plastic cover off the unit.

2.

Loosen the clamps securing the doors to the frame. Open the doors and check the equipment inside:
Check that the air inlet opening in the roof is still covered up.
Check that loose com ponents, e.g. air outlet and drain valves, are still properly wrapped and secured to the bottom
of the m otor compartment.
Check that all vent holes are still plugged with plastic caps or closed-off with adhesive tape.
Check that any unpainted surfaces are still covered with a layer of highly adhesive grease.
Check that the moisture repellent adhesive tape is still covering the air compartments containing the silica gel bags.
If the tape has become undone, even partially, the silica gel bags are to be replaced. Re-order the silica gel bags
using part number (1619 2625 00). Insert new silica gel bags and close off the compartment(s) with new m oisture
repellent adhesive tape.
Note the location of the silica gel bags and adhesive tape: in the intercooler moisture drain compartm ent in ZR
units.

3.

Turn the drive shaft, dum my bush or pinion, several turns by hand.

4.

Rectify any possible fault conditions that you may find and proceed as per section 7.1 or section 7.2.

6.2.

Gen eral c o m m en t s

Pr o c ed u re fo r to u c h in g u p b o d y w o r k :
1.

First sand the spot slightly, next apply "Levis" cem ent paint.

2.

Spray the paint from a m inim um distance of 40 cm.

3.

Contact your local Levis supplier to source m atching paint and colour.

Reg en er atin g s ilic a g el b ag s :

This can be done quite easily. Silica gel bags that have not been stored airtight must be regenerated before use.
1.

Dry them out in an oven at a temperature of approx.100C (212F) for 1 hour.

2.

Spread the bags out on an open grating.

3.

Do not stack the bags or let them touch.

4.

During the drying process be sure that the moisture being released is also vented from the oven.

5.

Silica gel bags retrieved from ZR units after transport may also be regenerated and subsequently re-used.

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7. Pr ec au tio n s b ef o r e s t o rag e
7.1.

1.

Co m p r es s o r u n its ex f ac t o ry

It is im p o rtan t to carry out storage maintenance on any equipment that has been in shipment for close to a year, and
which is due for further storage (or transport).

Ren ew in g th e s il ic a g el b ag s
Rem ove the plate and take the silica gel bags out of the relevant air compartments.
Note down the num ber of bags fitted.
Location of the silica gel bags: intercooler moisture drain com partm ent of ZR units.

Ren ew in g th e p res erv ati ve o i l-fil m

ZR units are norm ally delivered ex factory with Roto-Z oil as first fill. This oil also has preservative qualities. The
duration of the protective period is 6 m onths. Using Roto-Z precludes the need for separate oil circulation procedures.
On units, filled with Roto-Z oil ex factory, turn the main drive coupling by hand during a few minutes in order to redistribute the oil film on bearings balls, rollers and drive gears.
Repeat this procedure once every six months.

W hen the unit does not contain oil, the following instructions apply:
Set up an oil circulation pump with a capacity of approx. 15 l/min. (4 US gallons) and an effective working pressure
of 1.5 to 2.5 bar (20 to 36 psi).
Connect the pump to the compressor lubricating system , as shown in Fig. 1.

Fill up the compressor sump with 80 l (21 US gallons) of Roto-Z oil.

Circulate the oil throughout the compressor for approximately 15 minutes. Meanwhile, turn the compressor coupling
over hand, once every two or three minutes.

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Drain the Roto-Z oil from the sum p and disconnect the circulating pum p. Re-install the original pipes. Store the oil in
a clean container for later use.
Place the nom inated quantity of dry silica gel bags inside the unit. It is best to im mobilise the bags, e.g. by tying
them together and then tying one string to a flange hole.
NOTE:

Take care to close off the opening really airtight, using moisture repellent adhesive tape. Moisture present in the intercooler
compartment during storage will be detrimental to the condition of the compressor stages.

2.

Close the m ain air inlet duct using the original protective material (or sim ilar). Close the doors of the unit. Cover the roof
with plastic sheeting to reach down just over the doors.

3.

Store the unit in a clean, dry, well ventilated warehouse. Stand the unit upright in its crate or on the pallet. Be sure there
is no source of vibrations nearby e.g : vibrations com ing up through the floor can have a detrimental effect on the
bearings long-term.

4.

Inspect the unit once a month. Turn the main coupling a few turns by hand, to change the position of balls and rollers in
the bearings and redistribute the oil-film.

The compressor unit is now ready for storage for maximum 6 m onths. The storage period rem ains valid provided that the
ambient conditions remain normal (meaning no excesses of heat, cold or high humidity). If the unit is to be stored for a
period longer than 6 months then repeat the storage maintenance procedures once, every subsequent 6 months.

7.2.

Co m p r es s o r u n its s t o r ed af ter o p erat io n

If the unit will not be started again for a period of:

Several hours to several days
Several months to 6 m onths

Sev er al h o u rs to s ev eral d ays

1.

Open or purge manual drains of intercooler and aftercooler drain receivers or EW Ds, LOADED just before stopping.

2.

Check if drain pipes are free from water. Close the valves after the condensate is drained.

3.

If frost can be expected, drain the cooling system carefully.

4.

Inspect the unit once a month. Turn the main coupling a few turns by hand, to change the position of balls and rollers in
the bearings and redistribute the oil-film.

Sev er al m o n th s to 6 m o n th s
1.

Proceed as above.

2.

Close off compressor air intake and compressor element vent holes.

3.

Close air outlet valve.

4.

Place 5 Silica gel bags in the intercooler and aftercooler m oister drain compartment. It is best to im mobilise the bags,
e.g. by tying them together and then tying one string to a flange hole.
NOTE:

Take care to close off the opening really airtight, using moisture repellent adhesive tape. M oisture present in the intercooler/
aftercooler compartment during storage will be detrimental to the condition of the compressor stages.

5.

Drain the condensate which may have collected in the bleed off cooler (if present).

6.

Put the correct number of VCI-plates (Volatile Corrosion Inhibitor) in the canopy and 1 plate in the cubicle.
(1 VCI plate/1000L volum e, part number VCI-plate (1614 8905 00)).

7.

Close the doors of the unit. Cover the roof with plastic sheeting to reach down just over the doors.

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8.

ZR and ZT units are normally delivered ex factory with Roto-Z oil as first fill. This oil also has preservative qualities. The
duration of the protective period is 6 m onths. Using Roto-Z precludes the need for separate oil circulation procedures.
On units, filled with Roto-Z oil turn the drive coupling a few turns by hand in correct rotation direction at least once a
week, to change the position of balls and rollers in the bearings and redistribute the oil-film.

9.

Store the unit in a clean, dry, well ventilated warehouse. Stand the unit upright in its crate or on the pallet. B e sure there
is no source of vibrations nearby e.g: vibrations coming up through the floor can have a detrimental effect on the
bearings long-term.

10. Put a warning label on the start cubicle, indicating to rem ove Silica gel bags, open compressor air intake and
compressor elem ent vent holes.
11. The compressor unit is now ready for storage for maximum 6 months. The storage period rem ains valid provided that
the am bient conditions remain norm al (meaning no excesses of heat, cold or high humidity). If the unit is to be stored
for a period longer than 6 m onths then repeat the storage maintenance procedures once, every subsequent 6 months.
12. Follow installation checklist before starting.

NOTE:

7.3.

If the unit is stored for more then one year a service plan type C should be carried out before starting the machine again.

Co m p r es s o r s t ag es

Compressor stages are occasionally held in transit for periods of up to one year or m ore. In such cases, carry out the
following storage maintenance before putting the equipment into (further) storage:
Renew the pleated VCI-paper (Volatile Corrosion Inhibitor) in the air inlet chamber. Renew the oil film on the bearings and
timing gears and the protective grease on the drive shaft.
The requisite procedures for this storage maintenance are as follows:
1.

Remove the tape from the in- and outlet flanges. The VCI-paper should still be attached to the tape when it is being
pulled off. If the paper has come loose rem ove it separately taking care that no pieces stay behind in the rotor chamber.

2.

Position the shaft of the stage with the oil injection orifice on top. The orifice is located next to the flange of the timing
gear cover. Take the plastic plug out of the orifice and insert a suitable funnel.

3.

Rotate the drive shaft while pouring a nom inated quantity of Roto Z oil into the oil inlet connection of the element
NOTE:

do not - ever pour oil into the compressor chambers.

Nom inated quantities of oil: ZR stages 3 to 6: 1 litre (0.26 US gal).

Perform this operation at an am bient temperature of minimum 20C (68F).
4.

Having poured in the oil, continue to rotate the drive shaft for another 3 minutes.

5.

Position the stage, or elem ent, with the lubricating drain orifice facing the bottom. Place a sufficiently large container
under the drain orifice.

6.

Take the plastic plug or cap out of the drain orifice and rotate the drive shaft. Let the excess oil drain into the container.

7.

W hen all excess oil has been drained clean the lubricating inlet- and drain orifices with a degreasing solvent. Close off
both orifices with a plastic plug or cap.

8.

Position the stage or element with the drive end pointing upwards. Spray an ample supply of Roto-Z oil into each of the
ball bearings. Use a spray can. Let the oil seep downwards onto the roller bearings underneath. Rotate the drive shaft
at regular intervals.

9.

Cover the drive shaft and bearings with a layer of highly adhesive grease. Cover up these parts with grease-proof
paper. Secure the wrapping using adhesive tape.

10. Close-off the air outlet orifice thoroughly using water repellent adhesive tape.

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11. Fold a strip of VCI-paper (Volatile Corrosion Inhibitor) in pleats. Insert it in the air inlet chamber with its edges folded
halfway over the flange, see Fig. 2.

12. Cover the air inlet flange, and the edges of the VCI-paper, with water repellent adhesive tape.
13. Check that the adhesive tape - covering the flange to be fitted to the gear case - is still firm ly in place. Replace the tape
if necessary.
14. Apply a layer of protective grease to all threaded holes.
15. Place the stage or elem ent in its original container. Close the lid of the container using nails or screws.
If the container is to be stored for an undetermined period of time, cover the element or stage in plastic sheeting,
including a strip of VCI-paper (Volatile corrosion inhibitor) attached to the elem ent or stage with adhesive tape.
16. Store the container in a dry, well ventilated warehouse. This preservative storage m aintenance is valid for a period of
maximum 18 months (36 months if wrapped in VCI-paper). At the end of this period re-inspect and renew the
preservative storage maintenance procedures.
17. Inspect the unit once a month. Turn the main coupling a few turns by hand, to change the position of balls and rollers in
the bearings and redistribute the oil-film.

7.4.

Fr eq u en c y c o n v ert er s
On ly ap p li cab le fo r VSD u n its!

To store a ZR-VSD, several actions are to be taken. All of these actions are described in section 7.1 (com pressor units).
Beside these actions to be taken for compressors in general, specific action is needed to safeguard the converter. The
presence of humidity can be detrimental to electronic devices. Because of this, all VCI-paper located inside the converter
must be taken out and has to be renewed.
Also take care of several precautions, given by the supplier of the converters, which in this case is Siemens or Vacon.
Make sure that:
The temperature during storage does not get too high. The permissible ambient and cooling-medium tem perature is set
at -25C to 70C (-13F to 158F).
The relative humidity may not exceed 95% during storage. If possible, install dehum idifiers, since damage could occur
above 60% relative humidity.
The compressor has to be stored in a well-ventilated warehouse, in order to avoid condensation inside the converter
cubicle and to m ake sure that the converter is protected against dust and excessive heating.

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8. In s t ru c tio n s f o r eq u ip m en t in tr an s it
8.1.

Co m p r es s o r u n its

The following instructions apply to equipment which has been inspected upon arrival, and which is due for further transport
to the end-user site. The purpose of these procedures is to ensure continued protection against corrosion or other damage.
These instructions also apply to units which (in exceptional cases) are to be returned to Atlas Copco Airpower.
1.

Verify that the cooling system has been properly drained and blown dry.

2.

Inspect the unit as per section 6.1 above. Dismount the blind flange, cover with m oisture trap, or elbow as indicated
under item 2 of section 5.1.

3.

Place the dismounted part in a safe place inside the unit. W herever it m ay prove useful, e.g. in the case of the moisture
trap, wrap the part in VCI-paper (Volatile Corrosion Inhibitor) secured with adhesive tape.

4.

Carry out the storage instructions as per section 6.1 and, where applicable, refit the gratings to the coupling housing.

5.

Secure the doors to the base fram e using the clam ps provided.

6.

Place the original plastic cover over the unit, or cover it up with plastic sheeting secured with adhesive tape. Be sure
that the roof and all side panels are fully covered.

7.

Place the unit in its original crate. Failing this, construct a wooden crate strong and safe enough to withstand routine
handling by fork lift or slings and crane.

8.

Apply the shipping data to the crate, using indelible ink. Apply the markings on both sides. If the original crate is used
delete the old markings.

9.

W here applicable be sure to include the requisite customs- and transport docum ents, for shipment with the unit.

8.2.

St ag es

The following instructions apply to stages which have been inspected upon arrival (as per section 5.2) and have been
prepared for storage (as per section 7.2 or 7.3).
1.

As soon as the top cover of the container (or crate) has been nailed or screwed down, the stage is ready for shipm ent.

2.

Instructions for storage m aintenance are also to be implemented for all stages and elem ents being returned to Atlas
Copco Airpower.
Im p o r tan t n o te: Th e w at er jac k et o f a stag e m u s t alw ays b e fu lly d rai n ed an d b lo w n d r y, b ef o re p lu g g i n g th e in - an d
o u tlet o ri fic es .

3.

8.3.

Stages originating from break-downs should not be treated with oil or grease as this would obstruct the subsequent
investigations to be carried out by the AIF Service Department in Airpower. The water jackets however must be blown
dry and all orifices plugged or closed off with adhesive tape. The stage or element is to be wrapped in V.C.I.-paper and
packed airtight in its container. If anti-corrosive V.C.I.-paper is not available then include several bags of dry silica gel
with the stage or element and pack these airtight using plastic sheeting or similar.

Fr eq u en c y c o n v ert er s
On ly ap p li cab le fo r VSD u n its!

Norm ally, the door of the frequency converter does not need to be opened. However, if the compressor has been underway
for a long time, or if the door has been opened for any reason, the VCI-paper has to be renewed.
During transport, the relative hum idity m ust not exceed 95%, as this would have a bad detrim ental effect on the electronic
components inside the converter. Avoid excessive variations in temperature. During transport, the perm issible variation of
ambient and cooling medium temperatures is set at -25C to 70C (-13F to 158F).

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