Reciprocating Compressors for industrial refrigeration GEA Grasso

Reciprocating Compressors for industrial refrigeration GEA Grasso
Reciprocating Compressors for industrial refrigeration
GEA Grasso 10
Installation and Maintenance Manual
0087125gbr_4
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
COPYRIGHT
All Rights reserved. No part of this publication may
be copied or published by means of printing, photocopying, microfilm or otherwise without prior written
consent of Grasso.
This restriction also applies to the corresponding
drawings and diagrams.
LEGAL NOTICE
This publication has been written in good faith. However, Grasso cannot be held responsible, neither for
any errors occurring in this publication nor for their
consequences.
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GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
SAFETY INSTRUCTIONS
Hint!
This manual must be carefull read and
understood prior to installing and
servicing the compressor (package)
Safety
This manual is written with great care, but the contractor/installer is held responsible to examine this
information and to take care of possible additional
and/ or deviated safety measures.
Safety instructions
It is the task of the contractor/installer to inform and
explain to his client the operation of the compressor
(Package).
Do respect all federal, state or local safety regulations/legislations during installing, connecting and
operating this compressor (package).
Construction changes
Warning!
In compliance with the regulations of
the Pressure Equipment Directive it is
mandatory that no changes be made
to the construction of pressurised
parts such as the crankcase housing,
suction filter housing etc.
Installer oriented information
The compressor (package) is filled with nitrogen to
prevent penetration of moisture. Therefore, keep the
compressor closed until the compressor (package) is
being installed.
Warning!
The compressor is not filled with oil.
Hint!
After the successful initial run of the
compressor (package) the warranty
chart must be filled in and returned to
Grasso. A warranty chart is attached
to each compressor.
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
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Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
PREFACE
General
1. All documentation can be downloaded via our
web site.
2. Grasso’s technical manuals includes “generic
paragraphs”; this means that it can occur that
not all data as described is relevant for the current compressor series as mentioned in this
manual. (For instance, not all compressor series
are suitable for all mentioned refrigerants or not
all compressor series includes two-stage compressors)
Directives
Equipment is based on Pressure Equipment Directive (PED 97/23/EG) regulations and according to
Machine Directive (MD 2006/42/EG) regulations.
The applied standards are:
NEN-EN-IEC 60204, NEN-EN-ISO 12100, NEN-ENISO 13857, NEN-EN 378
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Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
CYLINDER NUMBERING
Fig.1:
Cylinder numbering Grasso reciprocating compressors
Legend
1, 2, 3, ...
Cylinder numbers
T
Top view of compressor
M
Motor/Drive end of compressor
O
Oil pump of compressor
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Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
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GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
GENERALINFO
Main setup data Grasso 10
Description
Value
Start frequency
max. 6 starts per hour
Time interval between stopping and re-starting
min. 2 minutes
Time interval between starting and re-starting
min. 10 minutes
Time interval between capacity steps
min. 3 minutes
Oil level
25-75% crankcase sight glass
Min. oil temperature
> 10 oC and > Pcrankcase + 15 K
Max. oil temperature
Refer to oil selection table/applied type
of oil
Control oil pressure
suction pressure + 8 bar
Lubricating oil pressure difference
between 1.3 and 4.5 bar Setting
approx. 2.0 bar
Max. discharge temperature
170 °C
Min. suction pressure
0.3 bar (a)
Max. intermediate pressure
Max. suction pressure
Pdischarge - Psuction
Superheat
Oil suction filter
Remark
For continuous minimum part-load (i.e. more than
30 minutes) consult Grasso.
Adjust the steps between up and down loading, in
such a way that the system is running stable.
Required oil viscosity;
≥ 10 cSt during operation at location of bearings
After a mimimum of 15 minutes running time at an
oil temperature of approx. 50 oC (122 oF)
8.5 bar (a)
≤25.0 bar
>0 K for NH3, R22
>15K for R507/R404A/R134a
Blue coloured filter element
Hint!
Oil discharge - running in - filter
Red coloured filter element
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Factory mounted; to be replaced
after max. 100 running hours by
permanent oil discharge filter element
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Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Main setup data Grasso 10
Description
Value
Remark
Hint!
8
Oil discharge - permanent - filter
Grey filter element
Direction of rotation of compressor drive
shaft
Counterclockwise when facing shaft
end
Supplied loose; replacement for
factory mounted running in filter
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
TABLE OF CONTENTS
1
2
INSTALLATION AND PREPARATION FOR USE
1.1 Running-in oil filter has to be installed after an overhaul or big repair
1.2 INSTALLATION
1.2.1
Moving instructions and storage
1.2.2
Storage
1.2.3
Hoisting and moving instructions
1.2.4
Required free space
1.2.5
Foundation requirements
1.2.5.1
Concrete structure
1.2.5.2
Anchoring
1.2.5.3
Mounting the base frame on a concrete block
1.2.5.4
Mounting bare compressor on a concrete block
1.2.6
Connecting to refrigerating system pipework
1.2.7
Connecting the power supply
1.2.8
Earthing connections
1.2.9
Separately delivered components
1.3 PREPARATIONS FOR USE
1.3.1
Leak test of compressor and system
1.3.2
EVACUATION/DRYING THE REFRIGERATING SYSTEM
1.3.3
Initial oil charge
1.3.3.1
Initial oil charge
1.3.4
Initial refrigerant charge
1.3.5
Adjustment of instruments and safety devices
1.3.5.1
CONTROL DEVICES
1.3.5.2
Refrigerants R717 and halocarbons
1.3.5.3
Re-adjustment of oil pressure regulator
1.3.6
Checking direction of rotation of motor shaft
1.3.7
Installing the drive guards (if present)
1.3.8
Initial oil warm up
1.3.9
Initial start-up
1.3.9.1
Limitations of part load operation and start-up
1.3.9.2
WIRING LOGIC NORMALLY OPEN UNLOADED START SOLENOID
1.3.9.3
Frequency controlled compressor
1.3.9.4
Pre-start check list
1.3.10 Starting and stopping procedures
1.3.10.1 First start
1.3.10.2 Restart
1.3.10.3 Restart after a short standstill period of time (less than 1 month)
1.3.10.4 Restart after a long standstill period of time
1.3.10.5 Stopping the compressor
INSPECTION AND TROUBLE SHOOTING
2.1 Periodical inspection
2.2 Survey of periodical inspections
2.2.1
Check list periodical inspection
2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months)
2.4 LUBRICATION DATA
2.4.1
Topping up oil with compressor operating
2.5 EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE
2.5.1
EVACUATION OF REFRIGERANT BEFORE SERVICING
2.5.2
LEAK-TIGHTNESS AFTER SERVICING
2.5.3
EVACUATION AFTER SERVICING
2.5.4
START-UP AFTER SERVICING
2.6 DRAINING AND CHANGE OF OIL
2.6.1
DRAINING OIL REVERVOIR FOR MARINE USE (Optional)
2.7 REPLACEMENT OF OIL FILTERS
2.7.1
Oil discharge filter
2.7.2
Oil suction filter (Pos. B)
2.8 REPLACEMENT OF SUCTION GAS FILTER(S)
2.9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES
2.10 COMPRESSOR PURGING
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3
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2.11 TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS
MAINTENANCE
3.1 Post start-up maintenance
3.2 First maintenance
3.3 SMS FACTOR
3.4 Legend
3.4.1
Grasso 10
3.4.2
Checklist
28
31
31
31
31
32
33
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Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
1
1.1
INSTALLATION AND PREPARATION FOR USE
Running-in oil filter has to be installed after an overhaul or big repair
Hint!
This is why and when the running in
oil filters are required:
Warning!
A running in oil filter has always to be
installed after an overhaul or big repair
for the 1st 100 hours of operation!
5. The electric wiring should be completed as per
wiring diagrams. Do not energise the main power
control cabinet until oil is added and the direction
of rotation has been checked.
6. The compressor is to be filled with the correct
type and amount of lubricating oil and has to be
pre-lubricated (Refer ) before the first start.
7. ‘Open compressors’ only;
7.1
The drive system should be installed.
7.2
After 100 operating hours, the oil
could slightly become clear again.
1.2
8. The system should be charged with the correct
amount of refrigerant.
9. The oil should be warmed up above minimum
start up oil temperature (see "Product Information").
10. The control cabinet should be energised to
check the package controls.
INSTALLATION
Hint!
Do not forget to charge the oil separator (if present) initially with oil, to the
level of the float assembly
Warning!
The compressor is not charged with
oil, therefore, DO NOT start the compressor before it has been installed
and prepared according to Grasso’s
instructions.
This section contains instructions for the proper
installation of a Grasso compressor (package).
Before the compressor (package) is ready for the initial start up, the installation instructions in the following paragraphs must be followed:
1.2.1
Caution!
Every precaution must be taken while
moving the package to its final location. Pushing, pulling or climbing on
any package component or piping, can
easily create damage.
2. All piping should be completed.
3. The system and the compressor are to be pressure tested for leaks (see. Section 1.3.1,
Page 17)
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Moving instructions and storage
For loose component or compressor package
weights, refer either to the relevant component type
plate or package lay-out or to the suppliers document. For bare compressor weights, see "Product
Information".
1. The Compressor (Package) should be levelled
and securely anchored to the foundation.
4. The system should be evacuated to remove air
and moisture.
(Semi) hermitic compressors;
Mark R-S-T-N power supply in the terminal
box of the motor.
The oil and oil oil filters have to be
replaced by new oil and filters.
Due to running-in wear of liners and
piston rings, it's normal that the oil
becomes grey during the 1st 100 operating hours.
Open compressors;
1.2.2
Storage
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Reciprocating Compressors for industrial refrigeration
The compressor (package) is filled with dry nitrogen.
Keep the system closed until the package is installed. If the compressor (package) is stored, it should
be kept at all times in a dry location to prevent corrosion damage. If the compressor (package) is to be
stored for a prolonged period of time, it should be
checked weekly to ensure that the holding charge of
dry nitrogen remains above atmospheric pressure.
1.2.3
Hoisting and moving instructions
Fig.3:
Hoisting angle
Moving by fork-lift truck
Fig.2:
Hoisting a compressor package
Packaged base frame:
The only places that can be used for safe hoisting of
the package are the four hoisting eyes on the steel
base frame as shown in the above figure. Prior to
hoisting a compressor package with a V-belt drive
arrangement, the factory mounted drive guard has to
be removed. Attach spreader bars to the slings so as
to prevent damage to piping and components.
The bare compressor or package can be transported
with a fork-lift truck with the forks spread as much as
possible between the skids. To simplify moving, the
2 wooden transport beams must still be mounted
underneath the base frame and stored in this way,
until the package is positioned above its approximate
location.
1.2.4
For easy operating, servicing and maintenance
access, the compressor (package) should be installed with sufficient free space around it.
Hint!
Warning!
DO NOT use the compressor or motor
or oil separator hoisting eyes to move
the package! These hoisting eyes are
intended for lifting loose components
only and not for the entire package!
Bare compressor or loose components:
Determine the dead weight of the particular component (see "Product Information (ED)"), prior to moving a bare compressor or loose component. Use the
hoisting eyes only, DO NOT sling from other compressor parts (see Figure 3, Page 12).
12
Required free space
Refer to “Product Information“ for
minimum requirements.
1.2.5
Foundation requirements
Hint!
Compressor (package) has to be
mounted on a concreted block. On
request, Grasso can calculate the
exact dimensions of the concrete
block, based on the compressor size
and operating conditions.
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
This paragraph covers measures to be taken for a
compressor (package) mounting on a concrete
block.
Two foundation arrangements are described:
1. Compressor package with steel base frame
mounted on a concrete block.
The concrete block for compressor and motor or
compressor package should have a profile as illustrated in Page 13 and made according to the following recommendations:
•
The concrete block should be set on firm footings or on a floor capable of carrying the weight
of the concrete block and capable of absorbing
the free forces and gas forces of the compressor
during operation. The ground under the concrete
block should be horizontal and flat.
•
The top surface of the block should be level and
even.
•
There should be sufficient free space around the
block to install corkboard (or similar).
•
The block should be provided with anchor bolt
recesses or holes according to the anchor bolt
spacing as per package lay out drawing.
Following base frames are possible;
1.a
Frame designed for mounting on concrete
block.
For more instalation details refer to; Section 1.2.5.1, Page 13, Section 1.2.5.2,
Page 13, Section 1.2.5.3, Page 15,
Section 1.2.5.3.1, Page 15, Section 1.2.5.3.2, Page 15.
1.b
Frame designed for mounting on vibration
dampers.
For more details in case mounting base
frames on vibration dampers is applied,
refer to separate instruction sheet and
other order documentation like package
drawing, supplied with the compressor
package and consult Grasso if required.
2. Bare compressor direct mounted on a concrete
block via grouted anchors.
For more installation details refer to; Section 1.2.5.1, Page 13, Section 1.2.5.2,
Page 13, Section 1.2.5.4, Page 15.
1.2.5.1
Fig.5
Concrete structure
A
Chemical anchor
B
Grouted anchor, grounded to reinforcing steel
It is recommended to consult a concrete specialist/
constructor for the following items:
Fig.4:
Concrete block
1
Cork board
2
Concrete base
3
(Concrete) Floor
4
Sand
•
The compound of the concrete with/without reinforcement.
•
The exact grouting depth (dependent on the soil
conditions).
•
Installing foundation onto an existing floor, with
sealing corkboard or vibration isolators.
1.2.5.2
Anchoring
After the concrete block has cured the anchors
should be installed as shown above and in case of a
package in accordance with the package lay out
drawing. Templates should be made to locate the
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Reciprocating Compressors for industrial refrigeration
anchor bolts or chemical anchors to match the holes
in the bottom flange of the base frame.
Grout the mortar according to the supplier instructions. Install chemical anchors as illustrated in Figure 6, Page 14 and according to the instructions of
the anchor supplier.
Fig.6:
14
Anchoring details
A
Drilled chemical anchor (M20)
B
Grouted anchor recesses (M20)
1
Installed chemical anchor before placing the base
frame
2
Installing chemical anchor after placing the base frame
(base frame cannot be removed easily)
3
Drilling angle
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Reciprocating Compressors for industrial refrigeration
1.2.5.3
Mounting the base frame on a
concrete block
General
After the space between base frame and concrete
base has been filled-up with a filling grout, the package base frame must be secured tightly to the foundation block or floor.
1.2.5.3.1
Levelling the base frame
After levelling has been completed the adjusting bolt
ends must be greased to avoid bonding to the selflevelling grout. The space between concrete block
and frame must be completely filled with the self-levelling grout to ensure that the complete bottom surface of the base frame will be supported. Therefore,
it is not allowed to use shims between concrete base
and base frame.
Grouting must be carried out in accordance with the
instructions provided by the grouting supplier. After
complete de-aeration of the grouted layer, secure the
base frame by tightening the anchor bolt nuts and
remove all adjusting bolts. At this stage the drive
system can be installed. These (accessories) installation instructions can be found in the order manual.
1.2.5.4
Fig.7:
Grouting details
1
Self-levelling grout
2
Adjusting bolts (4x)
3
Washer
4
Temporary barrier strip around and inside frame
5
Complete cured concrete block
6
Grout layer
Mounting bare compressor on
a concrete block
If base frame is not applied the approximately the
same procedure of levelling the base frame has to
be applied for the bare shaft compressor (refer Section 1.2.5.3, Page 15).
The mounting surfaces of the compressor feet must
be level without any deviation and projecting at least
10 mm above the concrete base.
After the anchor filling mortar has completely cured
the frame should be levelled with a space between
block and lower frame flange of 3 - 5 mm*. This
space is necessary for levelling using the base frame
adjusting bolts with metal washers (supplied separately). The base frame should be levelled on each
frame side. Adjust the frame on each adjusting place
until all frame sides are horizontal.
This space largely depends on the sort of grout or
mortar used. Determine this space according to the
instructions of the grout or mortar supplier.
1.2.5.3.2
Finishing with a self-levelling grout
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Hint!
If an oil rectifier system is applied in
the refrigeration system, the oil return
line must be connected to the oil
return connection (see "Product Information").
Suspension of system pipework
To eliminate vibration transmission to the system
piping, the following is recommended:
Fig.8:
Grouting details of bare compressor on concrete block
Legend
1
Self leveling grout
2
Foundation anchor
3
Layer of self leveling grout (10 - 15 mm)
4
Temporary barrier strip aroud each compressor
foot
5
Complete cured concrete block
CF
Compressor foot
Width of grout layer
WL
Install all piping free of tension.
•
Secure the piping by clips or brackets in two
directions.
•
Install (stop) valves, piping and accessories
such, that there is no load exerted on the compressor.
1.2.7
Connecting the power supply
Information about further electrical connections to be
made (e.g. crankcase heater, drive motor starting
equipment, thermal protection of drive motor, automatic start/ stop and other external electrical devices) can be found in the plant manual (not supplied
by Grasso).
(WL-WC > 40 mm)
Width of compressor foot
WC
1.2.6
•
(WL-WC > 40 mm)
Connecting to refrigerating system pipework
1.2.8
Earthing connections
Grasso compressors and packages are equipped
with litz-wires and earth connecting points.
To avoid leakage current flowing through the components, disconnect all litz-wires when arc-welding.
After all installation functions are completed, reconnect the litz-wires and ground the package to earth.
Warning!
DO NOT ground through the compressor when arc welding
After the compressor (package) has been levelled
and secured to the foundation, the system piping
may be connected. The suction line(s) and discharge
line(s) should be installed and supported such that
there is no load exerted on the compressor. The size
and location of the suction and discharge connections, can be found in the "Product Information" (bare
compressor) and in case of a package, the package
lay out drawing.
16
1.2.9
Separately delivered components
Hint!
Check whether the sets/parts/components belonging to this compressor
are supplied loose! (Refer to order
confirmation)
Mount these separately delivered sets, components
and/or parts, according to the instructions as supplied with this compressor (package).
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
1.3
PREPARATIONS FOR USE
vi.
Wait approx. 24 hours.
After the Compressor (Package) has been installed
(excluding final connection of drive device), the following actions should be followed in the order given:
vii.
If pressure has increased (system still contains
moisture), repeat steps iv, and vi. Otherwise,
continue with the "Initial oil charge" procedure.
1.3.1
1.3.3
Leak test of compressor and system
Warning!
The compressor (package) has been pressure tested
prior to leaving the factory. In case an additional leak
test is required, this test is should be carried out with
dry nitrogen.
Oil charging via the suction line of the
compressor is not allowed.
Hint!
Used or filtered oil should NEVER BE
added to a compressor under any circumstance.
DO NOT add oil to the compressor
prior to pressure testing
Use only new oil as selected from the
Grasso oil table. (Refer )
A system leak test should be carried out over 24
hours to ensure that the system is tightly sealed.
Record during the pressure test, the pressure, ambient temperature and outside temperature. During the
initial 6 hours a pressure drop of 2% is permissable.
With respect to temperature variations, no further
pressure loss should be detected in the remaining 18
hours.
1.3.2
Initial oil charge
EVACUATION/DRYING THE
REFRIGERATING SYSTEM
Procedure:
i.
STATUS: System is dried and still evacuated.
ii.
Charge the oil separator (if present) initially
with oil .
iii.
Close suction and discharge stop valves of
compressor and oil return line of oil separator
(if present).
iv.
Charge the compressor crankcase with oil via
the oil charge valve.
Warning!
Pre-lubrication just before the first
start is obligatory.
For evacuation of compressor only, refer to Section 2.5, Page 25
Procedure to evacuate and to dry a system:
Hint!
i.
STATUS: System is filled with nitrogen and no
oil has been added (oil prevents any trapped
moisture from boiling off).
ii.
Verify that all valves in that part of the system
to be evacuated are opened (refer also to the
plant manual).
Filling of the afore mentioned components is also possible by means of a
separate oil filling pump via the oil
charge valves mounted onto the oil
pump housing.
iii.
Connect vacuum pump to the evacuation/purging valve(s) of the compressor (for location of
these valves refer to the "Product Information"
or to a connection as mentioned in the plant
manual and evacuate the system to approx. 6
mBar.
iv.
Break vacuum by charging dry nitrogen into the
system.
v.
Repeat step iii, "Connect vacuum pump ...".
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
1.3.3.1
Initial oil charge
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Pressure safety limit switches
QUANTITY OF OIL TO BE FILLED ( dm3)
2
0.6
3
0.7
Crankcase
Oil pump
0.5
0.7
6
0.8
9
8
0.9
13.5
Suction and intermediate pressure
6.5
1.3.5.1
Lubrication oil pressure difference
Min. =0.3 bar(a)
Setting
Max.= depends on
rotational speed,
refer to Product
Information (PI)
Setting
5oC above design
condensing temp.
Precondition
Max. =24 bar(a)
Setting
Min. =1.3 bar
Oil pressure regulators for R717 and halocarbons
Initial refrigerant charge
Adjustment of instruments and
safety devices
Setting
2.0 bar
Lubrication oil
pressure difference2
Precondition,
at 50 oC oil
temp.
Max. =4.5 bar
Control oil pressure difference
Setting
8.0 bar
Min. =1.3 bar
CONTROL DEVICES
Hint!
Refer to separate user manuals, in
case an electrionic control device is
installed.
1.3.5.2
Precondition
Discharge pressure
Refrigerant charging should be done in accordance
with the plant manual by qualified refrigeration engineers.
1.3.5
5oC below design
evaporating temp.
9.0
4
1.3.4
Setting
Suction pressure1
6.5
1.5 each
Number of
cylinders
Oil filters
for R717 and halocarbons
Shaft seal
housing incl.
internal circuit of
crnkshaft
Refrigerants R717 and halocarbons
1.3.5.3
Re-adjustment of oil pressure
regulator
It is possible that after the compressor(package) has
been installed, the lubrication oil pressure regulator
(located on the left side of the pump) needs to be readjusted.
Inside the oil pump two regulators are factory preset
and installed; One control oil pressure regulator
(right) to control the valve lifting mechanisms and
one lubricating oil pressure regulator for lubrication.
2
The oil pressure regulator is adjusted at the works, but it
may occur that this setting should be corrected during the
initial run and also if the value <1.5 or >2.5 bar. The re-
1
18
Settings Pdischarge - Psuction must never exceed max.
value as mentioned in Product Information
adjustment procedure is given in section “Re-adjustment
of oil pressure regulator.
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Fig.9:
Oil pressure regulator
Legend
1
Lubricating oil pressure regulator
2
Control oil pressure regulator
A
Oil suction filter
ii.
Determine the lubricating oil pressure difference (difference between the pressure gauges
of the oil and suction or [dOil]).
iii.
Determine the control oil pressure difference
(difference between the pressure gauges of oil
pump discharge 3 and suction.
iv.
Remove the cap nut of both oil pressure regulators if the pressures need to be re-adjusted.
v.
Turn the slotted pin with a screwdriver clockwise or counter clockwise for a higher or lower
oil pressure respectively, until the required control & lubricating oil pressure differences have
been achieved 4.
vi.
Replace both cap nuts.
Hint!
Oil discharge filter
If the valve lifting fails, check the control oil pressure regulator!
Hint!
A running in filter is factory mounted;
to be replaced after max. 100 running
hours by permanent oil discharge filter element
B
1.3.6
Oil charge valve for lubrication circuit.
Hint!
C
This connection to be used for prelubrication of the oil circuit
D
Oil charge plug for oil suction filter (Hand operarated
oil pump and stop valve are not included)
E
Connection to measure oil control pressure
F
Hand operated oil charge pump (optional).
Re-adjustment procedure:
Hint!
For settings, refer .
i.
Run the compressor for 15 minutes until the
crankcase oil is at its stable operating temperature [Toil] of 50 oC at which:
# The lubricating oil pressure difference should
be (A) according to .
Checking direction of rotation of
motor shaft
Prior to installing the intermediate coupling element
or V-belts, the direction of rotation of the motor shaft
must be checked. The direction of rotation can be
determined from the arrow-sticker at the oil pump.
1.3.7
Installing the drive guards (if
present)
Only after the compressor is ready for the initial
startup! Refer to the drive guard installing procedures included in the order documentation.
1.3.8
Initial oil warm up
Prior to the initial start-up, the crankcase heater (if
present) must be energised. For the min. oil temperature refer to “Product Information (PI)“.
1.3.9
Initial start-up
# The control oil pressure difference should be
approx. (B) according to .
After the initial run the oil pressure differences
should be slightly higher.
3
To be measured by means of a special control oil pres-
4
Re-adjusting one regulator will affect the other one, so be
sure gauge to be connected at position E on the oil pump.
sure that both regulators are properly (re-)adjusted.
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1.3.9.1
Limitations of part load operation and start-up
1.3.9.3
Frequency controlled compressor
Hint!
The capacity control serves to adapt the compressor
capacity at any moment as closely as possible to the
refrigerating capacity. In order to adjust the capacity,
a number of cylinders can be put in or out of action
either individually or collectively by means of solenoid valves.
In case of frequency controlled compressors, a separate instruction
00.87.041 is required. If you don’t have
this instruction consult Grasso.
Warning!
Due to start-up limitations and to limitations of part load operation it may be
that not all available part load steps
are allowed under certain conditions.
Use of incorrect control steps can
damage compressor and/or components.
For a detailed description about start-up and part
load limitations refer to the software program “Comsel”.
1.3.9.2
WIRING LOGIC NORMALLY
OPEN UNLOADED START
SOLENOID
1. If compessor is NOT running then NO-solenoid
is not energised.
2. Energise the NO-solenoid 10 - 20 seconds
before starting.
3. If compressor starts then NO-solenoid is energised and de-energised by means of an auxiliary
time relay.
1.3.9.4
The following Paragraph covers only the initial start
of the compressor and not the complete refrigeration
plant.
Be sure that all necessary system valves are open
and that the refrigeration system is ready for start up.
Use the following check to guarantee that no items of
importance regarding the compressor (package)
have been overlooked.
i.
System is charged with refrigerant.
ii.
Settings of safety limit switches are adjusted
properly.
iii.
Direction of rotation of compressor crankshaft
is correct.
iv.
Check capacity control: Set the electrical
capacity control to the position of the lowest
part load step.
v.
Oil level established in sight glass.
vi.
Stop valves to the pressure gauges are open.
vii.
Suction stop valve is closed (in case the evaporating temperature is much higher than the
design evaporating temperature) and the discharge stop valve is open and in case of twostage compressors that the stop valves in the
intermediate circuit lines are open.
viii.
Stop valve in the oil return line of the oil separator (if present) is closed.
4. Ensure that the NO-solenoid valve is not deenergised until the minimum allowed compressor
speed has been achieved and the specified lubrication oil pressure has been established.
5. Energise the NO-solenoid 5 seconds before
stopping until the compressor is stopped completely.
When all items are verified, the compressor (package) is ready for the start-up.
1.3.10
20
Pre-start check list
Starting and stopping procedures
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Reciprocating Compressors for industrial refrigeration
Hint!
Hint!
For all limitations refer to "Main setup
data"-overview! The values in the main
setup data tables, overrules the values
as mentioned in the text.
In the case of decreasing capacity for
two stage compressors, it is not
allowed to cut out all LP-cylinders.
When starting the compressor a distinction should be
made between:
1.3.10.1
i.
Notice "Pre-start check list", also consult the
plant manual and verify the following items:
–
–
ii.
First start
Check the oil temperature (refer to the
"Product Information").
v.
Watch maximum allowable motor current (refer
to motor type plate).
vi.
Watch discharge temperatures LP and HP,
max. intermediate pressure and max. allowable
motor current (refer to motor type plate).
vii.
Adjust pressure gauge stop valves, in order to
avoid vibration of the pointers.
viii.
Open the stop valve in the oil return line from
the oil separator (if present).
ix.
Open compressors only; After 50 hours of
operation retighten the coupling bolts or check
and/or correct the tension of the V-belts and
retighten the foundation bolts (with due respect
to the torque settings given by the supplier of
the fasteners!).
Check crankcase oil level (refer to Section 2.4.1, Page 25).
Start the compressor and check whether the oil
pressure increases.
Hint!
The time interval between stopping
and starting should be at least 2
minutes and between starting and restarting 10 minutes.
iii.
Refrigerant liquid hammer, will damage the compressor; Superheat is
always necessary! Refer to general
limits of operation to determine the
mimimum superheat for current refrigerant!
In case of electrically operated capacity control:
Restart
Hint!
For the time interval between stopping
and starting refer to "Main setup data"overview.
Slowly open suction stop valve and watch suction pressure, which may not exceed the max.
value.
Hint!
iv.
1.3.10.2
Proceed to the complete starting procedure like “First
start“
1.3.10.3
•
Restart after a short standstill
period of time (less than 1
month)
Refer to Section 1.3.10.2, Page 21.
iv.a Single-stage compressors: One or more
cylinders will be energized.
iv.b Two-stage compressors: 3 - 5 minutes
after starting and only when HP-cylinder(s) is (are) in operation, the LP cylinders can be energised.
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1.3.10.4
Restart after a long standstill
period of time
After a seasonal standstill (1 till 6 months) or
maintenance operations;
Warning!
After a standstill period of time more
than 1 month, pre-lubrication just
before starting is always obligatory.
Refer
•
Check settings of control and safety equipment.
•
Proceed to the complete starting procedure.
Warning!
Restarting compressor after a standstill period of time more than 6
months, consult your supplier. It is
recommended to proceed with the initial start up procedure.
1.3.10.5
Stopping the compressor
The compressor can be stopped at any moment,
however, consult the supplier if further actions are
required.
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2
2.1
INSPECTION AND TROUBLE SHOOTING
Periodical inspection
These inspections should be made during the normal
shut-down periods as much as possible, so the compressor is always ready to operate when required. If,
at that time, the number of running hours slightly differs from the scheduled period below, the inspection
should nevertheless be carried out.
In this way it will not be necessary to stop the compressor at inconvenient times.
The frequency of inspections is dependent on the
type of installation, operating conditions and local
regulations. In the case of automatically controlled
plants, the periodical inspection are particularly
important. The table below sums up all the points on
the compressor that have to be inspected or maintained along with inspection and maintenance frequencies.
2.2
Survey of periodical inspections
Apart from the check points in the table below, the
sound produced by the compressor also provides an
indication of its mechanical condition. If abnormal
sounds are audible, their cause should be traced and
removed immediately in order to prevent serious
breakdowns.
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Check list periodical inspection
Check list periodical inspection
Oil level in
crankcase
Between 25% and 75%
height of the sight glass.
For topping up oil, refer
to Section 2.4.1,
Page 25.
•
Colour of the
oil
Lubricating
oil pressure
difference
•
•
Oil temperature max.
•
Oil leakage
of shaft seal
max.
•
•
Suction
superheat
Intermediate
superheat
•
24
Discharge
temperature
max.
monthly
•
Oil temperature min.
170 °C.
•
The oil should be transparently clear. A disappearing white colour
points to dissolved refrigerant.
In case of more than 1
cc/hr contact supplier.
Check against design
conditions. Refer to plant
manual.
Refer to plant manual.
For the max. allowable
discharge pressure refer
to the technical data of
compressor.
≥0 K (NH3)
During the first 50 operating hours the compressor should
be checked regularly for all the points mentioned above, at
least twice every 24 hours and more frequently in cases
where irregularities are found.
During compressor
standstill the lower part
of the crankcase must
remain warmer than the
surroundings: ≥ 20 °C
(NH3)
Check belts for:
1) Wear (fraying, cuts
etc.) and ensure that
they do not touch the
groove bottom.
Condition of
V-belts
•
Adjustment
and operation of pressure safety
switches
•
Refer also to instructions
of switch manufacturer.
•
Check the number of
operating hours in view
of any maintenance
operations to be carried
out.
Refer to the "Product
Information"
•
Discharge
pressure
5
REMARKS
•
Min. control
oil pressure
Suction pressure
FREQUENCY
REMARKS
monthly
weekly
daily
FREQUENCY
CHECK
POINTS *
daily
CHECK
POINTS *5
Check list periodical inspection
weekly
2.2.1
Capacity
control (if
provided)
•
Switching
frequency of
the compressor
•
Number of
operating
hours
2.3
2) Tension. Too low a
tension gives rise to
excessive flapping or
oscillation in operation.
For correct tension consult Grasso instruction
0087516
STEPS FOR LONGER SHUTDOWN PERIODS (> 6 months)
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Reciprocating Compressors for industrial refrigeration
To shut down a compressor for long term periods,
proceed as follows:
i.
Tightly shut both the suction and discharge
stop valves and the stop valve of the oil return
line (if present).
ii.
Disconnect the power source from the compressor drive motor and the electrical control
cabinet.
iii.
Place a moisture absorbing compound (eg a
dessicant such as silica gel) inside the control
cabinet.
iv.
Place warning tags on the electric system and
all closed stop valves.
Prior to starting up after a shut down, change the oil
and exchange the oil filters. Determine the starting
and stopping procedure from prior to start the compressor.
2.4
LUBRICATION DATA
Determine max Toil and set this value in the safety
device.
Change the oil as soon as an oil analysis indicates
contaminated oil.
Warning!
It is expressly pointed out that it is not
permitted to mix different types of oil.
If another type of oil is used, first
remove all the stale oil in the filters, oil
pump, crankcase, shaft seal, oil separator and oil drains of the installation.
2.4.1
Topping up oil with compressor
operating
Hint!
Use Grasso’s hand-operated oil pump,
part. no. 18.13.121
Topping up oil is permitted during compressor operation.
Be sure that this oil is the same as in the plant (refer
to Section 2.4, Page 25).
Without affecting the operation of the compressor,
the oil may be topped up by means of a separate oil
pump. This pump enables the oil to be forced into
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
the crankcase via the oil charging valve, against suction pressure.
Fig.10:
2.5
Oil level in compressor sight glass
EVACUATION, LEAK TESTING
AND START-UP OF THE COMPRESSOR/PACKAGE
To evacuate the refrigeration system refer to Section 1.3.2, Page 17,
Always use a vacuum pump or pump-down unit to
evacuate the refrigerant from the compressor.
2.5.1
EVACUATION OF REFRIGERANT BEFORE SERVICING
Procedure to evacuate the compressor:
1. Switch off main control panel
2. Remove main fuses
3. Close shut-off valves
4. Remove the refrigerant by means of a vacuum
pump or pump-down unit, via the evacuation/
purging valve(s) as prescribed by local safety
regulations. For the location of these valves refer
to the "Product Information".
5. Drain the oil from the compressor and oil separator, oil return /oil rectifier system if present.
2.5.2
LEAK-TIGHTNESS AFTER
SERVICING
The necessary safety precautions should be taken
before carrying out the leak-tightness test. To check
leak-tightness use dry nitrogen at a positive pressure
which is less than the admissible operating pressure
of the low pressure stage.
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2.5.3
EVACUATION AFTER SERVICING
After the pressure test has been completed, the
compressor (package) must be evacuated and
undergo a vacuum test. Evacuation is used to
remove air and moisture from the compressor (package)
2.5.4
ii.
Drain the oil via the oil charging/drain valve.
Remove the cover of one or more service
openings on the compressor side.
iii.
Clean the inside of the crankcase with a nonfibrous cloth (do not use cotton waste!).
iv.
Replace the service cover(s) with a new seal.
v.
Charge crankcase with clean oil in accordance
with the procedure.
START-UP AFTER SERVICING
1. STATUS: Compressor (package) is dried and
still evacuated.
2.6.1
DRAINING OIL REVERVOIR
FOR MARINE USE (Optional)
2. Charge the oil separator, if present, with oil.
See the appropriate Product Information for the
correct quantity.
Hint!
In case an oil reservoir for marine use
is applied, this oil reservoir has also to
be drained via the oil drain plug of the
oil reservoir.
3. Charge the compressor crankcase with oil via
the oil charge valve until the minimum level is
seen at the sight glass at the level as indicated in
IMM.
It is mandatory to pre-lubricate the oil circuit by
adding the final quantity of oil via the charge
valve mounted onto the oil pump by means of a
separate oil filling pump. The required oil level is
indicated in the IMM.
2.7
Hint!
Tools; Use the ring spanner for
(dis)mounting the oil filter cups (included in set of special Grasso tools)
4. Re-install all accessories such as coupling, Vbelt guard etc.
5. Open the shut-off valves.
REPLACEMENT OF OIL FILTERS
6. Check the start-stop procedure.
Evacuate (refer to Section 2.5, Page 25) the compressor prior to exchange the filter(s).
7. Check all safeties and controls.
Facts:
8. Re-install the main fuses.
Oil suction filter = BLUE coloured
9. Start up the compressor.
Oil discharge - running-in - filter = RED coloured
10. Check running condition.
Oil discharge - permanent - filter= GREY coloured.
Note:
The job isn't finished until the paper work is done!
Complete the service report, e.g. Grasso report
00.89.062.
2.6
DRAINING AND CHANGE OF OIL
To top up oil see Section 2.4.1, Page 25, Oil changing procedure:
i.
26
Evacuate the compressor (refer to Section 2.5,
Page 25).
2.7.1
Oil discharge filter
Hint!
An oil discharge (running-in) filter is
factory mounted. This filter must be
exchanged after max. 100 running
hours. Oil filters can not be cleaned!
Replace this filter according to the schedule in Section 2.2.2 and to the replacement instructions included in the filter set (GREY = permanent) or in case
of a modified plant (RED = running-in).
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2.7.2
Oil suction filter (Pos. B)
Hint!
The frequency of exchanging this filter depends on
the condition of the refrigeration system. It is recommended to exchange this filter when the compressor
is overhauled or when pressure drop exceeds 1 bar.
2.8
In order to reduce the downtime
involved in the valve inspection, it is
recommended to have as many complete valve assemblies in stock as
there are cylinders on the compressor.These valves can be exchanged
with the original valves; in this case,
these original valves can be inspected
and repaired or replaced if necessary
later.
REPLACEMENT OF SUCTION
GAS FILTER(S)
Hint!
Running-in suction gas filter(s) is(are)
factory mounted. This(these) filter(s)
must be exchanged after max. 100 running hours. Running-in filters can not
be cleaned!
2.10
COMPRESSOR PURGING
Procedure to purge the compressor (after maintenance jobs):
Procedure:
STATUS:
i.
Evacuate the compressor.
ii.
Remove and exchange the suction gas filter(s).
iii.
Purge the compressor.
Stop valves of suction, discharge and oil return line
are still closed (refer to Section 2.5, Page 25) and
compressor is filled with oil (refer to Section 2.6,
Page 26).
2.9
i.
Connect a vacuum pump to the evacuation/
purging valve(s) and evacuate as prescribed
by local regulations. For the location of these
valves refer to the "Product Information".
ii.
When evacuation is completed open the discharge stop valve.
iii.
Watch suction and discharge pressure.
DISMANTLING, INSPECTION AND
RE-ASSEMBLY OF SUCTION AND
DISCHARGE VALVES
Hint!
A high working temperature and rapid
temperature variations shorten the life
time of the valves, which, for this reason, require regular inspection.
The suction and discharge valves of a refrigeration
compressor are parts that are heavily loaded both
mechanically and thermally. Wear and life time of the
valves strongly depend on the working conditions of
the compressor. It is recommended that valve condition is regularly checked.For dismantling, inspection
and re-assembly of the valves, refer to the relevant
paragraph of the Compressor Service Instruction
Manual.
Hint!
If suction pressure increases quickly,
the discharge valve assy is leaking.
iv.
Start compressor.
v.
Slowly open suction stop valve.
vi.
Open the stop valve in the oil return line of the
oil separator (if present).
vii.
For two stage compressor only;
vii.a Two-stage system A/B: open liquid supply to interstage cooler.
vii.b Two-stage system C/D: refer to the plant
manual.
viii.
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
If a Self-Limiting Automatic Purger is not installed, purge the refrigerating system (refer to the
plant manual).
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2.11
TROUBLESHOOTING TABLE
GRASSO RECIPROCATING COMPRESSORS
The troubleshooting table shown overleaf may be
helpful to quickly trace and remedy failures that interfere with the proper operation of the compressor. It is
emphatically pointed out that the cause of a failure
must often be sought in the refrigeration installation
itself. Therefore, it is necessary besides this table
also to consult the plant manual.
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Troubleshooting
FAULT
A
Discharge
pressure too
high
B
Discharge
temperature
too high
C
Suction pressure too high
Troubleshooting
CAUSE
REMEDY
1. Discharge stop
valve not fully open
Open fully
2. Discharge pressure gauge defective
Repair or replace
3. Non-condensables in the system
Purge with a Automatic
Purger
1. Discharge pressure too high
FAULT
CAUSE
REMEDY
1. Suction stop
valve not fully open
Open fully
2. Suction gas
strainer blocked
Renew
3. Injection control
not adjusted correctly
Re-adjust control
See A
4. Too little refrigerant in installation
Top-up with refrigerant
2. Too many cylinders cut out
Cut in more cylinders
5. Suction pressure
gauge defective
Renew
3. Suction pressure
too low
See D
4. Excessive superheat of suction gas
Eliminate excessive
superheat
D
Suction pressure too low
Warning!
Stop compressor and contact
installation engineer
1. Liquid refrigerant
in crankcase due to:
5. For two-stage
compressors: interstage cooling does
not operate properly
Repair
6. Room temperature too high
Ventilate engine room
better
7. Discharge valve
defective
Repair or renew
8. Pressure relief
valve is leaking
Repair or renew
1. Capacity control
does not operate
Repair
2. Compressor
capacity too small
Refer to plant design
E
Crankcase
frosted or wet
*6
F
3. Suction pressure
gauge defective
Repair or renew
4. One or more suction valves defective
Renew suction valve
rings
All cylinders
inactive while
compressor is
operating
G
5. One or more discharge valves
defective
Repair or renew
6. Pressure relief
valve is leaking
Repair or renew
Too high oil
consumption
6
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
1a. Room temperature too low
Provide for crankcase
heating or, if provided,
check it for proper operation
1b. Oil return from
separator contains
liquid refrigerant
Consult plant manual
1c. Installation operates too wet
Re-adjust installation
and provide for superheat
1d. Liquid separator
too small
Consult plant manual
1. Oil pressure for
valve lifting mechanism too low
See J
2. Incorrect wiring of
capacity control
Refer to the "Product
Information”
1. Type of oil not
according to oil
lubrication oil table
(too thin oil)
Change oil type
In case of R744 applications only, crankcase can be frosted
or wet, during normal operating conditions.
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Troubleshooting
FAULT
Troubleshooting
CAUSE
REMEDY
2. Compressor
operates unloaded
too frequently
Refer to design calculations
3. No return from oil
separator *7
Check the operation of
float valve in oil separator
4. Restriction plug
at the bottom of
suction chamber in
cylinder clogged
FAULT
Clean plug
K
5. Worn out oil scraper ring(s)
Replace ring(s)
6. Loss of oil due to
leakage
Repair
7. Leaking shaft
seal (max. 1 cc/hr)
8. Oil level in crankcase too high
Too low or no
control oil
pressure
(Not or Grasso
5HP)
CAUSE
REMEDY
4. Liquid refrigerant
in crankcase
See E
5. Defective oil
pressure and/or
suction pressure
gauge (if present)
Repair or renew
6. Worn bearings
Renew bearings
1. Failure of control
oil pressure regulator in oil pump
Re-adjust or renew regulator
2. A lack of oil in oil
system
Add oil to the system
3. Oil pump defect
Repair or renew oil
pump
Repair shaft seal
Refer to Section 2.2
Drain/Refill with oil
9. Oil separator is
Refer to section “Initial
not initially filled with
oil charge”
oil
H
Too high oil
pressure during normal
operation at
working temperature
J
Too low lubricating oil pressure
7
30
1. Lubricating oil
pressure regulator
not adjusted properly or defective
Re-adjust or renew
2. Defective oil
pressure and/or
suction pressure
gauge (if present)
Repair or replace
1. Too little oil in
crankcase
Top up oil
2. Disturbed oil circuit: Oil suction
and/or discharge filter is dirty
Renew the element of
oil suction filter and/or
oil discharge filter
3. Lubricating oil
pressure regulator
not adjusted properly or defective
Re-adjust or renew
During the initial start-up, the oil separator (if present) consumes oil before the first oil will be returned.
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3
3.1
MAINTENANCE
Maintenance
Post start-up maintenance
Number of operating hours
1008
After the compressor has run for the initial 100 operating hours:
i.
Replace the running oil discharge filter element
with the “permanent“ filter element in accordance with the filter replacement instructions.
iii.
Inspect suction gas filter (refer to the Compressor Service Instruction Manual).
iv.
Exchange or clean oil suction filter element.
v.
Check the compressor shaft seal for leakage. If
excessive (more than 1 cc/hr) replace the seal.
1) Retighten the coupling mounting bolts with
the torque settings as given by the coupling
manufacturer.
2) Verify and if necessary, correct the tension
of the V-belts as given in the Grasso instruction
0087516.
vii.
3.2
X
Renewal oil discharge filter
X
Inspect/clean oil suction filter
(strainer)
X
Oil analysis 9 10
X
Drain the oil and refill the compressor with the
correct amount of fresh oil.
ii.
vi.
Inspect/clean suction gas filter
3.3
> 100
refer to Service and
Maintenance
Schedules (SMS)
SMS FACTOR
General
The following maintenance has to be distinguished:
1. Grasso Maintenance Monitor (GMM) is applied
Maintenance A, B and C, service intervals are
determined on measured values of GMM
2. GMM is not applied:
Service intervals according to Service and Maintenance Schedules (SMS) tables in combination
with operating conditions
Verify and if necessary, correct the torque settings of all foundation bolts as given in Compressor Service Instruction Manual.
First maintenance
Hint!
For complete service schedules and
required service sets refer to Grasso"s
Service and Maintenance Schedules
(SMS).
After the refrigerating system has
been modified, the suction gas filter(s). the oil filters and the oil should
be changed.
9
8
Time dependent on pollution.
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
10
Take an oil sample every 3,000 running hours or once a
year and renew if any sign of discoloration and if the system
is contaminated.
Consult your oil supplier.
31
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Warning!
Actions
GMM is not used: The running hours
mentioned in the SMS tables should
only be used as a reference for maintenance intervals.
The number of running hours mentioned in the SMS tables have to be
adjusted accordingly depending on
the operating conditions of the compressor (speed, evaporating temperature, condensing temperature, refrigerant, start frequency, capacity control
steps, etc.. This means that the service
intervals could be significantly different.
Legend for service and maintenance schedules (SMS)
Item
Code/
Actions
Description
3
RE
Renewal
4
ME
Measure
5
CL
Clean
The running hours mentioned in the
tables are based on a single stage
compressor running at -10oC/+35oC,
NH3 at nominal speed. In this case the
SMS factor = 1, in all other cases the
maintenance intervals have to be
adjusted accordingly.
3.4
Legend
Warning!
These operations cover routine maintenance and are meant as a guide
only. Lack of maintenance, frequency
of stop/starting, extreme operating
conditions etc could lead to accelerated wear.
General;
The service and maintenance schedules use the
codes as explained in the table below;
Actions
Legend for service and maintenance schedules (SMS)
Item
Code/
Actions
Description
1
IC
Inspection / Alternatively renewal - correcting / Testing
2
IV
Inspection Visual / Alternatively electrical testing
32
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
3.4.1
Grasso 10
Service and maintenance schedules Grasso 10
Actions
Running hours * 100011
8
12
16
-
-
-
Description
Checkpoint
0.1
Yearly
Item
4
20
-
-
-
24
28
-
-
-
-
32
-
-
-
-
-
36
-
-
-
-
-
40
-
-
-
44
-
-
-
-
-
-
-
48
1
CL
RE
CL
RE
CL
RE
RE
CL
RE
Oil suction filter
2
RE12
RE
RE
RE
RE
RE
RE
RE
RE
Oil discharge filter13
-
ME
ME
ME
ME
ME
ME
ME
ME
Oil analysis
4
RE
RE
-
RE
-
RE
RE
-
RE
Oil refreshment (If hygroscopical oil is
used replace this always after each
opening of compressor or installation)
5
-
IC/CL
-
IC/CL
-
IC/CL IC/CL
-
IC/CL
Housing and element
6
-
IC/CL
-
IC/CL
-
IC/CL IC/CL
-
IC/CL
Control and lubrication oil pressure
regulator
7A
-
-
-
-
-
-
IC/M
E
-
IC/M
E
Main and intermediate bearing bushes
-
-
-
-
-
-
IC/M
E
-
IC/M
E
Main and intermediate bearing surfaces crankshaft
-
IC/M
E
-
IC/M
E
-
IC/M
E
IC/M
E
-
IC/M
E
Running surfaces con. rods
-
IC
IC
IC
IC
IC
IC
IC
IC
Oil/refrigerant leakage
3
Oil
Oil pump
7B
Crankshaft
8
9
11
12
13
Shaft seal
Check after every maintenance job the settings and working of all safety devices, regulators and the running conditions according to
the Service Instruction Manual (SIM)
A running-in oil discharge filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent filter. One permanent filter is supplied togehter with the compressor.
Oil discharge filter change every 4000 hours or check optional pressure drop indicator
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
33
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Service and maintenance schedules Grasso 10
Actions
Running hours * 100011
-
-
-
20
-
-
-
24
28
-
-
-
-
32
-
-
-
-
-
36
-
-
-
-
-
40
-
-
-
44
-
-
-
-
-
-
-
48
IC/M
E
-
IC/M
E
-
IC/M
E
IC/M
E
-
IC/M
E
Big and small end bearings
-
IC
-
IC
-
IC
IC
-
IC
Piston
-
IC
-
IC
-
IC
IC
-
IC
Piston rings
-
IC/M
E
-
IC/M
E
-
IC/M
E
IC/M
E
-
IC/M
E
Gudgeon pin
-
IC
-
IV/M
E
-
IV/M
E
IV/M
E
-
IV/M
E
Running surfaces/Axial play
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
Solenoid valves and coils
-
-
-
RE
-
RE
RE
-
RE
Seals of cap. control piston
17
-
IC
-
IC
-
IC
IC
-
IC
Cap. Control mechanism
18
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
IC/IV
Crankcase heater
19
CL
CL
-
CL
-
CL
CL
-
CL
Crankcase
-
-
-
-
-
IC
-
-
IC
Throttle valves LP/HP
21
-
IV
-
IV
-
IV
IV
-
IV
Relief valves
22
RE14
Conrod
11
12
Pistons
13
14
Thrust bearing
15
16
20
34
16
-
10
14
12
Checkpoint
0.1
11
8
Description
Yearly
Item
4
Capacity control
Compressor
housing
IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL
Suction gas filter
Check after every maintenance job the settings and working of all safety devices, regulators and the running conditions according to
the Service Instruction Manual (SIM)
A running-in suction gas filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent
filter. One permanent filter is supplied together with the compressor
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Service and maintenance schedules Grasso 10
Actions
Running hours * 100011
8
12
16
-
-
-
Description
Checkpoint
0.1
23
Yearly
Item
4
20
-
-
-
24
28
-
-
-
-
32
-
-
-
-
-
36
-
-
-
-
-
40
-
-
-
44
-
-
-
-
-
-
-
48
-
IC
IC
IC
RE
IC
RE
IC
RE
Valves, springs and damper rings
-
IC
IC
IC
IC
IC
IC
IC
IC
Stroke limitor/Discharge valve seat
-
IC
IC
IC
RE
IC
RE
IC
RE
Valves, springs and damper rings
-
IV
-
IV
-
IV
IV
-
IV
Cap. Control lifting mechanism
-
IV/M
E
-
IV/M
E
-
IV/M
E
IV/M
E
-
IV/M
E
Dimension and running profile
IC
IC
IC
IC
IC
IC
IC
IC
IC
Alignment
IC
IC
IC
IC
IC
IC
IC
IC
IC
V-belts
Discharge valves
24
25
Suction valves
26
Cylinder liners
27
28
Drive
29
30
Electric motor
Refer to specification of motor manufacturer
31
IC
IC
IC
IC
IC
IC
CL/IC
IC
CL/IC
Oil level switch
32
IC
IC
IC
IC
IC
IC
IC
IC
IC
Safety switches
IC
IC
IC
IC
IC
IC
IC
IC
IC
Gauges
34
IC
IC
IC
IC
IC
IC
IC
IC
IC
Thermostats
35
IC
IC
IC
IC
IC
IC
IC
IC
IC
Thermometers
36
IC
IC
IC
IC
IC
IC
IC
IC
IC
Electrical control system
33
Optionals
11
Check after every maintenance job the settings and working of all safety devices, regulators and the running conditions according to
the Service Instruction Manual (SIM)
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
35
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Service and maintenance schedules Grasso 10
Actions
Running hours * 100011
Item
4
16
-
-
-
Yearly
Checkpoint
20
-
-
-
24
28
-
-
-
-
32
-
-
-
-
-
36
-
-
-
-
-
40
-
-
-
44
-
-
-
-
-
-
-
48
37
IC
IC
IC
IC
IC
IC
CL/IC
IC
CL/IC
Valve oil return protection
38
IV
IV
IV
IV
IV
IV
IV
IV
IV
Thermistors
39
IC
IC
IC
IC
IC
IC
IC
IC
IC
Vibration dampers and bolts
40
IC/M
E
IC/M
E
IC/M
E
IC/M
E
IC/M
E
IC/M
E
IC/M
E
IC/M
E
IC/M
E
Intermediate cooler and injection
valve
41
CL
CL
-
CL
-
CL
CL
-
CL
Oil separator refreshing oil and cleaning/testing of float valve
42
-
IC
IC
IC
IC
IC
RE
IC
IC
Heavy duty thrust bearing
43
CL
CL
CL
CL
CL
CL
CL
CL
CL
Oil cooler, air side
44
RE
RE
-
RE
-
RE
RE
-
RE
Oil cooler, oil side, refrigeration oil
45
Refer to specification of motor manufacturer
Oil cooler, electric motor (fan)
Check after every maintenance job the settings and working of all safety devices, regulators and the running conditions according to
the Service Instruction Manual (SIM)
3.4.2
36
12
Description
0.1
11
8
Checklist
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Item
Service and maintenance schedules Grasso RECIPROCATING COMPRESSORS
Description
A
Compressor type
B
Machine number
C
Date
D
Running hours
E
Refrigerant
E
Evaporating temperature/pressure To/Po
F
Intermediate temperature/pressure Tm/Pm
G
Discharge temperature/pressure Tc/Pc
H
Oil lubricating pressure
I
Oil control pressure
J
General
Notes
Checked/Remarks/Notes
Checkpoint/Setting/Value
1
Oil suction filter
2
Oil discharge filter
3
Oil
Oil analysis
Oil refreshment (If hygroscopic oil is used replace this always after each
opening of compressor or installation)
4
5
Housing and element
Oil pump
6
7
Control and lubrication oil pressure regulator
Crankshaft
Main and intermediate bearing bushes and running surfaces
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
37
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Item
Service and maintenance schedules Grasso RECIPROCATING COMPRESSORS
Description
8
Checked/Remarks/Notes
Checkpoint/Setting/Value
Running surfaces con. rods
9
Shaft seal
Oil/refrigerant leakage
10
Conrod
Big and small end bearings
11
12
Piston
Pistons
13
14
Gudgeon pin
Thrust bearing
15
16
Piston rings
Running surfaces/Axial play
Solenoid valves and coils
Capacity
control
Seals of cap. control piston
17
Cap. Control mechanism
18
Crankcase heater
19
Crankcase
20
Compressor
housing
Non return valves LP/HP
21
Relief valves
22
Suction gas filter
23
24
25
26
27
Discharge
valves
Suction
valves
Cylinder liners
28
Valves, springs and damper rings
Stroke limitor/Discharge valve seat
Valves, springs and damper rings
Cap. Control lifting mechanism
Dimension and running profile
Alignment
Drive
29
30
38
V-belts
Electric
motor
Consult motor manufacturer
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Item
Service and maintenance schedules Grasso RECIPROCATING COMPRESSORS
Description
Checked/Remarks/Notes
Checkpoint/Setting/Value
31
Oil level switch
32
Safety switches
33
Gauges
34
Thermostats
35
Thermometers
36
Electrical control system
37
Valve oil return protection
38
Thermistors
Optionals
39
Vibration dampers and bolts
40
Intermediate cooler and injection valve
41
Oil separator refreshing oil and cleaning/testing of float valve
42
Heavy duty thrust bearing
43
Oil cooler, air side
44
Oil cooler, oil side, refrigeration oil
45
Consult motor manufacturer
46
Oil cooler, electric motor (fan)
Cylinder head water cooling system
Settings pressure safeties
Safety
Remark
1
Suction pressure
2
LP discharge pressure (safety)
two stage only
3
LP discharge pressure (limitor)
two stage only,
TUV
4
High pressure suction (safety)
two stage only
5
High pressure (safety)
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Value
39
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
Settings pressure safeties
Safety
Remark
6
High pressure (limitor)
TUV only
7
OIl differential pressure
40
Value
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
Installation and Maintenance Manual | GEA Grasso 10
Reciprocating Compressors for industrial refrigeration
GEA Refrigeration Netherlands N.V. | 0087125gbr_4 | Created 25.04.2016
41
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Phone: +31 73 6203911
info@gea.com, www.gea.com
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