GEA Grasso 5, Installation And Maintenance Instructions Manual

Page 1: ...Reciprocating compressors for industrial refrigeration GEA Grasso V Installation and Maintenance instructions Original text 0089288_imm_v_english_19 ...

Page 2: ...herwise without prior written consent of GEA This restriction also applies to the corresponding drawings and diagrams LEGAL NOTICE This publication has been written in good faith However GEA cannot be held responsible neither for any errors occurring in this publication nor for their consequences 0089288_imm_v_english_19 2 07 04 2021 ...

Page 3: ...Hint This manual must be careful 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 cli...

Page 4: ...hat will corrode the inside and working components of the compressor To store the compressor fill it with dry nitrogen after fully evacuating it Warning The compressor oil filters oil lines etcetera are not filled with oil Pre lubrication is obligatory Refer Section 4 7 Page 61 Hint After the successful initial run of the compressor package the warranty chart must be filled in and returned to Gras...

Page 5: ...oned 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 2014 68 EU regulations and according to Machine Directive MD 2006 42 EG regulations The applied standards are NEN EN IEC 60204 NEN EN ISO 12100 NEN EN ISO 13857 NEN EN 378...

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Page 7: ...er numbering Fig 1 Example cylinder numbering 6 cylinder compressor Booster or single stage operation 1 Booster operation applies if condensing temperature 5 oC 2 Single stage operation applies if condensing temperature 5 oC 0089288_imm_v_english_19 07 04 2021 7 ...

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Page 9: ...me interval between loading and unloading min 3 minutes 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 Oil level 25 75 crankcase sight glass Control oil pressure suction pressure 8 bar g Lubricating oil pressure difference between 1 3 and 4 5 bar Setting approx 2 0 bar g After a m...

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Page 11: ...r shaft 29 1 4 7 Installing the drive guards if present 29 1 4 8 Initial oil warm up 29 1 4 9 Initial start up 29 Limitations of part load operation and start up 29 WIRING LOGIC NORMALLY OPEN UNLOADED START SOLENOID 29 Frequency controlled compressor 30 Pre start check list 30 1 4 10 Starting and stopping procedures 30 First start 30 Restart 31 Restart after a short standstill period of time less ...

Page 12: ...art 3 of 3 49 Most operated cylinders 49 3 4 4 Package components 50 4 APPENDIX Product Information PI 51 4 1 GRASSO MAINTENANCE MONITOR 51 4 2 GENERAL LIMITS OF OPERATION GRASSO V 51 4 3 STARTING UP OF TWO STAGE COMPRESSORS 53 4 4 DIAGRAMS SINGLE STAGE AND BOOSTER 55 4 5 DIAGRAMS TWO STAGE 57 4 6 LUBRICATING OILS choice and recommendations 59 4 6 1 STRONGLY RECOMMENDED OIL TYPES 59 4 6 2 ACCEPTED...

Page 13: ...onsible for arranging the dual safety valve according the Pressure Equipment Directive 2014 68 EU 1 3 INSTALLATION 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...

Page 14: ...1 3 1 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 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 cr...

Page 15: ...ings so as to prevent damage to piping and components 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 ...

Page 16: ...ing and maintenance access the compressor package should be installed with sufficient free space around it Hint Refer to Product Information for minimum requirements 1 3 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 This paragra...

Page 17: ...2 Page 18 Section 1 3 5 4 Page 21 1 3 5 1 Concrete structure Fig 4 Concrete block 1 Cork board 2 Concrete base 3 Concrete Floor 4 Sand The concrete block for compressor and motor or compressor package should have a profile as illustrated in Page 17 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 t...

Page 18: ... 1 3 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 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 i...

Page 19: ...he base frame base frame cannot be removed easily 3 Drilling angle 1 3 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 INSTALLATION AND PREPARATION FOR USE INSTALLATION 0089288_imm_v_english_19 07 04 2021 19 ...

Page 20: ...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 Finishing with a self levelling grout After levelling has been completed the adjusting bolt ends must be greased to avoid bonding to the self levell...

Page 21: ...ing at least 10 mm above the concrete base 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 WL Width of grout layer WL WC 40 mm WC Width of compressor foot WL WC 40 mm 1 3 6 Connecting to refriger...

Page 22: ...ping by clips or brackets in two directions Install stop valves piping and accessories such that there is no load exerted on the compressor Recommendation Fig 9 To ensure quick and easy maintenance work the following is recommended 1 In all situations install a removable section of pipe 200 mm on the suction flange of the compressor 2 In case oil separator is not mounted onto the package install a...

Page 23: ...t manual not supplied by Grasso 1 3 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 1 3 9 Separately delivered components Hint Check ...

Page 24: ...g 18 hours 1 4 2 EVACUATION DRYING THE REFRIGERATING SYSTEM For evacuation of compressor only refer to Section 2 5 Page 35 Procedure to evacuate and to dry a system 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 iii Con...

Page 25: ...ge the compressor crankcase with oil via the oil charge valve Warning Pre lubrication just before the first start is obligatory Hint 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 1 4 3 1 Oil quantities Number of cylinders Shaft seal housing incl internal circuit of crankshaft Oil filter...

Page 26: ...ls in case an electrionic control device is installed 1 4 5 2 PRESSURE SETTINGS Pressure safety limit switches Suction pressure 1 Setting 5oC below design evaporating temp Min 0 3 bar a Suction and intermediate pressure Setting Max refer to Product Information PI Discharge pressure Page 26 Setting 5oC above design condensing temp Max 26 bar a Grasso V 300 T Grasso V 450 T Grasso V 600 T 1 Settings...

Page 27: ...EGULATORS It is possible that after the compressor has been installed the lubrication oil pressure regulator needs to be adjusted Location pressure regulators control and lubricaton Fig 12 Oil lubrication pressure regulator A 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 r...

Page 28: ...etermine the control oil pressure difference difference between the pressure gauges of oil pump discharge 3 and suction iv Remove the plug 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...

Page 29: ... in or out of action either individually or collectively by means of solenoid valves 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 GEA...

Page 30: ...ectrical 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 two stage compressors that the stop valves in the intermediate circ...

Page 31: ...cessary 4 In case of electrically operated capacity control One or more cylinders will be energized 5 Watch maximum allowable motor current refer to motor type plate 6 Watch discharge temperature and max allowable motor current refer to motor type plate 7 Adjust pressure gauge stop valves in order to avoid vibration of the pointers if present 8 Open the stop valve in the oil return line from the o...

Page 32: ...ion 4 7 Page 61 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 4 10 5 Stopping the compressor The compressor can be stopped at any moment however consult the supplier if further actions...

Page 33: ...stallation 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 produ...

Page 34: ...ture min During compressor standstill the lower part of the crankcase must remain warmer than the surroundings 20 C NH3 Hint Refer to the Product Information Condition of V belts Check belts for 1 Wear fraying cuts etc and ensure that they do not touch the groove bottom 2 Tension Too low a tension gives rise to excessive flapping or oscillation in operation For correct tension consult Grasso instr...

Page 35: ...ning 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 oper...

Page 36: ...essure 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 START UP AFTER SERVICING 1 STATUS Compressor package is dried and still evacuated 2 Charge the oil separator if present with oil See the appropriate Product Information for the correct quantity 3 Charge the compressor cran...

Page 37: ... crankcase with clean oil in accordance with the procedure 2 7 REPLACEMENT OF OIL FILTERS General The frequency of exchanging oil discharge filter oil suction filter and compressor suction gas filter s depends on the condition of the refrigeration system Besides the maintenance schedules it is recommended to exchange all filters when the compressor is overhauled and also in case the refrigeration ...

Page 38: ...e 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 2 9 COMPRESSOR PURGING Procedure to purge the compressor after maintenance jobs STATUS Stop valves of suction discharge ...

Page 39: ...er to the plant manual 2 10 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...

Page 40: ...ted correctly Re adjust control 4 Too little refrigerant in installation Top up with refrigerant 5 Suction pressure gauge defective Renew E Crankcase frosted or wet 6 Warning Stop compressor and contact installation engineer 1 Liquid refrigerant in crankcase due to 1a Room temperature too low Provide for crankcase heating or if provided check it for proper operation 1b Oil return from separator co...

Page 41: ... if present Repair or replace J Too low lubricating oil pressure 1 Too little oil in crankcase Ensure oil return from oil separator 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 4 Liquid refrigerant in crank...

Page 42: ...l vi 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 GEA instruction 0087528 vii Verify and if necessary correct the torque settings of all foundation bolts as given in Compressor Service Instruction Manual 3 3 First maintenance Hint For complete conditional service sched...

Page 43: ...the standard for B maintenance for compressors running at To 10 C Tc 35 C and 1200 min 1 When running mainly at 1500 min 1 speed the B maintenance interval becomes 10 000 running hours fixed Maintenance to execute to be monitored and registered by the operator 3 4 1 Description Maintenance A B and C General The following maintenance has to be distinguished 1 Small maintenance Maintenance A Yearly ...

Page 44: ...ion maintenance B 1 Maintenance A activities 2 Replace suction and discharge valve rings and springs top end overhaul 3 Inspection of pistons and cylinder liners Most activated cylinders Description maintenance C 1 Maintenance B activities 2 Major inspection General Complete disassembly required as far as necessary to inspect or replace parts as prescribed by the maintenance table Replacement of b...

Page 45: ... PL Product Information PI Installation and Maintenance Manual IMM Service Instruction Manual SIM 2 Unless otherwise stated All checkpoints have to be visually assessed for irregularities like leakages fractures overheating discolourations dents bursts presence of sludge debris and solid particles etc 3 If applicable also the original manufacturer s documentation has to be consulted Particularly f...

Page 46: ...or before re starting Used or filtered oil should NEVER be added to a compressor under any circumstance Use only new oil as selected from the Grasso oil table Oil charging via the suction line of the compressor is not allowed Oil and oil return systems The quality of the oil effects the oil consumption and the life time of the moving parts For oil return systems or systems in which soluble oil is ...

Page 47: ... CLEAN CLEAN Oil cooler fan and heat exchanger CLEAN CLEAN CLEAN Lubrication control system Lubrication oil pressure regulator CHECK CHECK CHECK Control oil system Control oil pressure regulator CHECK CHECK CHECK CAPACITY CONTROL SYSTEM Control oil lines connections INSPECT INSPECT Hydraulic Capacity control actuators CHECK CHECK Push handle valve lifting CHECK CHECK O rings shaft guides Seals CHE...

Page 48: ...ing INSPECT Note For A maintenance keep inspection limited to 1 or 2 most frequently activated cylinders or cylinder s nearest to the compressor s shaft end Refer Section 3 4 3 4 Page 49 PISTON CONNECTING ROD ASSEMBLY Piston assembly Piston body INSPECT INSPECT Piston rings INSPECT REPLACE Gudgeon pin INSPECT MEASURE Connecting rod assembly Small end bearing bushing INSPECT MEASURE Tightening conn...

Page 49: ...re Fixation Intake suction filter screen CLEAN CLEAN Crankcase oil heating CHECK CHECK CHECK Oil return orifices HP LP INSPECT INSPECT INSPECT Safety relief valve s Inside CLEAN CLEAN CLEAN BASE FRAME Structure INSPECT INSPECT Fixation INSPECT INSPECT Vibration dampers INSPECT INSPECT COMPRESSOR PROTECTION SAFETY CONTROL DEVICES Temperature gauges sensors switches transmitters Connection lines wor...

Page 50: ... Coupling alignment 3 Oil level float switch on compressor and oil separator 4 Pressure safety switches 5 Pressure gauges 6 Thermostats and thermometers 7 Electrical control system 8 Oil return protection and oil return system 9 Electric motor and thermistors Consult motor manufacturer 10 Base frame vibration dampers and bolts 11 Piping 12 Oil cooler oil side and air side and fan 13 Thermo Master ...

Page 51: ...ance This results in nearly all cases in longer service intervals and significantly less maintenance costs For industrial refrigeration compressors this is a unique development To maintain the highest level of reliability even with extended service intervals this series is fitted with the best possible components available Besides this practical instrument Grasso is able to make in advance an anal...

Page 52: ...s 16 Grasso V T 26 5 bar a This pressure deviates from the so called max discharge pressure condensing pressure allowed during operation as stated in the table 10 In practice it is not so much the individual operation limits as combinations of them that are decisive for the conditions under which a compressor may operate To check the various possibilities in this respect use should be made of the ...

Page 53: ...oil temperature depends on the operating conditions of the compressor and the oil type used A minimum actual oil viscosity of 10 cSt in the bearings is always required Min allowed start up temperature compressor casings and castings t min start up C min 10oC From 10 oC the elastomer seals that seal discharge parts from other parts have their optimal sealing capacity 4 3 STARTING UP OF TWO STAGE CO...

Page 54: ...tted to switch over to two stage operation with minimum capacity until the H P cylinders already in operation have lowered in single stage the evaporating temperature so that the corresponding working point at the condensing temperature tc lies inside the field of application of the two stage minimum part load step concerned Only then after this step has been energized the saturation intermediate ...

Page 55: ...V 450 V 1100 3 4 2 5 6 1 V 600 Before July 2019 5 6 7 8 2 4 1 3 V 600 From July 2019 5 6 7 8 1 2 3 4 V 1400 5 6 7 8 2 4 1 3 V 1800 Before Sept 2014 7 8 5 6 9 10 1 2 3 4 V 1800 From Sept 2014 5 7 8 9 10 1 2 3 4 6 Capacity control steps Compressor type Capacity 17 Cylinders Solenoids V 300 V 700 25 1 50 1 2 1 75 1 2 3 1 2 100 1 2 3 4 1 2 3 V 450 V 1100 33 3 4 50 3 4 2 1 67 3 4 5 6 2 83 3 4 5 6 1 2 3...

Page 56: ...4 1 3 1 2 3 4 V 1800 Before Sept 2014 20 7 8 30 7 8 5 1 40 7 8 5 6 1 2 50 7 8 6 9 10 2 3 60 7 8 5 6 9 10 1 2 3 70 7 8 5 1 2 3 4 1 4 80 7 8 5 6 1 2 3 4 1 2 4 90 7 8 6 9 10 1 2 3 4 2 3 4 100 7 8 5 6 9 10 1 2 3 4 1 2 3 4 V 1800 From Sept 2014 30 5 7 8 40 5 7 8 6 4 50 5 7 8 9 10 1 60 5 7 8 9 10 6 1 4 70 5 7 8 9 10 1 2 1 2 80 5 7 8 6 3 4 1 2 2 3 4 90 5 7 8 3 4 9 10 1 2 1 2 3 100 5 7 8 3 4 9 10 1 2 6 1 ...

Page 57: ...0 450T 1100T 0 4 0 0 Starting only Fast pull down 25 1 4 1 1 0 Starting only Fast pull down 50 2 3 4 2 2 0 50 1 4 5 6 1 3 1 0 Starting only Fast pull down 75 1 2 3 4 1 2 3 0 75 2 3 4 5 6 2 3 1 5 Starting only Fast pull down 100 1 2 3 4 5 6 1 2 3 2 0 600T 1400T 0 6 0 0 Starting only Fast pull down 33 1 2 6 1 2 0 33 3 6 4 8 2 3 1 0 Starting only Fast pull down 18 UNL Unloaded start 19 Numbers betwee...

Page 58: ... 1 0 Starting only Fast pull down 43 1 2 5 6 1 3 3 0 43 3 4 10 5 6 3 4 1 5 Starting only Fast pull down 57 1 2 6 7 8 9 1 2 2 0 71 1 2 5 6 7 8 9 1 2 3 2 5 86 1 2 3 4 10 7 8 9 6 1 2 4 2 0 100 1 2 3 4 10 5 6 7 8 9 1 2 3 4 2 3 20 Refer to the swept volume expressed as a percentage of the full load swept volume of the LP cylinders 21 Each phi has its own field of application Refer Page 57 22 For starti...

Page 59: ... crankcase is expected Remarks 1 Using ISO VG100 oils to increase viscosity at high expected cranckcase temperatures makes no sense as the friction heat will increase that much that the oil temperature limit related to the minimum viscosity of 10 cSt will also be exceeded Only in case of expected high refrigerant concentrations in the cranckcase this viscosity gradeoil is an alternative 2 Using IS...

Page 60: ...EXXON MOBIL Zerice S46 Zerice S68 Arctic 300 48 68 68 47 68 FUCHS Reniso KS 46 Reniso KC 68 KROON OIL Carsinus FC 46 68 46 PETRO CANADA Reflo 68A Reflo XL 58 H2 H2 GEA PR OLEO C MH68A PR OLEO C MH68A FG 68 68 H2 H1 Klüber Summit RHT 68 68 H2 Kuwait Petroleum Q8 Stravinsky C 55 SHELL Refrigeration Oil S2 FR A 68 SUN OIL Suniso 3 5 GS Suniso 4 GS Suniso 5 G Suniso 4 SA 43 55 94 57 TEXACO Capella WF ...

Page 61: ...dry running is minimized or even better eliminated Dry running of oil pump bearings pistons and piston rings will initiate and after initiation worsen the wear of the parts mentioned and eventually even damage the crank shaft and cylinder liners or even more parts When pre lubrication 1 Before initial start up 2 Before start up after overhauling compressor 3 Before start up after renewal of oil 4 ...

Page 62: ...ne of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 Index We live our values Excellence Passion Integrity Responsibility GEA versity GEA Refrigeration GEA Refrigeration Netherlands N V Parallelweg 25 5223 AL s Hertogenbosch Netherlands Phone 31 0 73 6203 911 info gea com gea com ...