grasso compressor operators manual

8/11/2019 grasso compressor operators manual

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- 1-Reciprocating Compressors for industrial refrigeration / GrassoUM2012/v010

Reciprocating Compressors for industrial refrigeration

Grasso

Operating Manual (OM)

0089292


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General

This manual must be carefull read and understood priorto servicing and running the compressor (package). Forall safety instructions refer to Chapter 1

This user manual is written with great care, but thecontractor/installer is held responsible for examining thisinformation and to take care of possible additional and/or deviated safety measures. Please consult yourcontractor (supplier).

Symbols used in this manual

WATCH OUT, BE CAREFUL, IMPORTANT

WARNING; This is an important warning. Ignoring these

warnings can result into considerable personal accidents

or considerable damage to the compressor or the

refrigeration plant.

TIP, HINT

Hint

Before consulting your contractor (supplier) for anyreason, make note of the data on the type plate fixed onthe compressor, package and/or other packagecomponents.


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Table of Contents

Section Title Page

1 SAFETY 9

1.1 REGULATIONS 9

1.2 MAINTENANCE AND REPAIRS 9

1.3 REFRIGERANT 9

1.4 OIL 9

1.5 OPERATING INSTRUCTIONS PRESSURE EQUIPMENT 9

1.5.1 Intended Use 10

1.5.2 Safety Notes and Warnings 10

1.5.3 Transport and Storage 10

1.5.4 Finishing and Installation 10

2 INTRODUCTION 13

2.1 SURVEY COMPRESSOR TYPES 13

3 INSPECTION 15

3.1 DAILY, WEEKLY AND MONTHLY INSPECTIONS 15

3.2 PERIODICAL INSPECTIONS TO BE CARRIED OUT BY YOUR CONTRACTOR (SUPPLIER) 17

4 FAULT ANALYSIS 19

4.1 GENERAL 19

5 MAINTENANCE 21

5.1 CONSULT YOUR CONTRACTOR (SUPPLIER) 21


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PREFACE

This operating manual is meant for the end-users ofGrasso reciprocating compressors and/or packages.This manual describes all safety instructions, globalproduct information, required periodical inspections anda trouble shooting list.The users of this equipment have to follow allinstructions as given in this manual. In case of any doubt,the supplier of the refrigeration plant should beconsulted.For safety instructions refer to Chapter 1.

GEA Grasso herewith declares that the machinesmentioned are intended to be incorporated into arefrigeration package (= assembly of refrigerationcomponents) or to be assembled with other equipmentto constitute machinery covered by Machinery Directive2006/42/EC and do therefore comply with the provisionsof this directive that apply to partly completed machines.Furthermore it is not allowed to put the machinesmentioned into service until the machinery in which it isto be incorporated, or, of which it is to be a component,has been found and declared to be in compliance withthe provisions of Machinery Directive 2006/42/EC i.e. asa whole system including the machinery referred to inthis declaration.


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1. SAFETY

UM2012/v010

1. SAFETY

1.1 REGULATIONS

It is the task of the contractor (supplier) to inform andexplain to you as user, about the operation of thecompressor (Package).

Do respect all international, federal, state and localsafety regulations/legislations during inspection, troubleshooting and operating this compressor (package).

1.2 MAINTENANCE AND REPAIRS

All maintenance and repairs have to be carried outonly by your contractor (supplier), except the

maintenance as explicitly mentioned in this manual.

Do not open the compressor for service.

In compliance with the regulations of the PressureEquipment Directive it is mandatory that no changes bemade to the construction of pressurised parts such as thecrankcase housing, suction filter housing, oilseparator(s), etc.

After having run the initial 100 operating hours,it isessential (in both new and modified plants) to replacethe running-in filter element with the permanent filterelement supplied. This operation is only to be carried outby well-trained and qualified personnel. Consult yoursupplier to carry out this service.

This manual includes a check list for daily, weekly andmonthly inspections. Temperatures and pressures needto be checked at several point (eg setting of all pressuresafety switches). In case this manual does not give thesevalues then your contractor (supplier) should instruct

you with regard to their correct setiings. When referenceis made to the plant manual, your contractor (supplier)should take care that your are instructed in being able toundertake proper inspections and trouble shooting.

Hint

In case of shut downs longer than 1 month, it is advisableto put warning labels on vital parts of the compressorsaying that the plant is out-of-operation and must not be

started up. Consult your contractor (supplier).

1.3 REFRIGERANT

The compressor/package must be filled withREFRIGERANT, to be able to operate.

For safety instructions in relation to the refrigerant used

in this refrigeration plant, refer to separate information,

to be supplied by your contractor (supplier).

1.4 OILThe compressor/package must be filled with oil, to beable to operate.

For safety instructions in relation to the oil used in this

refrigeration plant, refer to separate information, to be

supplied by your contractor (supplier).

1.5 OPERATING INSTRUCTIONS PRESSUREEQUIPMENT

For pressure equipment (oil separator OS, housingsuction gas strainer, Economizer ICH, compressorpackage) manufactured by Grasso according to theEuropean Parliament's and the European Council'sPressure Equipment Directive 97/23/EG of 29 May 1997

General

The following operating instructions according to theEuropean Pressure Equipment Directive No. 97/23/EG(subsequently referred to as PED) describe how tohandle the pressure equipment for finishing and

installation.The pressure equipment is intended for installation incompressor packages or refrigeration plants and can be


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1. SAFETY

UM2012/v010

equipped with specific accessories during installation bythe customer.The pressure equipment has been manufacturedaccording to the requirements of the PED. Its designmeets the requirements of the AD2000 regulations.If applicable the finisher/installer (at installation incompressor package or refrigeration plants andequipping ready for operation) is obliged to prepare hisown risk analysis and operating manual according to theEuropean Pressure Equipment Directive 97/23/EG.

The type plates for identification of the pressureequipment looks like this:

Fig. 1.5-1 Example type plate Housing suction gas strainer, EconomizerICH, Compressor package

Fig. 1.5-2 Example Type plate oil separator

If the type plate is covered by finishing/installation,make sure that the information can be seen by the enduser on another location on the pressure equipment.Incase of queries regarding the operating instructions,please contact Grasso.

1.5.1 INTENDED USE

The pressure equipment described here may not be usedfor any other than the stated purpose. The equipmentmay only be installed by the finisher/installer and not bythe end user.If the pressure equipment is not used according to theseregulations, safe operation of the equipment is notguaranteed.The finisher/installer or the operator and not themanufacturer is responsible for all personal injury anddamage to property resulting from unintended use.

When not installed by Grasso the finisher/installer has toproperly install accessories for the pressure equipment.The pressure equipment may not be damaged duringinstallation and it shall be painted after installation.The pressure equipment may only be filled withrefrigerant of refrigerant groups L1 and L2, substancegroups 1 and 2. The pressure equipment has to beinstalled in the compressor package or plant so that novibrations or pulsations can be transmitted to theequipment.The connecting lines have to be installed tobe tension free. The pressure equipment is not designedfor dynamic loads.Where there is a risk of lightningstrikes, the pressure equipment must be earthed. Thefinisher/installer has to include instructions for regularinspection of the pressure equipment in his instructionmanual and has to define the end user's behaviour incase of damage.To avoid burns or frostbite, the pressure vessel may notbe touched in the operating state. This can be achievedby means of contact guards. Install appropriate warningsigns.

Optionally supplied safety valves are only intended forthe protection of the oil separator against excessivepresssure caused by an external heat source duringstandstill. This device may not be used for the protectionof the complete refrigeration system. (Thefinisher/installer has to equip the installation with asafety valve acc. EN 378)

The oil separator may only be installed vertically. Thefoundation has to be of sufficient stiffness.

1.5.2 SAFETY NOTES AND WARNINGS

Visually inspect the pressure equipment with the nakedeye for corrosion, scoring and similar damage.Check the equipment for shape consistency of theconnection areas. In particular check and assess thesealing surfaces for possible damage such as scratches,scoring or similar.Keep corrosive substances such as acids away from theoil separator.Wall thicknesses may be no more than 1 mm less thanthose given in the drawing.

Drain or suck off the medium (refrigerant/oil) prior toservice and repair. These tasks may only be carried out bytrained professionals and in compliance with theappropriate safety regulations, see standard EN 378.Carry out a detailed check of the previous operatinghistory, when an oil separator that has already been inservice is newly finished, installed and equipped. Thisincludes visual inspection (as described above for thenew part). For recurring tests please refer to EN 378 T1to T4 and local regulations.

1.5.3 TRANSPORT AND STORAGE

Transport and store the oil separator in a dryenvironment. Ensure that the oil separator is not subjectto damage relevant to its further use.

In case of transport damage notify Grasso immediately.

1.5.4 FINISHING AND INSTALLATION

Design details can be seen in drawings at Grasso.


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1. SAFETY

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Compare the identification (type plate) with thedocumentation included in the delivery before finishing,installing and equipping the oil separator. Mark the oilseparator with the note "Do not use" until the issue hasbeen resolved with Grasso or an authorised third party(named authority according to the PED).


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1. SAFETY

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2. INTRODUCTION

UM2012/v010

2. INTRODUCTION

2.1 SURVEY COMPRESSOR TYPES

General

A survey of the full range of Grasso reciprocatingcompressors, is given in the table below. Please refer tothe type plate of the compressor to determine the typeof compressor you are currently using.

SeriesTypea

Single stage Two stage

Grasso 12E

Grasso 212Eb Grasso 2112Ec

Grasso 312E Grasso 3112E





- Grasso 8412E

- Grasso 9312E

- Grasso 10212E

Grasso 12

Grasso 212 Grasso 2112






- Grasso 8412

- Grasso 9312

- Grasso 10212

Grasso 10





Grasso 810 -

Grasso 6

Grasso 46 -

Grasso 66 -

Grasso 86 -

Grasso 7S

Grasso 37S -

Grasso 47S -

Grasso 57S -

Grasso 67S -

Grasso 77S -

Grasso 87S -

Grasso 8SGrasso 58S -

Grasso 68S -

Grasso 5HP

Grasso 35HP -

Grasso 45HP -

Grasso 55HP -

Grasso 65HP -

Grasso V

Grasso V 300 -

Grasso V 450 -

Grasso V 600 -

Grasso V 700 -

Grasso V 1100 -

Grasso V 1400

Grasso V 1800

Grasso V 2200

Grasso VCM

Grasso V 700 CM

Grasso V 1100 CM

Grasso V 1400 CM

Grasso V 1800 CM

Grasso V 2200 CM

a. Type designationCANBEextended on the type plate of the compressor withK(Approval), M(Marine application), ...

b. Grasso 12E compressor, with 2 cylinders.c. Grasso 12E compressor, with 2 low pressure cylinders and 1 high pressure

cylinder.

SeriesTypea

Single stage Two stage


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2. INTRODUCTION

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3. INSPECTION

UM2012/v010

3. INSPECTION

3.1 DAILY, WEEKLY AND MONTHLYINSPECTIONS

These inspections should be made during the operatingperiods.

The table below sums up all the points on thecompressor that have to be inspected by the user.

The compressor can be factory fitted with gauges and

switches and/or with a micro processor system. In the

case of a micro processor system, refer to the usermanual(s) of the micro processor and/or to the plant

manual. Consult your contractor (supplier).

CHECKPOINTSa

FREQUENCY

REMARKSb

daily

weekly

monthly

Oil level incrankcase

Between 25% and 75%height of the sight glass.For topping up oil, consultyour contractor (supplier).

Colour of theoil

The oil should betransparently clear. Adisappearing white colourpoints to dissolvedrefrigerant.

Lubricating oilpressure

difference

Grasso 12E,Grasso 12,Grasso 10;bRange1.5-3.0barSetting 2.0 bar

Grasso 6, Grasso 7;b

Range 1.7 - 2.5 barSetting 2.2 bar

Min. control oilpressure

Consult your contractor(supplier):Min. __________barb

Oiltemperature

max.

Refer to plant manual,consult your contractor(supplier);

Max. __________oC

Oil leakage ofshaft seal

Consult your contractor(supplier).

Suctionpressure

Check against designconditions. Refer to plantmanual, consult yourcontractor (supplier);Min./Max. __________oC

Dischargepressure

Refer to plant manual,consult your contractor(supplier);Min./Max. __________oC

Suctionsuperheat

Intermediatesuperheat

R404A/R507 15 Kb

Other refrigerants 0Kb

Min. __________oC

Dischargetemperature

max. Max. 170 Cb.

Oiltemperature

min.

During compressorstandstill the lower part of

the crankcase must remainwarmer than thesurroundings: 20 C

(NH3) and 30 C(halocarbons).

Cooling watertemperature

(if present)

Min. Actual condensingtemperature+ 10 K(Tc + 10 K)b

a. During the first 50 operating hours the compressor should be checkedregularly for all the points mentioned above, at least twice every 24 hoursand more frequently in cases where irregularities are found.

b. Values of temperatures, pressures etc. as mentioned in this table, are givenby the manufacturer. Actual values for this refrigeration plant, currently usedcan differ for the min./max. values as given in this table. Your supplier has toinform you about the actual/currently used values for this plant.

CHECKPOINTSa

FREQUENCY

REMARKSb

daily

weekly

monthly
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3. INSPECTION

UM2012/v010


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3. INSPECTION

UM2012/v010

3.2 PERIODICAL INSPECTIONS TO BE

CARRIED OUT BY YOUR CONTRACTOR(SUPPLIER)

SAFETY

For a safe operation of the compressor/package, yourcontractor (supplier) must carry out the checks asmentioned in the table below.

Table 3.2-1 Inspections by contractor

CHECKPOINTSa

a. During the first 50 operating hours the compressor should be checkedregularly for all the points mentioned above, at least twice every 24 hours

and more frequently in cases where irregularities are found.

FREQUENCY

REMARKS

daily

weekly

monthly

Condition ofV-belts

Wear (fraying, cuts etc.)and ensure that they donot touch the groovebottom.

Tension. Too low a tensiongives rise to excessiveflapping or oscillation inoperation. For correct

tension consult theinstructions given by theV-belt supplier.

Adjustment

and operationof pressuresafety switches

Refer to instructions ofswitch manufacturer.

Capacitycontrol (ifprovided)

The time lag between theunloading and loading ofone cylinder or cylindergroup should generally beat least 3 - 5 minutes.

Switchingfrequency of

thecompressor

The time interval betweenstopping and startingshould be at least10minutes and betweenstarting and restarting 15minutes.


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3. INSPECTION

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4. FAULT ANALYSIS

UM2012/v010

4. FAULT ANALYSIS

4.1 GENERAL

In case you find any problems in the installation, or one

of the issues mentioned in the inspection list are not OK,

(temperatures, oil level, pressures , ...), the compressor

must be switched off. Your contractor (supplier) should

inform you how the compressor has to be stopped

safely. Refer also to the plant manual.

If crankcase is frosted or wet: stop compressor

immediately.

Instructions in case of any failure;

1. Stop compressor2. Make note of the information on the type plate of

the compressor3. Consult your contractor (supplier)

Typical faults, to be solved by your contractor

(supplier) are:

Table 4.1-1 Typical faults

FAULTS

1 Discharge pressure too high

2 Discharge temperature too high

3 Suction pressure too high

4 Suction pressure too low

5 All cylinders inactive while compressor is operating

6 Too high oil consumption

7Too high oil pressure during normal operation at working

temperature

8 Too low lubricating oil pressure

9Too low or no control oil pressure (For Grasso 12, Grasso 12Eand Grasso10 only)


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4. FAULT ANALYSIS

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5. MAINTENANCE

UM2012/v010

5. MAINTENANCE

5.1 CONSULT YOUR CONTRACTOR(SUPPLIER)

All maintenance works are only to be carried out by thecontractor (supplier).

Example of works to be carried out by your contractor;

Leak testing

Evacuation, drying the refrigeration system

Initial oil charging

Initial refrigerant charging Adjustment of all safety devices

Checking direction of rotation compressor

Installing drive guard

Initial start of the compressor

Preparing the compressor for a shut down period (>6

months)

Topping up oil

Draining and change of oil

Evacuation and purging compressor

Replacement of filters

Etc.


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grasso compressor operators manual

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