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GEA Refrigeration Germany GmbH _251011_pi_ssp1_gbr_2_.doc 1 13.12.2012

Screw Compressor Packages Grasso SSP1 Smart ScrewPack

Product Information

(Translation of the original text)

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack

2 _251011_pi_ssp1_gbr_2_.doc GEA Refrigeration Germany GmbH 13.12.2012

COPYRIGHT All Rights reserved.

No part of this publication may be copied or pub-lished by means of printing, photocopying, microfilm or otherwise without prior written consent of

• GEA Refrigeration Germany GmbH

herein after called manufacturer. This restriction also applies to the corresponding drawings and dia-grams.

LEGAL NOTICE This product information is a part of the documenta-tion for the Grasso scope of delivery and serves as product presentation and customer advisory service. It contains important information and technical data regarding the product.

The product information makes the technical, prod-uct related and commercial information available to the customer in detail before the sale of the product.

This product information serves as a support and technical advisory service for our partners and cus-tomers as well as for the marketing team. Apart from serving as the medium for transfer of product know-how, it also forms the basis for product demonstra-tions, the organisation and conduction of technical seminars as well as the technical support at trade fairs.

This product information should be supplemented with the information about the industrial safety and health related regulations at the site of installation of the product. The regulations vary form place to place as a result of the statutory regulations applicable at the site of installation of the product and are there-fore have not been considered in this product infor-mation.

In addition to this product information and the acci-dent prevention regulations applicable for the re-spective country and area where the product is used, the accepted technical regulations for safe and professional work must also be observed.

This product information has been written in good faith. However, GEA Refrigeration Germany GmbH cannot be held responsible for any errors that this document may contain or for their consequences.

GEA Refrigeration Germany GmbH reserves the right to make technical changes during the course of further development of the equipment covered by this product information.

Illustrations and drawings in this product information are simplified representations. As a result of the

improvements and changes, it is possible that the illustrations do not exactly match the current devel-opment status. The technical data and dimensions are subject to change. No claims can be made on the basis of them.



TABLE OF CONTENTS 1 Characteristic of the series, product code ....................................................................................... 6 2 Technical specifications ................................................................................................................. 8 3 Scope of delivery ............................................................................................................................ 9 4 Series overview ............................................................................................................................ 10 5 Main dimensions .......................................................................................................................... 11

5.1 Smart ScrewPack SSP1 with screw compressor types P, R, S, T .................................... 11 5.2 Smart ScrewPack SSP1 with screw compressor types V, W, Y ....................................... 12 5.3 Smart ScrewPack SSP1 with screw compressor types Z, XA .......................................... 13

6 Description of Design and Function .............................................................................................. 14 6.1 Main components ............................................................................................................ 14

6.1.1 Screw compressors.............................................................................................. 15 6.1.2 Compressor drive motor ....................................................................................... 15 6.1.3 Coupling ............................................................................................................... 15 6.1.4 Oil separator ........................................................................................................ 15 6.1.5 OMC block with oil filter system............................................................................ 16 6.1.6 Oil cooler .............................................................................................................. 16 6.1.7 Oil pump .............................................................................................................. 16 6.1.8 Suction filter combination SFC ............................................................................. 17 6.1.9 Safety devices ...................................................................................................... 17

6.2 Method of working, process flow diagram ........................................................................ 18 6.3 Refrigerant circuit............................................................................................................. 19 6.4 Oil System ....................................................................................................................... 19

6.4.1 Oil separation ....................................................................................................... 19 6.4.2 Oil heater ............................................................................................................. 19 6.4.3 Oil cooling ............................................................................................................ 19 6.4.4 Oil filter................................................................................................................. 19 6.4.5 Oil pump .............................................................................................................. 19 6.4.6 Oil injection .......................................................................................................... 20 6.4.7 Oil circuit, OMC block ........................................................................................... 20

6.5 Capacity control ............................................................................................................... 20 7 Control device GSC TP ................................................................................................................ 21

7.1 View ................................................................................................................................ 21 7.2 TouchPanel ..................................................................................................................... 21 7.3 Monitoring and display of process values ........................................................................ 22

8 Option frequency converter .......................................................................................................... 23 9 Option economizer ....................................................................................................................... 26

9.1 Type A - economizer port pipe ......................................................................................... 26 9.2 Type C - Economizer for single stage pressure relief (closed flash) ................................. 26

10 Oil fill capacities ........................................................................................................................... 27 11 Sound power level, sound pressure level ..................................................................................... 28 12 Enquiry sheet ............................................................................................................................... 29 13 Manufacturer information ............................................................................................................. 30



TABLE OF FIGURES fig. 1: Product code Smart ScrewPack SSP1 ......................................................................................... 6 fig. 2: Smart ScrewPack SSP1, view .................................................................................................... 10 fig. 3: Elevation drawing, Smart ScrewPack SSP1 with screw compressor types P, R, S, T ................ 11 fig. 4: Elevation drawing, Smart ScrewPack SSP1 with screw compressor types V, W, Y .................... 12 fig. 5: Elevation drawing, Smart ScrewPack SSP1 with screw compressor types Z, XA ....................... 13 fig. 6: Grasso Smart ScrewPack SSP1 ................................................................................................ 14 fig. 7: Grasso SSP1, position of the screw compressor ........................................................................ 15 fig. 8: Grasso SSP1, position of the compressor drive motor ............................................................... 15 fig. 9: Grasso SSP1, position of the coupling ....................................................................................... 15 fig. 10: Grasso SSP1, position of the oil separator ............................................................................... 15 fig. 11: Grasso SSP1, position of the OMC-block with oil filter system ................................................. 16 fig. 12: Grasso SSP1, position of the oil cooler .................................................................................... 16 fig. 13: Grasso SSP1, position of the oil pump ..................................................................................... 16 fig. 14: Grasso SSP1, position of the suction filter combination SFC .................................................... 17 fig. 15: Grasso SSP1, process flow diagram ........................................................................................ 18 fig. 16: GSC TP, front view ................................................................................................................... 21 fig. 17: TouchPanel .............................................................................................................................. 21 fig. 18: Smart ScrewPack SSP1 with power panel and frequency converter, view ............................... 23 fig. 19: Economizer type A ................................................................................................................... 26 fig. 20: Economizer type C ................................................................................................................... 26

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack CHARACTERISTIC OF THE SERIES, PRODUCT CODE


1 CHARACTERISTIC OF THE SERIES, PRODUCT CODE The new series of screw compressor packages Smart ScrewPack SSP1 was developed for the intermediate compressor sizes This series ensures the trouble-free compressor operation with a horizontal oil separator series. This ensures all functions necessary for the operation of the screw compressor.

The Smart ScrewPack SSP1 series is available in single stage design for up to 28 bar operating pressure and uses R717 (ammonia) as the refrigerant.

The Smart ScrewPack SSP1 series consists of 9 types for a theoretical swept volume from 805 m³/h to 3250 m³/h.

Product code

fig. 1: Product code Smart ScrewPack SSP1

X = frame size of screw compressor package

Code letter Theoretical volume flow at 2940 min-1 in m³/h

P 805

R 1040

S 1290

T 1460

V 1640

W 1940

Y 2296

Z 2748

XA 3250

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack CHARACTERISTIC OF THE SERIES, PRODUCT CODE


Y = design variant of screw compressor package

Code letter Design type

A Horizontal oil separator installed below Refrigerant R717 (ammonia)

9 = design variant of screw compressor

1 Standard refrigerating compressor Vi = 1.8; 2.0; 2.2; 2.6

2 Standard refrigerating compressor Vi = 3.0; 3.6

3 Standard refrigerating compressor Vi = 4.8

4 Standard refrigerating compressor Vi = 5.5

5 Standard refrigerating compressor Vi = variable

6 Booster Vi = fixed

A = oil separation, oil cooling

Code letter Oil separation and...

A Water cooled oil cooler

B Refrigerant cooled oil cooler

C Refrigerant injection

D Water or refrigerant-cooled oil cooler

E Water or refrigerant-cooled oil cooler and refrig-erant injection

F Without oil cooler

Naming example

TA - 1A

Grasso Smart ScrewPack SSP1 with screw compressor 1460 m³/h (T) refrigerant R717 (ammonia) and horizontal oil separator installed below (A) fixed internal volume ratio Vi=1.8; 2.0; 2.2 or 2.6 (1) with oil separation and water-cooled oil cooler (A)

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack TECHNICAL SPECIFICATIONS


2 TECHNICAL SPECIFICATIONS

Operating voltage: 400V / 50 Hz 460V / 60 Hz 380V / 50 Hz

Operating pressure: Max. 28 bar

Intended environment: Closed machine rooms

Ambient temperatures: +5℃ to +40℃

Refrigerant: R717

Types of oil: all of the oils recommended by GEA Refrigeration Ger-many GmbH

Suction pressure: ≥ -45°C

Oil cooling: refrigerant cooled using thermosiphon principle (evapo-ration on tube-side) liquid cooled Refrigerant injection

Oil heating: Default scope of delivery

Oil filter: Single-stage filter/ OMC block

Spare oil filter: optional

Oil level switch (min.): optional

Pressure sensors: with stop valve for easy maintenance

Overflow valve: Default scope of delivery

Safety valve: single or double safety valve with change-over valve

Controller: GSC TP alternatively: wiring on terminal box

Power panel and frequency converter: optional

Economizer / Economizer port: optional

Colour: RAL 5014 (dove grey);

Approval: CE-PED Russian approval on request

Documentation: 2x paper form + 1 CD ROM

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack SCOPE OF DELIVERY


3 SCOPE OF DELIVERY The screw compressor packages of the Smart ScrewPack SSP1 series consist of the following components:

– Screw compressor,

– Electric motor with coupling

– Oil supply system with oil separator,

– Oil cooler,

– Oil filter and oil pump,

– Suction filter

– Check valves on the suction and discharge sides,

– Equipment for capacity control,

– Monitoring and safety devices,

– Compressor control system

All components are fully mounted. The compressor control system is wired.

The oil separators are arranged horizontally and suspended in a separate frame. A fine separation stage is provided for the oil separators.

The oil cooling is effected using water. Optionally solutions for heat recovery, refrigerant cooled oil cooler or a refrigerant injection system are available.

By default, a rigid installation on the foundation is intended. An installation insulated against structure-borne sound is available optionally.

The screw compressor packages are delivered with-out refrigerant and oil. They are filled with dry nitro-gen (0.2 bar overpressure).

All connections are closed tight.

Painting

The painting is done with 2 component EP paint RAL 5014 with a coating thickness of 120 µm. Other col-ours are optional or can be delivered on request.

Approval

After approval, the screw compressor packages of the Smart ScrewPack SSP1 series get a CE label in accordance with the Pressure Equipment Di-rective 97/23/EC.

Documentation

User documentation is delivered with each screw compressor package. The user documentation con-tains:

– Drawings and part lists

– Safety Instructions

– Operating manual

(with the description of the refrigerant and oil cir-cuits, the instructions for installation, commis-sioning and maintenance)

– Documentation of the main components (e.g., electric motor, control)

– Maintenance schedule

– Acceptance certificate for components requiring acceptance

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack SERIES OVERVIEW


4 SERIES OVERVIEW

fig. 2: Smart ScrewPack SSP1, view

Type Screw compressor

Swept volume in m³/h

Oil separator horizontal arrangement

Ø in mm

maximum number Fine oil separation car-

tridges

P 805 508 2

R 1040 508 2

S 1290 508 2

T 1460 508 / 610 2 - 4

V 1640 508 / 610 2 - 4

W 1940 508 / 610 / 711 2 - 4

Y 2296 508 / 610 / 711 2 - 4

Z 2748 610 / 711 / 813 4 - 8

XA 3250 610 / 711 / 813 4 - 8

Dimensions of fine oil separation cartridge: 234 mm x 490 mm

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack MAIN DIMENSIONS


5 MAIN DIMENSIONS

5.1 Smart ScrewPack SSP1 with screw compressor types P, R, S, T

fig. 3: Elevation drawing, Smart ScrewPack SSP1 with screw compressor types P, R, S, T X = measurement for removal of fine oil separation cartridge 600mm

Main dimensions

Type

Nominal capacity

Motor in kW

Oil separator 1

Ø in mm

Dimensions2 in mm Nominal diameters Weight without motor in kg L1 L2 B1 B2 3 H DN1 DN2

P 55 ... 250 508 1880 3565 950 1280 2000 250-100 125-40 2125

R 75 ... 355 508 1880 3565 950 1280 2000 250-100 125-40 2495

S 90 ... 400 508 1880 3565 950 1280 2000 250-100 125-40 2560

T 90 ... 400 508 1880 3565 950 1280 2000 250-100 125-40 2660

610 2080 3565 950 1380 2100 250-100 125-40 2970

1 depending on the operating conditions and the refrigerant used 2 depends upon the type of the compressor drive motor and the design of the components (subject to technical changes) 3 depends upon the type of the oil cooler

DN2 40 50 65 80 100 125 150 200 250

L3 235 255 285 310 365 420 475 525 615



5.2 Smart ScrewPack SSP1 with screw compressor types V, W, Y

fig. 4: Elevation drawing, Smart ScrewPack SSP1 with screw compressor types V, W, Y X = measurement for removal of fine oil separation cartridge 600mm

Main dimensions

Type

Nominal capacity

Motor in kW

Oil separator 1

Ø in mm


V 110 ... 550 508 1880 3565 950 1560 2250 250-150 150-50 3096

610 2080 3765 1050 1660 2350 300-150 200-50 3396

W 110 ... 630 508 1880 3565 950 1560 2250 250-150 150-50 3110

610 2080 3765 1050 1660 2350 300-150 200-50 3410

711 2080 3820 1050 1660 2500 300-150 200-50 3620

Y 132 ... 630 508 1880 3565 950 1560 2250 250-150 150-50 3218

610 2080 3765 1050 1660 2350 300-150 200-50 3518

711 2080 3820 1050 1660 2500 300-150 200-50 3728


DN2 40 50 65 80 100 125 150 200 250

L3 235 255 285 310 365 420 475 525 615



5.3 Smart ScrewPack SSP1 with screw compressor types Z, XA

fig. 5: Elevation drawing, Smart ScrewPack SSP1 with screw compressor types Z, XA X = measurement for removal of fine oil separation cartridge 600mm

Main dimensions

Type

Nominal capacity

Motor in kW

Oil separator 1

Ø in mm


Z 110 ... 750 610 2080 3765 1050 1660 2550 350-200 200-50 4350

711 2080 3820 1050 1660 2550 400-200 250-50 4570

813 2280 4275 1150 1760 2800 400-200 250-50 5025

XA 200 ... 900 610 2080 3765 1050 1660 2550 350-200 200-50 4420

711 2080 3820 1050 1660 2550 400-200 250-50 4640

813 2280 4275 1150 1760 2800 400-200 250-50 5095


DN2 40 50 65 80 100 125 150 200 250

L3 235 255 285 310 365 420 475 525 615

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack DESCRIPTION OF DESIGN AND FUNCTION


6 DESCRIPTION OF DESIGN AND FUNCTION

6.1 Main components The Grasso Smart ScrewPack SSP1 series of screw compressor packages consist of the following main assem-blies and components:

fig. 6: Grasso Smart ScrewPack SSP1

010 Screw compressor

015 Compressor drive motor

020 Oil separator

025 OMC block (oil management block) with oil filter system

030 Oil cooler (not shown in the picture)

040 Oil pump

045 Suction filter combination SFC, with check valve function

060 Check valve - discharge side (*not shown in the picture)

095 Coupling

180 Control device "Grasso System Control"

360 Oil heater

Safety devices



6.1.1 Screw compressors

fig. 7: Grasso SSP1, position of the screw compressor

The screw compressors are characterized by a compact design, a high reliability, high quality com-ponents and the ease of maintenance.

Screw compressors are dual rotor positive dis-placement machines that run according to the prin-ciple and are operate by oil injection.

The screw compressors are operated with ammonia (NH3) as the refrigerant. When ammonia is used as refrigerant the refrigerating machine oil is to be se-lected in accordance with the information about lu-bricating oild for screw compressors.

Various series and sizes of screw compressors are available for different fields of application.

The screw compressors are driven directly by the compressor drive motor via a flexible coupling.

Hint!

The documentation of the screw com-pressor (installation instructions, part lists, drawings) is a part of the product documentation.

6.1.2 Compressor drive motor

fig. 8: Grasso SSP1, position of the compressor drive

motor

Standard: The compressors are driven by an air-cooled 2-pole electric motor IP23 with an operating voltage of 400 V; 50 Hz using a coupling.

Optional: Other protection classes, operating volt-ages and frequencies as well as speed-controlled motors on request.

Hint!

The documentation of the electric mo-tor (operating manual) is a part of the product documentation.

6.1.3 Coupling

fig. 9: Grasso SSP1, position of the coupling

The coupling helps in transmission of torque be-tween compressor and compressor drive motor. The elastic design of the coupling brings about the neu-tralisation of the otherwise disturbing influences such as axial or radial forces, vibrations or offset.

Speed fluctuations and speed shocks are damped and cushioned, torsional vibrations are reduced.

Hint!

The documentation of the coupling (operating manual) is a part of the product documentation.

6.1.4 Oil separator

fig. 10: Grasso SSP1, position of the oil separator



The design of the oil separators is standardised and features less oil carry-over and low oil consumption.

The oil separator is installed horizontally.

Hint!

The documentation of the oil separator (operating and maintenance instruc-tion, acceptance certificate) is a part of the product documentation.

Oil heater

Electric oil heaters are built into the oil separator to heat the oil refrigerant mixture in the oil separator during the standstill of the screw compressor pack-age. The oil heater prevents condensation of the refrigerant into the oil and, thus, any foaming of the oil during start-up.

To protect against overheating, the heater is equipped with an overheating protection according to its output with a switching temperature of 110°C. This is self-resetting after cooling to below approx. 105°C.

Hint!

The documentation of the oil heater (operating and maintenance instruc-tion, acceptance certificate) is a part of the product documentation.

6.1.5 OMC block with oil filter system

fig. 11: Grasso SSP1, position of the OMC-block with oil

filter system

The OMC-block includes the oil distribution system of the oil circuit. Necessary control and shutoff fit-tings are integrated in the OMC-block. Connections for temperature and pressure sensors as well as service ports are present. The OMC-block is com-bined with a standardised filter system and oil pump units and forms the central control and operator unit in the oil circuit.

Optionally the OMC-block can be equipped with a 3-way valve element (for ensuring a minimum oil tem-perature when starting the compressor).

Hint!

The documentation of the OMC-block (operating manual, acceptance certifi-cate) is a part of the product documen-tation.

6.1.6 Oil cooler

fig. 12: Grasso SSP1, position of the oil cooler

The oil cooler is used for cooling the oil heated in the compressor in order to ensure sufficient oil viscosity for supplying to the compressor.

Hint!

The documentation of the oil cooler (operating manual, acceptance certifi-cate) is a part of the product documen-tation.

6.1.7 Oil pump

fig. 13: Grasso SSP1, position of the oil pump

The oil pump is an important component of the oil circuit. It is used for pumping and distributing refrig-erating machine oil.

The oil pump ensures that the oil is distributed to the individual lubrication points (e.g., sliding contact



bearings, balancing piston and the stuffing box of the compressor).

Hint!

The documentation of the oil pump (operating manual, acceptance certifi-cate) is a part of the product documen-tation.

6.1.8 Suction filter combination SFC

fig. 14: Grasso SSP1, position of the suction filter combina-

tion SFC

The suction filter combination SFC contributes sub-stantially to the high working reliability of the compo-nents and the overall product.

The suction filter combination SFC prevents dirt particles entrained in the intake stream from entering the screw compressor unit. The flow through the suction filter element is from the inside to the out-side. It is designed so that monitoring is not required. The filter element can be cleaned.

Hint!

The documentation of the suction filter combination SFC (operating manual, acceptance certificate) is a part of the product documentation.

6.1.9 Safety devices

The following safety devices are fitted onto the screw compressor package of the series Grasso SSP1 as standard or optionally:

Compressor drive motor safety devices

Rated current limitation (016)

The rated current limitation is realised by the com-pressor control system: When the rated motor cur-rent is exceeded, the control slide of the compressor is driven in the MIN direction until the motor current

reaches an allowable level. The normal output con-trol then comes back into force.

Thermistor (017)

The thermistor shuts down the compressor drive motor when its winding temperature limit has been exceeded.

Suction filter combination SFC with check valve function (suction side) (045 / 055)

The check valve function of the suction filter combi-nation SFC prevents a pressure equalisation with the LP side of the plant and simultaneously prevents a reverse rotation of the screw compressor.

Check valve - discharge side (060)

The discharge side check valve prevents refrigerant from re-condensing in the oil separator.

Oil pressure control valve (075)

The oil pressure control valve regulates the differen-tial pressure between the oil pump discharge side and the discharge pressure of the package. The oil pressure control valve is integrated into the OMC-block (oil management centre).

Safety device to prevent the discharge pressure from being exceeded (pressure transducer 105)

The compressor control sytem switches off the screw compressor package when the specified limit value has been exceeded.

Limit value = see parameter list

Safety device to prevent the differential pressure between the oil pressure after oil pump (pres-sure transducer 110) and the discharge pressure (pressure transducer 105) oil circuit monitoring from falling too low

The compressor control system switches off the screw compressor package when the pressure dif-ference between oil pressure after oil pump and discharge pressure falls below the specified limit value after a delay period.




Safety device to prevent the discharge tempera-ture from being exceeded (resistance thermome-ter 120)

The compressor control system switches off the screw compressor package when the specified limit value has been exceeded.


Safety device to prevent the oil temperature from being exceeded (resistance thermometer 125)

The compressor control system switches off the screw compressor package when the specified limit value has been exceeded.


The minimum oil viscosity for safe compressor oper-ation is ≥ 7 cSt. In case of oils soluble in the refriger-ant, the minimum oil viscosity is to be ensured de-pending on the discharge pressure and temperature, oil temperature, as well as the type of oil.

Overflow valve (340)

The overflow valve protects the compressor against impermissibly high pressures. The overflow valve must be connected with the suction pipe on site.

Lifting Pressure = see parameter list and P+I dia-gram

The overflow valve is designed in accordance with DIN EN 13136 "Refrigerating systems and heat pumps - pressure relief devices and associated pip-ing - methods for calculation“.

Warning!

The overflow valve must be connected to the suction side when installing the package in the refrigeration plant!

Safety valve (345) at oil separator

The safety valve protects the screw compressor package against unallowably high pressure.

Lifting Pressure = see parameter list and P+I dia-gram

If the screw compressor package is installed into a refrigeration system comprising an emergency blow-off station, only the oil separator connection is used.

The valve is available as an option, depending on the required acceptance.

The safety valve is designed in accordance with DIN EN 13136 "Refrigerating systems and heat pumps - pressure relief devices and associated piping - methods for calculation“.

Safety pressure limiter (350)

Safety pressure limiter with two separate release contacts, one of which can only be reset using tool (see UVV VBG20). The safety pressure limiter switches off the compressor drive motor if the dis-charge pressure rises above the set point.

Switching off pressure 1 = see parameter list

Switching off pressure 2 = see parameter list

If the liquid in the oil separator can reach more than 90% of the oil separator’s volume, the client has to install an additional safety valve against liquid pres-sure in oil separator. (design in compliance with DIN EN 13136 "Refrigerating systems and heat pumps - pressure relief devices and associated piping - methods for calculation“)

6.2 Method of working, process flow dia-gram

The Grasso SSP1 screw compressor packages are components of refrigerating plants and serve to compress the refrigerants such as ammonia.

fig. 15: Grasso SSP1, process flow diagram



6.3 Refrigerant circuit The screw compressor draws in refrigerant vapour through the suction filter combination and suction filter and then discharges the compressed vapour into the plant via the oil separator and discharge check valve.

The check valve function of the suction filter combi-nation SFC prevents pressure equalisation with the LP side of the plant and simultaneously prevents reverse rotation of the screw compressor.

The discharge check valve prevents refrigerant from re-condensing in the oil separator.

Hint!

The discharge check valve can be in-tegrated in the oil separator for screw compressor packages with discharge side nominal diameters up to NB 150.

The suction filter combination prevents dirt particles carried by the suction flow from entering the com-pressor. The filter element is characterised by a very large filtering area. The filter has a fineness of 140 µm.

Gas vibrations which can occur in the compressor compression chamber at high pressure ratios in the zero discharge zone are avoided by a gas vibration protection device. This consists of a pressure equal-isation line between the oil separator and the com-pressor working chamber.

6.4 Oil System The screw compressors operate oil-flooded. During the compression process, refrigerating machine oil is supplied to the compressor for lubrication, sealing, noise reduction, and absorption of part of the com-pression heat. After the compression process, the oil is separated again from the refrigerant in the oil sep-arator.

6.4.1 Oil separation

The refrigerant-oil mixture is led into the first part of oil separator. The first part of the oil separator con-sists of two chambers. The first chamber employs gravity separation. The hot gas passes the demister while flowing out of the first chamber into the second chamber. The oil separated thereby is collected in the second chamber. Both the chambers of the first part of oil separator simultaneously serve as oil re-ceivers.

In the second part of the oil separator, the fine sepa-ration of the aerosol oil portion from the refrigerant is performed by means of replaceable fine oil separa-tion cartridges. The oil separated in the fine separa-tion part of the oil separator is returned to the com-pressor via an additional orifice.

6.4.2 Oil heater

The oil heater on the oil separator is to be started when the package is shut down in order to ensure a minimum oil temperature and sufficient oil viscosity required for restarting the package. The oil heating is not regulated. The maximum temperature of the heating rod is restricted.

6.4.3 Oil cooling

Before it is returned to the compressor for use, the oil heated up in the compressor has to be cooled down to a temperature at which it has sufficient vis-cosity.

The following oil coolers are available:

1. liquid-cooled (non corrosive media)

– water (non corrosive)

– propylene glycol (25%)

– ethylene glycol (35%)

– Other refrigerants on request

2. Thermosiphon

3. Refrigerant injection

6.4.4 Oil filter

After cooling, the oil enters the oil filter which retains solid particles from the entire oil flow.

Due to its large surface, the star-folded glass fibre element has a high absorbing capacity and thus a long operating lifetime. The filter has a relative filter fineness of 25 µm.

6.4.5 Oil pump

The oil pump runs for pre- and during compressor operation.

It draws the refrigeration compressor oil from the receiver space in the oil separator, through the the oil cooler and oil filter and pumps it to the bearings, the balance piston, the shaft seal, to the capacity control system and, if fitted, to the compressor's hydraulic Vi adjustment system.

The oil pump pumps more oil than the compressor uses. This surplus quantity of oil is returned to pump



suction via the spring loaded oil pressure regulating valve. The oil pressure regulating valve regulates a pressure difference between the oil pump discharge side and the unit final pressure (according to the value in the P+I diagram).

6.4.6 Oil injection

The injection oil is fed without a pump via the oil injection regulating valve. The oil injection control valve is used to adjust the necessary compression discharge temperature. The control valve is provided with a check function to prevent sucking refrigerant through the oil pump.

6.4.7 Oil circuit, OMC block

An OMC-block (oil management block) is flanged on to the oil filter as an oil distributor system. The oil flow is distributed via the bore-holes and channels to functional ranges of the screw compressor. All regu-lating valves and shut-off valves necessary for the regulation of the oil circuit are integrated into the block. As a result, a centralised control unit is avail-able for the screw compressor package.

The oil filter with OMC-block (oil management block) is fitted with an oil drain and refilling stop valve which may be connected to a separate oil pump or receiver.

Vent valves are fitted to oil filters for maintenance and repair purposes.

The oil in oil filter may be drained for changing oil filter via a separate stop valve.

6.5 Capacity control The screw compressors are fitted with a continuous capacity control with a range of 10 -100%.

The capacity is adjusted by shortening the screw compressor stroke. The defining factor for the com-pression process is the effective rotor length; this is altered by a hydraulically operated control slide.

The position of the control slide is recorded by the position sensor. The control device signals the at-tainment of the MIN or MAX end position and the relative control slide position can be displayed on the Touch Panel in percent.

The hydraulic adjustment of the control slide is done using four solenoid valves which are integrated into a single block.

The control slide travel speeds in the MIN and MAX directions should be the same as much as possible during operation to ensure better compressor con-trol.

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack CONTROL DEVICE GSC TP


7 CONTROL DEVICE GSC TP

7.1 View

fig. 16: GSC TP, front view

7.2 TouchPanel The TouchPanel is the interface between the man and the machine.

All switching, operating and control actions are car-ried out via this TouchPanel.

The TouchPanel is available in different languages.

fig. 17: TouchPanel TouchPanel with information bar (top), navigation bar (on the top, with "Pull down" menus), main display (central display and selec-tion area) and function key bar (bottom)

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack CONTROL DEVICE GSC TP


7.3 Monitoring and display of process values The following operating parameters are continuously monitored and displayed by the control device:

Symbol Remark

Suction pressure Suction pressure in bar (a) and the corresponding evaporation temperature in °C

Discharge pressure Discharge pressure in bar (a) and the corresponding condensation temperature in °C

Oil pressure Oil pressure in bar (a)

Oil differential pres-sure Oil differential pressure in bar

Oil filter pressure Oil filter pressure in bar (a)

Oil filter diff pressure Oil filter differential pressure in bar

Suction temperature Suction temperature in °C

Discharge tempera-ture Discharge temperature in °C

Oil temperature Oil temperature in °C

External temperature External temperature in °C

Economizer pressure Economizer pressure in bar (a) (optional)

Economizer tem-perature Economizer temperature in °C (optional)

Primary slide position Primary slide position in %

Motor current Motor current in A

Motor speed Motor speed in rpm (optional)

Running hours Running hours

Slide to minimum Slide to minimum time in sec, remaining time for slide for reaching the minimum position

Start delay Remaining time for auto start delay in sec.

Stop delay Remaining time for auto stop delay in sec.

Start to start Start to start, Remaining time between two starts of the compressor in sec.

Stop to start Stop to start timer, remaining time in sec.

Oil pump by itself Oil pump by itself, remaining time the oil pump may run by itself in sec.

Oil drain Oil drain time, remaining time after "Oil pump by itself"

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack OPTION FREQUENCY CONVERTER


8 OPTION FREQUENCY CONVERTER

fig. 18: Smart ScrewPack SSP1 with power panel and frequency converter, view

The screw compressor packages with screw com-pressors and frequency controllers are driven with a minimum speed of 1500 rpm. The permissible max. speed is 3600 rpm.

The power panel with frequency converter is deliv-ered separately and is connected to the compressor drive motor using shielded cables on-site. When connecting, the output side power cables must be kept as short as possible for minimising the electro-magnetic disturbances.

The communication of the control unit with the fre-quency converter is effected via hardware cabling.

The driving power of the compressor drive motors of the series of the screw compressor packages with frequency controllers is limited to 630 kW. Higher capacities are possible only on request.

The capacity is regulated using a combined slide/speed regulation.

Technical data for frequency converter

(GEA Refrigeration Germany GmbH guidelines)

Operating fre-quency: 25 – 60 Hz

Operating volt-age: 3 phase, 400 V +/- 5%

Filter: EMV filter class A according to EN 55011

Communication: Hardware cabling

Display: Display for displaying operating parameters, error and warning messages

Type of control: Sine weighted pulse width modula-tion, U/f – characteristic curve design

Protective func-tions: Overcurrent

Resonance protection: Suppressible frequency bands

Conditions of use:

< 93 % rel. humidity, +5°C to +40°C, max. 1000 m above mean sea level



Power panel

The power panel includes the controller with operat-ing / display unit, the input and output sub-assemblies as well as the frequency converter with the described components.

Oil pump and oil heater are switched on/off using the MCBs included in the power panel.

Motor current transformer, motor winding protection and emergency stop switch are integrated into the power panel.

Compressor drive motor

For a screw compressor package with frequency controller, compressor drive motors with special roller bearings corresponding to the requirements of the frequency converter operation are used.

The sound power level in case of operation with frequency controller increase by 4 dB - 8 dB.

Dimensions and weights:

Nominal capacity Compressor drive

motor in kW

Power panel weight with frequency

converter in kg

Dimensions of power panel with frequency converter

B in mm H in mm D in mm

45 210 800 2160 400

55 210 800 2160 400

75 210 800 2160 400

90 210 1200 2160 600

110 285 1200 2160 600

132 285 1200 2160 600

160 285 1200 2160 600

200 435 1600 2160 600

250 435 1600 2160 600

315 435 1600 2160 600

355 510 1600 2160 600

Subject to technical changes by GEA Refrigeration Germany GmbH



As an alternative to the described complete solution, the screw compressor package can be delivered without the power panel.

In this case, the screw compressor package is deliv-ered with a built on controller. The frequency con-verter is provided as a built-in device (IP20). The customer takes over the complete responsibility for the installation as well as the wiring of the frequency converter with the compressor drive motor and the controller in accordance with the EMC Directive 2004/108/EC (shielded cables, separate cable ducts).

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack OPTION ECONOMIZER


9 OPTION ECONOMIZER

9.1 Type A - economizer port pipe

fig. 19: Economizer type A Economizer port pipe

Suction line (mounted on the screw compressor package) consisting of:

– Stop valve

– Suction filter

– Check valve

– Thermometer

– Service valve

– Pressure sensor (optional)

– Temperature sensor (optional)

Hint!

Several screw compressor packages can be connected to an economizer in parallel. When doing so, each connec-tion line must be provided with a pres-sure controller (constant/differential pressure controller).

9.2 Type C - Economizer for single stage pressure relief (closed flash)

... with shell and tube heat exchanger

fig. 20: Economizer type C Economizer for single-stage pressure relief (closed flash) with shell and tube heat exchanger

S Lateral load connection (optional) K from the condenser V to the evaporator

Scope of delivery:

– Suction line as in economizer type A

– Shell and tube heat exchanger mounted on the screw compressor package

– Expansion valve

– Stop valve

– Filter

– Solenoid valve

– Safety valve

– Oil drain valve

– Pressure sensor (optional)

– Temperature sensor (optional)

– Lateral load connection (optional)

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack OIL FILL CAPACITIES


10 OIL FILL CAPACITIES The values indicated in the table apply to the hori-zontal oil separators installed below and are guide values. Deviations are possible depending upon the frame size of the oil cooler. The specifications of the oil fill capacity are based on screw compressor packages with single-stage filter and an oil cooler in the system.

Screw compressor packages with screw compressor type

Oil separator Ø in mm

Oil filling capacity in l

P 508 130 - 160

R / S 508 140 - 180

T 508 610

150 - 220 220 - 290

V 508 610

160 - 240 240 - 310

W / Y 508 610 711

170 - 250 250 - 310 290 - 350

Z/ XA

508 610 711 813

190 - 270 270 - 350 310 - 390 340 - 420

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack SOUND POWER LEVEL, SOUND PRESSURE LEVEL


11 SOUND POWER LEVEL, SOUND PRESSURE LEVEL

The sound pressure level is applicable for free field conditions in an all-round clearance of 1 m from a rectangular block, whose external surfaces are de-fined by the position of the outside edges of the con-cerned screw compressor package.

The specifications cover the sound emission of the complete screw compressor package including the main components screw compressors, oil separators and compressor drive motor in IP23 design at full load with 100% output.

The tolerances are ± 3 dB.

The sound specifications are applicable to the fol-lowing operating conditions: -10 °C / +35 °C with R717 (ammonia)

The selection of the compressor drive motor has a significant effect on the noise emission, since the compressor drive motor is the main source of noise. Basis for the specifications is the compressor drive motor defined as standard by GEA Refrigeration Germany GmbH. Other motor types can create dif-ferent sound emissions.

The sound specifications have been arrived at through extensive measurements in accordance with ISO 9614 - 2 on the test stands of GEA Refrigeration Germany GmbH.

Screw compressor package type Sound pressure level Lp

in dB (A) Sound-power level LW

in dB (A)

P 83.3 99.9

R 83.2 100.1

S 84.9 101.8

T 85.7 102.6

V 86.5 103.8

W 86.5 103.8

Y 86.7 104.0

Z 87.8 105.3

XA 88.8 106.3

Lp [dB (A)] sound pressure level A-weighted Lw [dB(A)] sound-power level A-weighted

Lw [dB (A)] sound-power level A-weighted

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack ENQUIRY SHEET


12 ENQUIRY SHEET

PRODUCT INFORMATION SCREW COMPRESSOR PACKAGESGRASSO SSP1 Smart ScrewPack MANUFACTURER INFORMATION


13 MANUFACTURER INFORMATION GEA Refrigeration Germany GmbH is a company within GEA Refrigeration Technologies, the Refrig-eration Technology Segment of the GEA Group and provides its customers around the world with high-quality components and services for refrigeration and process technology applications.

Locations:

GEA Refrigeration Germany GmbH

Holzhauser Str. 165

13509 Berlin, Germany

Phone: +49 30 43592-6

Fax: +49 30 43592-777

Web: www.gearefrigeration.de

E-Mail: [email protected]

GEA Refrigeration Germany GmbH

Werk Halle

Berliner Straße 130

06258 Schkopau/ OT Döllnitz, Germany

Phone: +49 345 78 236 - 0

Fax: +49 345 78 236 - 14

Web: www.gearefrigeration.de

E-Mail: [email protected]

GEA Refrigeration Technologies GEA Refrigeration Germany GmbH

Holzhauser Strasse 165 13509 Berlin Germany Phone +49 30 43 592 6 Fax +49 30 43 592 777 [email protected] www.gearefrigeration.com

Screw Compressor Packages Grasso SSP1 Documents/Grasso Smart... · 2015-06-10 · fig. 12: Grasso...

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