Grasso SSP1 Screw Compressor Packages Documents/Grasso Smart... · 2015-06-10 · PREFACE Dear...

Screw Compressor PackagesGrasso SSP1

Maintenance Checklist (Translation of the original text)P_252511_4

COPYRIGHTAll Rights reserved.No part of this publication may be copied or pub-lished by means of printing, photocopying, microfilmor otherwise without prior written consent of

• GEA Refrigeration Germany GmbHherein after called manufacturer. This restrictionalso applies to the corresponding drawings and dia-grams.

LEGAL NOTICEThis documentation has been written in all con-science. However, the manufacturer cannot be heldresponsible, neither for any errors occurring in thisdocumentation nor for their consequences.

Maintenance Checklist |Screw Compressor Packages

Grasso SSP1

2 GEA Refrigeration Germany GmbH | P_252511_4 | Generated 16.08.2013

SYMBOLS USED IN THIS MANUALDanger!

Stands for an immediate danger whichleads to heavy physical injuries or tothe death.

Warning!

Stands for a possibly dangerous situa-tion which leads to heavy physicalinjuries or to the death.

Caution!

Stands for a possibly dangerous situa-tion which could lead to light physicalinjuries or to damages to property.

Hint!

Stands for an important tip whoseattention is important for the designa-ted use and function of the device.

Maintenance Checklist |Screw Compressor PackagesGrasso SSP1

GEA Refrigeration Germany GmbH | P_252511_4 | Generated 16.08.2013 3

PREFACEDear Customer,By purchasing a Screw Compressor PackageGrasso SSP1 (SmartScrew Pack) you have acquiredan excellent value technical product. We hope youwill be pleased with your purchase and would like tothank you for the confidence placed in us.The Grasso SSP1 has been constructed and manu-factured in line with the latest technical researchresults and has been designed for a long and reliableperformance. In order to make a full use of all theadvantages of the package regular maintenance andinspections are necessary.This

– guarantees the perfect working order of thepackage,

– increases the product's durability,

– enables stoppages to be planned at the mostfavourable time,

– and costs caused by unscheduled repairs can begenerally avoided.

The attached maintenance manual contains all themaintenance instructions and certifications for thefirst 10 years of performance of the Grasso SSP1.The maintenance certificates are completed andsigned as part of the inspection and maintenance byauthorized fitters as evidence of the work done.During the warranty period, these validated mainte-nance certificates also serve as a precondition for apossible warranty claim put to GEA RefrigerationGermany GmbH. We advise you to sign a long-termservice agreement with a qualified firm authorised byGEA Refrigeration Germany GmbH to carry out thenecessary service and maintenance work. Our serv-ice department is at your disposal whenever youneed assistance in selecting a partner suitable foryou.

Warning!

Please observe the maintenanceinstruction given in the manufacturer'stechnical documentation for individualcomponents! The service and mainte-nance work and maintenance intervalsare directly matched to the compo-nents used.The manufacturers' instructions arebinding and must be observed by thecustomer to safeguard the guaranteeprovided by GEA Refrigeration Ger-many GmbH!If the manufacturer does not specifyany special maintenance instructions,the details given in the maintenancemanual apply.

GEA Refrigeration Germany GmbHFrank Müller, Product Manager


Grasso SSP1


TABLE OF CONTENTS1 MAINTENANCE INSPECTION, TYPE OF SERVICE A2 92 MAINTENANCE INSPECTION, TYPE OF SERVICE B1 113 MAINTENANCE INSPECTION, TYPE OF SERVICE B2 134 MAINTENANCE INSPECTION, TYPE OF SERVICE B1 155 MAINTENANCE INSPECTION, TYPE OF SERVICE B3 176 MAINTENANCE INSPECTION, TYPE OF SERVICE B1 197 MAINTENANCE INSPECTION, TYPE OF SERVICE B2 218 MAINTENANCE INSPECTION, TYPE OF SERVICE B1 239 MAINTENANCE INSPECTION, TYPE OF SERVICE B3 2510 MAINTENANCE INSPECTION, TYPE OF SERVICE B1 2711 MAINTENANCE INSPECTION, TYPE OF SERVICE C 2912 SERVICE INSTRUCTION 31




Grasso SSP1


TABLE OF FIGURESfig. 1 flow direction 31




Grasso SSP1


1 MAINTENANCE INSPECTION, TYPE OF SERVICE A2(500 running hours)

Warning!

Please note service instruction Chapter 12, page 31 for all service and maintenance workson the depressurised compressor!

Package type:Package No:Compressor No:

Compressor Installation data Initials

Measure axial clearance Female = ______ mm, Male = ______ mm

X Check shaft seal Oil quantity = ______ ml/h

X Check primary slide movement

X Check position indicator adjustment

General check

Screw Compressor Package Installation data Initials

X Replacing the oil filter

Clean/ check suction filter

Change oil or oil quality analysis (physico-chemical) Quantity = ______ l

XChecking the oil levelFill up with oil

Set value upper thirdfill up quantity = ______ l

Inspect oil pump (coupling, seal) I = ______ Amp

Replace separator cartridges (if necessary)

X Tighten screw connections

Measure alignment/ coupling Axial/ radial misalignment = ______ / ______[mm]

Check functioning of check valves

X Leakage test

X Check sound of bearings


Maintenance inspection, type of service A2



Check solenoid valve capacity control

Check oil heater I = ______ Amp

Lubrication of the motor(Lubrication intervals and amount accordingto motor documentation or motor type label)

Clean motor (outside)

Check starting procedure (see user manual)

Test of safety devices (see parameter list /set values)

X Suction pressure p = ______ bar

X Discharge pressure p = ______ bar

X Oil pressure p = ______ bar

X Suction temperature t = ______ °C

X Discharge temperature/ regulate oil injektion t = ______ °C

X Oil temperature/ check oil cooling t = ______ °C

X Power consumption at 100% load I = ______ Amp

X Check/retighten all fixing bolts of controlpanel

Remarks of Service Engineer:

Place: Date: Signature (Stamp) Service Engineer:

Maintenance inspection, type of service A2 Maintenance Checklist |Screw Compressor Packages

Grasso SSP1


2 MAINTENANCE INSPECTION, TYPE OF SERVICE B1(5,000 hours e.g. in the first operating year)

Warning!




X Measure axial clearance Female = ______ mm, Male = ______ mm




General check



X Clean/ check suction filter

X Change oil or oil quality analysis (physico-chemical) Quantity = ______ l



X Inspect oil pump (coupling, seal) I = ______ Amp


Tighten screw connections

X Measure alignment/ coupling Axial/ radial misalignment = ______ / ______[mm]

XRegreasing the coupling (if provided for inthe maintenance instructions for the cou-pling).

X Check functioning of check valves


Maintenance inspection, type of service B1



X Leakage test


X Check solenoid valve capacity control

X Check oil heater I = ______ Amp

XLubrication of the motor(lubrication intervals and amount accordingto motor documentation or motor type label)


X Check starting procedure (see user manual)

X Test of safety devices (see parameter list /set values)











Maintenance inspection, type of service B1 Maintenance Checklist |Screw Compressor Packages

Grasso SSP1


3 MAINTENANCE INSPECTION, TYPE OF SERVICE B2(10,000 hours e.g. in the first operating year)

Warning!








General check

















X Leakage test




XLubrication of the motor(Lubrication intervals and amount accordingto motor documentation or motor type label)

X Clean motor (outside)














Grasso SSP1


4 MAINTENANCE INSPECTION, TYPE OF SERVICE B1(15,000 hours e.g. in the third operating year)

Warning!








General check

















X Leakage test



















Grasso SSP1


5 MAINTENANCE INSPECTION, TYPE OF SERVICE B3(20,000 hours e.g. in the fourth operating year)

Warning!








General check








X Replace separator cartridges (if necessary)









X Leakage test



















Grasso SSP1


6 MAINTENANCE INSPECTION, TYPE OF SERVICE B1(25,000 hours e.g. in the fifth operating year)

Warning!








General check

















X Leakage test



















Grasso SSP1


7 MAINTENANCE INSPECTION, TYPE OF SERVICE B2(30,000 hours e.g. in the sixth operating year)

Warning!








General check

















X Leakage test



















Grasso SSP1


8 MAINTENANCE INSPECTION, TYPE OF SERVICE B1(35,000 hours e.g. in the seventh operating year)

Warning!








General check

















X Leakage test



















Grasso SSP1


9 MAINTENANCE INSPECTION, TYPE OF SERVICE B3(40,000 hours e.g. in the eighth operating year)

Warning!








General check








X Replace separator cartridges (if necessary)









X Leakage test



















Grasso SSP1


10 MAINTENANCE INSPECTION, TYPE OF SERVICE B1(45,000 hours e.g. in the ninth operating year)

Warning!








General check

















X Leakage test



















Grasso SSP1


11 MAINTENANCE INSPECTION, TYPE OF SERVICE C(50,000 hours e.g. in the tenth operating year)

Warning!




Measure axial clearance Female = ______ mm, Male = ______ mm

Check shaft seal Oil quantity = ______ ml/h

Check primary slide movement

Check position indicator adjustment

X General check














Maintenance inspection, type of service C



X Leakage test


















Maintenance inspection, type of service C Maintenance Checklist |Screw Compressor Packages

Grasso SSP1


12 SERVICE INSTRUCTIONService and maintenance work at depressurized compressors [SI-2005-02]

Warning!

Please note service instruction Chapter 12, page 31 for all service and maintenance works atdepressurized compressors of screw compressor packages with stop valve on suction side( ≥ DN 200)!

1. The admissible closing pressure differences for manually operated stop valves are according to "EN 12284 /table 1" as follows:

DN (nominal diame-ter) 125 150 200 250 300 350 400

PS 25, Δp [bar] - 21 14 9 6 4,5 3,5

PS 40, Δp [bar] 33 21 14 9 6 4,5 3,5

fig.1: flow direction

1 flow direction

2 pilot stroke

These quoted admissible (maximum) closing pressure difference are valid, if the valves are mounted in flowdirection as shown in the figure.

Warning!

For all service works at an opened compressor or its unit, the pressure p at the inlet of thestop valve (e.g. in surge drum) must be kept below a maximum servic-ing pressure ofpservicing = value (table 1) minus 1 to 2 bar.


Service instruction


Following options for limiting the pressure level in front of the stop valve can be advised:

a. mobile removal device (if available)If a mobile removal device is used to depressurize the compressor unit, this device can also be used to limitthe pressure level at the inlet of the stop valve. Therefore the removal device must be connected on the inletside of the stop valve. The removed and condensed refrigerant can be returned to the liquid side of the plantby a manual control valve. Depending on the capacity of the removal device the suction pressure can belimited below the maximum servicing pressure..

b. Hose connection to another operating refrigerant system on siteAfter the compressor and its unit is depressurized, the pressure can be limited below the maximum servicingpressure by a hose connection at a suitable point between the system under service and the other systemunder operation.Eventuell auftretende Kältemittelverlagerungen werden mit der nächsten Wartung des zuvor in Betrieb befin-dlichen SVA wieder rückgängig gemacht.

Fundamentals for options "1a" and "1b":

• All work has to be carried out by competent staff. Gas masks must be carried close-by.

• Take precautions to ensure no pressure increase can occur due to load or heat impact.

• If the service work at the compressor unit cannot be finished in short term and a pressure increase in front ofthe stop valve cannot be excluded by 100%, the opened pipings have to be closed by adequate blind capsor flanges.

Warning!

Attention has to be paid while dismounting the blind caps or flanges! The unit may becomepressurized refrigerant!

If it is not possible to limit the pressure below the maximum servicing pressure pservicing as given in article "1",and if it is not possible to limit the pressure level according to article "1a" or "1b" the stop valves should beclosed by the tightening torques quoted in table 2.

DN (nominal diameter) 250 300 350 400 500

Tightening torque [Nm]to close the stopp valves

385 535 640 800 1270

If these tightening torques are applied with suitable tools a definite closing of the stop valve can be assured upto a pressure difference of 14bar.

NoteIf the mounting direction is reverse to specified flow direction (see figure 1), the quoted admissible closing pres-sures are not valid. In these cases higher closing pressure differences up to the maximum operation pressureare possible.

Service instruction Maintenance Checklist |Screw Compressor Packages

Grasso SSP1



Service instruction


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