Reciprocating Compressors for industrialrefrigerationTotal cost of ownership; precalculation and measured values

Product descriptionpador9084-gbr-TCO_4

COPYRIGHT

All Rights reserved. No part of this publication may be copied or published bymeans of printing, photocopying, microfilm or otherwise without prior writtenconsent of Grasso.This restriction also applies to the corresponding drawings and diagrams.

LEGAL NOTICE

This publication has been written in good faith. However, Grasso cannot be heldresponsible, neither for any errors occurring in this publication nor for theirconsequences.

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PREFACE

General

1. All documentation can be downloaded via our web site.

2. Grasso’s technical manuals includes “generic paragraphs”; this means that itcan occur that not all data as described is relevant for the currentcompressor series as mentioned in this manual. (For instance, not allcompressor series are suitable for all mentioned refrigerants or not allcompressor series includes two-stage compressors)

Directives

Equipment is based on Pressure Equipment Directive (PED 97/23/EG)regulations and according to Machine Directive (MD 2006/42/EG) regulations.

The applied standards are:NEN-EN-IEC 60204, NEN-EN-ISO 12100, NEN-EN-ISO 13857, NEN-EN 378

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TABLE OF CONTENTS1 CONDITIONAL MAINTENANCE GUIDELINE 71.1 INTRODUCTION CONDITIONAL MAINTENANCE 71.1.1 General 71.1.2 Daily inspections 81.1.3 Glossary/terminology 81.2 MAINTENANCE (A, B, C) 81.2.1 CONDITIONAL MAINTENANCE 8

NMI[B] AND NMI[C] (NOMINAL MAINTENANCE INTERVAL B/C) 9SERVICE FACTOR AND STANDARD OPERATING CONDITIONS (Sf= approx. 1) 9SERVICE FACTOR (Sf) 9

1.2.2 HOW SERVICE FACTOR “Sf” IS CALCULATED? 101.2.3 DESCRIPTION MAINTENANCE A, B AND C (refer Section 1.3, Page 13) 111.2.4 MAINTENANCE SCHEDULE EXAMPLE 121.3 CHECKLIST MAINTENANCE A, B, C 131.3.1 Compressor 131.3.2 Package components 15

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1 CONDITIONAL MAINTENANCE GUIDELINE

1.1 INTRODUCTION CONDITIONAL MAINTENANCE

Software

Grasso has the following types of software to calculate conditional maintenance:

1. Precalculation Sales software (sales configuration); Makes a prediction andestimation which results into an indication for all required maintenance, partsto be used, electric power consumption etc. The total costs of ownership willbe calculated. The output document of this software could be used bycontractors for their service contracts

2. GEA Omni™, Grasso Maintenance Monitor (GMM) or GSC-TP: Based onmeasured values, the system will inform the contractor/owner when andwhich maintenance has to be done.

This manual describes:

1. What kind of maintenance

2. When to perform maintenance

3. Under which conditions what maintenance is applicable

Hint!

This manual does not describe how the maintenance should be done.Therefore, refer to the Installation and Maintenance Manual (IMM)and/or the Service Instruction Manual (SIM) of the compressor seriesas concerned.

1.1.1 GeneralIn a refrigeration installation maintenance depends strongly on the use, theapplication and the correct selections of the main components and the use oforiginal spare parts. Well maintained machines will have a lower powerconsumption and, as a consequence, a better COP (coefficient of performance).Conditional maintenance, as a part of the total cost of ownership (TCO), isservicing the compressor at the right moment. Resulting in minimummaintenance cost and maximum reliability. Maintenance will be carried outdepending on the load and operating conditions of the compressor.A moderately loaded compressor has therefore less maintenance intervalscompared to a normal or heavy loaded compressor.Besides the operating conditions and proper maintenance, it is important that theinstallation is clean and dry. Furthermore the engine room should have easyaccess and be clean. The presence of moisture and non-condensing gasses hasa very big efffect on the eficiency of the plant. Checking the quality of therefrigerant, (presence of non-condensable gasses) and of oil are important.It is of great importance, that the installation and the compressor areharmoniously geared to one another and equipped with the correct securities andcontrol.

CONDITIONAL MAINTENANCE GUIDELINEINTRODUCTION CONDITIONAL MAINTENANCE

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After the compressor has been installed, the applicable conditional maintenanceprogramme should ensure many years of reliable operation of the compressor.

1.1.2 Daily inspections

Daily inspections are without doubt the basis for correct conditional maintenanceand should therefore be carried out accordingly.

For more detailed information about daily inspections refer to the Installation andMaintenance Manual (IMM).

1.1.3 Glossary/terminology

Terminology

# Term Explanation

1 Maintenance (A, B, C) Different kind of maintenance levels

2.1 Maintenance interval Interval (hours) between Maintenance A, B, C

2.2 Maintenance scheduleSequency of different type of maintenance, as

calculated in Grasso’s software(e.g. A-B-A-B-A-B-C)

3.1 NMi[B]Nominal “Maintenance interval B”; acc to Nominal

Maintenance Interval Table (Section 1.2.1.1,Page 9)

3.2 NMI[C]Nominal “Maintenance interval C”; acc to Nomimal

Maintenance Interval Table (Section 1.2.1.1,Page 9)

3.3 MMI[C]Maximum “Maintenance interval C”;

Table (Section 1.2.1.1, Page 9)

4.1 RMI[B] “REAL1 Maintenance interval B“ , in Hours or Months(calculated value)

4.2 RMI[C] “REALPage 8 Maintenance interval C“ , in Hours orMonths (calculated value)

5 Sf Service factor (calculated value)

1.2 MAINTENANCE (A, B, C)

The following type of Maintenance exists; (refer to Section 1.2.3, Page 11)

A. Maintenance A, “Inspection”

B. Maintenance B, “Top end overhaul“

C. Maintenance C, “Major inspection/overhaul“

For the work to be done, the estimated labour hours and the materials to be usedfor Maintenance A, B and C, refer to Section 1.2.3, Page 11 and to Grasso’ssoftware.

1.2.1 CONDITIONAL MAINTENANCE

Conditional maintenance is based on;

1. NMI, Nominal Maintenance Intervals (refer to Page 9)

1 REAL = Conditional maintenance

CONDITIONAL MAINTENANCE GUIDELINEMAINTENANCE (A, B, C)

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2. Standard operating conditions (refer to Page 10)

3. The number of operating hours per year

4. The Sf (service factor), calculated by Grasso’s software is dependant on theactual operating conditions of the compressor.

RMI[B] = NMI[B] x Sf(real maintenance interval B = Nominal maintenance interval x service factor)

RMI[C] = NMI[C] x Sf(real maintenance interval C = nominal maintenance service interval C x servicefactor)

1.2.1.1 NMI[B] AND NMI[C] (NOMINAL MAINTENANCE INTERVAL B/C)

In case of the standard operating conditions(Sf = 1, refer Section 1.2.1.2, Page 9), the maintenance B interval andmaintenance C are as follows;

Nominal Maintenance Intervals, NMI[B] and NMI[C] (where Sf=1)

“A” NMI[B] hrs NMI[C] hrs

At least every 24 months2 15000 48000 (At least at 55000!)

1.2.1.2 SERVICE FACTOR AND STANDARD OPERATING CONDITIONS (Sf= approx. 1)In case the compressor is running on the standard operating conditions and thedefaults of Sf Page 10 are taken into account, the Service factor Sf = approx. 1.

Standard operating conditions (Sf= approx. 1)

Compr. typeTooC

dTK

TcoC

Speedmin-1

V 300 .. 600 -105 35 1500

V 300T .. 600T -35

V 700 .. 1800 -105 35 1200

V 700T .. 1800T -35

1.2.1.3 SERVICE FACTOR (Sf)

The Nominal Maintenance Intervals (NMI[B] / NMI[C]) as described in Page 9 arevalid for the standard operating conditions as mentioned in Page 9 and thesoftware defaults (refer Page 10) for Sf dependancies are taken into account.

Hint!

For all operating conditions, the service factor (Sf) has to becalculated to determine the Real Maintenance Interval (RMI);

RMI[B] = NMI[B] x Sf(real maintenance interval B = Nominal maintenance interval B x Service factor)

RMI[C] =

2 In case RMI[B] < 25 months, "A" is not required

CONDITIONAL MAINTENANCE GUIDELINEMAINTENANCE (A, B, C)

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In case the service factor Sf <=1, “Maintenance C“ remains at 48.000 hours. SoRMI[C] = NMI[C]In case the service factor Sf >1,”Maintenance C” is necessary at RMI[C] = NMI[C]x Sf, however the maximum is MMI[C] according Page 9.

RMI[B] is calculated in hours. Depending on the number of operating hours/year,the RMI[B] in months can be calculated.(e.g. if RMI[B] = 12.000 hrs and the number of operating hour/year = 5.000,RMI[B] in months is 12.000/5.000 x 12 = 28.8 months;RMI[B] = 12.000 hrs equal RMI[B] = 28.8 months)

RMI[A] =If the maintenance interval RMI[B] < 25 (value from Page 9) in months then“Maintenance A“ is not required.

If the maintenance interval RMI[B] >= 25 and < 50 months, one (1) “MaintenanceA” has to be scheduled in between “Maintenance B” and “Maintenance C”.(e.g. If RMI[B]=28.8 months, one additional “Maintenance A” has to bescheduled; then the interval period between maintenance amounts 28.8/2 = 14.4months = 6.000 hrs)

Hint!

In case the number of operating hour/year decreases, the number of“Maintenance A“ (could) increase.

1.2.2 HOW SERVICE FACTOR “Sf” IS CALCULATED?The default Sf values in combination with the standard operating conditions of thecompressor, results into an Sf value = approx. 1.The service factor as calculated with Grasso’s software depends on the “weightfactors” as mentioned in the following table;

Dependancies (“weight factors“)Service factor Sf

Sf dependancies (“weightfactors“) Description Nominal values

Sf= approx. 1

Operating conditionsDischarge temperature;

lower discharge temperatures increase Sf.

Refer to standardoperating conditions

( Page 9)

Average part load atconstant speed3

Lower values will decrease Sf in case frequencycontrolled is not applied;

Lower values will increase Sf if frequency control isapplied.

80%

Frequency controlled

Assumption:If frequency control is applied, the standard capacitycontrol of the compressor (e.g.) will not be applied;

the partload conditions will be fully achieved byvariable compressor speeds

Single speed

Number of starts per 24 h More starts will decrease the service factor 8

3 Partload will be done by switching off cylinders. In case frequency controll is applied, the partload will bedone by decreasing the compressor speed. A lower compressor speed will increase the service factor.Switching off cylinders will decrease the service factor. A lower compressor speed will also increase theCOP.

CONDITIONAL MAINTENANCE GUIDELINEMAINTENANCE (A, B, C)

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1.2.3 DESCRIPTION MAINTENANCE A, B AND C (refer Section 1.3, Page 13)

Disclaimer

Grasso has pre-calculation software, to determine the service interval scheduleand the required materials."The service intervals and materials as calculated by Grasso’s pre-calculationsoftware, are based on predicted operating conditions. Therefore thesecalculated service intervals are only a prediction.

Warning

No rights can be derived from the information as pre-calculated byGrasso’s pre-calculation software

Hint!

The actual maintenance intervals have to be calculated by the GrassoMaintenance Monitor (GMM) or GSC-TP by measuring the actualoperating conditions.

Refer to IMM and SIM!

Hint!

The maintenance information as mentioned below is just a briefdescription. For etailed information how to do the maintenace theInstallation and Maintenance Manual (IMM) and the Service InstructionManual (SIM) has to be consulted.

Maintenance A:

1. Replace/clean oil filters

2. Oil analisys / change oil

3. Visual inspection of crankcase (inside)

4. Visual inspection of suction valve of one base load cylinder

5. Visual inspection of discharge valve assembly of one base load cylinder

6. Visual inspection of cylinder liner of one base load cylinder; The hone profilehas to be present. I any knocking positions, cylinder liner has to be renewed

7. Check operating conditions and fill in the log book

8. Check/test safety equipment; Check oil control pressure and oil difference.Check the functionallity of the discharge pressure safety switch

9. Maintenance A to be registrated on GMM or GSC-TP

10. Parts to be used for maintenance A, refer to Grasso’s software

Maintenance B:

= Maintenance A +

1. Replacing suction and discharge valve rings and springs (“top end” overhaul)

2. Inspection of all cylinder liners

CONDITIONAL MAINTENANCE GUIDELINEMAINTENANCE (A, B, C)

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3. Maintenance B to be registrated on GMM or GSC-TP

4. Parts to be used for maintenance B, refer to Grasso’s software

Maintenance C:

= Maintenance B +Major inspection/overhaul

1. Complete disassembly

2. Replacement of all bearings

3. Inspection/replacement of all remaining wearing parts (oil pump element,liners, pistons etc.)

4. Maintenance C to be registrated on GMM or GSC-TP

5. Parts to be used for maintenance C depends on the status of the compressor

Materials Maintenance A, B and C

A. The materials required for Maintenance A are calculated in Grasso’s software.

B. The materials required for Maintenance B are calculated in Grasso’s software.

C. Materials for Maintenance C depends on the status of the compressor.

Labour hours Maintenance A, B and C

The estimated labour hours for maintenance A, B and C are calculated inGrasso’s software and are based on the following conditions:

1. Compressor (and oil separator) is (are) still under refrigerant pressure

2. Compressor cooled down to ambient temp.

3. Stop valves available and working properly

4. Qualified service engineer

5. Required special tools available

1.2.4 MAINTENANCE SCHEDULE EXAMPLEConsult Grasso or refer to ouput documents of Grasso’s software.

CONDITIONAL MAINTENANCE GUIDELINEMAINTENANCE (A, B, C)

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1.3 CHECKLIST MAINTENANCE A, B, C

Hint!

Maintenance information as mentioned below is general for all Grassoreciprocating compressors. So not all data is relevant for all seriesand types.

1.3.1 Compressor

General remarks about check list;

1. Check list for compressor only; all other components have to be maintainedaccording to their specific manuals (IMM and SIM).

2. All items of the list below marked “check“, have to be checked visually andchecked for proper working.

3. Some components have to be measured.For measuring details refer to SIM.

4. Measuring means also that visual inspection is required.

5. Visual inspections:The visual inspections during maintenance are of importance; measurementsshould be carried out at the moment that visually abnormalities are detected.The result of the inspection determines whether one or more parts have to bereplaced. For more detailed information refer (SIM) and Installation andMaintenance Manual (IMM).

6. Oil and oil return systems:The quality of the oil effects the oil consumption and the life time of themoving parts. For oil return systems or systems in which soluble oil is beingused, we advise to check (or have checked) the quality of the oil every 5000hours and - if necessary - to renew the oil and/or filters. If there is no oilanalysis available, we advise to renew the oil. By regularly carrying out oilanalyses and registering them in a log, aberrations will be noticed in an earlystage, which may prevent or reduce resultant damage(s).

Note 1:When renewing the oil, in the crankcase the oil in the oil separator and the oilreturn or oil rectifier system (if fitted) has to be renewed.

Note 2:Pre-lubricate the compressor before re-starting. Used or filtered oil shouldNEVER be added to a compressor under any circumstance. Use only new oilas selected from the Grasso oil table. Oil charging via the suction line of thecompressor is not allowed.

Grasso Maintenance Monitor (GMM) is applied

Maintenance compressorDescription

A B C

Check Check CheckCapacity control

Solenoid valve and coils

Check Replace Seals of cap control piston / lifting mechanism

CONDITIONAL MAINTENANCE GUIDELINECHECKLIST MAINTENANCE A, B, C

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Grasso Maintenance Monitor (GMM) is applied

Maintenance compressorDescription

A B C

Check Check Check Compressorhousing Oil return orifice (LP and) HP

Check Check Check Crankcase heater

Measure Crankshaft Main (and intermediate) bearings, runningsurface

Visualinspection

Connecting rod

Cylinder located nearest to the shaft-end of thecompressor:

Visualinspection Measure Big and small end bearing, running surface

Clean Clean Clean Compressorhousing Inside and outside

Visualinspection Measure

Cylinder linersCylinder located nearest to the shaft-end of the

compressor

Measure All cylinder liners

Check Check Check Drive Coupling alignment

Check Check Check Interstage cooler Inspections and injection valves

Clean Clean Clean

Filters

Oil suction filter

Replace. Replace Replace Oil discharge filter

Check Clean Clean Suction gas

Check Check Check

Oil

Oil analysis recommended

Ifhygroscop

ic oil isapplied:Replace

Replace Replace Oil refreshment compresssor, oil separator andoil system

Visualinspection

Visualinspection

Oil pump element, oil control and lubricationpressure regulator

Check Check Check Lubrication and control system

Check Clean Clean Oil separator, test oil return system

Clean Clean Clean Oil cooler fan / heat exchanger

Visualinspection Replace

PistonRings

Visualinspection Measure Gudgeon pin

Visual

inspection+ TEST

Visualinspection+ TEST

Relief valve(s)

Check Check Check Shaft seal Oil & Refrigerant leak range

Visualinspection Compressor valves

Cylinder located nearest to the shaft-end of thecompressor:

Suction and discharge valves, springs, damperrings

Check Replace Replace Suction and discharge compressor valves

Check Thrust bearing Running surface

CONDITIONAL MAINTENANCE GUIDELINECHECKLIST MAINTENANCE A, B, C

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1.3.2 Package components

Checklist package components

Description/checkpoint

1 Drive guard

2 V-belts and alignment

3 Coupling alignment

4 Oil level float switch on compressor and oil separator

5 Pressure safety switches

6 Pressure gauges

7 Thermostats and thermometers

8 Electrical control system

9 Oil return protection and oil return system

10Electric motor and thermistors(Consult motor manufacturer)

11 Base frame, vibration dampers and bolts

12 Piping

13 Interstage cooler, interstage injection

15 Oil cooler (oil side and air side) and fan

16 Thermo-Master

CONDITIONAL MAINTENANCE GUIDELINE

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GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one 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

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Phone +31 (0)73 6203 911

info@gea.com gea.com