Reciprocating Compressors for industrial refrigeration Total cost of ownership; precalculation and measured values
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1 Reciprocating Compressors for industrial refrigeration Total cost of ownership; precalculation and measured values Product description
2 COPYRIGHT All Rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent 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 held responsible, neither for any errors occurring in this publication nor for their consequences
3 PREFACE General 1. All documentation can be downloaded via our web site. 2. Grasso s technical manuals includes generic paragraphs ; this means that it can occur that not all data as described is relevant for the current compressor series as mentioned in this manual. (For instance, not all compressor series are suitable for all mentioned refrigerants or not all compressor series includes two-stage compressors) Directives Equipment is based on Pressure Equipment Directive (PED 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
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5 TABLE OF CONTENTS 1 CONDITIONAL MAINTENANCE GUIDELINE INTRODUCTION CONDITIONAL MAINTENANCE General Daily s Glossary/terminology MAINTENANCE (A, B, C) CONDITIONAL MAINTENANCE 8 NMI[B] AND NMI[C] (NOMINAL MAINTENANCE INTERVAL B/C) 9 SERVICE FACTOR AND STANDARD OPERATING CONDITIONS (Sf= approx. 1) 9 SERVICE FACTOR (Sf) HOW SERVICE FACTOR Sf IS CALCULATED? DESCRIPTION MAINTENANCE A, B AND C (refer Section 1.3, Page 13) MAINTENANCE SCHEDULE EXAMPLE CHECKLIST MAINTENANCE A, B, C Compressor Package components
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7 CONDITIONAL MAINTENANCE GUIDELINE INTRODUCTION CONDITIONAL MAINTENANCE 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 and estimation which results into an indication for all required maintenance, parts to be used, electric power consumption etc. The total costs of ownership will be calculated. The output document of this software could be used by contractors for their service contracts 2. GEA Omni, Grasso Maintenance Monitor (GMM) or GSC-TP: Based on measured values, the system will inform the contractor/owner when and which 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 series as concerned General In a refrigeration installation maintenance depends strongly on the use, the application and the correct selections of the main components and the use of original spare parts. Well maintained machines will have a lower power consumption and, as a consequence, a better COP (coefficient of performance). Conditional maintenance, as a part of the total cost of ownership (TCO), is servicing the compressor at the right moment. Resulting in minimum maintenance cost and maximum reliability. Maintenance will be carried out depending on the load and operating conditions of the compressor. A moderately loaded compressor has therefore less maintenance intervals compared to a normal or heavy loaded compressor. Besides the operating conditions and proper maintenance, it is important that the installation is clean and dry. Furthermore the engine room should have easy access and be clean. The presence of moisture and non-condensing gasses has a very big efffect on the eficiency of the plant. Checking the quality of the refrigerant, (presence of non-condensable gasses) and of oil are important. It is of great importance, that the installation and the compressor are harmoniously geared to one another and equipped with the correct securities and control
8 CONDITIONAL MAINTENANCE GUIDELINE MAINTENANCE (A, B, C) After the compressor has been installed, the applicable conditional maintenance programme should ensure many years of reliable operation of the compressor Daily s Glossary/terminology Daily s are without doubt the basis for correct conditional maintenance and should therefore be carried out accordingly. For more detailed information about daily s refer to the Installation and Maintenance Manual (IMM). 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 schedule 3.1 NMi[B] 3.2 NMI[C] 3.3 MMI[C] Sequency of different type of maintenance, as calculated in Grasso s software (e.g. A-B-A-B-A-B-C) Nominal Maintenance interval B ; acc to Nominal Maintenance Interval Table (Section , Page 9) Nominal Maintenance interval C ; acc to Nomimal Maintenance Interval Table (Section , Page 9) Maximum Maintenance interval C ; Table (Section , Page 9) 4.1 RMI[B] 4.2 RMI[C] REAL 1 Maintenance interval B, in Hours or Months (calculated value) REALPage 8 Maintenance interval C, in Hours or Months (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 /overhaul For the work to be done, the estimated labour hours and the materials to be used for Maintenance A, B and C, refer to Section 1.2.3, Page 11 and to Grasso s software CONDITIONAL MAINTENANCE Conditional maintenance is based on; 1. NMI, Nominal Maintenance Intervals (refer to Page 9) 1 REAL = Conditional maintenance
9 CONDITIONAL MAINTENANCE GUIDELINE MAINTENANCE (A, B, C) 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 the actual 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 service factor) NMI[B] AND NMI[C] (NOMINAL MAINTENANCE INTERVAL B/C) In case of the standard operating conditions (Sf = 1, refer Section , Page 9), the maintenance B interval and maintenance 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 months (At least at 55000!) SERVICE FACTOR AND STANDARD OPERATING CONDITIONS (Sf= approx. 1) In case the compressor is running on the standard operating conditions and the defaults of Sf Page 10 are taken into account, the Service factor Sf = approx. 1. Standard operating conditions (Sf= approx. 1) Compr. type To oc V V 300T.. 600T -35 V V 700T T -35 dt K Tc oc Speed min SERVICE FACTOR (Sf) The Nominal Maintenance Intervals (NMI[B] / NMI[C]) as described in Page 9 are valid for the standard operating conditions as mentioned in Page 9 and the software defaults (refer Page 10) for Sf dependancies are taken into account. Hint! For all operating conditions, the service factor (Sf) has to be calculated 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] = In case RMI[B] < 25 months, "A" is not required 9
10 CONDITIONAL MAINTENANCE GUIDELINE MAINTENANCE (A, B, C) In case the service factor Sf <=1, Maintenance C remains at hours. So RMI[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] = hrs and the number of operating hour/year = 5.000, RMI[B] in months is /5.000 x 12 = 28.8 months; RMI[B] = 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) Maintenance A 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 be scheduled; then the interval period between maintenance amounts 28.8/2 = 14.4 months = hrs) Hint! In case the number of operating hour/year decreases, the number of Maintenance A (could) increase HOW SERVICE FACTOR Sf IS CALCULATED? The default Sf values in combination with the standard operating conditions of the compressor, results into an Sf value = approx. 1. The service factor as calculated with Grasso s software depends on the weight factors as mentioned in the following table; Dependancies ( weight factors )Service factor Sf 3 10 Sf dependancies ( weight factors ) Description Nominal values Sf= approx. 1 Operating conditions Discharge temperature; lower discharge temperatures increase Sf. Refer to standard operating conditions ( Page 9) Average part load at constant speed3 Lower values will decrease Sf in case frequency controlled is not applied; Lower values will increase Sf if frequency control is applied. 80% Frequency controlled Assumption: If frequency control is applied, the standard capacity control of the compressor (e.g.) will not be applied; the partload conditions will be fully achieved by variable compressor speeds Single speed Number of starts per 24 h More starts will decrease the service factor 8 Partload will be done by switching off cylinders. In case frequency controll is applied, the partload will be done 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 the COP
11 CONDITIONAL MAINTENANCE GUIDELINE MAINTENANCE (A, B, C) DESCRIPTION MAINTENANCE A, B AND C (refer Section 1.3, Page 13) Disclaimer Grasso has pre-calculation software, to determine the service interval schedule and the required materials. "The service intervals and materials as calculated by Grasso s pre-calculation software, are based on predicted operating conditions. Therefore these calculated service intervals are only a prediction. Warning No rights can be derived from the information as pre-calculated by Grasso s pre-calculation software Hint! The actual maintenance intervals have to be calculated by the Grasso Maintenance Monitor (GMM) or GSC-TP by measuring the actual operating conditions. Refer to IMM and SIM! Hint! The maintenance information as mentioned below is just a brief description. For etailed information how to do the maintenace the Installation and Maintenance Manual (IMM) and the Service Instruction Manual (SIM) has to be consulted. Maintenance A: 1. Replace/clean oil filters 2. Oil analisys / change oil 3. of crankcase (inside) 4. of suction valve of one base load cylinder 5. of discharge valve assembly of one base load cylinder 6. of cylinder liner of one base load cylinder; The hone profile has 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
12 CONDITIONAL MAINTENANCE GUIDELINE MAINTENANCE (A, B, C) 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 /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 in Grasso 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 MAINTENANCE SCHEDULE EXAMPLE Consult Grasso or refer to ouput documents of Grasso s software
13 CONDITIONAL MAINTENANCE GUIDELINE CHECKLIST MAINTENANCE A, B, C 1.3 CHECKLIST MAINTENANCE A, B, C Hint! Maintenance information as mentioned below is general for all Grasso reciprocating compressors. So not all data is relevant for all series and types Compressor General remarks about check list; 1. Check list for compressor only; all other components have to be maintained according to their specific manuals (IMM and SIM). 2. All items of the list below marked check, have to be checked visually and checked for proper working. 3. Some components have to be measured. For measuring details refer to SIM. 4. Measuring means also that visual is required. 5. s: The visual s during maintenance are of importance; measurements should be carried out at the moment that visually abnormalities are detected. The result of the determines whether one or more parts have to be replaced. For more detailed information refer (SIM) and Installation and Maintenance Manual (IMM). 6. Oil and oil return systems: The quality of the oil effects the oil consumption and the life time of the moving parts. For oil return systems or systems in which soluble oil is being used, we advise to check (or have checked) the quality of the oil every 5000 hours and - if necessary - to renew the oil and/or filters. If there is no oil analysis available, we advise to renew the oil. By regularly carrying out oil analyses and registering them in a log, aberrations will be noticed in an early stage, 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 oil return or oil rectifier system (if fitted) has to be renewed. Note 2: Pre-lubricate the compressor before re-starting. Used or filtered oil should NEVER be added to a compressor under any circumstance. Use only new oil as selected from the Grasso oil table. Oil charging via the suction line of the compressor is not allowed. Grasso Maintenance Monitor (GMM) is applied Maintenance compressor A B C Check Check Check Check Replace Description Capacity control Solenoid valve and coils Seals of cap control piston / lifting mechanism 13
14 CONDITIONAL MAINTENANCE GUIDELINE CHECKLIST MAINTENANCE A, B, C Grasso Maintenance Monitor (GMM) is applied Maintenance compressor A B C Check Check Check Compressor housing Check Check Check Crankcase heater Measure Measure Clean Clean Clean Measure Measure Crankshaft Connecting rod Compressor housing Cylinder liners Description Oil return orifice (LP and) HP Main (and intermediate) bearings, running surface Cylinder located nearest to the shaft-end of the compressor: Big and small end bearing, running surface Inside and outside Cylinder located nearest to the shaft-end of the compressor All cylinder liners Check Check Check Drive Coupling alignment Check Check Check Interstage cooler Inspections and injection valves Clean Clean Clean Oil suction filter Replace. Replace Replace Filters Oil discharge filter Check Clean Clean Suction gas Check Check Check If hygroscop ic oil is applied: Replace Replace Replace Oil Oil analysis recommended Oil refreshment compresssor, oil separator and oil system Oil pump element, oil control and lubrication pressure 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 + TEST Replace Measure + TEST Piston Relief valve(s) Rings Gudgeon pin Check Check Check Shaft seal Oil & Refrigerant leak range Compressor valves Cylinder located nearest to the shaft-end of the compressor: Suction and discharge valves, springs, damper rings Check Replace Replace Suction and discharge compressor valves Check Thrust bearing Running surface
15 CONDITIONAL MAINTENANCE GUIDELINE 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 10 Electric 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
16 We live our values. Excellence Passion Integrity Responsibility GEA-versity 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. GEA Refrigeration GEA Refrigeration Netherlands N.V. Parallelweg AL s-hertogenbosch, Netherlands Phone +31 (0) info@gea.com gea.com
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