Johnson Controls SAB 355 Installation and operation manual

SAB 355 (including ATEX)
Screw compressor unit
Engineering manual
en

Engineering manual - SAB 355 Screw compressor unit (including ATEX)
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Manual for SAB 355 screw compressors
Unit no.
Compressor 355 355B
Compressor type SL E X
Oil separator type OHU 7650/6050 OHU 6042/5030
Refrigerant R717 HFC/HCFC ____ Other: _________
Oil type Oil type: __________________ . Evap. temp. _______ . Cond. temp. _______
Control UniSAB III None Other
Oil filter Single Dual
Oil cooling Refrigerant-cooled oil cooler Water-cooled oil cooler
Liquid injection in compressor Single port Dual port
Discharge port Standard AC (Low Viport)
Oil pump
Economiser system
(ECO-system) Economiser connection Economiser type _________
Ex-execution (ATEX) T3 T4 Other: _________
Supply voltage
Motor 3 x _________V / _________ Hz
Control 1 x _________V / ________ Hz
Heating elements (phasing)1 x _________V / ________ Hz
Motor
IP23 IP55
Power ________ kw Size IEC _________
Anti-condensation heater
Drive type Fixed speed Variable speed (VSD)
Coalescer filter pcs.
UniSAB setting values Separator velocity ref. _____ Separator velocity ref. CR _____

Engineering manual - SAB 355 Screw compressor unit (including ATEX)
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Safety valve:
Data for calculation of
downstream line accord-
ing to EN 13136
Vessel data
Type External surface
[m2]
Design pressure
[bar]
Condenser
Evaporator
Liquid separator
Oil separator
Oil cooler
Economiser
Other
Pressure loss, if any, from safety valve to customer connection
(based on design pressure) [bar] _____________
Safety valve type:
Back-pressure dependent
Back-pressure independent

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Contents
1. Introduction ................................................................................... 11
1.1 Purpose .................................................................................. 11
1.2 Main users.............................................................................. 11
1.3 Compressor name, Sabroe/Frick.......................................... 11
1.4 Amendments to the manual.................................................. 12
1.5 Manufacturer's information .................................................. 12
1.6 Safety precaution definitions used in this manual ............... 13
1.7 Requirements for competent persons .................................. 13
2. Signs and warnings....................................................................... 14
2.1 Main users.............................................................................. 14
2.2 Identification of Johnson Controls Denmark
equipment.............................................................................. 15
2.3 Compressor name plate ........................................................ 16
2.4 Compressor name plate - ATEX ............................................ 17
2.5 Labelling of explosion-proof equipment ............................... 18
2.6 Vessel name plate.................................................................. 19
2.7 Unit/pipe system name plate ................................................ 20
2.8 Signs ..................................................................................... 22
3. Safety precautions ........................................................................ 23
3.1 Areas of application ............................................................... 23
3.1.1 Application of the screw compressor ............................. 23
3.1.2 Application of combustion engines ................................ 23
3.2 Safety precautions ................................................................ 24
3.2.1 General precautions ....................................................... 24
3.2.2 Work area safety ............................................................ 24
3.2.3 During operation ............................................................ 24
3.2.4 Safety during maintenance and service ........................ 25
3.2.5 Electrical installations .................................................... 26
3.2.6 Power supply .................................................................. 26
3.2.7 Lubricating oils ............................................................... 27
3.2.8 Refrigerants.................................................................... 27
3.2.9 Purging a refrigeration plant .......................................... 27
3.2.10 F-gas regulation (fluorinated greenhouse
gases) ............................................................................. 27
3.2.11 First aid for accidents with ammonia ............................. 30
3.2.12 First aid for accidents with HFC/HCFC ........................... 31
3.2.13 Protecting the operator as well as the
environment ................................................................... 32

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4. Technical description ................................................................... 35
4.1 Description of the compressor .............................................. 35
4.1.1 Marine application .......................................................... 37
4.1.2 Description of main components and systems.............. 38
4.1.3 Control system ............................................................... 38
4.1.4 Compressor .................................................................... 39
4.1.5 Variable speed drive (VSD) ............................................ 41
4.1.6 Suction filter with built-in non-return valve .................. 42
4.1.7 Compressor lubrication system ..................................... 42
4.1.8 No pump oil system........................................................ 43
4.1.9 Demand pump oil system .............................................. 43
4.1.10 Flow security................................................................... 43
4.1.11 Compressor oil separation system ................................ 43
4.1.12 Automatic oil return valve.............................................. 47
4.1.13 External oil filter ............................................................. 48
4.1.14 Unit with double oil filter ................................................ 48
4.1.15 Compressor hydraulic system ....................................... 49
4.1.16 Compressor oil cooling systems .................................... 50
4.1.17 Suction check valve by-pass.......................................... 52
4.1.18 Requirements for ambient temperatures and
humidity.......................................................................... 54
4.1.19 Balance piston pressure regulator................................. 55
4.1.20 Oil carry-over to plant .................................................... 56
4.1.21 Selecting lubricating oil for Sabroe screw
compressors ................................................................... 57
4.1.22 Oil charge........................................................................ 57
4.1.23 Heating rod element for oil heating, pos. 30 ................. 57
4.1.24 Oil level switch................................................................ 58
4.1.25 Cold-start system........................................................... 58
4.1.26 Compressor protecting system, pos. 220 and
221.................................................................................. 59
4.1.27 Oil cooling system and general piping layout................ 60
4.1.28 Liquid injection oil cooling .............................................. 61
4.1.29 Thermosyphon oil cooling .............................................. 62
4.1.30 Water-cooled oil cooling................................................. 64
4.1.31 KRACHT oil pump............................................................ 64
4.1.32 Economiser, high-stage (optional) ................................ 66
4.1.33 General key to piping diagram....................................... 69
4.1.34 General piping diagram.................................................. 71
4.1.35 General key to piping diagram - continued ................... 72
4.1.36 Instrumentation ............................................................. 73

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5. Physical and connection data ..................................................... 75
5.1 Physical data.......................................................................... 75
5.2 Connection data .................................................................... 76
5.2.1 Connections to the compressor unit .............................. 76
5.2.2 Electrical connections..................................................... 80
5.2.3 List of components ......................................................... 81
6. Technical data ................................................................................ 83
6.1 Data for SAB 355 ................................................................... 83
6.2 Other data.............................................................................. 84
6.3 Selection of vibration dampers ............................................. 84
6.4 Planning the machine room .................................................. 85
6.5 Minimum compressor flow at 3550 rpm ............................... 85
6.6 Operating limits ..................................................................... 85
6.7 Motor selection and starting torque...................................... 86
6.8 Motor/compressor torque ..................................................... 88
6.9 Direction of rotation .............................................................. 89
6.10 Emergency stop..................................................................... 89
6.11 Other emergency stop requirements ................................... 89
6.12 Series 52 coupling ................................................................. 90
6.13 Noise data .............................................................................. 90
6.15 Vibrations and test pressure levels....................................... 91
6.15.1 Vibration data for compressors (all compressor
types).............................................................................. 91
6.15.2 Test pressure levels for standard compressors and
components.................................................................... 93
7. Installation instructions.............................................................. 94
7.1 Installation............................................................................. 94
7.2 Safety precautions ................................................................ 94
7.3 Installation data .................................................................... 94
7.4 Installation and first start-up procedure .............................. 94
7.5 Installation drawings............................................................. 94
7.6 Personnel requirements ........................................................ 95
7.7 Preparing the installation ...................................................... 95
7.8 Tools and accessories ............................................................ 95
7.9 Safety equipment .................................................................. 95
7.10 Local regulations ................................................................... 95
7.11 Preparing the mounting site.................................................. 96
7.12 Space requirements .............................................................. 96

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7.13 Lifting accessories and equipment ....................................... 96
7.14 Preparing lifts ........................................................................ 96
7.15 Lifting and loading instructions............................................. 96
7.16 Unpacking and inspection ..................................................... 96
7.17 Disposal of non-reusable materials ...................................... 96
7.18 Moving the equipment to the mounting site......................... 96
7.19 Alignment of compressor and unit ........................................ 97
7.20 Alignment of unit against foundation ................................... 97
7.21 Laying the unit foundation .................................................... 98
7.22 Mounting directly on the foundation..................................... 98
7.23 Mass damping between unit and building ............................ 99
7.24 Damping using vibration dampers........................................ 99
7.25 VSD equipment.................................................................... 102
7.26 Calculation of centre of gravity, support reactions and
tipping angle ........................................................................ 104
7.27 Auxiliary tools for coupling alignment ................................ 107
7.28 Mounting of series 52 coupling ........................................... 108
7.29 Alignment procedure for coupling ...................................... 110
7.30 Piping connections............................................................... 112
7.31 Connecting electricity supply .............................................. 114
7.32 Pressure testing................................................................... 115
7.33 Evacuation of the refrigeration plant .................................. 116
7.34 Oil charging.......................................................................... 116
7.35 Final installation check ........................................................ 117
8. Components ................................................................................. 118
8.1 UniSAB III ............................................................................ 119
9. Settings ......................................................................................... 120
9.1 Control system .................................................................... 120
10. Operating instructions ............................................................... 121
11. Maintenance instructions.......................................................... 122
11.1 Safety precautions .............................................................. 122
11.2 Maintenance of compressor unit......................................... 122
11.3 Stopping routine.................................................................. 123
11.4 Long-term storage .............................................................. 123
11.5 Maintenance intervals ......................................................... 124
11.6 Visual inspection.................................................................. 125

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11.7 Measures to be taken .......................................................... 125
11.8 General rules for use of lubricating oil in refrigeration
compressors ........................................................................ 127
11.9 Assessing the oil .................................................................. 127
11.10 Visual assessment ............................................................... 128
11.11 Analytical evaluation ........................................................... 128
11.12 Analysing the oil .................................................................. 128
11.13 Oil change ............................................................................ 129
11.14 Charging compressor with lubricating oil ........................... 130
11.15 Oil charge............................................................................. 132
11.16 Motor.................................................................................... 132
12. Fault-finding instructions ......................................................... 133
12.1 How to carry out faultfinding............................................... 133
12.2 Troubleshooting................................................................... 134
13. Service instructions.................................................................... 139
14. Transport instructions ............................................................... 140
14.1 Safety precautions .............................................................. 140
14.2 Transport data ..................................................................... 141
14.3 Personnel requirements ...................................................... 141
14.4 Handling of compressor and unit ........................................ 141
14.5 Loading instructions ............................................................ 143
14.6 Preparations before lifting................................................... 143
14.7 Loading ................................................................................ 143
14.8 Transport instructions ......................................................... 143
14.9 Transport regulations .......................................................... 144
14.10 Unpacking and inspecting the unit...................................... 144
14.11 Moving the equipment to the mounting site....................... 144
14.12 Storage ................................................................................ 144
15. Commissioning instructions ..................................................... 145
15.1 Safety precautions .............................................................. 145
15.2 Preparations for commissioning ......................................... 145
15.3 Preparations on the mounting site...................................... 146
15.4 Evacuation and charging of refrigerant .............................. 146
15.5 Start-up ............................................................................... 147
15.6 Commissioning set .............................................................. 147
15.7 Commissioning checklist..................................................... 148

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16. Spare parts list............................................................................. 149
17. Spare parts drawings ................................................................. 150
18. Final disposal ............................................................................... 151
18.1 Safety precautions .............................................................. 151
18.2 Waste disposal..................................................................... 151
19. Torque............................................................................................ 152
Index.............................................................................................. 153