KIRLOSKAR KC Series Manual

Kirloskar KC Series Refrigeration Compressors
Instruction and
Operation Manual
Versions:
Single Stage : KC2, KC3, KC4, KC6, KC9, KC12
Two Stage : KC21, KC31, KC42, KC51, KC63, KC72, KC84,
KC93 & KC102
KIRLOSKAR
KIRLOSKAR PNEUMATIC CO. LTD.
Kirloskar Refrigeration
INDIAN REGISTER
©
OF SHIPPING 1993
MGMT.SYS.
RvAC071
ISO 9001 : 2000

ACR FOR USER’S RECORD
To
TO BE FILLED IN BY KPCL
MODEL: SPEC. (SBM) NO.:
KPCL O.A. NO. UNIT SR.NO.:
CUSTOMER’S P.O. NO. DATE OF MFG.:
TO BE FILLED IN BY OWNER/USER
DATE OF RECEIPT: DATE OF COMMISSIONING:
APPLICATION INFORMATION:
ADDRESS OF SITE (PLANT):
USER’S REF. NO. OF PLANT/MACHINERY:
ADDRESS OF OWNER/USER:
NAME OF CONTACT PERSON:
TEL. NO.: FAX NO.: E-MAIL:

ACR
FOR USER’S RECORD
To
TO BE FILLED IN BY KPCL
MODEL: SPEC. (SBM) NO.:
KPCL O.A. NO. UNIT SR.NO.:
CUSTOMER’S P.O. NO. DATE OF MFG.:
TO BE FILLED IN BY OWNER/USER
DATE OF RECEIPT: DATE OF COMMISSIONING:
APPLICATION INFORMATION:
ADDRESS OF SITE (PLANT):
USER’S REF. NO. OF PLANT/MACHINERY:
ADDRESS OF OWNER/USER:
NAME OF CONTACT PERSON:
TEL. NO.: FAX NO.: E-MAIL:
FEEDBACK SHEET
MANAGER MARKETING (ACR DIVISION)
KIRLOSKAR PNEUMATIC COMPANY LIMITED
NEAR WAGHIRE COLLEGE, SASWAD-412 301.
TALUKA: PURANDAR, DIST: PUNE (MAHARASHTRA)
PLEASE COMPLETE THE FOLLOWING AND SEND BACK

PREFACE
ThismanualintendedasaguidefortheattendantoftheKirloskar
Refrigeration Compressors type KC, contains a description of
the compressor as well as service and maintenance instructions.
It is necessary to go through the text carefully before installing
andstartingthecompressor.
Symbolsusedinthismanualandtheirmeanings:
Reading the instructions periodically will result In a better
knowledge, thereby assisting in preventing avoidable
breakdowns. If abnormal operating conditions occur, the trouble
shooting chart will be of great help in tracing and rectifying the
trouble. Repairs should be carried out by qualified personnel
(refrigeration/mechanical engineer, technician, mechanic only)
assoonaspossible,otherwiseirreparabledamagemayoccur.All
thedescriptionandillustrationsarewithoutengagement.
The 'KIRLOSKAR' factories are always aspiring to improve their
productsandworkingmethods.Howeverwereservetherightsto
improve the KC series described and maintaining the main
characteristics without being obliged immediately to alter this
manualaccordingly.
Please put caution plate at the plant room entrance as “ENTRY
PROHIBITEDFORUNAUTHORISEDPERSONS”
WARNING - Read it carefully
SPECIAL ATTENTION - Important note/procedure
CAUTION
IMPORTANT

SAFETY
It is assumed that your safety department has established a
program of safety based upon a thorough analysis of industrial
hazards. Before installing and operating or performing
maintenance on the equipment described in this Manual, it is
suggested that you again review this program to be certain that it
coversthehazardsarisingfromhighspeedrotatingmachinery.
It is also important that due consideration is given to those
hazardswhicharisefromthepresenceofelectricalpower,hotoil,
high pressure, high temperature, toxic and flammable liquids,
and gases etc. Proper installation and care of protective guards,
shutdown devices and over pressure protection should also be
consideredforessentialpartsofanysafetyprogram.
Also essential are special precautionary measures to prevent the
possibility of applying power to the machine at any time when
maintenance work is in progress. The prevention of rotation due
toreverseflowindynamicmachineryshouldnotbeoverlooked.
Designofrefrigerantsystemandplantshouldabidewithdirective
principles, standards, ordinance regulatory rules and laws
established by state/local authorities. This is in view of safety and
functionality of plant operation as well as essential health and
environmentsafetyforsocietymankind.
In general, you should be guided by all basic safety rules
associatedwiththeequipmentandtheprocess.
IMPORTANT

Do's & Do Not's
Do
DONOT
1) Do STUDY the manual in detail.
2) Do ASCERTAIN what tools & equipments are required to
carryoutthejob.
3) Do USE proper tools to suit the job. Avoid unnecessary
dismantling.
4) Do ENSURE that all nuts, screws, pipe connections,
electricalcableconnections&coversareproperlytightened.
5) DoENSUREthatsuctionfilterelementsareclean.
6) Do ENSURE sufficient & recommended grade of lube oil for
compressor.
7) DoDRAINcondensatesfromallmanualdrainpoints.
8) DoCHECK oil level in tank.Oil Should be visible& should be
well above minimum level marked on oil level indicator
duringworkingcondition.
9) DoENSUREproperdirectionofrotationbeforestarting.
10) Do WATCH for unusual/abnormal sound and remove the
faultwithoutdelay.
11) Do ENSURE that the compressorroom is properly ventilated
&thereissufficientcirculationoffreshairfromatmosphere.
12) Do ENSURE that stipulated water flow is maintained, else
reduced heat transfer will lead to high temperatures, &
subsequentproblems.(Whereverapplicable)
1) DoNOTATTENDtheunitwhentheunitisinoperation.
2) DoNOTUSEcottonwasteforcleaningpurpose.
3) DoNOTATTEMPTtostarttheunitunlessfaultisrectified.
4) DoNOTCHANGEthesettingsofanyfotheinstruments.
5) Do NOT ATTEMPT to carry out maintenance/service
operation on the equipments unless the system is
depressurised(Whereverapplicable)
IMPORTANT

HANDLING
UNPACKING:
KIRLOSKAR PNEUMATIC
CO.LTD.
LIFTINGANDHANDLING:
STORAGE:
Remove the crating and boxes and account for all the items
shown on the shipping/packing list. Make sure that there are no
missing or damaged parts. Handle all the parts carefully. If the
equipment is damaged during transportation/shipment, contact
immediately the transporter and also
Lifting and handling of compressor must be planned as per the
facilities available at the installation site. Caution must be
exercisedsuchthatnocompressorpartscomeincontactwiththe
lifting ropes. Use lifting sling whenever required.Refer next page
on“LiftingandHaulingofCompressors”.
Store the compressor indoors whenever possible. Keep the
storage area clean, dry and free from extreme temperature
conditions. A rust preventive is applied to the compressor parts
before shipment. The protective effectiveness of this rust
preventiveissignificantlyaffectedbytheconditionsencountered
during an outdoor storage. Precautions must be observed in
case of an outdoor storage such that the equipment is not
subjected to extreme conditions of temperature, corrosive
environmentandexcessivemoisture.
If the compressor is to be stored for a long time after receipt
at site, please refer instructions on “Preservation of
RefrigerationCompressor”inthismanual.
IMPORTANT

Before hauling/moving of compressor consider its weight given
inmanual/brochureprovidedalongwithcompressor.
Select correct size/type of lifting tackles like slings, wire ropes,
shackles, rings, etc. (refer selection guidelines provided by such
toolsmanufacturers).
Tie the compressor at proper location as shown in sketch with
lifting tackles, balance the compressor at its CG and natural
position (do not lift in tilted condition). Lift the compressor to just
adequate heightabove the ground level formoving. See, check,
give alert to the workmen around the work area that hauling of
compressorisbeingstarted.
In short, take all necessary precautions to avoid any sort of
accidentordamageinworkplace.
It is mandatory to follow directive principles, ordinance and
regulatory laws established by state/local authorities, in view of
safetyandfunctionalityofworkenvironment.
LIFTING AND HAULING OF COMPRESSOR

SELECTION GUIDELINE OF LIFTING SLINGS AND SHACKLES
FOR MATERIAL HANDLING
Min. Rope Vertical Basket Choker
Size (mm)
12 1200 2400 900
14 1750 3500 1300
18 2500 5000 1875
20 3300 6500 2475
22 4000 8000 3000
24 4600 9200 3450
25 5000 10000 3750
28 6500 13000 4875
32 8000 16000 6000
35 9200 18400 6900
36 10400 20800 7800
38 12000 24000 9000
40 12700 25400 9625
MAXIMUM SAFE WORKING LOAD IN
KG FOR SINGLE PART SLINGS Min. Rope Vertical Basket Choker
Size (mm)
12 2400 4800 1800
14 3500 7000 2600
18 5000 10000 3750
20 6600 13200 4950
22 8000 16000 6000
24 9200 18400 6900
25 10000 20000 7500
29 13000 26000 9750
32 16000 32000 12000
35 18400 35800 13800
36 20800 41800 15600
38 24000 48000 18000
40 25400 50800 19050
MAXIMUM SAFE WORKING LOAD IN
KG FOR DOUBLE PART SLINGS
BASKET
TYPE OF SINGLE PART SLINGS
TYPE OF DOUBLE PART SLINGS
CHOKER
Note: The capacity indicated in the above table for basket hitch and choker hitch is for guidance only. Vertical
columnistheactualloadandsafeworkingloadisapplicableforverticalfallonly.
S
W
d
D
Jaw Inside Body Pin Eye Safe working loads
Inside Length Material Dia Outside tonnes
width Dia Dia
W S d D min e min Grade 30 Grade40 Grade 63 Grade
18 40 10 12 24 - - 1.0 -
20 44 12 14 28 - 1.0 1.25 -
22 49 14 16 32 1.0 1.25 1.6 2.0
25 55 16 19 36 1.25 1.6 2.0 3.25
28 62 17 20 40 1.6 2.0 2.5 -
32 70 19 22 44 2.0 2.5 3.2 4.75
34 79 22 26 52 2.5 3.2 4.0 6.5
48 80 24 28 56 3.2 4.0 5.0 8.5
45 99 27 31 62 4.0 5.0 6.3 9.5
50 110 30 35 70 5.0 6.3 8.0 12
56 124 34 39 78 6.3 8.0 10 13.5
63 139 38 44 88 8 10 12.5 17
70 154 43 50 100 10 12.5 16 25
80 176 48 55 110 12.5 16 20 35
90 198 54 62 124 16 20 25 40
100 220 60 69 138 20 25 32 55
107 236 65 75 152 25 32 40 -
117 258 71 82 164 32 40 50 -
130 206 79 91 182 40 50 63 -
140 308 84 97 194 50 63 80 -
153 337 93 110 220 63 80 - -
Note: Shackles of grade 30, 40, 63
conform to ISI specification 6132. Grade
80 shackles are made of carbon
manganese forged steel shackles with
alloy steel pins heat treated for optimum
strength.

PRESERVATION OF REFRIGERATION COMPRESSOR
If the compressor is not to be commissioned immediately after receipt at site &
to be stored for long time, then in order to avoid rusting/ damages to internal &
external parts of the compressor & to water jackets, following preservation
actionshouldbetakenbytheenduser/contractor/erector.
oWATER JACKET RUSTING: Each water jacket has two sockets of 3/4"
BSP size, one at top & other at bottom. Fit 3/4" dummy plug at the bottom
socketofwaterjacket&pouranyoneoffollowingbrandsofoil:
1.RustolinDW901ofCastroIOilCompany.
2.RP150or330ofIOCL,
3.Rustop387or388ofHP
Keep the oil in water jacket area for a day or two & then open the dummy
plug & drain oil. Or else, oil can be kept inside the water jacket till the
compressoriscommissioned.Refittheplugattopsocketofthewaterjacket
afteraboveoperation.
oSEAL COVER & SEAL: Open 3/8" BSP plug on seal cover. Pour new
refrigeration oil in sufficient quantity & rotate crankshaft. This will protect
seal assembly & also crankshaft main bearings & conn. rod big end
bearings.Refittheaboveplugafteroilapplication.
oPUMP END : Remove pressure gauge union 1/4" BSP size fitted on top of
pump housing. Pour new refrigeration oil in sufficient quantity & rotate
crankshaft. This will protect pump gears, bearings & also main bearings &
intermediatebearings.Refittheaboveunionafteroilapplication.
oINTERNAL PARTS OF THE COMPRESSOR: At the time of dispatch of
compressorfromSaswadfactory(aftershoptesting&paintingofthesame)
each compressor is evacuated & filled with Nitrogen gas at pressure of
about 2 Kg/sq.cm. However during transit/storage at site Nitrogen gas may
leak out. So, after application of oil in seal cover & pump end as described
above,evacuatethecompressor&chargeitwithdryNitrogengas.
oCRANKSHAFT PROTECTION: Apply heavy-duty grease (Servogem 3 of
IOCL)onentiretaperportionofcrankshafttoprevent rusting.
IMPORTANT