SABROE SAB 193 S Installation and operation manual

SAB 193-233-283 S A-frame (including ATEX)
Screw compressor units
Engineering manual EN

Engineering manual - SAB 193-233-283 S A-frame (including ATEX)
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Manual for SAB 193/233/283 A-frame screw compressors
Unit no.
Compressor 193 233 283
Compressor type S L E X
Oil separator type OHU 04123/2719 D1 OHU 04136/3231 D2
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
No 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)
UniSAB setting
values Separator velocity ref. _______ Separator velocity ref. CR _______

Engineering manual - SAB 193-233-283 S A-frame (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 ......................................................... 13
1.6 Safety precaution definitions used in this manual.......................... 14
1.7 Requirements for competent persons .......................................... 14
2. Signs and warnings............................................................................. 15
2.1 Main users ................................................................................15
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.......................................................21
2.8 Signs .......................................................................................23
3. Safety precautions .............................................................................. 24
3.1 Areas of application.................................................................... 24
3.1.1 Application of the screw compressor ....................................24
3.1.2 Application of combustion engines ....................................... 24
3.2 Safety precautions .....................................................................25
3.2.1 General precautions............................................................ 25
3.2.2 Work area safety.................................................................25
3.2.3 During operation .................................................................25
3.2.4 Safety during maintenance and service ................................ 26
3.2.5 Electrical installations.......................................................... 27
3.2.6 Power supply...................................................................... 27
3.2.7 Lubricating oils ................................................................... 28
3.2.8 Refrigerants ....................................................................... 28
3.2.9 Purging a refrigeration plant................................................. 28
3.2.10 F-gas regulation (fluorinated greenhouse gases)................... 29
3.2.11 First aid for accidents with ammonia..................................... 31
3.2.12 First aid for accidents with HFC/HCFC .................................32
3.2.13 Protecting the operator as well as the environment ................ 33

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4. Technical description .......................................................................... 36
4.1 Description of the screw compressor ...........................................36
4.2 Marine application...................................................................... 38
4.3 Description of main components and systems.............................. 39
4.4 Control system .......................................................................... 39
4.5 Compressor .............................................................................. 40
4.6 Variable speed drive (VSD)......................................................... 42
4.7 Compressor lubrication system ...................................................42
4.8 Oil injection valve ....................................................................... 43
4.9 No pump oil system.................................................................... 43
4.10 Demand pump oil system ........................................................... 43
4.11 Flow security ............................................................................. 43
4.12 Compressor oil separation system...............................................43
4.13 Automatic oil return valve ........................................................... 46
4.14 External oil filter .........................................................................47
4.15 Unit with double oil filter.............................................................. 48
4.16 Compressor hydraulic system ..................................................... 48
4.17 Compressor oil cooling systems.................................................. 50
4.18 Suction check valve by-pass.......................................................51
4.19 Requirements for ambient temperatures and humidity ..................53
4.20 Oil carry-over to plant .................................................................54
4.21 Selecting lubricating oil for Sabroe screw compressors ................. 55
4.22 Oil charge.................................................................................. 55
4.23 Heating rod element for oil heating, pos. 30.................................. 55
4.24 Oil level switch........................................................................... 56
4.25 Cold-start system....................................................................... 56
4.26 Compressor protecting system, pos. 220 and 221 ........................ 58
4.27 Oil cooling system and general piping layout ................................ 59
4.28 Liquid injection oil cooling ........................................................... 59
4.29 Thermosyphon oil cooling........................................................... 61
4.30 Water-cooled oil cooling ............................................................. 63
4.31 Connection to AlfaNova oil cooler................................................ 65
4.32 KRACHT oil pump ...................................................................... 66
4.33 Economiser, high-stage (optional) ...............................................67
4.34 General piping diagram .............................................................. 71
4.35 Key to piping diagram.................................................................74
4.36 Instrumentation.......................................................................... 76

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5. Physical and connection data ............................................................. 78
5.1 Physical data ............................................................................. 78
5.2 Allowable flange loads................................................................ 79
5.3 Mounting of suction isolation valve .............................................. 80
5.4 Connection data ........................................................................81
5.4.1 Connections to compressor unit ...........................................81
5.4.2 Electrical connections ......................................................... 87
5.4.3 List of components..............................................................88
6. Technical data ..................................................................................... 90
6.1 Data for compressor units........................................................... 90
6.2 Other data ................................................................................. 92
6.3 Planning the machine room ........................................................ 93
6.4 Minimum compressor flow at 3550 rpm........................................94
6.5 Operating limits.......................................................................... 95
6.6 Selecting electric motor .............................................................. 96
6.7 Motor dimension ........................................................................96
6.8 Motor selection and starting torque.............................................. 97
6.9 Motor/compressor torque ........................................................... 98
6.10 Direction of rotation .................................................................... 99
6.11 Emergency stop.........................................................................99
6.12 Other emergency stop requirements............................................99
6.13 Noise data............................................................................... 100
6.14 Noise data for SAB 193-233-283 .............................................. 100
6.15 Vibrations and test pressure levels ............................................ 101
6.15.1 Vibration data for compressors (all compressor
types) .............................................................................. 101
6.15.2 Test pressure levels for standard compressors and
components ..................................................................... 103
6.15.3 Tightness of Sabroe equipment.......................................... 104
7. Installation instructions..................................................................... 105
7.1 Installation............................................................................... 105
7.2 Safety precautions ................................................................... 105
7.3 Installation data ....................................................................... 105
7.4 Installation and first start-up procedure ...................................... 105
7.5 Installation drawings................................................................. 105
7.6 Personnel requirements ........................................................... 106
7.7 Preparing the installation .......................................................... 106
7.8 Tools and accessories .............................................................. 106

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7.9 Safety equipment..................................................................... 106
7.10 Local regulations...................................................................... 106
7.11 Preparing the mounting site ...................................................... 106
7.12 Space requirements................................................................. 107
7.13 Lifting and loading instructions .................................................. 107
7.14 Unpacking and inspection......................................................... 107
7.15 Disposal of non-reusable materials............................................ 107
7.16 Moving the equipment to the mounting site ................................ 107
7.17 Alignment of compressor and unit ............................................. 108
7.18 Alignment of unit against foundation .......................................... 108
7.19 Alignment of compressor and motor .......................................... 108
7.20 Laying the unit foundation..........................................................111
7.21 Mounting directly on the foundation ............................................111
7.22 Mass damping between unit and building................................... 112
7.23 Damping using vibration dampers ............................................. 112
7.24 VSD equipment ....................................................................... 115
7.25 Calculation of centre of gravity, support reactions and tipping
angle ...................................................................................... 117
7.26 Instruction for mounting of coupling ........................................... 125
7.27 BPU coupling installation procedure .......................................... 126
7.28 Piping connections................................................................... 128
7.29 Connecting electricity supply..................................................... 129
7.30 Pressure testing....................................................................... 131
7.31 Evacuation of the refrigeration plant .......................................... 132
7.32 Oil charging ............................................................................. 132
7.33 Final installation check ............................................................. 133
8. Components...................................................................................... 134
8.1 UniSAB III ............................................................................... 135
9. Settings............................................................................................. 136
9.1 Control system ........................................................................ 136
10. Operating instructions ...................................................................... 137
11. Maintenance instructions .................................................................. 138
11.1 Safety precautions ................................................................... 138
11.2 Maintenance of compressor unit ............................................... 138
11.3 Stopping routine ...................................................................... 139
11.4 Long-term storage ................................................................... 139

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11.5 Visual inspection...................................................................... 141
11.6 Measures to be taken............................................................... 141
11.7 General rules for use of lubricating oil in refrigeration
compressors............................................................................ 143
11.8 Assessing the oil...................................................................... 143
11.9 Visual assessment ................................................................... 144
11.10 Analytical evaluation ................................................................ 144
11.11 Analysing the oil....................................................................... 144
11.12 Charging compressor with lubricating oil .................................... 145
11.13 Oil charge................................................................................ 148
11.14 Motor ...................................................................................... 149
12. Faultfinding instructions ................................................................... 150
12.1 How to carry out faultfinding...................................................... 150
12.2 Troubleshooting....................................................................... 151
13. Service instructions .......................................................................... 156
14. Transport instructions....................................................................... 157
14.1 Safety precautions ................................................................... 157
14.2 Transport data ......................................................................... 158
14.3 Personnel requirements ........................................................... 158
14.4 Handling of compressor and unit ............................................... 158
14.5 Loading instructions ................................................................. 159
14.6 Preparations before lifting......................................................... 159
14.7 Loading................................................................................... 159
14.8 Transport instructions............................................................... 160
14.9 Transport regulations ............................................................... 160
14.10 Unpacking and inspecting the unit ............................................. 160
14.11 Moving the equipment to the mounting site ................................ 160
14.12 Storage ................................................................................... 160
15. Commissioning instructions ............................................................. 162
15.1 Safety precautions ................................................................... 162
15.2 Preparations for commissioning ................................................ 162
15.3 Preparations on the mounting site ............................................. 163
15.4 Evacuation and charging of refrigerant ...................................... 163
15.5 Start-up................................................................................... 164
15.6 Commissioning set................................................................... 164
15.7 Checklist for commissioning...................................................... 165

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16. Spare parts list .................................................................................. 167
17. Spare parts drawings ........................................................................ 168
18. Final disposal.................................................................................... 169
18.1 Safety precautions ................................................................... 169
18.2 Waste disposal ........................................................................ 169
19. Appendices ....................................................................................... 170
Index ................................................................................................. 171