Johnson Controls SGC1913 Manuel utilisateur

SAB 193-233-283 S A-frame (including ATEX)

Screw compressor units

Engineering manual

Engineering manual - SAB 193-233-283 S A-frame (including ATEX)

008831 en 2020.10 3/168

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 .................................................. 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.............................................................................. 14

2.3 Compressor name plate ........................................................ 15

2.4 Compressor name plate - ATEX ............................................ 16

2.5 Labelling of explosion-proof equipment ............................... 17

2.6 Vessel name plate.................................................................. 18

2.7 Unit/pipe system name plate ................................................ 19

2.8 Signs ..................................................................................... 21

3. Safety precautions ........................................................................ 22

3.1 Areas of application ............................................................... 22

3.1.1 Application of the screw compressor ............................. 22

3.1.2 Application of combustion engines ................................ 22

3.2 Safety precautions ................................................................ 23

3.2.1 General precautions ....................................................... 23

3.2.2 Work area safety ............................................................ 23

3.2.3 During operation ............................................................ 23

3.2.4 Safety during maintenance and service ........................ 24

3.2.5 Electrical installations .................................................... 25

3.2.6 Power supply .................................................................. 25

3.2.7 Lubricating oils ............................................................... 26

3.2.8 Refrigerants .................................................................... 26

3.2.9 Purging a refrigeration plant .......................................... 26

3.2.10 F-gas regulation (fluorinated greenhouse

gases) ............................................................................. 27

3.2.11 First aid for accidents with ammonia ............................. 29

3.2.12 First aid for accidents with HFC/HCFC ........................... 30

3.2.13 Protecting the operator as well as the

environment ................................................................... 31

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4. Technical description ................................................................... 34

4.1 Description of the screw compressor.................................... 34

4.2 Marine application ................................................................. 36

4.3 Description of main components and systems..................... 37

4.4 Control system ...................................................................... 37

4.5 Compressor ........................................................................... 38

4.6 Variable speed drive (VSD) ................................................... 39

4.7 Compressor lubrication system ............................................ 40

4.8 Oil injection valve .................................................................. 40

4.9 No pump oil system ............................................................... 41

4.10 Demand pump oil system...................................................... 41

4.11 Flow security.......................................................................... 41

4.12 Compressor oil separation system ....................................... 41

4.13 Automatic oil return valve..................................................... 44

4.14 External oil filter .................................................................... 45

4.15 Unit with double oil filter ....................................................... 46

4.16 Compressor hydraulic system .............................................. 46

4.17 Compressor oil cooling systems ........................................... 48

4.18 Suction check valve by-pass ................................................. 49

4.19 Requirements for ambient temperatures and

humidity................................................................................. 51

4.20 Oil carry-over to plant ........................................................... 52

4.21 Selecting lubricating oil for Sabroe screw

compressors .......................................................................... 53

4.22 Oil charge............................................................................... 53

4.23 Heating rod element for oil heating, pos. 30 ........................ 53

4.24 Oil level switch ....................................................................... 54

4.25 Cold-start system .................................................................. 54

4.26 Compressor protecting system, pos. 220 and 221 .............. 56

4.27 Oil cooling system and general piping layout ....................... 57

4.28 Liquid injection oil cooling ..................................................... 57

4.29 Thermosyphon oil cooling ..................................................... 59

4.30 Water-cooled oil cooling ........................................................ 61

4.31 Connection to AlfaNova oil cooler ......................................... 62

4.32 KRACHT oil pump................................................................... 63

4.33 Economiser, high-stage (optional) ....................................... 64

4.34 General piping diagram......................................................... 68

4.35 Key to piping diagram ........................................................... 71

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4.36 Instrumentation .................................................................... 73

5. Physical and connection data ..................................................... 75

5.1 Physical data.......................................................................... 75

5.2 Allowable flange loads........................................................... 76

5.3 Mounting of suction isolation valve....................................... 77

5.4 Connection data .................................................................... 78

5.4.1 Connections to compressor unit .................................... 78

5.4.2 Electrical connections..................................................... 84

5.4.3 List of components ......................................................... 85

6. Technical data ................................................................................ 87

6.1 Data for compressor units..................................................... 87

6.2 Other data.............................................................................. 88

6.3 Planning the machine room .................................................. 89

6.4 Minimum compressor flow at 3550 rpm ............................... 90

6.5 Operating limits ..................................................................... 91

6.6 Selecting electric motor ........................................................ 92

6.7 Motor dimension.................................................................... 92

6.8 Motor selection and starting torque...................................... 93

6.9 Motor/compressor torque ..................................................... 94

6.10 Direction of rotation .............................................................. 95

6.11 Emergency stop..................................................................... 95

6.12 Other emergency stop requirements ................................... 95

6.13 Noise data .............................................................................. 96

6.14 Noise data for SAB 193-233-283 ......................................... 96

6.15 Vibrations and test pressure levels....................................... 97

6.15.1 Vibration data for compressors (all compressor

types).............................................................................. 97

6.15.2 Test pressure levels for standard compressors and

components.................................................................... 99

7. Installation instructions............................................................ 100

7.1 Installation........................................................................... 100

7.2 Safety precautions .............................................................. 100

7.3 Installation data .................................................................. 100

7.4 Installation and first start-up procedure ............................ 100

7.5 Installation drawings........................................................... 100

7.6 Personnel requirements ...................................................... 101

7.7 Preparing the installation .................................................... 101

7.8 Tools and accessories .......................................................... 101

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7.9 Safety equipment ................................................................ 101

7.10 Local regulations ................................................................. 101

7.11 Preparing the mounting site................................................ 101

7.12 Space requirements ............................................................ 102

7.13 Lifting and loading instructions........................................... 102

7.14 Unpacking and inspection ................................................... 102

7.15 Disposal of non-reusable materials .................................... 102

7.16 Moving the equipment to the mounting site....................... 102

7.17 Alignment of compressor and unit ...................................... 103

7.18 Alignment of unit against foundation ................................. 103

7.19 Alignment of compressor and motor .................................. 103

7.20 Laying the unit foundation .................................................. 106

7.21 Mounting directly on the foundation................................... 106

7.22 Mass damping between unit and building .......................... 107

7.23 Damping using vibration dampers...................................... 107

7.24 VSD equipment.................................................................... 110

7.25 Calculation of centre of gravity, support reactions and

tipping angle ........................................................................ 112

7.26 Instruction for mounting of coupling .................................. 120

7.27 BPU coupling installation procedure ................................... 121

7.28 Piping connections............................................................... 123

7.29 Connecting electricity supply .............................................. 124

7.30 Pressure testing................................................................... 125

7.31 Evacuation of the refrigeration plant .................................. 126

7.32 Oil charging.......................................................................... 126

7.33 Final installation check ........................................................ 127

8. Components ................................................................................. 128

8.1 UniSAB III ............................................................................ 129

9. Settings ......................................................................................... 130

9.1 Control system .................................................................... 130

10. Operating instructions ............................................................... 131

11. Maintenance instructions.......................................................... 132

11.1 Safety precautions .............................................................. 132

11.2 Maintenance of compressor unit......................................... 132

11.3 Stopping routine.................................................................. 133

11.4 Long-term storage .............................................................. 133

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11.5 Visual inspection.................................................................. 135

11.6 Measures to be taken .......................................................... 135

11.7 General rules for use of lubricating oil in refrigeration

compressors ........................................................................ 137

11.8 Assessing the oil .................................................................. 137

11.9 Visual assessment ............................................................... 138

11.10 Analytical evaluation ........................................................... 138

11.11 Analysing the oil .................................................................. 138

11.12 Charging compressor with lubricating oil ........................... 139

11.13 Oil charge............................................................................. 142

11.14 Motor.................................................................................... 143

12. Faultfinding instructions ........................................................... 144

12.1 How to carry out faultfinding............................................... 144

12.2 Troubleshooting................................................................... 145

13. Service instructions.................................................................... 150

14. Transport instructions ............................................................... 151

14.1 Safety precautions .............................................................. 151

14.2 Transport data ..................................................................... 152

14.3 Personnel requirements ...................................................... 152

14.4 Handling of compressor and unit ........................................ 152

14.5 Loading instructions ............................................................ 153

14.6 Preparations before lifting................................................... 153

14.7 Loading ................................................................................ 153

14.8 Transport instructions ......................................................... 154

14.9 Transport regulations .......................................................... 154

14.10 Unpacking and inspecting the unit...................................... 154

14.11 Moving the equipment to the mounting site....................... 154

14.12 Storage ................................................................................ 154

15. Commissioning instructions ..................................................... 156

15.1 Safety precautions .............................................................. 156

15.2 Preparations for commissioning ......................................... 156

15.3 Preparations on the mounting site...................................... 157

15.4 Evacuation and charging of refrigerant .............................. 157

15.5 Start-up ............................................................................... 158

15.6 Commissioning set .............................................................. 158

15.7 Commissioning checklist..................................................... 159

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16. Spare parts list............................................................................. 160

17. Spare parts drawings ................................................................. 161

18. Final disposal ............................................................................... 162

18.1 Safety precautions .............................................................. 162

18.2 Waste disposal..................................................................... 162

19. Appendices ................................................................................... 163

Index.............................................................................................. 164

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