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SABROE HPC 100 Mk 4 LL Operating Manual

Reciprocating compressor unit
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Operating manual
EN
HPC 100 Mk 4 LL & Mk 5
(including ATEX)
Reciprocating compressor unit

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Summary of Contents for SABROE HPC 100 Mk 4 LL

  • Page 1 Operating manual HPC 100 Mk 4 LL & Mk 5 (including ATEX) Reciprocating compressor unit...
  • Page 3 Manual for HPC 100 Mk 4 LL & Mk 5 Compressor type Compressor no. Refrigerant Other ______ R717 R744 Control UniSAB None Other Water-cooled top and side covers Air-cooled top and side covers Compressor cooling Air-cooled top covers and water-cooled side covers...
  • Page 4 Vessel data Design pressure External surface Type [bar] Condenser Evaporator Liquid separator Oil separator Oil cooler Safety valve: Data for calculation of Economiser downstream line accord- ing to EN 13136 Desuperheater Subcooler Other Pressure loss, if any, from safety valve to customer connection (based on design pressure) [bar] _____________ Safety valve type: Back-pressure dependent...

  • Page 5: Table Of Contents

    Contents Introduction ...................7 Amendments to the manual ............8 Safety precaution definitions used in this manual ......9 Requirements for competent persons ..........9 Safety ....................10 Application of the compressor ............. 10 Application of combustion engines ..........10 Identification ................11 2.3.1 Identification of equipment ...........
  • Page 6 Installation and first start-up procedure ........29 3.10 Preparations for starting ............. 30 3.11 Monitoring of operation ............... 31 3.12 Brief stop ................... 33 3.13 Shutting down for a long standstill period ........33 3.14 Problems ................... 33 3.15 Troubleshooting ................. 33 Maintenance instructions ..............

  • Page 7: Introduction

    Introduction 1. Introduction The Sabroe reciprocating compressor and unit can be configured with various types of equip- ment depending on its function and requirements. Some of the equipment may be described in this manual even though it is not featured on your particular unit.

  • Page 8: Amendments To The Manual

    Introduction Amendments to the manual 2023.05 Version 8 • The compressor, vessel and unit pipe system name plates have been updated. • Updated information about oil charge in subsection 4.11 and Table 12: Oil charge/ Table 13: Oil level. • Updated cover page and other minor corrections.

  • Page 9: Safety Precaution Definitions Used In This Manual

    Introduction Safety precaution definitions used in this manual Danger! Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning! Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or serious injury.

  • Page 10: Safety

    Safety 2. Safety Application of the compressor To prevent unintentional application of the compressor, which could injure personnel or dam- age equipment, the following must be observed: • The compressor must only be used as a refrigeration compressor and within the oper- ating limits specified in the manuals or in a written agreement with Johnson Controls Denmark.

  • Page 11: Identification

    Safety Warning! Johnson Controls Denmark is not liable for injuries to personnel or damage to equipment re- sulting from using the equipment for other purposes than the ones stated above. Identification 2.3.1 Identification of equipment All equipment from Johnson Controls Denmark can be identified by one or several name plates positioned as illustrated below.

  • Page 12: Unit/Pipe System Name Plate

    Johnson Controls Denmark ApS 1000010127 Johnson Controls Denmark ApS 1000010126 Christian X's Vej 201 Christian X's Vej 201 8270 Højbjerg, Denmark 8270 Højbjerg, Denmark MADE IN DENMARK MADE IN DENMARK www.sabroe.com www.sabroe.com Serial Serial Year Year Type Type Scope Scope...
  • Page 13 Safety The unit name plate is positioned on the frame and contains this information: Unique identification number. Serial No. Year of manufacturing. Year Type Manufacturer's type designation. For EC PED/EAC approval: ‘Unit & Piping’ means that the CE/ EAC mark applies to the complete unit including the piping sys- tem.

  • Page 14: Compressor Name Plates

    1000010131 1000010132 Johnson Controls Denmark ApS Johnson Controls Denmark ApS Christian X's Vej 201 Christian X's Vej 201 8270 Højbjerg, Denmark 8270 Højbjerg, Denmark MADE IN DENMARK MADE IN DENMARK www.sabroe.com www.sabroe.com Serial Year Year Compressor Type Speed Compressor Type...
  • Page 15 Safety The compressor name plate is positioned on the compressor and contains this information: Unique identification no. Serial no. Year of manufacturing. Year Type Manufacturer's type designation. Allowable refrigerant or refrigerants for the compressor. Refrigerant (The actual refrigerant for the unit is stated on the unit name plate).

  • Page 16: Labelling Of Explosion-Proof Equipment

    Safety 2.3.4 Labelling of explosion-proof equipment ATEX: The compressor area of application is indicated next to the Ex-sign on the name plate. II 2 G T3/T4 Material group: II indicates that the equipment is suitable for use in industrial areas above ground. Material category: 2 indicates that the equipment is suitable for use in areas with possible occurrence of explosive gasses.

  • Page 17: Vessel Name Plate

    Note: Depending on the supplier of the pressure vessel/heat exchanger, the layout and con- tent of the vessel name plate may differ from the Sabroe name plate above. Operating manual - HPC Mk 4 LL & Mk 5 (including ATEX) 001752 en 2023.05...

  • Page 18: Safety Precautions

    Safety Safety precautions 2.4.1 Signs All signs which may be found on your equipment are shown below. The number of signs, how- ever, may vary from one product to another. High surface High voltage/ The compressor may be top- temperature Risk of electric shock High pressure heavy...

  • Page 19: Emergency Stop

    Safety 2.4.2 Emergency stop Emergency stop button Fig. 12: Emergency stop button on the reciprocating compressor unit with UniSAB control system The compressor control system must be equipped with an emergency device. If the compressor is delivered with a UniSAB control system, the emergency device is inte- grated in the control system.

  • Page 20: Electrical Installations

    Safety • Use gloves and protective goggles and make sure to have a gas mask close at hand. Also use electrical protection equipment and tools suited for electrical operation purposes. • When dismantling the top covers, pay attention to the considerable spring force be- neath the covers.

  • Page 21: General Precautions

    Safety 2.4.5 General precautions These precautions should be used as a supplement to the safety precautions and warnings in- cluded in: • All other manuals pertaining to the compressor/unit • Local, plant and shop safety rules and codes • National safety rules and regulations. Read and understand all safety instructions before setting up, operating or servicing/perform- ing maintenance on the compressor/unit.

  • Page 22: Cooling Water System

    Synthetic oils based on poly-alfa-olefin Synthetic oils based on polyol esters Synthetic oils based on polyalkylene glycols See the Sabroe oil recommendation for the recommended type of oil. Warning! When charging oil, follow the safety instructions given by the oil supplier (MSDS: Material Safety Data Sheet).

  • Page 23: F-Gas Regulation (Fluorinated Greenhouse Gases)

    Safety • Refrigerants must not be released into the atmosphere, except CO , which can be re- leased slowly into the atmosphere. • When purging an ammonia system, use an approved air purger. The purged air must pass through an open container or water for any remaining ammonia (R717) to be ab- sorbed.

  • Page 24: Transmission Safety

    Safety Leakage test It is the operator’s responsibility to ensure that the unit is checked for leakages by a competent person. For units charged with fluorinated greenhouse gases, the following conditions apply depending on type of plant and amount of charge: •...
  • Page 25 Safety Warning! Do not start the compressor until the coupling guard is mounted correctly. Before performing any kind of work on the coupling, make sure that the compressor motor cannot start up inadvertently. When performing service where the motor is dismantled from the base frame, follow the in- structions for coupling alignment in the Installation instructions chapter in the Engineering manual.

  • Page 26: Sound Measurement And Noise Data

    Safety Sound measurement and noise data 2.5.1 Noise data Noise data is stated in: SWL: A-weighted sound power level SPL: A-weighted sound pressure level, in free field over reflecting plane (1 m distance). • Noise data is based on measurements according to ISO 9614-2. •...
  • Page 27 Safety • The actual SPL value on site will be between the stated SPL and SWL depending on the acoustic environment in the machine room. • In a typical machine room without any noise absorbing materials, the actual SPL will be approximately 14 dBA higher than the stated SPL (free field value).

  • Page 28: Operating Instructions

    Operating instructions 3. Operating instructions Safety precautions Danger! A number of safety precautions, which must be read before operating the unit, are presented in the following. General safety instructions/regulations must be studied carefully. Failure to do so may result in personal injury or even death. Moreover, equipment may be damaged or destroyed.

  • Page 29: Unisab Reading, Safety And Capacity Regulating System

    Operating instructions UniSAB reading, safety and capacity regulating system The UniSAB control system is described in a separate manual that will be delivered with all units equipped with UniSAB. Heating element To keep the compressor lubricating oil warm during a period of standstill, a heating element is built into the oil reservoir.

  • Page 30: Preparations For Starting

    Operating instructions accordance with this standard is stated in the vessel data table for the specific unit in the begin- ning of this manual. Make sure that all necessary documents are available, including declarations, certificates, identification plates, manuals, machine card, logbooks and/or other documentation required according to local rules and/or EN 378.

  • Page 31: Monitoring Of Operation

    EN 378 and national laws. Checklist Along with your Sabroe equipment, we have provided a Checklist as shown in Fig. 15. This checklist will be useful to the service engineer, and it must be filled in during commission- ing and start-up.
  • Page 32 Operating instructions Fig. 15: The checklist, which MUST be filled in during commissioning and start-up. Operating manual - HPC Mk 4 LL & Mk 5 (including ATEX) 32/48 001752 en 2023.05...

  • Page 33: Brief Stop

    Operating instructions 3.12 Brief stop Before stopping the compressor, reduce the capacity to the lowest capacity level for a couple of minutes. It is not necessary to shut the suction and discharge stop valve when it is only a brief stop. If the compressor is water-cooled, the water flow must always be stopped when the compressor is not in operation.

  • Page 34: Maintenance Instructions

    Maintenance instructions 4. Maintenance instructions Compressor maintenance and service Before performing any kind of service on the compressor, it is important to make sure that the motor cannot start up inadvertently. Please read chapter 2. Safety before servicing the com- pressor in any way.

  • Page 35: Service Intervals

    Maintenance instructions Service intervals Determine the service intervals for a reciprocating compressor as follows: Choose the appropriate diagram depending on compressor and refrigerant type. Read the operating hours/service interval from the curves in the diagram. Service intervals based on P and P are shown in Fig.
  • Page 36 Maintenance instructions HPC (R744) ° F °C 7,000 8,000 9,000 10,000 11,000 12,000 °C -130 -112 - - 7 6 - - 58 - - 40 3 2 ° F Evaporating temperature Service intervals, pressure SMC/TSMC/HPC/HPX (All refrigerants) bara 6,000 7,000 8,000 9,000...
  • Page 37 Maintenance instructions 1170 1460 1760 Correction factor 1.25 1.00 0.83 Table 7 Correction may also be calculated according to this formula: 1460 Correction = Example The service interval of a compressor is 10,000 hours according to the diagram. If the compressor runs at 970 rpm, the service interval will be 1.5 x 10,000 = 15,000 h. Regardless of the above calculation, a maximum service interval has been set to mitigate time-dependent aging of certain components.

  • Page 38: Annual Service

    Maintenance instructions Annual service If the time interval between two standard service visits exceeds one year, an annual service in- spection should be carried out. Please check national rules. The service inspection includes the activities specified in Table 8 and Table 9. Prescribed service Change oil filter Check leak rate of shaft seal...

  • Page 39: Regular Service Schedule - Refrigeration Plant

    Maintenance instructions Regular service schedule - refrigeration plant As stated in EN 378-4:2016, section 5 and Annex E, refrigeration systems must be maintained and repaired by competent personnel only (see EN 13313). Service to be performed at each periodic minimum Safety maintenance annually...

  • Page 40: Regular Service Schedule - Compressor Unit

    Maintenance instructions Regular service schedule - compressor unit As stated in EN 378-4:2016, section 5 and Annex E, refrigeration systems must be maintained and repaired by competent personnel only (see EN 13313). Planned service activities (enter in logbook) Compressor parts Annual 1 x interval 2 x interval...

  • Page 41: Charging The Compressor With Lubricating Oil

    4.10 Charging the compressor with lubricating oil As all Sabroe reciprocating compressors are supplied with a special oil charging valve on the crankcase, lubricating oil may be charged while the compressor is operating. For this purpose, use a hand-operated oil pump as mentioned earlier, or follow the procedure below.

  • Page 42: Oil Charge

    Maintenance instructions Amount of oil Compressor in crankcase Type Litre Cylinders SMC/HPC/HPX SMC/HPC/HPX TSMC Table 12: Oil charge Compressor 10 mm difference in oil level corresponds to Type Cylinders SMC/HPC/HPX 1.8 litre TSMC SMC/HPC/HPX 4.7 litre TSMC Table 13: Oil level 4.11 Oil charge Usually, the compressor is delivered without any oil in the crankcase.

  • Page 43: Shaft Seal

    Maintenance instructions The Sabroe hand-operated oil pump, part no. 3141-155, is recommended as prelubrication pump, see Table 14. For prelubrication: use clean fresh refrigeration oil of the same type as the one in the compressor, and pump as follows: Pump strokes with Sabroe...

  • Page 44: Motor Lubrication

    Maintenance instructions 4.14 Motor lubrication In connection with electric motors, it is absolutely essential to lubricate the bearings correctly and use the appropriate type of grease. Please refer to the motor manual and/or the motor name plate. 4.15 Major overhaul of the compressor Contact your local service provider.

  • Page 45: Final Disposal

    Final disposal 5. Final disposal Safety precautions Danger! Before dismantling the plant, read the safety precautions carefully. Dismantling a refrigeration unit to be scrapped must be carried out safely. Only competent refrigeration personnel must perform the dismantling as fundamental knowl- edge of refrigeration systems and the risks involved are required.

  • Page 46: Compliance

    Compliance 6. Compliance Declaration of conformity Johnson Controls Denmark declares on the signed declaration of conformity that the unit is manufactured and CE-marked in conformity with relevant directives and standards. The printed documentation, which is delivered with the unit, includes safety instructions in Eng- lish and local language and a translated version of the declaration of conformity, however not filled in with the specific data for your unit.

  • Page 47: Index

    Index Amendments to the manual ......................Annual service..........................ATEX .......................... 10, 16, 20, 29 Batteries ............................. Combustion engines - application....................Competent persons - requirements ..................... Compliance ..........................Compressor name plates ......................Cooling water system......................... Declaration of conformity ......................Emergency stop ......................... F-gas regulation .........................
  • Page 48 Purging ............................Refrigerants..........................Safety during maintenance and service..................Safety precaution definitions......................Safety signs..........................Service intervals ......................... Service schedule ........................Temperature class, T1–T6 ....................16, 20 Troubleshooting.......................... Unit/pipe system name plate...................... Vessel name plate ........................Visual inspection ........................Operating manual - HPC Mk 4 LL & Mk 5 (including ATEX) 48/48 001752 en 2023.05...
  • Page 50 Johnson Controls Denmark ApS Sabroe Factory Christian X's Vej 201 ∙ 8270 Højbjerg Denmark Phone +45 87 36 70 00 www.sabroe.com Version 8...

This manual is also suitable for:

Hpc 100 mk 5 ll

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