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f CONFIDENTIAL! Subject to Protective Order Of 14th Judicial District Court No. 91-1145 TE-Il/VC REFRIGERATION UNIT TRAINING MANUAL MANUAL NO.: ISSUED TO: SL 007756 May 1988  TABLE OF CONTENTS SECTION 1. Purpose Of The Unit 2. Refrigerant Tables and Basic Refrigerant Cycle 3. Description Of Rotary Screw Compressors 4. Description Of System Components 5. TE-II VC Refrigerant Flow 6. Start-Up and Shutdown Procedures 7. Troubleshooting Charts 8. Engineering Data C0^ oi SL 007757 TE-II/VC Refrigeration Unit Training Manual 1-1 TE-II/VC REFRIGERATION UNIT An ammonia refrigeration unit has been added to the VC-HC1 still condensing train to condense more VCM. This added cooling will allow the maximum transfer of vinyl to VC-II during the entire year. The cooling tower water condensers cannot provide adequate cooling in the summer. The exchanger that does this additional cooling is an ammonia exchanger called the evaporator/process condenser. This exchanger has the process flow on the tube side and ammonia on the shell side. There are two (2) automatic valves that make the tie between the process and the refrigeration system. These valves are F-518 and F-516. F-518 controls the process flow to the evaporator/process condenser and F-516 is to the process bypass. Both of these valves are tied into the shutdown system of the refrigeration unit. If the refrigeration unit trips off, F-516 will go wide open. When F-516 reaches the wide open position, a switch will close F-518. The evaporator/process condenser is then floating on the line with the outlet open to the process. After the refrigeration unit is started, before any process vent is sent to the evaporator/process condenser, a reset switch inside the control room must be activated to operate F-518 and F-516. This will help remind the operator of the position of the control valves. Another added safety feature is if P-156 would reach 200 psig, L-150 will go 100% open. This is in case F-518 and F-516 would both shut for some reason. When pressure drops below 200 psig, L-150 would become operational again. CONFIDENTIAL*. Order Subject to otective ct Court of !*> Jue,lC1fl-U45 S1- 007758 TE-XI/VC Refrigeration Unit Training Manual 2-1 REFRIGERANT TABLES & BASIC REFRIGERANT CYCLE GENERAL By keeping track of operating pressures and temperatures the operator can know if his equipment is operating properly. To help keep track of relationships between temperatures and pressures and between condensing temperature and discharge temperature, refrigerant tables are essential. But to be useful, the operator must know how to use these tables. SATURATED TABLES Curves are valuable to give an overall picture of pressure-temperature relationships. But unless curves are plotted to a much larger scale than can be included in lesson sheets this size, they cannot be read as accu rately as is sometimes required. Most of these tables give pressure for every 2F at common evaporator temperatures. Pressures for every 5F are given for less common evaporator temperatures and for condensing temperatures. Beside gage pressures, absolute pressures are also given for the temperatures listed. Absolute pressures are required for some calculations. Notice in all cases, absolute pressure is 14.7 psi more than gage pressure. Some tables give pressures for fewer temperatures to save space. Other tables are available which give pressures for each degree of temperature in the commonly used ranges. This of course, requires more space. Tables are also available which give a great deal of information: volume, heat and other data of both liquid and vapor. Such tables are valuable for the theoretical engineer or designer. But they include a lot more than we shall need. SUBCOOLED LIQUID - SUPERHEATED VAPOR Pressure-temperature tables are very valuable to give the relationships already listed. But they do have limitations. Liquid away from its vapor SL 007759 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 TE-II/VC Refrigeration Unit Training Manual 2-2 can be cooled below its saturation temperature. Such a liquid is called subcooled. Vapor away from its liquid can be heated above its saturation temperature and is called superheated vapor. Thus water at atmospheric pressure is subcooled if it is below 212F, and is saturated if it is at 212F. Vapor or steam off the water is saturated if it is at 212F. But if separated from the water and further heated, its temperature will rise to form superheated steam. A liquid cannot be superheated. It would boil Instead. A vapor cannot be subcooled. It would condense. The following tables show the pressure-temperature relationships only when liquid and vapor are in contact with each other. This condition exists in the evaporator and in the condenser. It also exists in a tank of refrig erant which is not completely full of liquid. Vapor will then be over the top of the liquid. If a refrigerant tank is completely full of liquid and should warm up, the liquid will expand against the tank walls. A pressure is then built up which is only limited by the strength of the walls. This is what causes overfilled tanks to explode. Liquid refrigerant in the receiver or in the liquid line may or may not be subcooled. Suction vapor entering the compressor will then be super heated, that is, warmer than evaporator temperature. Compressor discharge temperature is superheated, that is, warmer than condensing temperature. The amount of superheat in the discharge vapor under normal operation depends on the evaporator pressure, condensing pressure and the amount of superheat in the suction line. SL 007760 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No, 91-1145 TE-II/VC Refrigeration Unit Training Manual 2-3 TEMPERATURE/PRESSURE RELATIONSHIP CHART PRESSURE TEMPERATURE 22.1 23.8 25.6 27.5 29.4 31.4 33.5 35.7 37.9 40.2 42.6 45.0 47.6 50.2 52.9 55.7 58.6 61.6 64.7 67.9 71.1 74.5 78.0 81.5 85.2 89.0 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 PRESSURE TEMPERATURE 92.9 96.9 101.0 105.3 109.6 114.1 118.7 123.4 128.3 133.2 138.3 143.6 149.0 154.5 160.1 165.9 171.9 '178.0 184.2 190.6 197.2 203.9 210.7 217.8 225.0 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 SL 007761 C ON FIDEN T iL : Subject to Protective Order of 14th Judicial District Cour No. 91-1145 IE-II/VC Refriqeration Unit Training Manual COMPRESSION REFRIGERATION SYSTEM 2-4 * A schematic diagram of a complete compr ssi n r frig ration system is illustrated in Fig. 11. Note the high and low sides of th system. S' Fig. 11: Compresion Refrigeration System A schematic diagram of a complete ammonia compression refrigeration system is illustrated in Fig. 12. If liquid ammonia is fed by a valve into a coil at 16 psig, the ammonia will boil or evaporate at OF (see Fig. 10). In a refrigeration system* this feed valve is called an expansion valve. The coil is the evaporator or cooling coil. EXPANSION UQUIO RECEIVER CONDENSER 8 *F VALVE No. 3 SL 007762 CONFIDENTIAL:' Subject to Protective Order of 14th Judicial District Court No. 91-1145 COMPRESSOR Fig.12: Ammonia refrigeration system TE-II/VC Refrigeration Unit Training Manual 2-5 The vapor produced Hn the evaporator must be removed to keep the pressure from building up. The suction side of the compressor is used to remove this vapor. The compressor may be a reciprocating, rotary screw or centrifugal type. The compressor compresses this vapor to (in this case) 150 psig. The work done in compressing the vapor heats the vapor. The boiling temperature of ammonia at 150 psig is 80F. At this pressure ammonia in liquid form cannot exist above 84F. But also, vapor cannot exist below this temperature. If an attempt is made to cool this vapor below 84F, it will condense back to a liquid. This cooling is done in a coil over which air or water is circulated. This coil is called the condenser. The air or water used over the condenser is heated as it absorbs heat. The total heat rejected from the vapor by the condenser must equal all of the heat picked up in the evaporator plus the heat of compression of the compressor. The condensed liquid is drained to a tank to be stored until needed by the expansion valve. This tank is called the liquid receiver, also called "receiver", or high pressure receiver. These parts; expansion valve, evaporator, compressor, condenser and receiver are often called the five basic parts of the refrigeration system. They are the major parts through which fluid flows to make the complete refrigeration cycle. The expansion valve reduces the high pressure warm liquid to the low pressure needed in the evaporator. It also feeds the evaporator the proper amount of liquid as needed. A small amount of this liquid immedi ately vaporizes to cool the remaining liquid to low temperature. The vapor formed is called flash gas. The evaporator is at low pressure, sometimes called the low side of the system. It absorbs heat from the room or product, which evaporates the cold liquid to a cold vapor. SL 007763 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 TE-II/VC Refrigeration Unit Training Manual 2-6 The compressor compresses the cold low pressure vapor to a high pressure. During compression, the work done on the vapor heats it to a high temperature. This heating effect is called the heat of compression. The condenser cools the hot, high pressure vapor to condensing pressure, then condenses it to a liquid, still at high pressure. Only a small part of the condenser is necessary to cool the vapor, remove superheat as it is called. Most of the condenser surface is used to conduct heat from the condensing vapor to the water or air, and to condense the vapor back to a liquid. The high pressure receiver merely stores the high pressure warm liquid until it is needed by the expansion valve and evaporator. It makes no change in the liquid. Domestic and some small commercial refrigeration systems do not include a liquid receiver. The bottom part of the con denser acts as a receiver. The compressor, condenser and receiver are often called the high side of the compression refrigeration system. This combination plus a motor to drive the compressor is also called the condensing unit. Of course these parts must be joined by interconnecting pipes. The expansion valve feed directly into the evaporator. The line from the evaporator to the compressor is called the suction line. The line from the compressor to the condenser is the discharge line. The condenser usually feeds directly into the liquid receiver. The line from the receiver to the expansion valve is the liquid line. Hand valves are in the lines to be used when needed. The hand valve on the inlet of the compressor is the suction service valve, and on the outlet is the discharge service valve. The hand valve on the receiver outlet is the liquid line valve or king valve. Large systems will also have a valve on receiver inlet. A motor of some kind must be used to drive the compressor. Electric motors are the most common drive. They may be direct connected, or may SL 007764 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 TE-II/VC Refrigeration Unit Training Manual 2-7 drive the compressor through a V-belt drive. and Diesels also are occasionally used. Steam engines, gas engines FLOODED SYSTEMS Heat transfer to refrigerant vapor is much less than to liquid. There fore, it is desirable to keep the heat transfer surface wetted with liquid refrigerant throughout the evaporator. Systems which accomplish a fully wetted surface are called flooded systems. Both flooded and dry expansion coil type evaporators will contain a large volume of vapor due to the boiling of refrigerant. A flooded coil does contain a greater portion of liquid than a dry expansion coil. A properly designed flooded system will provide a fully wetted evaporator surface without allowing liquid to pass into the suction line to the compressor. The flooded control consists of a tank, called a surge drum, with a liquid level control device which maintains a liquid level in the tank. A liquid leg extends from the bottom of the tank to the liquid inlet connection to the coils. The suction outlet of the evaporator is connected to the upper portion of the surge drum. The surge drum must be designed with suffi cient flow area so that the gas returning from the coil is reduced in velocity. This causes liquid entrained with the gas to drop into the bottom of the tank for re-entry into the evaporator. The dry suction gas will pass out of the top of the surge drum to the compressors. The surge drum has a comparatively small amount of heat transfer surface as compared with the volume of liquid refrigerant therein, so there is very little boiling action within the vessel. The density of the refrig erant contained in the vessel can be assumed to be the same as the density of liquid refrigerant. SL 007765 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 TE-XI/VC Refrigeration Unit Training Manual 2-8 The liquid passing into the evaporator will boil causing a large volume of vapor. The mixture of gas with the liquid results in a much lower average density of refrigerant. SL 007766 confidential^ order Subject to trict cou"` TE-II/VC Refrigeration Unit Training Manual 3-1 DESCRIPTION OF ROTARY SCREW COMPRESSORS The Place Of The Screw Compressor In Refrigeration HISTORY A form of the screw compressor was invented by Kruger in Germany in 1878, but the screw compressor as known today was invented by Professor Lysholm of Sweden in the early 1930's. He was then Chief Engineer of the Swedish company now known as Svenska Rotor Maskiner AB, who still hold the patent rights. The compressor was intended for use with a gas turbine, but first became established commercially as an industrial air and gas compressor largely because of the absence of wearing parts and the oil free delivery. The injection of oil in 1955 resulted by 1958 in a far wider market with the introduction of the portable oil-injected screw compressor for 100 psig air. Refrigeration was commenced industrially in 1958 by using essentially oil free air compressors fitted inside pressure vessels to contain the seal leakage. A number of two stage sets were produced and supplied to UDEC for installation in an ammonia plant in Russia. The total installed compressor horsepower of 15,150 HP made it one of the largest refrig eration plants in the world. The oil free compressor, however, had three limitations in refrigeration, namely pressure ratio, pressure difference and seal leakage. The com pressor had to be fitted in a pressure vessel and each application care fully engineered, which limited it to large plants. It was known that screw compressors would pass liquids, and experiments were carried out using injection of liquid refrigerant. These were largely unsuccessful and were followed by oil injection which was by then established for air compressors. It is the oil injection screw compressor that has broken into refrigeration. CONFIDENTIAL: SL 007767 TE-II/VC Refrigeration Unit Training Manual 3-2 OIL INJECTION The injection of oil into the compression chamber serves three functions: sealing, cooling, and lubricating. The sealing of gas "slip" means higher volumetric efficiency, particularly at low speeds, so that direct coupling to an electric motor is possible. The cooling effect means that the discharge temperature is greatly reduced and pressure ratio is no longer limited. On test, compressors have been run for prolonged periods with closed suction valves. Cavitation, similar to that when a gear pump is throttled, is heard as the oil continues to circulate. The discharge temperature, instead of being a function of pressure ratio, becomes one of input power and oil flow rate. The overall effect is that the discharge temperature remains constant at 176F over a wide range of pressure ratio. A compressor that is oil injected is also capable of passing liquid refrigerant, and this fact can be very useful in refrigeration, particu larly on start-up. Because of the large quantity of oil injected, no harmful washing of lubricated quantity of oil injected, no harmful washing of lubricated surfaces occurs, even on compressors without timing gears. SUMMARY Screw compressors maintain high volumetric efficiencies even at a very high compression ratio due to the cooling function of the injected oil which keeps the temperature of discharge gas lower. Since the compressor contains few friction prone parts, replacements through mechanical wear are minimal. The principal wearing parts are the main bearings, thrust bearings, shaft seals, and meshing parts of the rotors all of which are adequately lubricated. Therefore, the possibility of liquid return causing damage to valves is no longer a threat as the suction and discharge valves are eliminated. SL 007768 Subject of 14th Ju TE-II/VC Refrigeration Unit Training Manual 3-3 Stable surge free running is performed under all operating conditions as this is a positive displacement type compressor. It is neat and very compact, having low weight and requiring a light foundation. A small installation space can be allotted to produce large capacities. SL 007769 <; lJ I Subject l:j Protective Order Of 14th .Judicial D i. a r. j. c t Court Wo. 91-1145 TE-II/VC Refrigeration Unit Training Manual 3-4 Rotary Screw Compressors For Refrigeration I. Development A. Dry Screws - In the late 1950's, oil free, dry air compressors were applied on refrigerations service. To eliminate metal to metal contact, the dry screw utilized timing gears to prevent contact; however, it proved to be not the best compressor for refrigeration service due to its limitation in compression ratios, differential pressure capability, and seal leakage. B. Wet Screws - In the early 1960's experimentation led to the oil injected screw compressor. During the last twenty years, numerous improvements have brought the oil injected screw compressor to be the dominant factor in the medium to large horsepower range. C. Oil Separation - Due to the large quantities of oil injected into the screw compressor, the earliest compressors developed a history of oil loss due to unsophisticated oil separators until the mid-1970's. The use of coalescer elements in lieu of mesh pad eliminator and lower design discharge and oil temperatures have resulted in oil carryover as low as 1 to 2 ppm. D. Rotor Profile - Original symmetrical (circular) profiles have given way to asymmetrical profile with improved mechanical operation and rotor dynamics providing increases in displacement and less BHP. E. Economizing - Although the oil injected screw compressor was capable of high ratios, it was not until the early 1970's that an intermediate pressure side flow could be introduced into the casing to produce an improvement in the refrigeration cycle efficiency by providing subcooling of the condensed liquid to be expanded in the evaporator. This has greatly reduced BHP/ton. SL 007770 CONFIDEITTIAL: Subject to Order Of 14th Judicial Dint-, rce Court No. 51-1145 TE-II/VC Refrigeration Unit Training Manual 3-5 II. Description A. Rotor - A four lobe male rotor, direct connected to the driver communicates with a six flute female rotor. Unlike the dry screw, no timing gears are utilized since the injected oil produces a hydrodynamic film of oil between the surfaces to eliminate metal contact, B. Oil Injection - The injection of oil into the rotors lubricates, seals the gas between the rotors and housing, and cools. Sealing the gas produced higher volumetric efficiencies, and reduced BHP/ton of refrigeration. The oil injected absorbs some of the heat of compression, reducing the discharge temperature greatly, allowing the compressor to operate at the high com pression ratios that it is capable of mechanically. C. Compression - Suction gas is drawn into the cavity formed between the male and female rotor and the gas is sealed in the cavity by the injected oil. The volume of gas decreases along the length of the rotor as the gas approaches the discharge, and the pressure of the vapor is increased due to the decrease in III. volume being created. As the gas comes in contact with discharge port opening, the oil and gas is expelled into discharge separator. Capacity Control the u 3 (DO the* r O 4-> d) *OH > l-l ---! -i-> m < -P Ld T M D -H rH Eh CD Q i--i Q i-i ITS ON In order to operate in a system with varying load requirements, a & positive displacement compressor must have some means of unloading oro 40-> SO O3 it will reduce the suction pressure until it comes into balance, or 1-3 can cause the compressor to cycle. CD .C r-i X! 3 t--i CO A. Slide Valve - The screw compressor utilizes a slide valve fit o into the lower portion of the casting, fitting into the contour between the lower part of the rotors. At reduced loads, it opens a cavity to allow gas to escape back to the suction port. SL 007771 Subject of 14th TE-II/VC Refrigeration Unit Training Manual 3-6 The cavity opening moves toward the discharge end of the com pressor, thus reducing the effective displacement of the compressor. B. Unloader Piston - The movement of the slide valve is controlled by an external, hydraulically actuated piston connected to the slide valve. Oil pressure is exerted on one side of the piston or the other, at the same time relieving pressure from the other side and moving the piston in either direction as it receives a signal from the main suction pressure controller or process temperature controller. When the compressor is full loaded, the slide valve is in the closed position. Since no significant amount of work has been done on the recycled gas, there are no appreciable losses incurred. C. Range - Capacity reduction to 10% of full load is realized by operation of the slide valve producing infinite increments of capacity in between. At 10% capacity the compressor will typically draw approximately 35% design power. IV. Application A. CFM and Horsepower Range - Initially, the helical rotary screw compressor was introduced to fit the range between reciprocating compressors (approximately 50 CFM and 200 HP) and centrifugal compressors (approximately 800 HP). The size range of screw compressors has grown with commercially available sizes of 200 CFM and an upper range of approximately 3300 CFM, or approx imately a 2000 HP motor driver. B. Compression Ratios - As previously noted, the rotary screw compressor was designed initially for high compression ratios, typically as low as -40F saturated suction compressed in a single casing to condensing pressure. SL 007772 CONFIDENTIAL: Subject to Prctsottv. of i4th Judicial z ' No. ci_^' Order n Court TE-II/VC Refrigeration Unit Training Manual 3-7 C. Reciprocating Compressor Comparisons - Although both are posi tive displacement compressors, there are the following distinctions: 1. Overhaul - Normal design operating time between major overhaul for a reciprocating compressor is typically 8000 hours, where as the rotary screw compressor is designed for a 50,000 hour period. 2. Liquid Slugging - The rotary screw compressor is capable of ingesting liquid refrigerant carryover without the damage incurred by a reciprocating compressor in breaking dis charge valves, rods or crank shafts. This does not elimi nate the need for a properly designed system which should not have but occasional occurrences, such as during start up. Liquid refrigerant will rob the screw compressor of effective displacement and capacity, and can cause cold liquid refrigerant to collect in the discharge separator contributing to lubrication problems, as in any compressor. (Higher ratios and cooler discharge.) 3. Capacity Control - As previously noted, the rotary screw compressor has infinite steps of capacity modulation, where as the reciprocating compressor has step type unloading which tends to be more cyclical in balancing with the system load. A. Vibration - Reciprocating compression, due to the unbal anced motion of its pistons, causes vibration and pulsation of the discharge gas flow. The rotary screw compressor is purely rotative motion. D. Centrifugal Compressor Comparisons 1. Speed - The head or pressure producing capacity of a centrifugal compressor is governed by the RPMs for a given SL 007773 L j, : of S1u4bthjec<tJuct7o,i ciPer1otnec; t ive Order " - Ocurt TE-II/VC Refrigeration Unit Training Manual 3-8 impeller diameter. The speed is normally obtained by the use of an internal or external speed increasing gear, which increases the number of associated bearings, etc. The screw compressor is direct connected, as previously noted. The selected speed, and pressure producing capability of a centrifugal compressor, does not permit reapplication of the compressor at higher ratios without the physical change of the speed producing gears. A screw compressor, being a positive displacement compressor, can operate at variable suction, and head conditions. 2. Capacity Control - As previously noted, the screw compres sor can unload to 10% of design capacity at any compression ratio. The higher the compression ratio for a centrifugal compressor, the more stages or impellers are required to produce the pressure differential. As the number of stages increase, the reduced capacity capability decreases for a centrifugal, often resulting in the need for recycle, hot gas, at a point as high as 75% or 80% of design capacity with a corresponding constant BHP of 80% with capacities from 80% to 0%. A phenomena acquainted with centrifugal compressors, commonly referred to as "surging", is an unstable operating range caused by a backflow of gas through the compressor when the compressor cannot produce the discharge pressure required. This is not a phenomena in screws. E. Refrigerant - Since the rotary screw compressor is a positive displacement compressor, like a reciprocating compressor, the common choice of refrigerants are ammonia and R-22. Centrifugal compressors commonly utilize R-ll and R-12, which are lower pressure refrigerants, thus producing more volume needed for the centrifugal impellers. These refrigerants go into a vacuum at higher temperatures, requiring purging. Also, the need for R-12 SL 007774 CONFIDENTIAL: Subject to Protective Order of 14th Judicial Distri ct Court to, 91-1145 TE-II/VC Refrigeration Unit Training Manual 3-9 or R-502 to produce lower discharge temperatures for recipro cating compressors is not a factor for screw compressors, since the injected oil greatly minimizes the discharge temperatures in the first place for either ammonia or R-22. SL 007775 CONFIDENTIAL: Subject to Protective Order of 14th Judicial Dic-'-rict Court No. 91-1145 TE-II/VC Refrigeration Unit Training Manual 3-10 V. Compressor Unit A. Piping - Major compressor inlet connections are equipped with check valves on the suction and side port connections to prevent the flow of oil out to the system and prevent the backflow and escape of discharge pressure from the separator that might possibly backspin the compressor. The discharge connection is equipped with a check valve for normal refrigeration purposes to prevent discharge gas from condensing into the compressor unit. Inlet connections are also equipped with large area fine mesh strainers to prevent foreign matter from entering the compressor unit of a size larger than the rotor clearances. B. Oil Separator - The oil separator also acts as the oil reservoir for the compressor unit. Thus, the typical occurrence of "foam out" associated with reciprocating and centrifugal compressors which have oil reservoirs equalized to suction pressure, or slightly above, due to standby pressure being rapidly lowered to operating pressure on start-up, does not occur. The screw compressor reservoir pressure would actually tend to increase from standby pressure. The basic separation principles of the discharge gas and oil in the separator is a combination of impingement, drastic velocity reduction, change of direction, and separation of gravity. The final separation step is by means of multiple coalescer elements which are removable through an access cover plate. Changes in refrigerants will vary the size of a separator for a given compressor based upon mass flows. Ammonia and oil are not miscible and will tend to separate into layers, whereas freon and oil are miscible and the oil will absorb refrigerant. Thus, oil temperatures are kept elevated to minimize the amount absorbed and keep the oil as refrigerant free as possible. The necessary amount of in t*ie SubjectCto protective onlr SL 007776 of 14th Judicial District No. 91-1145 TE-II/VC Refrigeration Unit Training Manual 3-11 reservoir for degassing is easier to provide in the horizontal design vs a vertical separator. C. Oil Pump/Strainer - The main oil pump is motor driven and includes a large area strainer at the inlet. A pre-lube cycle should be included since oil will drain down during extended shutdowns. Dual pumps are often specified and provided. D. Oil Filtration - All the oil for both lubrication and injection is filtered through a large multiple core oil filter. For continuous operation, dual oil filters with individual block valves for changeover during running are often specified and furnished. VI. New Developments A. Single Screw - A recent variation to the twin screw, is the single screw, which has been in operation since the 1970s. Two idlers (stars) replace the female rotor and trap the gas, biit compression takes place on both opposite sides of .the rotor, resulting in very balanced forces. It has also proven to have more efficient part load horsepower economy. B. Large Screw - Within the last couple of years an even larger twin screw has entered the market in limited numbers, which is a 510 mm having a displacement of 6600 acfm. It is driven at 1800 rpm, and can require a 4000 HP motor, further cutting into the centrifugal's market. vive Order Sub.ject ttoo p,, r0otte0t.cl^6tai^ ct tCo'0wurt of 9^ll4b SL 007777 CONFIDENTIAL: Subject to Protect''ve of 14th Judicial "o No. 91- -- ' TE-II/VC Refrigeration Unit Training Manual 3-12 Discharge COMPARISON WITH OTHER TYPES OF COMPRESSORS a. Reciprocating. Compressor Compression is accomplished by reciprocating motion of pistons and valves. Mechanical limit of piston speed and valve movement restrict speed and displacement. This tends to limit economic employment of large volumetric displacement compressor in connection with size limitations. Compression by reciprocating motion causes vibration and pulsation of gas flow. The parts are readily subjected to damage in the event of liquid slugging. Capacity control is obtained by steps only. TURBO type ' b. Turbo Compressor The compressors, both axial flow and centrifugal type, are restricted in impeller speed owing to aerodynamics and strength of the material. Rotating speed is faster but compression ratio, which is greatly effected by the specific gravity of refrigerant vapor, is lower than those of screw type compressor. The compressor is also very susceptible to variations of system design and machinery performance which often cause unstable pressure conditions. A variation in condensing temperature, evaporating tempera* ture or the like produces a sudden change in refrigeration capacity, or surging, which makes continued operation impossible. c. Rotary Compressor The compressor requires sliding blades in order to accomplish compres sion. The blades move against casing and are easily worn ... generally resulting in shorter life than can be expected fr m screw type com pressor. The blade wear factor limits tip speed making it impossible to manufac ture the c mpressor with capacity as large as screw type compressor. CONFIDENTIAL: Subject to Protective Order of 14th Ju,,dicia/-% il Dt isi;trict Couet TE-II/VC Refrigeration Unit Training Manual 3-13 C learance (R ecip. SL 007779 VOLUME 1 confidential: der . . to Protective CoUr,fc ftZrUicial Di.triet Principl Of Op ration Th exceptional reliability of FES twin rotor screw compressors has been proven in thousands of installations worldwide. The screw compressor consists of two meshing helically grooved rotors--a male (with four lobes) and a female (with six flutes), that are enclosed in a stationary housing. The housing is fitted with suction and discharge ports, as shown below. SUCTION LOBE MALE ROTOR COMPRESSOR HOUSING FEMALE ROTOR FLUTE DISCHARGE The male rotor, direct driven by a 2-pole motor, powers the female rotor. Compression of the refrigerant gas is caused by the direct volume reduction of gas trapped in the flutes of the female rotor by the lobes of the intermeshing male rotor. This process can be divided into three distinct segments: 1. Suction As the male rotor unmeshes from the flute of the female rotor, a void is caused and vapor is drawn into th open flute through the suction port (see illustration). As the rotors continue to turn, the flute volume increases and vapor is drawn continually into the compressor. Wh n the open flute rotates beyond the inlet port, the entire flute is filled with vapor. As rotation continues, the vapor filled flute is moved around the circumference of the stationary housing at the suction pressure prior to the compression process. 2. Compression When the flute is rotated to the point that it meshes with another lobe of the male rotor, compression begins. Oil is injected to lubricate, cool, and provide a seal to prevent vapor blow-by. The engaged lobe gradually decreases the volume of the flute toward the dis charge end of the compressor creating compression. See illus tration. 3. Discharge As rotation continues and the flute volume is further decreased to complete the compression cycle, the discharge port is uncovered and the compressed vapor is discharged from the flute by the lobe. See illustration. While the vapor is compressed and dis charged by the leading edge of the meshed lobe in a flute, the trailing side of the lobe draws a fresh charge of suction vapor into the reopening flute through the compressor suction port, to repeat the cycle. COMPRESSION DISCHARGE PORT SPINDLE Compressor--Exploded View ROTOR CASING INLET CASING DISCHARGE iD < -r D <y -P o r3 >~ HYDRAULIC u THRUST BALANCER -p ASSEMBLY DISCHARGE PLATE FEMALE ROTOR SL 007780 HYDRAULIC UNLOADER CYLINDER UNLOADER PISTON TE-II/VC Refrigeration Unit Training Manual 3-15 CAPACITY CONTROL SYSTEM Slide valve design for capacity reduction is shown within the rotor housing in Figuies 12Aand 12B. Axial movement of this valve is programmed by pressure or temperature initi ated, hydraulic actuated control arrangement. When the compressor is fully loaded, the slide valve is in the closed position (Figure 12A) and the flow of all the gas through the rotor housing is as described above. Unloading starts when the slide valve is moved back away from the valve stop (Figure 12Di. Movement of valve creates an opening in thebottom of the rotor housing through which suction gas can pass back from the rotor housing to the inlet pnrt area be fore it has yet been compressed. Since no significant amount of work has been done on this return gas, there are no ap preciable losses incurred. Reduced compressor capacity is obtained from the gas which is inside the inner part of the rotors and which is compressed in the ordinary manner. Capacity reduction down to 10% of full load is realized by progressive backward movement of the slide valve away from the valve stop. In principle, enlarging the opening in the rotor housing effectively reduces compressor displace ment. This action permits infinite steps of compressor capacity reduction with reduction in brake horsepower as Shown in Figure 13. SLIDE VALVE FIGURE 12-A SL 007781 FIGURE 12-B p' x\> *v TE-II/VC R e frig e ra tio n Unit T ra in in g Manual \ SL 007782 i SPINOLE ROTOR CASING INLET CASING HYDRAULIC THRUST BALANCER ASSEMBLY DISCHARGE END PLATE FEMALE ROTOR FIGURE 1-Compressor, Exploded View HYDRAULIC UNLOADER CYLINDER UNLOADER PISTON . 3-16 1 A*=> TE-II/VC R e frig e ra tio n U nit T ra in in g Manual Val.ve 3-17 UNLOADED &uY -u 007784 TE-II/VC R e frig e ra tio n U nit T ra in in g Manual I COMPRESSOR -.HOUSING MICRO SWITCH SUB PIATE. C/\Pfc.CITY DIM. Vl-i^DlCKTOR NEEDLE COMPRESSOR \CkPP\CITY 3-19 TE-II/VC R e fria e ra tio n U nit T ra in in g Manual SL 007786 SUCTION CHECK VMVE 60-G5 PSIG MUST BE VAMNTJMNED FOR PROPER `SOC** OPERATION NEEDLE VkLVE SUCTION LINE PRESSURE REGULATOR VKLVE SOLENOID VKLNE IS OPEN WHEN COi MPR. IS RUNNING COMPRESSOR , HIGH PRESS. LIQUID SIGHT GLRSS 0 ** tf) 1---- DISCHARGE LINE 5-' ^o O ^ % <1 %. w* ahr* ^ 0(t <%3 1 u. T Ti \T GKS SIDE ^ ai (* V __________________________ ,* OIL SE.PI\R/\TOR OIL HIGH PRESS. GKS NOTE \ ON LOW STMaE COMPRESSORS , THIS GJ LINE MUST BE CONNECTED TO HIGH PRESS. GAS SOURCE % c* SOC" SCREW OIL COOLING CIRCUIT (HI-STA*GE COMPRESSORS MAY-OS-'80 THU 09:02 ID:FES SOUTHWEST INC TEL NO:713 440-6311 4530 P01 CD MICROPROCS90R eBWTHOL l TE-II/VC Refrigeration Unit Training Manual 3-22 Lubrication System OIL FILTER The oil filter is a replaceable 15 micron high efficiency multiple car tridge type. All of the oil supplied to the compressor is filtered. Isolating valves are provided for servicing. Replace the filters when the pressure drop across the filters exceeds 15 psi. OIL PUMP STRAINER The unit has a 100 mesh stainless steel screen which has a total free area 10 times greater than the pump suction. OIL SEPARATOR A mixture of refrigerant gas and oil enters the oil separator from the compressor discharge. The separator is a two stage design. The first stage removes well over 99% of the oil circulated and acts as the reser voir for the oil pump. Gas entrained oil mist particles are removed from the gas in the second stage. Oil accumulated in the second stage is returned to the reservoir. The cooled oil under pressure is circulated to the compressor sleeve bearings, rotary shaft seal, and rotor housing. The oil injected directly into the rotor housing lubricates, provides gas seals, and cools the compressor while it is in operation. SL 007788 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 TE-II/VC Refrigeration Unit Training Manual DESCRIPTION 0? SYSTEM COMPONENTS 4-1 This 190 ton refrigeration package unit consists of the following major components: COMPRESSOR FES Model 135 ammonia direct drive, screw compressor with liquid injection, dual oil filters and a 115 volt, microprocessor control panel. The compressor is designed to produce 190 tons of refrigeration at 3540 rpm with a 508F suction temperature, a 102F condensing temperature and requir ing 208 BHP. MOTOR This is a 250 HP, 3600 RPM motor, WPII enclosure, across the line start, 3 phase 60 Hertz 2300 volts, 115 volt space heater - NEMA B design, class B-VPI insulation, Klixon winding temperature detector, a 1.0 service factor and a 500 NN frame. OIL SEPARATOR This is a 24" diameter oil separator with a 1500 watt heater and a 1/2" dual safety assembly set at 300 psig. OIL FILTER This is 43-1/8" long x 12-1/4" diameter, 2 element oil filter with a 1/4" drain valve connection. SL 007789 . ctcv* V *\o* ot ct c TE-II/VC Refrigeration Unit Training Manual 4-2 CONDENSER This is 32" diameter x 18' long, 6-pass, ammonia condenser with 3/4" drain and vent valve connection, a 3/4" dual safety connections set at 300 psig and (282) 1-1/4" diameter steel tubes. Maximum design pressure: 300 psi at 400F on the shell side and 75 psi at 400F on the tube side. v> Capacity - -706- gpm of 90F water with a 15 psi pressure drop, and a .002 fouling factor. RECEIVER This is a 30" diameter x 16' long, horizontal, ammonia liquid receiver with a 3/4" dual safety set at 300 psig and a gauge glass connection. Maximum design capacity - 300 psi at 400F on the shell side. EVAPORATOR/PROCESS CONDENSER This is a 24" diameter x 24' long, 1 pass, flooded ammonia evaporator, 3/4" drain and vent valves connections; 20" diameter x 19' long surge drum with a 3/4" FPT dual safety valve assembly set at 259 psig. Maximum design pressure - 250 psig at 400F on the shell side. Capacity - Condenses 23,044 #/hr of VCM/HC1 from 90F to 62F using 50F ammonia SL 007790 TE-II/VC Refrigeration Unit Training Manual TE-II VC REFRIGERANT FLOW 5-1 The high pressure ammonia gas enters the shell of the condenser and gives up heat to the water flowing in the vessel tubes. The water absorbs the heat of compression and the heat necessary to change the ammonia into a high pressure liquid. When the ammonia has condensed, it drops to the bottom of the condenser and drains into the liquid receiver. The receiver provides a storage area for the liquid refrigerant, so a constant supply is available to the system. A 1-1/4" equalizing line is provided between the receiver and condenser. This line permits the equalization of pressure in both of the vessels. The 1/2" purge valve should be manually opened only when non-condensibles are to be expelled from the system. Under normal operating conditions, keep this valve closed. After leaving the receiver and before entering the evaporator/process condenser, the ammonia liquid passes through a globe valve, sight glass, control valve with actuator, and globe valve. A hand expansion valve bypass is provided. The hand valve, during normal operation, is closed. It can be used to continue the operation of the system when service of the primary expansion valve becomes necessary. Liquid ammonia is metered into the evaporator/process condenser shell by a liquid feed control valve (expansion valve). This valve is controlled by a "level-trol" which senses the liquid level in the evaporator/process condenser shell. The "Level-trol" converts a liquid level into a propor tional pneumatic air signal. The air signal is transmitted to the actua tor of the control valve. The control valve throttles the liquid feeding the evaporator/process condenser, in sufficient quantity to maintain the desired liquid level. SL 007791 CONFIDENTIAL; -chive Order District Court TE-II/VC Refrigeration Unit Training Manual 5-2 The control valve is the dividing point between the high and low pressure sides of the system. The ammonia enters the chiller with a drop in pressure across the system. The ammonia enters the chiller with a drop in pressure across the valve and at the corresponding saturation temperature. A hot gas system is provided to artificially load the system when the suction pressure is below pre-determined value or setting. When the ammonia absorbs enough heat to reach and exceed its boiling point, the ammonia vaporizes and rises into the surge drum. Any ammonia liquid entrained in the gas drops to the bottom of the surge drum and drains into the evaporator/process condenser. The suction line from the surge drum then goes to a knock out pot called the accumulator, which accumulates any liquid NH^ carried over from the surge drum. The ammonia gas is pulled out of the suction accumulator through the suction strainer into the compressor. The refrigeration cycle starts again. SL 007792 CO dic^ pJj * 0' " ; of ct A&X re 0^ at-f v 3UC 9V tso o TE-II/VC Refrigeration Unit Training Manual 5-3 DESIGN OPERATING CONDITIONS The TE-II VC refrigeration unit is a 190 ton unit originally designed for the old Tetra unit. It has been modified for TE-II. The evaporator is flooded with NH^ on the shell side. O.D. tubes. It has 404, 3/4" A. Evaporator Condenser Design Condition Or Parameters 1. Inlet VCM/HC1 Flow - 90F @ 23,044 ///hr. 2. Outlet Vent Gas - 62F @ 10,150 ///hr. 3. Outlet Liquid - 62F @ 12,894 ///hr. or 28.8 gpm @ 89.9 TPD. 4. Liquid NH^ Level - 95% of evaporator tube bundle. 5. Liquid NH^ Pressure and Temperature - 74 psig @ 50F. B. NH^ Condenser 1. Cooling Tower Water Flow - 220 gpm @ 90F. 2. Condensed NH^ Pressure and Temperature - 204 psig @102F. C. High Pressure Receiver 1. Normal Operating Level - 20% from bottom of sight glass. D. Oil Separator 1. Normal Oil Level - 50-75% of sight glass E. Suction Accumulator Level - no visible level in sight glass F. Normal Analog Input Data Display 1. Suction Pressure 2. Discharge Pressure 3. Inlet Oil Pressure SL 007793 74 psig 204 psig 40 psig o TE-II/VC Refrigeration Unit Training Manual 4. Oil Filter 5. Inlet Oil Temperature 6. Discharge Temperature 7. Slide Valve 8. Compressor Motor Amps 9. Suction Temperature 5-4 10 psi 120F 140F 0-100% P 52F SL 007794 ;S- O <0 vo V -V -V / v -a, ^rry a'"-' 0 S' zf/ > Cq ^ S' TE-II/VC Refrigeration Unit Training Manual 5-5 OIL SYSTEM Oil is removed from the bottom of the oil separator through strainers to the oil pump. Oil is pumped through a filter to a motorized valve which opens to a manifold that supplies the compressor bearings, slide valve injection, and capacity control piston, via the compressor loading sole noid valves. The oil pressure is maintained by an oil pressure regulator that returns the excess oil pressure back to the oil separator. It is normal for small amounts of oil to be carried out with the refrig erant flow. Once in the evaporator/process vent condenser it must be drained to the suction accumulator and the heated oil pot so it can be resued if needed. It can be pumped back into the oil system. SL 007795 &? A* '*y V f#o & * .-SCO/ -c*5J C.oo -^^ C*tAM A' i SL 007798 i TE-11 /VC Refrigeration Unit Training Manual 5-8 REVISIONS OPERATING CONDITIONS FOR wrcpinroiNT , TONS OF REFRIGERATION SUCTION rnnnniNr; sprrn DPrvF BRAKE HORSE POWER__ MOTOR*SPCDfTOniONS miwpnwFB wrn VfirTARF FOlMr FNnOSURF TYPE OF STARTING, Xsv faa J/COAJtaO */r-zr 1,1 1 VfM_TAOT HFRT7 NEHA ni'* moj - DIVISION /tr . -7 / ' J> JX Q.jymtft MtuUrrp w/sjfltf **l*BtJG - PX-*L/i XWXJTtfP *4 p/p sc-pptr iai^C pPCr 1 - * ^ttPt^t*ffo//vrvtu4/fPtX4r*^LirwCCC/otv/-CrjpCrcppiM.c<T6w.PawuO. s*Lc%* . J/reV Pi'f S SUPC 0.4' K r#s\5vnc, Co^mtou^kjt- P5- 4*<vS - ***C*Sur:`2\^*TC*T a4o/<tcp*jr*'2olPv4P4iVtf 7 -- Ttf/t^WPTirtre z/VOtCA Tax h su/jrtfVTIC : TC ++PCTJ4TU/r &io*CATtrJ& CMinro&fM TQ+*j>cjr*Tvmc - s^rcry 6P4 - . Z>rr-rc*c+sTun. Uuc, iwirew iM^pnr *r-wr rcttau*+sti t/*tfJ*- pj &*** *v Pipe ixtfrM sr*f<M _'iCsr+W#v//UOCcJi<cI,//44u/--crp-P.p' pTfSiM.,'juvJCa/KCC0MwriPui*,v' -*tv^ 4SWdcnfOtfwn/ 44.IrWeC> rkpppi.pvfC.s.4o*aPi CcChMpt'PC.5'TI0f*l ftI**f0n;*w * L (p-'-f- l/<d2t * J*S * o/- Msr J INDUSTRIAL CHEMICAL DIVISION LAXZ QUtUS. LOUmAKA. AJtf / D/jQG&tl/Vtf -DWG RK -3QG8-3 TE-II/VC Refrigeration Unit Training Manual START-UP AND SHUTDOWN PROCEDURES 6-1 1. Energize the following breakers: a. Compressor b. Oil pumps c. Lighting 2. Check the oil separator level. Notify supervision if it is low. Supervision will get oilers to add oil. 3. Check the refrigerant level in the high pressure receiver. If level is low, supervision should notify the Refrigeration Group. 4. Check the refrigerant level in the evaporator/process condenser. If level is low supervision should notify the Refrigeration Group. 5. Check the suction accumulator level. There should be a zero (0) level. If there is a level proceed as follows: a. Close valves 12 and 15 (bleed valves). b. Open valves 10, 11, 13, and 14. c. After the level is drained out, reverse the valving process. Close valves 10, 11, 13 and 14. Open valves 12 and 15. 6. Check all drains. a. Inlet and outlet on the cooling tower water condenser. b. Oil separator. c. Oil filters (2). JJ M ^D CD O T3 U d. Oil pump suction drains (2). e. Oil separator bleed valve. O 4-> CD .. G>J -tH U -H +j ITI C 4-> OT H O --t -t 7. Establish cooling tower water flow to the ammonia condenser. FChZ 4O-J Q ^I M O -H a. Open bleed on the condenser. P v c* f-i Ui b. Unblock water inlet. It.' w 4 7: n ; O c. Bleed air until water flows out the bleed. d. Close the bleed. O 4- ^ 3 U .' T= CD SL 007799 ja ^ 3 fH in 44 O TE-II/VC Refrigeration Unit Training Manual 6-2 e. Open the water outlet. f. Water flow should be established. 8. Open the following valves. a. Oil separator level switch and level glass. b. High pressure receiver level switch and level glass. c. Evaporator/process condenser level switch and level controller. d. Suction accumulator level switch and level glass. SL 007800 A :\v- 9V TE-II/VC Refrigeration Unit Training Manual 6-3 INTRODUCTION OF PROCESS TO EVAPORATOR 1. Start the refrigeration unit, have it lined out on hot gas and liquid injection. 2. Check to make sure F-516 is open and F-518 is closed. 3. Open manual process block valves to the evaporator/process condenser. 4. When ready for process, reset switch to make F-518 and F-516 operable. a. F-516 will be wide open. b. F-518 will be closed. 5. Close manual bypass valve around process block valves. 6. Have inside operator check F-254 flow to DCE reactor. the same. It should be 7. Start raising VC rates to predetermined amount of transfer to VC-II. 8. As VC rates increase, open F-518 until it fully open, increase VC transfer to VC-II as reflux drum level rises. 9. Close back on F-516 to keep L-150 in the operating position for control of reflux drum level. 10. When VC rates are lines out, F-516 should be closed or slightly open and L-150 slightly open. 11. At maximum rates, L-150 may be closed and reflux drum level con trolled by transfer flow. SL 007801 CO Subi^c h t of 14th U*-'. * r-.r-'-or VC TE-II/VC Refrigeration VALVE # SERVICE 6-4 POSITION CHECK 1 Compressor Suction Open 2 Oil separator outlet Open 3 Ammonia condensor outlet Open 4 High pressure receiver outlet Open J 5 Level control valve inlet Open 6 Level control valve outlet Open 7 Level control valve bypass Closed 8 Hot gas inlet Open 9 Hot gas outlet Open 10 Suction accumulator gas equalizing Closed 11 Suction accumulator gas equalizing Closed 12 Gas equalizing bleed Open 13 Suction accumulator liquid drain Closed 14 Suction accumulator liquid drain Closed 15 Suction accumulator liquid drain Open bleed 16 # 1 Oi1 pump suction Open 17 # 2 Oil pump suction 18 # 1 Oil pump discharge Open Open 4-> u t-4 3 nO U !-l O -U o ^u - ,;J m -h'` -` '5 -r-Mn <rHr v r-H :* ! O 1 L; C3 CTt >*{ ^ Ui u K0 o o -iJ '"O 3 U3 n o cj jz 19 # 2 Oil pump discharge 20 Oil fi1 ter inlet Open Open 1f used XI 3 >-t Oi 4-t 0 21 Oil filter inlet Open If used 22 Oil f11 ter out let Open 23 Oil f11 ter out 1et Open 24 Liquid injection pilot line to Open regu1ator 25 Liquid injection inlet Open 26 Liquid injection outlet 27 Oil separator outlet Open Open SL 007802 TE-II/VC Refrigeration Unit Training Manual 6-5 E. Compressor Start Sequence (Upseq) 1. Check the anti-recycle time. a. If it is timed out# proceed* b. If time reamins, the compressor is not allowed to start. 2. Check the oil separator temperature. a. If it is above the lower limit, proceed. b. It it is below the lower limit, signal "Lo Oil Sep T" failure and abort the start-up. 3. Check the discharge pressure. a. If it is not within 10 psi of the maximum limit, proceed. b. If it is within 10 psi of the maximum limit, signal "Hi Disch Press" failure and abort the start-up. 4. Indicate the "Start Delay" message on home screen. 4J n => o 5. Activate the unload soleniod output. O 4J .6 Activate the open motorized check valve output. o 1 > i~l A 1 second on, 1 second off pulse is actually L: ' -J , ! issued for purposes of slow vessel equilizationr - 7. Activate the oil pump starter output. .8 Check the oil pump starter interlock.. P ^ rP ' >< -f~4 O CJ * o a. If it is made within 5 seconds, proceed. o^ ai x: b. If not, signal "Oil Pmp Strt" failure and -Q ^ abort the start-up. => r-i c/3 9. Check the oil pressure. 0 a. If it is within the starting limits for 5 seconds within a 20 second period, proceed. b. If the oil pressure is lower th$m the Oil Pr ssure Start Lower paramet r, signal "Lo Oil Press" failur and abort th start-up. 007803 SL c. If th oil pressur is higher than th Oil Pressur Start Upper parameter, signal "Hi Oil Press" failur and abort the start-up. TE-II/VC Refrigeration Unit Training Manual % 6-6 10. Check the slide valve position. a. If it is less than 5% within 5 minutes, deactivate the unload solenoid output and proceed. b. If not, signal "Compress Unld" failure and abort the start-up. 11. Check the motorized check valve. a. If it is open within 59 seconds, deactiveate the open motorized check valve output and proceed. b. If not, signal "Check Valve" failure and abort the start-up. 12. Activate the compressor starter output. 13. Indicate the "Load Delay" message on home screen. 14. Check the compressor starter interlock. a. If it is made within 5 seconds, proceed. b. If not, signal "Compress Strt" failure and abort the start-up. 15. Check the compressor motor current. a. If it is greater than 1/4 of the lower limit, proceed. b. If not, signal "Compress Strt" failure and abort the start-up. 16. Start the load delay timer. 17. Start the anti-recycle countdown timer. 18. Check the load delay timer. a. If it is timed out, proceed. b. If not, exit. 19. Start the oil temperature failure test delay timer. 20. Go to "Run" status. SL 007804 t r er ou rd C tO c tv rei tsi cr t De o l CO NFIDENTIAL: Pr c ia i to d u t J c u b je 1 4 th S f o TE-II/VC Refrigeration Unit Training Manual 6-7 F. Compressor Running Control Sequence 1. In addition to the prealarm checks that are made independent of compressor run status, the following prealarm checks are only made while the compressor is running. a. Depending on the current selection of capacity control (suction pressure or process temperature), the following prealarm messages may occur due to excessive or insufficient pressure or temprature* "LO SUCT 1 P" Low Suction 1 Pressure "HI SUCT 1 P" High Suction 1 Pressure "LO SUCT 2 P" Low Suction 2 Pressure "HI SUCT 2 P" High Suction 2 Pressure "LO PROC 1 T" Low Process 1 Temperature "HI PROC 1 T" High Process 1 Temperature "LO PROC 2 T" Low Process 2 Temperature "HI PROC 2 T" High Process 2 Temperature The "1" and1 "2" in the above prealarm messages are used to depict the setpoint which was valid at the time the prealarm condition resulted. b. In the event process temperature is the controlling medium, another prealarm check is made. A check is made to insure that the suction pressure as monitored at the compressor exceeds the value entered for "P Alarm Trip Limits Process Temp Control Lo Suet." Otherwise, the following prealarm message will be issued "Lo Suet P." Note this message does not have a "1" or a "2" to differentiate this prealarm from those when suction pressure is the controlling medium. C O N F ID E N T IA L : S u b je ct to P ro te c tiv e O rder Of 14th J u d ic ia l C lc c ric t C ourt SL 007805 TE-II/VC Refrigeration Unit Training Manual 6-8 c. In addition the following prealarm messages may occur if the monitored Analog Data value exceeds or dips below its respective "Hi" or "Lo" prealarm setpoint. "Hi Oil Fil P* High Oil Filter Pressure Drop "Lo Disch T" Low Discharge Temperature "Hi Motor Cur" High Compressor Motor Current "Hi Oil Press* High Inlet Oil Pressure "Lo Oil Press" Low Inlet Oil Pressure "Hi Oil Temp" High Inlet Oil Temperature "Low oil Temp" Low Inlet Oil Temperature The following are additional safety checks made while the compressor is running and their associated failure messages: a. "Lo Oil Press" Low Oil Pressure -- inlet oil pressure dipped below the "Oil Press Run Lower" safety parameter limit for 5 seconds continuously. Compressor shutdown results. b. "Hi oil Press" High Oil Pressure -- inlet oil pressure exceeded the "Oil Press Run Upper" safety parameter limit for 5 seconds continuously. Commpressor shutdown results. c. "Oil Fltr Press" High Oil Filter Pressure Drop -- oil filter pressure drop exceeded the safety parameter limit for 5 seconds continuously. Compressor shutdown results. d. "Lo Inlet Oil T" Low Inlet Oil Temperature -- inlet oil temperature dipped below the safety parameter limit for 5 seconds continuously. Compressor shutdown r suits. SL 007806 t r er ou rd C tO c itvrei iost LDo P ro c ia l r\ i C O N F ID E N T IA L : i to ud .. ct J S u b je 1 4 th f O TE-II/VC Refrigeration Unit Training Manual 6-9 e. "Hi Inlet Oil T* High Inlet Oil Temperature -- inlet oil temperature exceeded the safety parameter limit for 5 seconds continuously. Compressor shutdown results. f. "Oil Pmp 1 Intlk" Oil Pump #1 Interlock -- a 5 second continuous loss of oil pump #1 interlock was detected. This condition results in a compressor shutdown. (If the compressor package is not equipped with dual oil pumps or even with dual oil pumps if 0 (zero) is entered for the "Compressor Set-Up" screeen labeled "Lead Oil Pump Select." If A "1" is entered for "Lead Oil Pump Selects" then fl oil pump is considered lead oil pump and #2 oil pump is considered lag oil pump. In this case, A 1 second continuous loss of oil Pump #1 interlock (rather than 5 seconds) will result with this non-fatal (compressor will not shutdown) error message and the starting of the #2 oil pump (lag oil pump). This failure message could also be the result of absence of oil pump #1 interlock for 5 seconds, while attempting to start #1 oil pump when it is the lag oil pump and #2 is the lead oil pump. In the later case compressor shutdown results. NOTE: When 0 (zero) is entered for "Lead Oil Pump Select," #1 oil pump is assumed to be the only oil pump on the compressor package. g. "Oil Pump 2 Intlk" u 4 O J-> o <1) >U .1 W , .r4 Oil Pump 12 Interlock -- this failure message can only occur if a "1" or "2" was entered in the "Compressor Set-Up" screen labeled "Lead Oil Pump Select." This message can either be fatal (results in compressor shutdown) or non-fatal (no compressor shutdown). If #2 oil pump is lead oil pump and a 2 second loss of interlock is detected, th n this m ssag r suits as a non-fatal m ssag and th #1 oil pump is started. i rt J.i -H U tS 3 An U Q) A m 4-> A 3 r-t . W u-t SL 007807 No. 91-1145 TE-II/VC Refrigeration Unit Training Manual 6-10 If #1 oil pump is the 1 ad oil pump and it fails for any reason, then #2 oil pump (lag oil pump) will be started. If when attempting to start oil pump #2, no interlock is detected within 5 seconds, then this message results as a fatal failure message. h. "Compress Intlk" Compressor Interlock -- A 5 second continuous loss of compressor interlock was detected. This condition results in a compressor shutdown. i. "Compress Cur't" Compressor Motor Current -- the compressor motor current dipped below 10% of the safety parameter limit "Motor Current Lower" for 5 seconds continuous. This condition results in a compressor shutdown. j. "Lo Oil P Pmp 1" Low Oil Pressure Pump i 1 -- while pump #1 is lead oil pump as per "Lead Oil Pump Select" entry in the "Compressor Set-Up Screens," this non-fatal failure message is used if the oil pressure dips below the "Lag Oil Pump Start". Oil pressure entry value or 5 seconds continuously "Lag Oil Pump Start" screen is a "Parameter Limits" entry screen which is only accessible when the entry for "Lead Oil Pump Select" is non-zero. Oil pump i2 will be started when this condition occurs. k. "Lo Oil P Pmp 2" Low Oil Pressure Pump #2 -- while pump #2 is lead oil pump, this non-fatal failure message is issued if the oil dips below the "Lag Oil Pump Start" oil pressure entry value for 5 seconds, continuously. Oil pump #1 will be started when this condition occurs. h% rS! O ^0 O 4J <v S>i-7J0-JU)u*-rVE-JjJJw ft! n in I SL 007808 * O - oO ^ s,9 -u U v<-ui -2Q1 s: 4J CO o TE-II/VC Refrigeration Unit Training Manual Dual Oil Pump Control (Only valid if "Lead Oil Pump Select" is non-zero) If a "1" or "2" is entered into the "Lead Oil Pump Select" display on the "Compressor Set-Up" section, while the compressor is running, the newly selected lead oil pump will be started* Therefore, it is possile to have both oil pumps started and running at the same time. If at any time while both oil pumps are running, the oil pressure exceeds the "Lag oil Pump Start" value plus 10 psi, the new lead will be allowed to continue to run and the other pump (previously "Lead" now considered "Lag") will be stopped. If the same value was entered into the "Lead oil Pump Select" as is currently displayed, then no effective change in lead oil pump selection occurs and the above action is not taken. If while attempting to change lead pump selection the "Examine Failures" message is encountered, refer to the explanation on display entry covering "Compressor Set-Up Lead Oil Pump Select" to resolve this condition. An automatic start of the lag oil pump will result if the oil pressure dips below the "Lag Oil Pump Start" oil pressure value for 5 seconds continuous. A non-fatal failure will result for the lead oil pump concerning low oil pressure (see g. and k. of previous Section B) when the oil pressure exceeds "Lag Oil Pump Start" value plus 10 psi. The lead oil pump will be stopped. An automatic start of the lag oil pump will also result if a 1 second loss of oil pump interlock is detected. A non-fatal failure will result for the lead oil pump concerning interlock (see f and g. of previous Section B) when the oil pressure exceeds "Lag Oil Pump Start" value plus 10 psi. The lead oil pump will be stopped. V TE-II/VC Refrigeration Unit Training Manual 6-12 3. Capacity Control a. Mode Selection -- The capacity control mode is selected by depressing the appropriate key on the keypad. The modes of capacity control that may be selected are Hold, Unload, Load, External and Auto* A description of each mode appears below. 1. Hold -- When selected, neither load nor unload pulses are generated, unless there is an OVERLOAD CONDITION as described below. 2. Unload -- When selected, a 100% unload pulse width is generated. 3. Load -- When selected, a 100% load pulse width is generated, unless there is a LOAD PULSE INTERVENTION CONDITION or an OVERLOAD CONDITION as described below. 4. External -- When selected, load and unload pulse widths are generated in accordance to the status of the "External Load" and "External Unload" input modules, unless there is a LOAD PULSE INTERVENTION CONDITION, an OVERLOAD CONDITION, or the slide valve is below the minimum slide valve setpoint as described below. If the input module pulse on time or off time is less than 0.1 seconds, the time is ignored. The minimum output pulse width is 0.25 seconds. If both input modules are energized simultaneously, an unload pulse will be generated. 5. Auto -- When selected, the microprocessor control generates unload or load pulses based on a control setpoint and other parameters in a formula as described below, unless there is a LOAD PULSE INTERVENTION CONDITION or an OVERLOAD CONDITION as described below. SL 007810 , Vo v\ u ,.V \> ,\VC" <$> TE-II/VC Refrigeration Unit Training Manual 6 Auto capacity control may b based on suction pr ssure or process temperature. If DIP switch U17 sw#5 is op n, then th input module "Control Press/Temp Select" determines if capacity control is based on pressure or temperature. If the DIP switch is closed/ then a display in the "Compressor Set Up" display section determines if capacity control is based on pressure or temperature. The display, which may be changed via the keypad or a Tele-Data command, is "Control Mode Press/Temp." Two different setpoints may also be used, called setpoint 1 and setpoint 2. If DIP switch U17 sw#7 is open, then the input module "Cap Control Setpoint #2" determines which setpoint is selected. If the DIP switch is closed, then two displays in the "Compressor Set Up" display section determine which setpoint is selected. The displays, which may be changed via the keypad or a Tele-Data command are "Control Change Time Setpoint 1 On" and "Control Change Time Setpoint 2 On". Switching from setpoint 1 to setpoint 2 could be used to adjust the compressor from a daytime production load to a reduced nighttime or weekend load. If the capacity control is set for AUTO, based on suction pressure, and the suction pressure is below the setpoint, the microprocessor calculates an unload pulse width based on the following formula: UNLOAD WIDTH = PERIOD (SPsp - SP - (SPdb/2)) / SP pb If the capacity control is set for AUTO, based on suction pressure, and the suction pressure is above the setpoint, the microprocessor calculates a load pulse width based on the following formula: LOAD WIDTH => PERIOD (SP - SPsp - (SWb/2)) / SFpb PERIOD * Capacity Load-Unload Period (paraneter) SP * Suction Pressure SPsp = Suction Pr ssure Setpoint (paraneter) SFdb = Suction Pr ssur Dead Band (paraneter) SFpb = Suction Pressur Proportional Band (paranet r) SL 007811 TE-II/VC Refrigeration Unit Training Manual 6-14 Process temperature control operates similarly to suction pressure control with the temperature parameters being substituted into the formulas instead of the pressure parameters. There are three additional parameters that are only valid when operating in process temperature control and they are used in LOAD PULSE INTERVENTION CONDITION and OVERLOAD CONDITION as described below. These parameters are LOAD ADJUST# PROPORTIONAL BAND AND LOW SUCTION. Setpoint 2 operates similarly to setpoint 1, with the setpoint 2 parameters being substituted into the formulas instead of the setpoint 1 parameters. b. Minimum Slide Valve Setpoint -- When either EXTERNAL or AUTO mode are selected and if an OVERLOAD CONDITION or .LOAD PULSE INTERVENTION CONDITION does not exist# minimum slide valve setpoint is enabled. If the slide valve position is at or less than the minimum slide valve setpoint# the microprocessor will generate a 0% unload pulse width. If the slide v ive position is less than the minimum slide valve setpoint by more than 2%, the microprocessor will generate a 50% load width until the slide valve position is at or greater than the minimum slide valve setpoint. Load Pulse Intervention Condition -- When a load pulse is calculated by a LOAD# EXTERNAL, or AUTO mode selection# it is possible for this calculation -P to be overridden by two conditions: O* o= u o 1. When motor current exceeds the lower setpoint# p O 4J the following formula is used to calculate the maximum allowable load width# which is o Q) 'r-t p compared to the previously calculated load iJ-h jj m < 4J B'a* width. The smaller of the two load widths U -P tH OQh is issued. S -p | W o I-) ,-H MC S*~il -IT(! ON fc, O MAX LD WIDTH PERIOD (0.99 * MCUP - MC) /.(0.99 * MCUP. - MCIWg ^O -H 0 O FERIOD > Capacity Load-Unload Period (paranet r) MC = Motor Current MCUP = Motor Current Upper (paranet r) MCIW Motor Current Lower (parameter) g\_ 007" O -> -p Q 3 i-H 3 o TE-II/VC Refrigeration Unit Training Manual 6-15 The above formula proportionally trims the allowable load pulse until the actual motor current reaches 99% of the motor current upper setpoint. The amount of amps between 99% and 100% is used as a dead band. In this dead band zone, no load pulses are allowed. Thus, the compressor works to maintain maximum allowable motor current without overshooting in either load or unload, thereby eliminating hunting actions. 2. When in AUTO mode and process temperature control is selected, if the suction pressure is less than the "LOAD ADJUST" parameter, the following formula is used to calculate the maximum allowable load width, which is compared to the previously calculated load width. The smaller of the two load widths is issued. MAX LD WIDTH - PERIOD (IAPB + SP -LA) / IATB LAPB = LA - IS - PB PERIOD = Capacity Load-Unload Period (parameter) IAPB = Load Adjust Proportional Band SP * Suction Pressure IA = Process Temperature Control Load Adjust (parareter) IS = Process Tenperature ControlLow Suction (parameter) PB = Process Temperature Control Proportional Band (parameter) 4. Overload Condition Two different types of overload conditions may occur. If an overload is detected, a proportional unload pulse is calculated, issued to the module, and the appropriate overload message is displayed on the home screen. The minimum unload pulse issued is 1/4 second. This is done because as the calculated unload pulse gets smaller and smaller when the overload condition is about to be resolved, if the pulse gets too small, the compressor will not unload enough to reset the overload condition. SL 007813 Subject to : of 14th Judic No. TE-II/VC Refrigeration Unit Training Manual 6-16 If an overload p rsists for 5 minutes# a fatal failure will be issued. The three types of overload are as follows: a. When motor current exceeds the upper setpoint# the following formula is used to calculate the minimum unload width# which is compared to the previously calculated unload width* The larger of the two unload widths is issued. The compressor will not be permitted to load for any reason until the motor current drops below 99% of the motor current upper setpoint. MIN UNLD WIDTH = PERIOD (MC - MCUP) / MCPB PERIOD = Capacity Load-Unload Period (parameter) MC = Motor Current MCUP = Motor Current Upper (parameter) MCPB = Motor Current Proportional Band (paraneter) SL 007814 CONFIDENTIAL: Order Subject to Frt'!^t,trict Court of 14th Judical v,- 91-1145 TE-II/VC Refrigeration Unit Training Manual 6-17 b. When in Auto mode and process temperature control is selected, if the suction pressure is within the proportional band (SP > LS +PB), the following formula is used to calculate the minimum allowable unload width, which is compared to the previously calculated unload width. The larger of the two unload widths is issued. The compressor will not be permitted to load for any reason until the suction pressure rises above the proportional band. MIN INID WIDTH PERIOD (LS + PB- SP) / HJ PERIOD = Capacity load-Unload Period (parameter) SP 3 Suction Pressure IS * Process Temperature Control Low Suction (paraneter) IB 3 Process Temperature Cntrol Proportional Band (paraneter) NOTE: It is possible for a manual unload request or an external unload request to output a longer unload pulse than is required by the OVERLOAD CONDITION logic. Compressor Shutdown Sequence (DNSEQ) 1. Deactivate the compressor starter output. 2. Activate the unload solenoid output. 3. Check the compressor starter interlock. a. If it is released within 8 seconds, proceed. b. If not, signal "Compressor Shdwn" 'ailure. Deactivate the oil pump starter output for 5 seconds. If the compressor starter interlock releases, proceed. If not, reactivate the oil pump starter output to protect the compressor, and continue checking the compressor starter interlock until it releases, then proceed TE-II/VC Refrigeration Unit Training Manual * C*< 1f 6-18 4. Check the compressor motor current- a. If it is less than 5 amps within 8 seconds, proceed. b. If not, signal "Compress Shdwn" failure. Deactivate the oil pump starter output for 5 seconds. If the compressor motor current is less than 5 amps, proceed. If not, reactivate the oil pump starter output to protect the compressor, and continue checking the compressor motor current until it drops below 5 amps, then proceed. 5. Activate the close motorized check valve output. .6 Check the slide valve position. a. If it is less than-5% within 5 minutes, proceed. b. If not, indicate "Compress Unld" failure and proceed. 7. Deactivate the unload solenoid output. .8 Deactivate the oil pump starter output. 9. Check the motorized check valve. a. If it is closed within 45 seconds', proceed. b. If not, signal "Check Valve" failure and proceed. .10 Deactivate the close motorized check valve output. u M V-i 3 O0 TD O O 4-) (J Q> -H .11 Check the oil pump starter interlock. 1-4 > 4^.4 u'l 4-1 IJ T H O -H , -j EH c a -< a. If it is released within 5 seconds, proceed^ O --' r--j Q ^ r} c\ b. It not, signal "Oil Pmp Intlk" failure and ^ u . proceed. .12 Indicate "Stop" message on home screen. 0+o4-^H 3o u3 4-) >31 ^^ ri 4J JQ "T 3 -H W 4-1 0 SL 007816 TE-II/VC Refrigeration Unit Training Manual 6-19 /\ 7 b> Ml f ,V to* </> ni>11' '4>- T SELF DIAGNOSTIC TESTS SL 007817 A ALARM FAIL M M3 oo T5 u M o D u'JH jm , r 1"^ r,; cr> '< -J c> ., -J^ '.3H zO 3 *j <r) O 0 jZ ri Xt *r 3 r-l to M-l 0 TE-II/VC Refrigeration Unit Training Manual 6-20 o f 1 4 th J u d ic ia l D is t r ic t Co No. 91-1145 SL 007818 TE-II/VC Refrigeration Unit ning Manual 6-21 SL 007819 TE-II/VC Refrigeration Unit Training Manual C FtIL ) 6-22 c ALARM DISPLAY PRE-ALARM IN PRE-ALARM ANNUNCIATOR TURf4 ON ALJ*RM ^ RETURN SL 007820 Ov cow,,o 6 ca.o\o X> V? TE-II/VC Refrigeration Unit Training Manual 6-23 TURN ON ALARM DISPLAY FAILURE | SELF DIAGNOSTIC TESTS I UNLOAD CAPACITY SL 007821 CLOSE MOTORIZED CHECK VALVE i ^wlK ,NO <T CLOSED IN> JYES /oilV <T PRESSURE NO X. OK?/ JYES UNLOAD COMPRESSOR 0 FAIL FAIL > <bO, ' ., . ..V s ' cOv/ \)\t^ v' *P. t> or" ,0 TE-II/VC Refrigeration Unit Training Manual 6-24 NO ANTIRECYCLE YES NO SL 007822 0 \ TE-II/VC Refrigeration Unit Training Manual SHUTDOWN VALVES 6-25 I. A. If the refrigeration unit does not shut down but the trouble is in the process unit: valve F-518 must be closed and valve F-516 opened. B. If F-518 and F-516 are blocked the manual bypass must be opened before F-518 and F-516 are blocked. II. Normal shutdown with no maintenance: The following valves must be closed: 1, 2, 5, 8, and 25. III. Shutdown for maintenance: A list of valves to close and clearing procedure will be provided at the time of the shutdown. SL 007823 **!&?* c c^ O \ O- .\V 9V C> rX r>v AV C c> ::v v* . ..J-' - 'Sy 'V ^ * CA>0> &v TE-II/VC Refrigeration Unit Training Manual 6-26 SHUTDOWN OF REFRIGERATION UNIT FOR MAINTENANCE 1. If rates are higher than cooling tower water condenser can handle as far as a transfer is concerned, reduce furnace rates and cut transfer back or off. 2. Refrigeration unit will unload as rates are cut. 3. When VC rates are cut back to where cooling tower water condensers will handle the load without the refrigeration unit, open F-5I6 and close F-518. When F-516 is open and F-518 is closed, open manual bypass block valve around the two manual block valves going to the evaporator/process condenser. These valves are located on top of the bottom cooling tower water condenser. 4. F-516 should be wide open. F-518 should be fully closed. 5. The refrigeration unit will be ready for shutdown. 6. Manually block inlet block valve to the evaporator/process condenser located before F-518 on top of bottom cooling tower condenser. (Manual bypass valve must be open.) SL 007824 C cf0 ^ TE-II/VC Refrigeration Unit Training Manual LOSS OF VC TRANSFER 6-27 1. Cut furnace rates. 2. The refrigeration unit will have to be unloaded by opening F-516. 3. When rates are cut enough to balance with DCE and MC, open F-516 fully and close F-518. 4. Open the manual bypass. 5. Block the manual block valve to F-518. 6. Leave the refrigeration unit running on hot gas and liquid injection. SL 007825 TE-II/VC Refrigeration Unit Training Manual OIL POT RECOVERY SYSTEM 6-28 Oil will accumulate in the oil recovery pot over a period of time. If the oil separator is low, check the oil recovery pot. If it shows a level in the sight glass, there is an oil pump to pump oil back to the suction lien of the compressor. This should get the level back up to normal in the oil separator. If the oil separator is still below normal then oil will have to be added to the refrigeration unit. The oiler will normally add oil to the unit during regular working hours. Oil can only be pumped back to the suction of the compressor while it is running. Close the drain valve between the accumulator, @38, and open block valve at the suction line tie-in. Shut pump down, open valve (#28) and close valve (#29). SL 007826 c*l ^ \z ^ <)V TE-II/VC Refrigeration Unit Training Manual SWITCH OIL FILTERS 6-29 1. Outlet valves (22 and 23) should be open before you start. If outlet valves are not open, notify supervision. These valves should have been left open by the service mechanics when they finished changing the filter elements. The filter could be full of air if the outlet is closed because the mechanic may not have filled it with oil. This air could cause a loss of oil pressure if the filter is put in service improperly. It is important that the Refrigeration Group be notified if both outlet valves are not open. 2. If both outlet valves are open, slowly open the inlet valve on the new filter. 3. After the inlet valve on the new filter is fully open, slowly close the inlet valve on the old filter. 4. Check the oil pressure to verify it has not dropped. 5. Leave the outlet valves open. Isolation of the oil filter could result in over-pressurization due to ammonia entrained in the oil. 6. Record in the log book that the oil filters have been switched. SL 007827 6VV- ,, 0 CP .rss^Vv .V >' A > *o*N TE-II/VC Refrigeration Unit Training Manual SWITCH OIL PUMPS 6-30 !. Switching of oil pumps should be a two (2) person operation. One in the switchgear room and one at the pump. 2. Verify that the suction and discharge valves are open on both oil pumps. If the valves are not open, open them before attempting to switch oil pumps. 3. Slowly block the suction valve on the pump. If the main oil pump is being taken out of service, the lag pump should come on when the oil pressure reaches 25 psi. 4. When the oil pump comes on, block the suction on the bad pump. 5. Have the person in the switchgear room turn off the breaker on the bad pump. SL 007828 Or & O' 0-c C kP. cy v 'O X TE-II/VC Refrigeration Unit Training Manual 7-1 VI. Troubleshooting A. Power Supply (Reference Drawing No. 035-00576D) The following sections require making accurate D.C. voltage readings. A digital multimeter (DMM) is recommended. 1. Valid Voltage Settings a. The +15 VDC supply voltage should read between 14.5 VDC and +15.5 VDC for proper operation. This can be measured between ground (negative meter probe) and +15 volt as shown on the drawing. If adjustm nt is necessary, see the following section on voltage adjustment. b. The -15 VDC supply voltage should read between -14.5 VDC and -15.5 VDC for proper operation. This can be measured between ground (negative meter probe) and -15 volt as shown on the drawing. No adjustment is available or this voltage. 2. SL 007829 c. The +5 VDC supply voltage should read between +5.1 VDC and 5.3 VDC for proper operation. This can be measured between ground (negative meter probe) and +5V as shown on the drawing. If adjustment is necessary, see the following section on voltage adjustment. Voltage Adjustment Power supply adjustments require a short shut down time. No power supply adjustments should be made with power supply connector connected to the processor board. First switch off panel power with the control switch on front of panel. Next, disconnect power connector to processor board and switch panel power-on again. Locate proper voltage adjustment potentiometer (pot) on power supply. The adjustment pots are on th painted circuit board below the power supply housing and are visible through the holes in th top fram of th power supply. A 1/8" x 4" Xcelite R-184 screwdriver (preferably non-conductive) can b us d. Care must b tak n if using a conductiv screwdriver not to touch anything other 4J <^u o3 'U u y o .y ,,0) -wO *4 < >u -y m o -H r-i Eh S CJ Q ry I m a, CTi Sfer O -H o O y TJ S -y y3, u tt! -Q CO o TE-II/VC Refrigeration Unit Training Manual 7-2 a. + 5 VDC adjustment pot increases voltage if turned clockwise and decreases voltage when turned counterclockwise. Proper operating voltage is +5,1 VDC to +5.3 VDC. b. +15 VDC adjustment pot decreases voltag if turned clockwise and increases voltag when turned counterclockwise. Proper operating voltage is +14.5 VDC to +15.5 VDC. Upon completion of power supply adjustment, switch off panel power, reconnect power supply connector to processor board, switch panel power on again. If the +5 volt DC supply is properly adjusted, the 5 volt DC range indicator on the processor board will glow green. If the range indicator is red, then th +5 volt DC is adjusted too low or too high. B. Motor Current Calibration (Reference Drawing No. 035-00576D)i If this is initial calibration of machine, it should be verified that the proper CT ratio was selected for this application. While in the service mode enter the "Compressor Set Up" mod display. Push the "Step/Enter" Key until "Motor Current Xformer Ratio" is displayed. Valid entries are from 100:5 to 1200:5. If necessary enter proper data and press "Step/Enter." SL 007830 No adjustment is provided to zero the motor *jj g current as this is accommodated through hardware, "o u O Start the compressor and load to 100%, if possibl , a but at least to 501. rPlace in hold for constant ^ load' (motor--current should remain constant whil < > w * making this adjusCfiiemt.-j " $q3 'Z 4J I * WO H Using a hand held clamp on amprobe, put it around every wire going through the CT. &0^j p -u T! a While monitoring motor current on the analog datau ^ display, adjust th motor curr nt span pot on the g ^ processor board until the readings on both th display and clamp on amprobe coincide. J2 " 4-4 o TE-II/VC R frigeratlon Unit Training Manual 7-3 C. Slide Valve Calibration (Reference Drawing 035-00576D) 1. Without the compressor runnings a. Set DIP switch U18 switch II to the open position. "Oil Pump Test" is enabled. b. Press the "Local Start" key and "Oil Pmp Tst* -- should be displayed. The oil pump (lead otl- pump if 2 installed) should also be running. c* Press "Unload" to provide a continuous unload signal. d. After 1 or 2 minutes, it can be assumed the slide valve has reached the full unload position. e. Adjust the slide valve zero pot on the processor board until the display indication changes between Ot and 1%. No value less than 0 will be displayed. Therefore, it is important to adjust as just mentioned. f. Press the "Load" key to provide a continuous load signal. After 1 to 2 minutes, it can be assumed the slide valve has reached its full load position. g. Adjust the slide valve span pot on the processor board until the display indication changes between 99% and 1001. No value greater than 100 will be displayed. Therefore, it is important to adjust as just mentioned. h. Repeat c - g as necessary until full side valve travel results in 0% to 100% readings without further adjustment. i. Set DIP switch U18 switch II to the closed position. SL 007831 CONFID^IFT C AO f tive Order Subject to Protec Dl strict" Of nth 1 TE-II/VC Refrigeration Unit Training SYMPTOM POSSIBLE CAUSE jngjChart SUGGESTED REMEDY /-H- ft. High Discharge Pressure a) Excessive load b) Reduced condenser capacity a. Reduce load b. Check cooling condenser perforaance b. Check for tube fouling, obstruction b. Check for non-condensibles - Purge thru high side b. Check for refrigerant overcharge Unit loads continuously but uill not load to 100 % capacity a) High discharge pressure a. Refer to syaptoa 'A* b) Excessive eotor current b. Check conpressor aotor current and coapare c) Ieproper setting or ealfunction with aotor naaeplate rating of load liait control c. After checking aotor current, readjust load liait control to alldu the aotor to run at full naaeplate AMPS or replace it if found to be defective C. Coepressor uill not load 'Loading* light 'Off* D. High discharge teeperature E. Unit cycling on Ioh oil pressure F. Loh suction pressure $ % a) 'Load* operating pressure suitch aalfunctioning b) Excessive aotor current c) Load liait control aalfunction d) Manual load control snitch iaproperly set or defective a) High discharge pressure b) Insufficient oil cooling effect in coepressor c) Excessive discharge soperheat a) Restricted oil filter b) Loh oil level in suap a) Chiller Mater puap or fan not operating b) Lack of refrigerant c) Evaporator dirty or iced up d) Clogged liquid line filter- drier e) Clogged suction line or coa- pressor. suction gas strainers. f) Expansion valve Malfunctioning g) Condensing teeperature too Ioh h) Coepressor uill not unload i) Evap. fan or chiller puap off off a. If unit Mill not `load' Manually, check pressure setting. Readjust or replace as U necessary a b. Refer to syaptoa B, reaedy b ^ o u c. If to the 'load* light Mill not glov nhile trying Manually load the conpressor, refer to TM -p syaptoa B, reaedy c u d. Check suitch and Miring for an open circuits 4-> m w "T a. Refer to syaptoa A Q rH B\ b. Insure proper oil flow thru coepressor W A ttJ ON c. Discharge superheat range 30F to 60F for R-h,i 30F to 90F for HH3 % Check for 1) Hon-condensibles 0 2) Excessive suction superheat 3) Excessive pressure differential sz across coepressor 4-> Q -a- e S3 iH a. Check pressure drop across oil filter. If in excess of IS LBS., replace filter b. Check discharge superheat - If belou 30F. Oil nay be carrying over onto refrigerant systea +3 Increase discharge superheat by: 1) Insuring proper suction superheat 2) Insuring proper oil teeperature ZT c u b. Second stage of ail separator is oil logged b. Oil second stage eleaents ruptured or 0-rings V bloun. Reaove separator head and inspect eleaents ^f p u. a. Check and start fan of puap t b. Check for leaks. Repair and add charge. c. Clean or defrost d. Replace cartridges o M , -r- L O ) 'H T3 ZO u3 e. Clean strainers x: -p a1 f. Check and reset for proper superheat. Repair or replace as necessary. g. Check aeans for regulating condensing teaperature h. See steps for failure of conpressor to load i. Check. Add interlock 4-1 o TE-II/VC Refrigeration Unit Training Manual REFRIGERATION SYSTEM PRQSLEMg 7-5 EVAPORATOR PROBLEMS PROBLEM Low H20 flow Refrigerant shortage Dirty tubes Low I condensing T | Low outlet | chill water VISIBLE SYMPTOMS LOWSIDE AT AP PSIG WATER WATER SUPER HEAT T 1tl 1 1 Same t 1 1 S (f) l 1 1S t 1 S s s (1) IDENTIFYING FACTOR ATt A AP| * SH| At J a sh t ( look for restrictions) ATJ & SHf * Ambient temp rature & Condensing PSIG Temp observation CONDENSER PROBLEMS PROBLEM Air trapped in H20 side Scale tubes Low H20 flow High inlet water temp Refrigerant overcharge Non condensables Baffle by - pass VISIBLE SYMPTOMS DISCH PSIG At AP WATER WATER t l? t? t Same tt1 t ? (si) S 1 ?t S t ? <s|) s t SS AT SUB j COOLING IDENTIFYING FACTOR Open vents, plugs \1 AT f and subcooling ? APi ( A T | ) ? (Si) t ? (si) 1 Inlet Temp Gage Subcooling f Perform non condensable test All of the above fail (Cond shell temp hot) SL 007833 Subject to Protecti ve Ortei Of 14th Judicial Distric ' No. 91-.U ' TE-II/VC Refrigeration Unit Traipi^q ENGINEERING DATA SHEET ROTARY SCREW COMPRESSOR PACKAGE MICROPROCESSOR II PARAMETER SETTINGS 8-1 Job No. RETROFIT ESTIMATED VALUES PRESSURE CAPACITY CONTROL, AMERICAN UNITS Cate: 3/25/88 88-0092-1001___________ Rev.: Project Engineer: BBC:cd Refrigerant: R- 717 Pkg. Model VILTER/HOWDEN Oil Pump Type: Full Flow Progran: FES Part No. HPCO Limit: 225 PSIG [X] 270 PSIG [ ] ____ t ) LANGUAGE: English [X] [] Application: High Stage [X], Swing [ ], Booster [ ] Please refer to Microprocessor II instruction manual for parameter details. Parameter Recommended Settings Actual Start-Up Settings COMPRESSOR SET-UP 1 lead oil pump: select oil pump # (only set-up with dual oil pump application) 2 Compressor Identification Number (I.D. #) 3 Anti-recycle timer (20 min. to 15 hr.) 4 Motor current transformer ratio ___ 00:5 0 1 20 min. Existing PRE-ALARM TRIP LIMITS 1 Suction 1 Pressure Upper 2 Suction 1 Pressure lower 3 Suction 2 Pressure Upper 4 Suction 2 Pressure lower 5 Oil Filter Pressure Drop 6 Motor Current Upper 7 Oil Separator Temp. Upper 8 Oil Separator Temp. Lower 9 Discharge Pressure 10 Discharge Temp. Upper 11 Discharge Temp. Lower 12 Oil Pressure Run Upper 13 Oil Pressure Run lower 14 Inlet Oil Temp. Upper 15 Inlet Oil Temp. Lower By Customer NA NA 15 psi 145 F. 102 F. 210 200 F. 105 F. 55 psi 25 psi 145 F. 100 F. 49- k. dp1 & o I(3f 4J' tj y-W / > u ^ -H 49 -M W -rf W '& r-4 v, & r* IS 4J I O Dhta hm i-< -fH ,o . P ts a tl* *Q = i-J to 0 it-ii/VL Kem qeration unit train mu nanuai MICROPROCESSOR II PARAMETER SETTINGS o- PRESSURE CAPACITY CONTROL, AMERICAN UNITS Step PARAMETER LIMITS Parameter Recommended Settings Actual Start-Up Settings 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 NOTE: Suction 1 Pressure Setpoint (29.9" Hg. - 85 psig) Suction 1 Pressure Upper (cutin) Suction 1 Pressure lower (cutout) Suction 2 Pressure Setpoint (29.9" Hg. - 85 psig) NA Suction 2 Pressure tapper (cutin) NA Suction 2 Pressure lower (cutout) NA Oil Filter Pressure Drop, Max. (20 psi max.) 20 psi Discharge Pressure Prop Band (unload) 10 psi Motor Current Ojpper (F.L.A. x S. F.) Unload Motor Current lower (F.L.A. x S.F. x 0.85) Load Motor Current Prop Band (unload) (Nom. 10% F.L.A.) Oil Separator Heater Setpoint 115 F. Oil Separator Temp. Upper (Prevents Start) 155 F. Oil Separator Temp. Lower (Prevents Start) 92 F. Capacity Load/Unload Period 4 sec. Suction Suction Suction 1 Pressure Prop Band 1 Pressure Dead Band 2 Pressure Prop Band 4 psi .5 psi 4 psi * tJ' Suction 2 Pressure Dead Band .5 psi Slide Valve Position Setpoint 1 Slide Valve Position Setpoint 2 Slide Valve Position Setpoint 3 Slide Valve Position Minimum Discharge Pressure Maximum (cutout) Discharge Temp. Upper (cutout) Discharge Temp. lower (cutout) Lag Oil Pump Start (cutin) (select pump segjence at "Ccmp. Set-Up" Step 1) Oil Pressure Start Upper (cutout) Oil Pressure Start Lower (cutout) Oil Pressure Run Upper (cutout) Oil Pressure Run Lower (cutout) Inlet Oil Temp. Upper (cutout) j 0% 225 212 F. 95 F. 25 psi 80 psi 20 psi 60 psi 20 psi 155 F. uP L3 Q) O nV u o -P o Q> p V > p -P in &H< 4-> Q0) CPO Q -P tl 0 N Oh u 0 H 8 ^ TD 3 -P n o <D JS r-> Q -P 3 10 O Inlet Oil Temp. Lower (cutout) 92* F. Parameters 9-33 are only accesssible when dip switch U16 Switch #1 is open for service mode. TE-II/VC Refrigeration Unit Training Manual ELECTRICAL SYSTEM 1. Oil Pump #1 - CKT #29618 2. Oil Pump #2 - CKT #29619 3. Compressor Motor - OL-196 4. Control Power - ICE-8 & ICE-11 5. Oil Recovery Pump - ICE-10 - 1/2 HP Pump 6. Oil Heater - ICE-9 8-3 SL 007836 V-v O