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Page 1 of 30
Procedure
Screw Compressor-DRAFT
Developed
by:
2.8
Revision date:
11/4/2014
Name:
Title
Name:
Osagie Evbuomwan
Title
Maintenance Manager
Signature
Instructions: The following SOP provides information on the normal and emergency operation of the
Screw Compressors. The document includes information required by the Process Safety Management
program.
Reference:
International Institute of Ammonia Refrigeration Bulletins 109, 110
Ben & Jerry's Waterbury Plant Maintenance Personal
Ben & Jerry's Safety Staff
OSHA standard 29 CFR 1910.119
Ben & Jerry's Waterbury lockout/tag out program.
Start-Up, operation, and Maintenance Manual, section 5
Consult the Anhydrous Ammonia Safety Data Sheet (SDS) for additional information.
Chemical Properties:
Volatile (lighter than air), strong alkali, extreme affinity for water, colorless gas
with pungent odor, can be detected at concentrations far below that which would be
harmful, flammable in air between 16 25% where ignition source is present,
incompatible with strong oxidizers, acids, halogens, salts of silver, zinc and
Screw Compressor
Page 2 of 30
Procedure
mercury.
Ammonia when mixed with air produces two types of safety hazards. The mixture
in concentrations from 16-25% by volume is explosive. Also, concentration above
1500 ppm can be lethal or produce serious injury. Please reference and become
familiar with the contents of the Safety Data Sheet (SDS) for Liquid Anhydrous
Ammonia.
Health Hazards:
Precautions,
Engineering and
Administrative
Controls to Prevent
Exposure
Skin Contact Damages all body tissue, causes caustic burn, dehydration burn or
freeze burn.
Eyes Chemical splash goggles approved for use with ammonia and / or full-face
shield.
Other Emergency eyewash stations and deluge showers available and operational,
emergency response contacts and telephone numbers posted.
Screw Compressor
Page 3 of 30
Procedure
date.
Follow individual isolation and pump out procedures for the equipment before
performing any maintenance requiring that the equipment be opened up to atmosphere.
Tools and Equipment Needed
Personal Protective
Equipment (PPE):
Maintenance Schedule
Ammonia checklist
Valve stem wrench
Crescent wrench
Pipe wrench
Channel locks
Torque Wrench
Gauge (in cabinets)
Hose (on wall)
PPE
Ammonia Gloves
Face Shield or
Respirator (if needed)
Wear rubber gloves, respirator, apron and goggles when performing work where
there is the potential for ammonia to be released.
Skin- Approved chemical resistant gloves and protective clothing. Goggles and face
shield if warranted.
Hazmat Quick Response Steps
1. Gauge ammonia level by scanning Manning Panel (use location given as point
of reference)
2. 2 Person response
3. Grab meter
4. If Manning Panel is already over 35PPM bring a meter with response
5. Grab jump kit of tools in the Engine Control Room
PPM
35 ppm 300 ppm - Use a respirator
>300 ppm - Use an SCBA, even in engine room
>1500 ppm - Use level A suit
Screw Compressor
Page 4 of 30
Procedure
Tool Jump Kit Location
Hazmat Cabinet
Engine Control Room
Top of Stairs to the Roof
Control Measures if
Physical Exposure
Occurs:
Control of Hazardous
Material Inventory
Ingestion Do not induce vomiting. Have the victim drink large quantities of water
if conscious.
Special or Unique
Hazards
For each shipment, verify quantity received and review SDS and Bill of Lading to
ensure quality (Refrigeration Grade Anhydrous Ammonia).
Special or Unique Hazards Related to the Operation of the Anhydrous Ammonia
System:
Slips, Trips & Falls - Proper housekeeping practices are necessary to keep floors
near refrigeration compressors free of oil to prevent slips, trips and falls.
Machine Guarding Fan blades and rotating shafts can cause lacerations and pinch points.
Screw Compressor
Page 5 of 30
Procedure
Safety Issues
See Safety Issues in Book 3.3 Standard Operating Procedures Section 18 for detailed safety information.
OSHA does require that you adhere to Pipe Breaking Regulations. Ben & Jerrys does have a pipe
breaking program and permit process when breaking ammonia lines. A risk assessment has been
completed for breaking ammonia pipe lines. To review the Pipe Breaking program, print a permit, or
review the risk assessment, follow the electronic path provided.
/var/www/apps/conversion/tmp/scratch_7/335856351.doc
Type of energy to
be locked out
Electrical
Mechanical
Electrical
Mechanical
Electrical
Mechanical
Electrical
Mechanical
Electrical
Mechanical
Electrical
Mechanical
Electrical
Mechanical
Location of isolation
East Wall, Disconnect labeled COMPRESSOR #1
Discharge valve RCB1-1 suction valve RCB1-2 on compressor
East Wall, Disconnect labeled COMPRESSOR #2
Discharge valve RCB2-1 suction valve RCB2-2 on compressor
South Wall, Disconnect labeled COMPRESSOR #3
Discharge valve RCB3-1 suction valve RCB3-2 on compressor
South Wall, Disconnect labeled COMPRESSOR #4
Discharge valve RCB4-1 suction valve RCB4-2 on compressor
South Wall, Disconnect labeled COMPRESSOR #5
Discharge valve RC1-1 suction valve RC1-2 on compressor
South Wall, Disconnect labeled COMPRESSOR #6
Discharge valve RC2-1 suction valve RC2-2 on compressor
South Wall, Disconnect labeled COMPRESSOR #7
Discharge valve RC7-1 suction valve RC7-2 on compressor
Screw Compressor
Page 6 of 30
Procedure
Safety Features
1. Oil separator 250 psi relief valve
2. Oil pressure failure cutout
3. High discharge pressure cutout
4. High discharge temperature cutout
5. Low discharge temperature cutout
6. Low oil temperature cutout
7. Motor overload relay
8. Shaft coupling guard
OPERATING PHASES
Phase
Conditions
Initial Startup
Before startup of facility or modified system.
Normal Startup
Normal startup of equipment.
Normal Operations
Automatic operation and monitoring.
Temporary
Special conditions other than normal
Operations
operations.
Emergency Shutdown Exceeding design specifications; NH3 release.
Emergency
Specific procedures during emergency
Operations
situations.
Normal Shutdown
Shutdown of equipment expected under normal
operating conditions.
Startup Following a
Re-starting the equipment other than automatic
Turnaround, or After
mode.
an Emergency
Shutdown
Responsibility
Qualified Technician
Qualified Technician
Qualified Technician
Qualified Technician
Qualified Technician
Qualified Technician
Qualified Technician
Qualified Technician
Screw Compressor
Page 7 of 30
Procedure
All required items under operating procedures must be completed before commissioning equipment.
Setup for initial start of the condensers by SOP-2 and evaporator by SOP-5 before performing this
SOP-1 compressor is required.
1. Check compressors oil level. Oil level should be: Maximum, in the middle of the top sight glass during
shutdown. Minimum-middle of bottom sight glass during shutdown.
Valve Position
Open
Open
Open
Open
Open
Open
Open
Valve #
RC-X-B
RC-X-C
RC-X-D
RC-X-E
RC-X-F
RC-X-G
RC-X-H
Valve Position
Closed
Closed
Closed
Closed
Open
Open
Open
Valve #
RC-X-R
RC-X-S
RC-X-T
RC-X-U
RC-X-V
RC-X-W
RC-X-X
Valve Position
Closed
Closed
Closed
Open
Closed
Closed
Open
Screw Compressor
Page 8 of 30
Procedure
RC-X-8
Check Valve
RC-X-9
Open
RC-X-10
Open
RC-X-11
Check Valve
RC-X-12
Open
RC-X-13 Pressure Relief - Auto
RC-X-14
Open
RC-X-15 Pressure Relief - Auto
RC-X-A
Closed
RC-X-I
RC-X-J
RC-X-K
RC-X-L
RC-X-M
RC-X-N
RC-X-O
RC-X-P
RC-X-Q
Open
Open
Open
Open
Closed
Non-Existent
Open
Closed
Closed
RC-X-Y
RC-X-Z
RC-AA
RC-BB
RC-CC
RC-DD
RC-X-EE
RC-FF
RC-GG
Open
Open
Open
Open
Open
Open
Open
Open
Closed
Initial Startup Valve Positions for Compressor Booster RCB-1 through RCB-4 (X=1, 2, 3 or 4)
Valve #
Valve Position
RCB-X-1
Open
RCB-X-2
Open
RCB-X-3
Open
RCB-X-4
Open
RCB-X-5
Open
RCB-X-6
Open
RCB-X-7
Open
RCB-X-8
Open
RCB-X-9
Open
RCB-X-10
Open
RCB-X-11
Open
RCB-X-12
Open
RCB-X-13 Pressure Relief - Auto
RCB-X-14
Open
RCB-X-15 Pressure Relief - Auto
RCB-A
Closed
Valve #
RCB-B
RCB-C
RCB-D
RCB-E
RCB-F
RCB-G
RCB-H
RCB-I
RCB-J
RCB-K
RCB-L
RCB-M
RCB-N
RCB-O
RCB-P
RCB-Q
Valve Position
Closed
Closed
Closed
Closed
Open
Open
Open
Open
Open
Open
Open
Closed
Closed
Open
Closed
Closed
Valve #
RCB-R
RCB-S
RCB-T
RCB-U
RCB-V
RCB-W
RCB-X
RCB-Y
RCB-Z
RCB-AA
RCB-BB
RCB-CC
RCB-DD
RCB-EE
Valve Position
Closed
Closed
Closed
Open
Closed
Closed
Non-Existent
Open
Non-Existent
Check Valve
Check Valve
Check Valve
Closed RCB 1 Only
Check Valve
Valve Position
Open
Open
Open
Open
Non-Existent
Non-Existent
Open
Open
Open
Valve #
RC-7-C
RC-7-D
RC-7-E
RC-7-F
RC-7-G
RC-7-H
RC-7-I
RC-7-J
RC-7-K
Valve Position
Closed
Closed
Closed
Open
Open
Open
Open
Open
Open
Valve #
RC-7-T
RC-7-U
RC-7-V
RCB-W
RCB-X
RCB-Y
RCB-Z
RCB-AA
RCB-BB
Valve Position
Closed
Open
Closed
Closed
Non-Existent
Open
Non-Existent
Check Valve
Check Valve
Screw Compressor
Page 9 of 30
Procedure
RC-7-10
RC-7-11
RC-7-12
RC-7-13
RC-7-14
RC-7-15
RC-7-A
RC-7-B
Open
Check Valve
Open
Pressure Relief - Auto
Open
Pressure Relief - Auto
Closed
Closed
RC-7-L
RC-7-M
RC-7-N
RC-7-O
RC-7-P
RC-7-Q
RC-7-R
RC-7-S
Open
Closed
Check Valve
Open
Closed
Closed
Closed
Closed
RCB-CC
RCB-DD
RCB-EE
RC-FF
RC-GG
Check Valve
Closed RCB 1 Only
Check Valve
Check Valve
Closed
Normal Startup
Depress the EXTERNAL pushbutton. This allows the machine to be controlled by the PLC sequencer that
will allow the machine to control capacity.
2. In the event of a computer failure, switch compressor control from remote to local.
3. Press the remote start button. This will allow for the compressor to be sequenced by an auxiliary control in the
PLC and enable the compressor to start depending on the set up. From this point the startup sequence will be
automatic and the following will occur:
A. If the compressor was started previously within the anti-recycle time delay period, ANTIRECYCLE
will be displayed. The compressor start will be delayed until the anti-recycle timer has completed its
timing cycle (20 minutes).
B. If the compressor has not been started recently or the anti-recycle timer has timed out the
following will occur simultaneously:
The oil pump will start and establish oil pressure. Oil pressure must be established within 20 seconds or
the startup sequence will terminate and the compressor will not start.
START DELAY will be displayed. The startup time delay allows time for the oil pump to build oil
pressure and for the slide valve to move to the unload position (less than 5%)
1.
UL (unload) will be displayed and will remain on until the load delay period has expired, and the
capacity control has caused the compressor slide valve to load.
PH ON (preheat on) will be replaced by PH OFF (preheat off).
4. Once the compressor slide valve has reached less than 5% and the oil pressure has been established the
following will occur:
A. The compressor will start
B. START DELAY will be replaced by LOAD DELAY or 10 seconds during which UL will be
displayed.
C. The elapsed time meter will start timing to display compressor operating hours, as soon as LOAD
DELAY is displayed.
5. The compressor will now operate automatically. The capacity controller will cause the compressor slide valve
to load and unload to maintain the desired system pressure or temperature.
Normal Operation
1. Ensure that the system conditions will allow a safe startup.
Document Name: Screw Compressor- DRAFT
Document Owner: Maintenance Manager
Revision No: 2.8 November 4, 2014
Supersedes: February 11, 2013
Path & Filename: http://teamsites.unilever.com/collab/VMPS/03 Standard Operating Procedures/W/Screw Compressor
SOP.doc
The contents of this page are proprietary and shall be considered Unilever Confidential
Screw Compressor
Page 10 of 30
Procedure
2. Depress EXTERNAL capacity control button.
3. Press the REMOTE START button.
4. The start sequence will now be automatic.
Normal Shutdown Sequence
It is recommended that the compressor is first unloaded before shutdown. The normal shutdown sequence, when
not in computer control is initiated by pressing the STOP/RESET button. This will cause the following:
Temporary Operation
The swing compressor (compressor #7) is normally set up to run as a high stage (+12) compressor. It may also run
as a low stage (-38 or 50) booster. Listed below are the steps taken to make the change over.
A. Changing from a +12 compressor to a 38 booster
1. Lock out and tag out the compressor at the disconnect.
2. Close valve Incl-1-28 located above compressor #7.
3. Open valve PR-2-54 above and between compressors #1 and #2.
4. Change parameters of compressor #7. A list of the parameters are in blue book on book shelf in
engine room. Refer to and enter the parameters for the 38 booster.
5. 5. Unlock the disconnect and restore power to the compressor.
6. Start the compressor and assure it is running properly.
B. Changing from a +12 compressor to a 50 booster
1. Lock out and tag out the compressor at the disconnect.
2. Close valve Incl-1-28 located above compressor #7.
3. Open valve PR-1-54 above and between compressors #1 and #2.
4. Change parameters of compressor #7. A list of the parameters are in blue book on book shelf in
engine room. Refer to and enter the parameters for the 50 booster.
5. Unlock the disconnect and restore power to the compressor.
6. Start the compressor and assure it is running properly.
C. Changing from a -50 booster to a +12 compressor
1. Lock out and tag out the compressor at the disconnect.
2. Close valve PR-1-54 located above and between compressors #1 and #2.
3. Open valve Incl-1-28 above compressor #7.
4. Change parameters of compressor #7. A list of the parameters are in blue book on book shelf in
engine room. Refer to and enter the parameters for the +12 compressor.
5. Unlock the disconnect and restore power to the compressor.
6. Start the compressor and assure it is running properly.
Document Name: Screw Compressor- DRAFT
Document Owner: Maintenance Manager
Revision No: 2.8 November 4, 2014
Supersedes: February 11, 2013
Path & Filename: http://teamsites.unilever.com/collab/VMPS/03 Standard Operating Procedures/W/Screw Compressor
SOP.doc
The contents of this page are proprietary and shall be considered Unilever Confidential
Screw Compressor
Page 11 of 30
Procedure
D. Changing from a -38 booster to a +12 compressor
1. Lock out and tag out the compressor at the disconnect.
2. Close valve PR-2-54 located above and between compressors #1 and #2.
3. Open valve Incl-1-28 above compressor #7.
4. Change parameters of compressor #7. A list of the parameters are in blue book on book
shelf in engine room. Refer to and enter the parameters for the +12 booster.
5. Unlock the disconnect and restore power to the compressor.
6. Start the compressor and assure it is running properly
Screw Compressor
Page 12 of 30
Procedure
8. To service oil filters and screens, follow steps 7-11.
9. Close the oil filter inlet valve and oil filter outlet valve. Numbered RCB-X-3, 4.
10. Close off all remaining oil valves # RCB-X-5, 6, 7, 8, 10, 11 & 14. Also, close lettered valves F, O, K, L.
11. To remove the filters, crack the drain valve (letter B) and let the oil drain into a bucket. When the oil flow
stops remove all but two cover bolts, back last two bolts out slightly, tap cover to break seal, and let remaining
oil flow into a bucket. When the oil stops flowing remove the cover. Remove the nut and washer then
reach in removing the retainer, filter, spacer, and final filter.
12. When reinstalling the screen make sure the hole faces the bottom, and the o-ring in the cover is not damaged.
Install the cover and tighten the bolts to 40ft. lbs. Close the drain valve.
13. Wipe out the housing and install filter, spacer, another filter, retainer, washer and nut. Check o-ring in cover
and reinstall. Tighten covering bolts to 40ft. Lbs. Close the drain valve (letter B).
14. Replace oil through valve M. The oil shall be fill between the two sight glasses on the side of the compressor.
These sight glasses on drawing on the print.
15. Clean and check valve strainer located just after valve K.
16. Open all valves and check for leaks. Close oil pump dip switch to start the machine.
17. Restart compressor.
ISOLATING COMPRESSORS FOR SERVICE - +12 suction
Screw Compressor
Page 13 of 30
Procedure
15. Replace oil through valve M with the oil pump located next to the waste oil tank. The oil should be filled
between the two sight glasses on the side of the compressor. These sight glasses are drawn on the print.
16. When replacing the oil strainer, be careful of any pressure that was trapped in the line. Slowly loosen the
cover letting excess oil drain into a bucket or pan. Remove the cover draining off oil in the cover into a
bucket. Be sure to inspect the gaskets condition, if necessary replace the gasket with a new one. Tighten the
oil strainer cover to 25ft.lbs.
17. Clean and check the valve strainer located just after valve K.
18. Open all valves and check for leaks. Close oil pump dip switch to start the machine.
19. Restart compressor.
1. ALWAYS start the high side (+12 suction) compressors first. RC-5, RC-6, or RC-7.
2. Clear failures by pressing the reset buttons (hold for a few seconds) on the door of FES-1 PLC cabinet in the
control room. a. Pump receiver #2 reset
b. Pump receiver #1 reset
c. Alarm silence reset
d. Intercooler reset
3. Go to the failed compressor or booster Micro Control Panel press the change display button four times or
until the screen reads Failure Annunciator with the cause of the failure listed below it. (Example: Aux.
Safety) Do the following:
a. Press STOP/RESET button
b. Failure will flash
c. Press clear button
d. Failure will disappear
e. Press CHANGE DISPLAY button until you return to the home screen
f. Press LOCAL START and manually load the compressor/booster. Gradually, using the HOLD button and
approximately 25% of the slide valve until the machine is fully loaded. At this time push REMOTE START and
the EXTERNAL CONTROL so the computer will take over the compressor/booster operation.
Document Name: Screw Compressor- DRAFT
Document Owner: Maintenance Manager
Revision No: 2.8 November 4, 2014
Supersedes: February 11, 2013
Path & Filename: http://teamsites.unilever.com/collab/VMPS/03 Standard Operating Procedures/W/Screw Compressor
SOP.doc
The contents of this page are proprietary and shall be considered Unilever Confidential
Screw Compressor
Page 14 of 30
Procedure
Description
RC-X-1
RC-X-2
RC-X-3
Discharge valve
Low side suction valve
High pressure liquid valve to oil cooler from
thermosiphon
Discharge valve on oil cooler back to
thermosiphon
Oil cooler shutoff valve before Amot valve
and oil cooler
Oil cooler shutoff valve between separator and
Amot valve
Oil filter shutoff valve
Oil check valve to compressor
RC-X-4
RC-X-5
RC-X-6
RC-X-7
RC-X-8
RC-X-9
RC-X-10
RC-X-11
RC-X-12
RC-X-13
Valve
Size /
Model
3" Angle
6" Angle
11/2" Globe
Manufacturer
General
Location
Danfoss
Danfoss
Hansen
Engine Room
Engine Room
Engine Room
3" Globe
Hansen
Engine Room
11/2" Angle
Danfoss
Engine Room
2" Globe
Danfoss
Engine Room
2" Angle
/4" 2-bolt
flange
CK4A
3
/4" A4AL
3
/4" Ball
2" CK4A
3
/4 x 1"
1
/2 x 3/4"
3
/4" Globe
1/2"
SS80221
1
/2" Angle
1
/2" Angle
3
/8" Angle
3
/8" Angle
1
/2" Angle
3
/4" Ball
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
1
/2" Ball
3
/4" Ball
3
/8" Angle
Danfoss
Engine Room
Refrigeration Specialties Engine Room
Refrigeration Specialties
Watts
Refrigeration Specialties
Hansen H5602 768scfm
Hansen H5600 768scfm
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Henry
Reg-o
Engine Room
Engine Room
Henry
Henry
Henry
Henry
Henry
Watts
Henry
Henry
Henry
Henry
Watts
Watts
Henry
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Screw Compressor
Page 15 of 30
Procedure
RC-X-O
RC-X-P
RC-X-Q
RC-X-R
RC-X-S
RC-X-T
RC-X-U
RC-X-V
RC-X-W
RC-X-X
RC-X-Y
RC-X-Z
RC-AA
RC-BB
RC-CC
RC-DD
RC-EE
RC-FF
RC-GG
/2" Ball
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
1
/4" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
5
/8" HCK4
3
/4" CK4A
1
/2" Globe
2" 73041139K
21931
6"
3
/8" Angle
3
Watts
Henry
Henry
Henry
Henry
Henry
Henry
Henry
Henry
Henry
Henry
Henry
Henry
Refrigeration Specialties
Refrigeration Specialties
Wolf Linde
Refrigeration Specialties
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Description
Valve Size /
Model
3" Angle
6" Angle
1-1/4" Globe
Manufacturer
Discharge valve
Danfoss
Low side suction valve
Danfoss
High pressure liquid valve to oil cooler
Hansen
from thermosiphon
Discharge valve on oil cooler back to
2-1/2" Globe
Hansen
thermosiphon
Oil separator shutoff valve
11/2" Angle
Danfoss
Oil cooler shutoff valve
2" Globe
Danfoss
Oil filter shutoff valve
2" Angle
Danfoss
Oil strainer shutoff valve between separator 2" Angle
Danfoss
and strainer
Oil pressure differential valve
1" A4AL Refrigeration Specialties
3
Bearing lube oil supply valve
/4" Ball
Watts
Oil supply to balance piston valve
1" Ball
Watts
3
Oil separator pressure relief valve 250 psi
/4" x 1"
Hansen H5602
w/ 3 way
General
Location
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Screw Compressor
Page 16 of 30
Procedure
RCB-X-13
RCB-A
RCB-B
RCB-C
RCB-D
RCB-E
RCB-F
RCB-G
RCB-H
RCB-I
RCB-J
RCB-K
RCB-L
RCB-M
RCB-N
RCB-O
RCB-P
RCB-Q
RCB-R
RCB-S
RCB-T
RCB-U
RCB-V
RCB-W
RCB-X
RCB-Y
RCB-Z
RCB-AA
RCB-BB
RCB-CC
RCB-DD
RCB-EE
RCB-X-14
RCB-X-15
/2" x 3/4"
Hansen H5600
Engine Room
/4" Globe
1/2"
SS80221
1
/2" Angle
1
/2" Angle
3
/8" Angle
3
/8" Angle
1
/2" Angle
3
/4" Ball
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/4" Angle
1
/2" Ball
3
/4" Ball
3
/8" Angle
1" Angle
1
/2" Ball
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
1
/4" Angle
3
/8" Angle
Henry
Reg-o
Engine Room
Engine Room
Henry
Henry
Henry
Henry
Henry
Watts
Henry
Henry
Henry
Henry
Watts
Watts
Henry
Wolf Linde
Watts
Henry
Henry
Henry
Henry
Henry
Henry
Henry
Henry
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
/2" Globe
/2" Globe
3
/4" CK4A
w/ 2 bolt
flange
5
/8" ACK4
2" 7304 1139K
21931
1" Angle
6"
1
Wolf Linde
Engine Room
Wolf Linde
Engine Room
Refrigeration Specialties Engine Room
Refrigeration Specialties Engine Room
Refrigeration Specialties Engine Room
Hansen
Engine Room
Refrigeration Specialties Engine Room
Screw Compressor
Page 17 of 30
Procedure
Description
Valve Size /
Model
Discharge valve
3" Angle
Low side suction valve
6" Angle
High pressure liquid valve to oil cooler from 1-1/2" Globe
thermosiphon
Discharge valve on oil cooler back to
3" Globe
thermosiphon
Non-Existent
Non-Existent
Oil filter shutoff valve
2" Angle
Oil cooler shutoff valve between separator
2"
and cooler
3
Oil pressure differential regulator
/4" A4AL
3
Oil filter shutoff valve
/4" Ball
3
Oil check valve to compressor
/4" 2-bolt
flange
CK4A
3
Pressure relief valve 250 psi w/3way
/4 x 1"
1
Oil cooler pressure relief valve 250 psi
/2 x 3/4"
w/3way
3
Oil metering valve
/4" Globe
Thermo relief on oil cooler, Hydrosttic Relief
1/2"
400 psi
SS80221
1
Oil cooler drain (oil)
/2" Angle
1
Oil cooler drain (NH3)
/2" Angle
3
Oil separator Drain
/8" Angle
3
Oil filter drain
/8" Angle
1
Oil header drain
/2" Angle
3
Main oil injector valve
/4" Ball
3
Oil supply to load solenoid valve
/8" Angle
3
Oil supply to load cylinder valve
/8" Angle
3
Oil supply to unload cylinder valve
/8" Angle
3
Bleed to suction valve
/8" Angle
1
Liquid to strainer shutoff valve
/2" Ball
3
Differential regulator return valve
/4" Ball
3
Oil fill valve
/8" Angle
Oil Check valve for oil filter
2" CK4A
Manufacturer
Danfoss
Danfoss
Hansen
General
Location
Engine Room
Engine Room
Engine Room
Hansen
Engine Room
Danfoss
Danfoss
Engine Room
Engine Room
Engine Room
Engine Room
Henry
Reg-o
Engine Room
Engine Room
Henry
Henry
Henry
Henry
Henry
Watts
Henry
Henry
Henry
Henry
Watts
Watts
Henry
Refrigeration Specialties
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Screw Compressor
Page 18 of 30
Procedure
RC-7-O
RC-7-P
RC-7-Q
RC-7-R
RC-7-S
RC-7-T
RC-7-U
RC-7-V
RC-7-W
RC-7-X
RC-7-Y
RC-7-Z
RC-AA
RC-BB
RC-CC
RC-DD
RC-EE
RC-FF
RC-GG
Check on suction
Suction By-pass
/2" Ball
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/4" Angle
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
3
/8" Angle
5
/8" HCK4
3
/4" CK4A
1
/2" Globe
2" 73041139K
21931
6"
3
/8" Angle
3
Watts
Henry
Henry
Henry
Henry
Henry
Henry
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Henry
Henry
Henry
Henry
Henry
Henry
Refrigeration Specialties
Refrigeration Specialties
Wolf Linde
Refrigeration Specialties
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Engine Room
Screw Compressor
Page 19 of 30
Procedure
Checklist - 1
Screw Compressor
Page 20 of 30
Procedure
Checklist - 2
Screw Compressor
Page 21 of 30
Procedure
Suction +12F
Suction By Pass
HSD to
Condensers
RC-5-3
Control
Panel
Gage
Ports
RC-5-10
Differential
Pressure
Regulator
RC-5-9
Oil Filter
RC-5-7
Oil Pump
Oil Level
Oil Level
Legend (Examples)
Valve
RC-5-??
Direction of Flow
Hot Gas
Gas
Hot
Type of Line
Document Name: Screw Compressor- DRAFT
Document Owner: Maintenance Manager
Revision No: 2.8 November 4, 2014
Supersedes: February 11, 2013
Path & Filename: http://teamsites.unilever.com/collab/VMPS/03 Standard Operating Procedures/W/Screw Compressor
SOP.doc
The contents of this page are proprietary and shall be considered Unilever Confidential
Screw Compressor
Page 22 of 30
Procedure
Suction +12F
RC-5-2
RC-5-3
RC-M
RC-5-4
RC-5-1
Oil Cooler
RC-5-6
Legend (Examples)
Valve
RC-5-??
Direction of Flow
Document Name: Screw Compressor-Type
DRAFTof Line
Document Owner: Maintenance Manager
Revision No: 2.8 November 4, 2014
Supersedes: February 11, 2013
Path & Filename: http://teamsites.unilever.com/collab/VMPS/03 Standard Operating Procedures/W/Screw Compressor
SOP.doc
The contents of this page are proprietary and shall be considered Unilever Confidential
Screw Compressor
Page 23 of 30
Procedure
Hot Gas
RC-7-2
RC-7-3
RC-7-4
Amot Valve
Oil Cooler
Legend (Examples)
Valve
RC-7-??
Screw Compressor
Page 24 of 30
Procedure
Hot Gas
RC-7-N
Oil Pump
Oil Filter
Control
Panel
Legend (Examples)
Valve
RC-7-??
Direction of Flow
Screw Compressor
Page 25 of 30
Procedure
Hot Gas
Separator
RCB-1-1
Suction 50F
PR-1
RCB-1-2
RCB-1-4
Oil Cooler
RCB-1-3
Legend (Examples)
Document Name: Screw Compressor- DRAFT
Document Owner: Maintenance Manager
Valve
RCB-1-??
Revision No: 2.8 November 4, 2014
Supersedes:
February 11, 2013
Path & Filename: http://teamsites.unilever.com/collab/VMPS/03 Standard Operating Procedures/W/Screw Compressor
SOP.doc
Direction of Flow
The contents of this page are proprietary and shall be considered Unilever Confidential
HotGas
Gas
Hot
Type of Line
Screw Compressor
Page 26 of 30
Procedure
Oil Filter
Oil Pump
Control
Panel
Screw Compressor
Page 27 of 30
Procedure
Legend (Examples)
Valve
RCB-1-??
Direction of Flow
-10-??
(RED)
S
Type of Line
-38/-50F
SUCTION
Hot Gas
NC
SERVICE VALVE RCB-V
RCB-X-2
SUCTION
STRAINER
THERMOMETER
SUCTION BYPASS
NC
4T
COMPRESSOR
C19
SITE GLASS
LOAD
INCR
VI
C11
C12
LOW STAGE
DISCHARGE
C4
C15
C16 C10
C22
C9
C8
C3
RCB-X-1
BLEED RCB-J
3T
THERMOMETER
LOAD RCB-I
NC
D
OIL SEPERATOR
UNLOAD
(3 SOL)
LOAD
(2 SOL)
RCB-X
1T
RCB-X-8
NC
STRAINER RCB-K
DIFFERENTIAL PRESSURE
REGULATOR
RCB-X-9
HIGH PRESSURE LIQUID
AMMONIA
INLET RCB-X-3
RCB-DD
OIL
PUMP
MAIN OIL INJECTION RCB-F
RCB-X-14
NC
METERING VALVE RCB-Z
THERMOMETER
MICROPROCESSOR
CONTROL PANEL
DRAIN RCB-C
ONLY ON
#1
COMPRESSOR
HYDROSTATIC
RELIEF VALVE
RCB-X-15
LIQUID/VAPOR
AMMONIA
OUTLET RCB-X-4
LIQUID
INLET
RCB-X-11
00
OIL FILTER
OIL HEADER
1TD
2TD
3TD
4TD
2T
5TD
NC
DRAIN RCB-D
OO
10
TEST POINTS P, Q, R, S, T
10
RCB-X-6
RCB-X-5
RCB-X-7
IN LINE
STRAINER
(BETWEEN
FLANGES)
DRAIN RCB-E
Screw Compressor
Page 28 of 30
Procedure
(RED) RC-U
S
+12F
SUCTION
NC
RC-N
SUCTION
STRAINER
RC X-2
THERMOMETER
NC
SUCTION BYPASS
NC
4T
RC-W
RC-AA
C20
RC-DD
RC-O
COMPRESSOR
C19
SITE GLASS
LOAD
INCR
VI
C11
C12
HIGH STAGE
DISCHARGE
C4
C15
C16 C10
C22
C9
C8
C3
B
A
RC-Y
RC-1-X
RC-X
RC-I
3T
RC-EE
RC-Z
THERMOMETER
RC-H
RC-J
UNLOAD
(5 SOL)
X
P
DEC VI
INCR VI
OIL SEPERATOR
A
(14 SOL)
X
P
UNLOAD
(3 SOL)
LOAD
(2 SOL)
UNLOAD
(16 SOL)
X
RC-C
1T
NC
RC-L
RC-X-8
RC-K
RC-CC
DIFFERENTIAL PRESSURE
REGULATOR RC X-9
RC-BB
RC-F
HYDROSTATIC
RELIEF VALVE RC-X-15
RC X-14
LIQUID/VAPOR
AMMONIA
OUTLET RC-X-4
THERMOMETER
RC X-11
LIQUID
INLET
MICROPROCESSOR
CONTROL PANEL
RC X-10
RC X-8
00
OIL FILTER
2T
1TD
2TD
3TD
4TD
OO
5TD
RC-G
NC
RC-D
10
RC-B
10
SERVIVE POINTS P, Q, R, S, T
RC-A
PART TIME
OIL PUMP
RC-X-5
RC-X-6
C
A
RC-X-7
RC-E
IN LINE
STRAINER
(BETWEEN
FLANGES)
Screw Compressor
Page 29 of 30
Procedure
70 PSIG
70 PSIG
70 PSIG
70 PSIG
70 PSIG
70 PSIG
Hot Gas
70 PSIG
Booster Discharge
70 PSIG
Screw Compressor
Page 30 of 30
Procedure
Definitions:
RCB: Tag given to Booster compressors
RC: Tag given to high side compressors
Compressor: A specific machine used to compress refrigerant.
Compressor Booster: A compressor for very low pressures, usually discharging into the suction line of another
compressor, after the discharge gas is de-superheated.
Initial Startup: procedures for starting a piece of equipment after its initial installation or replacement of the
equipment.
Normal Startup: at any point after installation, procedures to be followed when starting a piece of equipment
under controlled circumstances.
Normal Shutdown: procedures to be followed to carefully and safely shut down a piece of equipment for
maintenance or schedule downtime.
Temporary Operation: procedures to be followed on a temporary basis for the equipment, if applicable.
Emergency Shutdown: procedures to be following in the event of an emergency or ammonia leak requiring this
piece of equipment to immediately cease operation.
Emergency Operation: operation of a piece of equipment during an emergency situation.
Startup after Emergency Shutdown: following a normal or emergency shutdown situation, the equipment
would be restarted following the same procedures as normal startup.