INSTALLATION CHECKS
(A) CRANKSHAFT RUSTING OCCURRING IN THE FIELD
(I) It is found that during installation/pressure testing stage, the
site staff use lot of soap-water at shaft seal area. As stationary
seal cover and bronze ring of 'Seal Assembly' has greater
inner-diameter, soap water reaches and accumulates in this
space. If this water is not blown-off, the crankshaft rusting can
take place.
To prevent this, blow compressed air and then pour sufficient,
clean refrigeration oil in seal cover, crankshaft and rotate the
crankshaft manually so that oil reaches inner area adequately.
If this is done, crankshaft rusting can be prevented.
(ii) Rust preventive oil applied on Crank shaft taper during
despatch of compressor, should be removed during
coupling/flywheel fitment only. If this rust oil is removed earlier,
rusting will occur and affect taper fitment of mating parts.
(B) COUPLING/FLYWHEEL/MOTOR PULLEY FITMENT
Use oil on mating surfaces. Do not fit dry. Ensure correct key size &
its fitment. Key should be push fitin side ways and there should be
gap above key top when fitted on mating parts, ie. flywheel motor
pulley and coupling.
For fitment on taper diameters :
(i) Fit flywheel/coupling half on compressor shaft without key
check fitment depth from face of crankshaft and flywheel or
coupling half face.
(ii) Refit flywheel/coupling with key fitment depth should be same
as checked in (i) above. After fitment of flywheel/coupling, fit
retainer plate and ensure full tightening of bolt/screws on
crankshaft, pour oil on threads of bolts/screws, for smooth
fitment and rust prevention.
During tightening crankshaft/flywheel/coupling will rotate.
Hence flywheel/ coupling should be locked mechanically and
after ensuring full tightness of bolts/screws. Remove this
mechanical lock and check free rotation of compressor
crankshaft. If this is not done damage will occur to keyway of
crankshaft/coupling or flywheel bore/the key and may result in
crankshaft breakage.
For fitment on parallel shaft
(i) Fitment of motor pulley/coupling half on motor shaft should be
tight (diametrically and there should be a gap of 1 to 1.5 mm
above key top, after the motor pulley/coupling half is fitted on
motor shaft.
Fit retainer plate and centre bolt to lock the motor
pulley/coupling half axially on motor shaft.
(B) BASE FRAME :
(i) Only KPCL supplied base frame should be used. Ensure
correct base frame is received at site (as per motor frame size
informed while placing your order.) Foundation should be
done as per KPCL recommendations/foundation layout
drawings provided.
(ii) Levelling of base frame should be done.correctly.
(iii) Foundation studs for base frame fitment and for compressor
mounting on base frame should be separate i.e., Do not use
the same stud for foundation, base frame and compressor.
For compressor fitment on base frame use separate bolts,
nuts, plain and spring washers, Ensure sufficient bolt length
so that all thread of nuts are utilised after fitment of plain and
spring washers.
(iv) Foundation grouted bolts/studs should be cast vertically/right
angle to floor face as slant bolts/stunds will result in little or no
face-contact of nuts on base-frame channel.
Slant bolt/studs will have to be corrected as the bolt/studs will
break-off in the foundation during nut tightening or excessive
vibrations on compressor assembly will occur during running.
To take care of above, the foundation studs/bolts should be set
accurately. Inconcrete flooting, pipe sleeves of at least one
pipe Size larger than the bolt/stud diameter should be slipped
over the bolts/studs and cast in place. This will facilitate
adjustment of bolts/studs centres after the foundation has set
thus simplifying installation.
(v) Ensure full tightness of base frame to foundation after allowing
sufficient curing time of concrete.
(vi) Mount compressor on base frame, level it correctly and fix
compressor by nuts, bolts, plain and spring washers. Ensure
full tightness of all bolts and nuts. Wherever channel base
frames are used, use taper washers.
(vii) Align motor and compressor axis accurately with in 0.1 to 0.20
mm by dial indicator. During alignment work ensure suction
and discharge pipe line of compressor are not strained, so that
further connection should not be forced. Generally
compressor should be kept in position, and motor should be
moved axially, transversely or vertically.
(viii) For self driven compressor align flywheel and motor pulley
and ensure no-axial-pull exists on compressor crankshaft
after mounting belts and checking their tension.
If axial pull exists, then wear of main bearing of crankshaft will
be faster excessive and can cause premature failure /
breakage of the crankshaft.
(ix) After alignment and fitment of coupling/belts/solenoid valves,
gauges etc. fill compressor with clean specified refrigeration
oil up to required level and conduct air-run test for 10 minutes,
observe oil pressure, abnormal noise, local overheating, oil
return, loading/unloading of direct cylinder, vibration etc.
(D) STOP VALVES
We are using TAL Valves for suction and discharge side of com-
pressors as per the model. There are six types: TAL-32, 40, 50, 70,
80 & 100.
In the Top Housing we have fitted Teflon Gland Rope size 5mm x
5mm square for sealing refrigerant leakage through spindle. This
rope is below Gland Bush fitted with four screws, on top face
housing.
After completing erection/fitment of these valves in pipe lines and
before pressure testing entire system by Nitrogen gas, please fill
sufficient quantity of clean refrigerant oil in this gland rope. Oil can be
poured by loosening four screws and then retightening.
This is required as the gland rope can become dry by the time
erection work is completed at site.
(E) PIPING
(1) While connecting piping from compressor to other equipment,
please ensure that there are no undesirable stresses. All the
bolts between connecting flanges should be inserted
smoothly without pulling or pushing the pipes : abnormal
stresses on compressor would lead to severe vibration and
consequent compressor damage.
(2) Ensure that all pipes are thoroughly cleaned from inside
before installation: this will avoid dirt entering in to compressor
and resulting in costly damage to equipment.
(F) LIQUID FLOODBACK DURING OFF CYCLE :
On R12/R22 installation, insist upon crankcase heater to avoid
foaming at startup leading to lubrication failure.
(G) GENERAL PRECAUTIONS :
(1) Avoid hydraulic testing of heat exchangers and pressure
vessels, because it invariably leaves water in the vesse1s,
and on starting the plant, water frequently enters the
compressor, expansion valves and chokes driers.
(2) It is preferable to install an hour meter to know exact running
hour of equipment and to ensure timely preventive
maintenance.
IMPORTANT
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