JOHNSON CONTROLS
21
SECTION 2 - PRE-STARTUP AND SYSTEM OPERATING PROCEDURES
FORM 160.67-O2
ISSUE DATE: 10/9/2020
2
Once the mylar has been removed and you are ready
to begin the oil flushing procedure, the following steps
should be followed:
1. BUMP test the auxiliary oil pump to ensure that
the pump is rotating in the proper direction as in-
dicated by the rotation arrow on the pump. While
viewing the TURBINE SCREEN on the OptiV-
iew™ Control Center, use the Manual Pump key
and enable manual operation. Place the pump mo-
tor protector disconnect switch (OL2) in the Pow-
er Panel in the ON position and immediately back
to the o position after the pump starts.
2. Install 100 mesh plain weave (.0059 opening)
screen mesh ahead of all bearing cases.
3. Place the auxiliary oil pump motor protector dis-
connect switch (OL2) in the Power Panel in the
ON position to start the auxiliary oil pump and
allow it to run for two hours. Using the Manual
Pump key on the TURBINE SCREEN, shut down
the pump and check all screens for particles.
Screens should not have any particles bigger than
.01 inch in diameter and show random distribu-
tion. No metallic particles should be present.
Flushing should continue until screens show no
more than 6 non-metallic particles.
4. Replace screens with new ones and continue
ushing in one-hour intervals until no metallic
particles and no more than 6 non-metallic parti-
cles are present on any of the screens.
5. Once clean screens are present, remove all
screens, service the turbine bearings and replace
them in the bearing housing. Housings must be
cleaned and resealed with Tite-Seal to prevent oil
leaks at the case split line.
6. Check the condition and cleanliness of the oil l-
ters furnished and replace them with new lters if
needed before continuing with the start up.
CHECK THE OIL LEVEL IN THE TURBINE
BEARING RESERVOIRS (RING OIL
LUBRICATION)
On a new turbine, remove the mylar protection that sta-
bilizes the shaft during shipment. To do this, remove
the upper half of the bearing housing, remove the up-
per half of the bearing and remove all pieces of my-
lar protection (above and below) from the shaft. This
must be done at both the steam and exhaust end bear-
ings. Housings must be cleaned and resealed with Tite-
Seal to prevent oil leaks at the case split line.
Ring Oil Lubrication
The oil level gauge on the side of the bearing
housing indicates the oil level. A mark inscribed
on the lower-half bearing housing indicates the
proper oil level. Oil levels in both bearing hous-
ings should be checked daily. Always use a strain-
er when adding oil to the systems and cover the
fill connection when finished. If there is any rea-
son to suspect water in the oil, open the low point
drain in each bearing housings slightly. If water
is present, it will be the first thing to come out of
the drain. Low point drains in the bearing housing
should be checked weekly for water.
The presence of oil in the constant level
oilers does not necessarily mean that oil
in the bearing housings is at the proper
level. CLEANLINESS is ESSENTIAL
for long and trouble free service from
the BEARINGS. Care must be taken to
ensure that no foreign material enters
bearing housings or constant level oilers
when performing maintenance, checking
oil, adding oil, or making adjustments.
CHECK THE COUPLING AND ALIGNMENT
If any maintenance or repairs have been performed on
the turbine or compressor that would possibly result in
a change in the shaft positions, check the alignment per
Form 160.67-N2.
CHECK THE REFRIGERANT CHARGE
The refrigerant level should be visible in the evapora-
tor sight glass at the level recorded after the chiller was
initially charged. Add refrigerant if required per Sec-
tion 6 of this manual.
OIL HEATERS
If the oil heater is de-energized during a shut down pe
riod, it must be energized for 12 hours prior to start
ing compres sor, or remove all oil and re charge com
pressor with new oil. (See “Oil Charging Procedure”,
Section 4 of this manual.)
OIL HEATER OPERATION
The oil heater operation is controlled by the OptiV-
iew™ Control Center. The heater is turned on and off
to maintain the oil temperature differential to a val ue
50°F (27.8°C) above the condenser saturation tem per
a ture. This is the target value and if the oil tem per a
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