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Screw Compressor

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Procedure
Screw Compressor-DRAFT
Developed
by:

Initial development date:


Revision number:
Revised by:

2.8

Revision date:

11/4/2014

Name:
Title

Certified as accurate by:

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

Location: Engine Room


Function
An ammonia compressor is a mechanical device that creates refrigeration by removing heat from objects or
spaces. Compression systems refrigerate by changing ammonia from a liquid state to a gaseous state and back to
liquid.

SAFETY AND HEALTH CONSIDERATIONS


Properties & Hazards

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

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 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

Eye Contact Exposure to liquid or low concentration of vapor causes instant


painful and possibly irreversible damage to eye tissue, (conjunctiva, cornea, lens).
Glaucoma and opacities may occur.

Inhalation Mild throat irritation, bronchial spasms, pulmonary edema or severe


fatal damage to mucous membranes of respiratory tract, depending on the degree of
exposure.

Skin Contact Damages all body tissue, causes caustic burn, dehydration burn or
freeze burn.

Ingestion Tissue damage, chemical burns, nausea, vomiting.

Precautions Necessary to Prevent Exposure:


Follow Maintenance Instructions when performing maintenance or other procedures that
require opening any part of the system.

Eyes Chemical splash goggles approved for use with ammonia and / or full-face
shield.

Ventilation and Absorption Local positive pressure and / or exhaust ventilation,


allow ammonia to dissipate to the upper atmosphere, use water spray to control
vapor.

Other Emergency eyewash stations and deluge showers available and operational,
emergency response contacts and telephone numbers posted.

Engineering and Administrative Controls to Prevent Exposure:


Lockout/Tag out Procedures (LOTO).
Qualification and Training Standards.

Line and Equipment Opening Procedures.


The Waterbury maintenance staff performs all operations and preventive
maintenance. The maintenance manager or qualified designee will perform
the annual inspection. Yearly review of the operating procedures is
conducted in conjunction with safety, and Waterbury plant maintenance
personal. This ensures that operating procedures are accurate and up-to-

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 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.

Respiratory- NIOSH approved air purifying respirator or Self- Contained Breathing


Apparatus.

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

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 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

Emergency and First Aid (Seek immediate medical attention)


Note: Dial 911 and request emergency medical assistance. If necessary initiate plant
Emergency Action & Response Plan.

Eyes Flush with large amounts of water for at least 20 minutes.

Ingestion Do not induce vomiting. Have the victim drink large quantities of water
if conscious.

Inhalation Move to fresh air, administer artificial respiration or oxygen, as needed.


Skin Flush with large quantities of water for at least 20 minutes while removing
clothing. Clothing frozen to skin should be thawed before removal.

Means of Controlling Ammonia Inventory Levels and Quality:

Perform inspections, testing and maintenance as described in the Mechanical


Integrity PSM Element.

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:

Noise Where applicable plant Hearing Conservation program will be observed at


all times.

Slips, Trips & Falls - Proper housekeeping practices are necessary to keep floors
near refrigeration compressors free of oil to prevent slips, trips and falls.

Stored Energy Refrigeration compressors retain stored chemical energy and


pressure. LOTO and pump out procedures must be followed prior to opening.

Heat Refrigeration Compressors generate heat due to the compression of ammonia


gas.

Machine Guarding Fan blades and rotating shafts can cause lacerations and pinch points.

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 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

Lockout Tagout Worksheet for Ammonia / Electrical Isolation Only


Identification of
Machine or Motor
RCB-1
RCB-2
RCB-3
RCB-4
RC-5
RC-6
RC-7

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

Safety Systems & Functions


Main Electrical Disconnect: De-energizes all power to compressor.
Motor Overload Relay: Shuts down should motor current exceed upper limit.
Low Oil Pressure Cutout: Oil pressure falls below normal running pressure for 5 seconds.
High Discharge Pressure Cutout: Discharge pressure exceeds maximum parameter.
High Discharge Temperature: Discharge temperature exceeds upper parameter.
Low oil temperature: Inlet oil temperature drops below lower parameter for 5 seconds.
High oil temperature: Inlet oil temperature exceeds upper parameter for 5 seconds.
Dual pressure relief valve: System will not exceed set pressure of relief valve.
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 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

STANDARD OPERATING PROCEDURE


Initial Startup
The Initial Startup procedures refer to new equipment installation and equipment replacements.
Either the manufacturer of the described equipment or a qualified contractor will perform initial startup. Failure to
have this person present will void compressor packages warranty. Before initial startup, the responsible party
(manufacturer or contractor) and plant personnel will meet to review operating procedures and examine any
process hazards associated with the installed equipment. All initial startups will be done under supervision of Ben
& Jerrys plant personnel.
The responsible parties will be required to:
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
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Screw Compressor
Page 7 of 30

Procedure

Ensure integrity of equipment


Check for and repair leaks
Confirm proper operating procedures before commissioning equipment
Ensure plant personnel are aware of proper operating procedures

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.

2. Check for correct position of all valves as noted below.


A. Compressor suction valve should be open.
B. Compressor discharge valve should be open.
C. Open all oil supply and oil return valves.
D. Open all valves feeding the transducers to the microprocessor control panel. Be sure that the
purge and vent valves are closed.
E. Refer to the compressor schematic supplied for position and location of valves.

3. Set CONTROL POWER ON switch to the on position.


4. Close circuit breakers 3CB and 4CB (located inside Micro IIE Control Panel on Compressor) so
power will be applied to oil heaters to attain a minimum oil temperature of 70 F prior to initial
startup.
5. Open dipswitch U18 SW1 for oil pump test. Start the oil pump by pressing the LOCAL/START
pushbutton. Allow the oil pump to run for approximately 30 seconds to lubricate the compressor
bearings. Stop the oil pump by pressing the STOP/RESET button. Close U18 SW1.
6. Check compressor shafts rotation. Facing the compressor shaft, the rotation should be
CLOCKWISE. To check the rotation, start the oil pump and after going through the normal
starting sequence the compressor will start. As soon as the direction of rotation is confirmed,
stop the compressor motor by pressing the STOP/RESET button.
7. Enter variable set points in the microprocessor. Set points can be found it the FES Maintenance
Manual.
Initial Startup Valve Positions for RC-5 & RC-6, X=5 or 6
Valve #
RC-X-1
RC-X-2
RC-X-3
RC-X-4
RC-X-5
RC-X-6
RC-X-7

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

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 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

Initial Startup Valve Positions for Swing Compressor RC-7


Valve #
RC-7-1
RC-7-2
RC-7-3
RC-7-4
RC-7-5
RC-7-6
RC-7-7
RC-7-8
RC-7-9

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

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 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:

1. The compressor will stop immediately and STOPPED will be displayed.


2. The oil pump will continue to run until the slide valve moves to the less than 5% position,
and then it shuts down.
NOTE: The oil pump will stop if the compressor has already been unloaded. If the compressor is not fully
unloaded and the pump is off, the pump will restart.

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

Manual Emergency Shutdown


Some un-foreseen situation undetected by the automatic emergency shutdown controls may require
manual shutdown of a compressor. In such an event:
1. Turn compressor control panel switch to the OFF position.
2. Pull and lockout the disconnect for the motor starter of the effected compressor.
Emergency Operation
Ben and Jerrys do not operate under any emergency conditions. In the case of emergency, the appropriate
emergency shutdown procedures should be followed to decommission equipment. Startup will follow normal
operating procedures after the appropriate plant personnel have eliminated the emergency situation. All shutdown
units will be restored on a unit-by-unit basis.

Startup after Emergency Shutdown


Following approval from plant personnel, startup after emergency shutdown would follow the same startup as
after a normal startup.
ISOLATING BOOSTER COMPRESSOR VALVES (-38 and -50 suction) - For changing the oil filter and

cleaning the strainer


1. Unload and stop the machine.
2. Open the dip switch for the oil pump test. This is the #1 switch on the third bank of switches inside of the
control panel (U18-1).
3. Close the discharge valve RCB-X-1.
4. Open the suction bypass valve (labeled suction bypass) until the discharge pressure on the screen reads <0 psi.
5. Close the suction bypass valve.
6. Close suction valve RCB-X-2.
7. Compressor is now isolated.
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 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

1. Unload and stop the machine.


2. Open the dip switch for the oil pump test. This is the # 1 switch on the third bank of the switches inside of the
control panel (U18-1).
3. Close the discharge valve # RC-X-1.
4. Open the suction bypass valve (labeled suction bypass) until the suction reads 25-30 psi.
5. Close the bypass suction valve.
6. Close suction valve RC-X-2
7. Hook up a line from valve RC-X-M of the compressor to the suction bypass valve (RCB-X-V) of any of the
boosters Open both valves RCB-X-V (suction first) and pump down the compressor to <0 psi. Close both
valves (making sure the suction pressure doesnt rise).
8. Compressor is now isolated.
9. To service oil filters and screens, follow steps 10-14.
10. Close oil inlet and outlet valves # RC-X-3,4
11. Close all remaining valves numbered RC-X-5, 6, 7, 9, 10,14, and lettered valves G, K, O, L.
12. Crack open the drain valve (lettered B) to remove the filters and drain oil into a bucket. When the oil flow has
stopped remove all but two cover bolts. The last two bolts must be backed off slowly while tapping on the
cover to break the seal. Let the remaining oil drain into a bucket. When the oil flow has stopped, the cover can
be removed. Remove the nut and washer then reach in removing the retainer, filter, spacer, and final filter
13. When reinstalling the screen, make sure the hole faces the bottom and the o-ring (the o-ring is usually
replaced no matter the condition) in the cover is not damaged. Install the cover and tighten the bolts to 40ft.
Lbs. Close the drain valve (letter B).
14. 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).
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 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.

RESETTING BOOSTER & COMPRESSOR FAILURES

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

Valve Schedule for Refrigerated Compressors RC-5 & RC-6 (X=5 or 6)


Valve #

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

Oil pressure differential regulator


Oil filter shutoff valve
Oil check valve for oil filter
Pressure relief valve 250 psi w/3way
Oil cooler pressure relief valve 250 psi
w/3way
RC-X-14 Oil metering valve
RC-X-15 Thermo relief on oil cooler, Hydrosttic Relief
400 psi
RC-X-A Oil cooler drain (oil)
RC-X-B Oil cooler drain (NH3)
RC-X-C Oil separator Drain
RC-X-D Oil filter drain
RC-X-E Oil header drain
RC-X-F Main oil injector valve
RC-X-G Oil supply to load solenoid valve
RC-X-H Oil supply to load cylinder valve
RC-X-I Oil supply to unload cylinder valve
RC-X-J Bleed to suction valve
RC-X-K Liquid to strainer shutoff valve
RC-X-L Differential regulator return valve
RC-X-M Oil fill valve
RC-X-N Non-Existent

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

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 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

Oil return to suction valve


Suction test point valve
Discharge test point valve
Oil pressure test point valve
Oil outlet pressure test point valve
Oil inlet pressure test point valve
Suction service valve to sample valve RC-5-P
Suction service valve
Suction service valve
Oil vent valve to suction for low Vi
Oil supply valve from solenoid for low Vi
Oil vent to suction for medium Vi
Oil vent valve from Vi solenoid
Check valve from liquid strainer
Check valve after RC-5-9
Metering valve oil return
Check valve at discharge of compressor

RC-FF
RC-GG

Check valve on suction


Suction By-pass

/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

Refrigeration Specialties Engine Room


Henry
Engine Room

Valve Schedule for Compressor Booster RCB-1 through RCB-4 (X=1, 2, 3 or 4)


Valve #
RCB-X-1
RCB-X-2
RCB-X-3
RCB-X-4
RCB-X-5
RCB-X-6
RCB-X-7
RCB-X-8
RCB-X-9
RCB-X-10
RCB-X-11
RCB-X-12

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

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 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

Oil cooler pressure relief valve 250 psi


w/3way
Oil metering valve
Thermo relief on oil cooler, Hydrostatic
Relief 400 psi
Oil cooler drain valve (oil)
Oil cooler drain valve (NH3)
Oil strainer drain valve end of strainer
Oil filter drain valve
Oil header drain valve
Main oil injector valve
Oil supply to load solenoid valve
Oil supply to load cylinder valve
Oil supply to unload cylinder valve
Bleed to suction valve
Liquid shutoff valve to strainer
Differential regulator return valve
Oil fill valve
1" pump out valve
Oil return to suction valve
Suction test point valve
Discharge test point valve
Oil pressure test point valve
Oil outlet test point valve
Oil inlet pressure test point valve
Suction service valve
Suction service valve
Suction service valve
Non-Existent
Metering valve on the oil return
Metering Valve, Main injection
Check Valve before RCB-14

RCB-BB
RCB-CC

Check valve before oil strainer


Check Valve at discharge of compressor

RCB-DD
RCB-EE

Valve on branch from HPL to #1 oil cooler


Check valve on suction

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

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 17 of 30

Procedure

Valve Schedule for Swing Compressor RC-7


Valve Schedule for Refrigerated Swing Compressor RC-7
Valve #
RC-7-1
RC-7-2
RC-7-3
RC-7-4
RC-7-5
RC-7-6
RC-7-7
RC-7-8
RC-7-9
RC-7-10
RC-7-11
RC-7-12
RC-7-13
RC-7-14
RC-7-15
RC-7-A
RC-7-B
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
RC-7-L
RC-7-M
RC-7-N

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

Refrigeration Specialties Engine Room


Watts
Engine Room
Refrigeration Specialties Engine Room
Hansen H5602 768scfm
Hansen H5600 768scfm

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

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 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

Oil return to suction valve


Suction test point valve
Discharge test point valve
Oil pressure test point valve
Oil outlet pressure test point valve
Oil inlet pressure test point valve
Suction service valve to sample valve RC-7P
Suction service valve
Suction service valve
Oil vent valve to suction for low Vi
Oil supply valve from solenoid for low Vi
Oil vent to suction for medium Vi
Oil vent valve from Vi solenoid
Check valve from liquid strainer
Check valve after RC-7-9
Metering valve oil return
Check valve at discharge of compressor

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

Refrigeration Specialties Engine Room


Henry
Engine Room

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 19 of 30

Procedure

Checklist - 1

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
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Screw Compressor
Page 20 of 30

Procedure
Checklist - 2

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
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Screw Compressor
Page 21 of 30

Procedure
Suction +12F

High Stage Compressor RC-5 Photo

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
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Screw Compressor
Page 22 of 30

Procedure

High Stage Compressor RC-5 back view Photo


HSD to
Condensers

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
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Screw Compressor
Page 23 of 30

Procedure

Hot Gas

Swing Compressor RC-7 Rear View Photo


HSD to
Condensers

Suction +12F, -38F or 50F

RC-7-2

RC-7-3

RC-7-4

Amot Valve

Oil Cooler

Legend (Examples)
Valve

RC-7-??

Document Name: Screw Compressor- Direction


DRAFT
of Flow
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
ot Gas
Type of Line
SOP.doc
The contents of this page are proprietary and shall be considered Unilever Confidential

Screw Compressor
Page 24 of 30

Procedure

Hot Gas

Swing Compressor RC-7 Front View Photo

RC-7-N

Oil Pump

Oil Filter

Control
Panel

Legend (Examples)
Valve

RC-7-??

Direction of Flow

Document Name: Screw Compressor- DRAFT


Document Owner: Maintenance Manager
Revision No: 2.8 November 4, 2014
Supersedes: February 11, 2013
Type of Line
Path & Filename: http://teamsites.unilever.com/collab/VMPS/03
Standard
Procedures/W/Screw Compressor
HotOperating
Gas
SOP.doc
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Screw Compressor
Page 25 of 30

Procedure

Hot Gas

Booster Compressor RCB-1 Rear View Photo


Intercooler
LSD

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
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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

Booster Compressor RCB-1 Front View Photo

Oil Filter

Oil Pump

Control
Panel

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 27 of 30

Procedure
Legend (Examples)
Valve

RCB-1-??

Direction of Flow

-10-??

(RED)
S

SERVICE VALVE RCB-U

Type of Line

-38/-50F
SUCTION

Hot Gas

OIL SCHEMATIC FOR


BOOSTER COMPRESSORS

NC
SERVICE VALVE RCB-V

RCB-X-2

SUCTION
STRAINER

(TYPICAL RCB-1, RCB-2, RCB-3, RCB-4)

THERMOMETER

SUCTION BYPASS

NC
4T

SERVICE VALVE RCB-W


NC
C20

OIL RETURN RCB-O


METERING VALVE RCB-Y

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

1 FPT PUMP OUT


CONNECTION VALVE RCB-N
UNLOAD RCB-H

THERMOMETER

DUAL RELIEF VALVES


RCB-X-12

LOAD RCB-I

OIL FILL RCB-M

NC
D

OIL SEPERATOR

UNLOAD
(3 SOL)

LOAD
(2 SOL)

RCB-X

1T

RCB-X-8

REGULATING RETURN RCB-L

NC

STRAINER RCB-K

DIFFERENTIAL PRESSURE
REGULATOR
RCB-X-9
HIGH PRESSURE LIQUID
AMMONIA
INLET RCB-X-3

CHECK VALVE RCB-BB

RCB-DD

OIL
PUMP
MAIN OIL INJECTION RCB-F
RCB-X-14

NC
METERING VALVE RCB-Z
THERMOMETER

CHECK VALVE RCB-AA


RCB-X-10
LOAD SOLENOID RCB-G

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

THERMOSIPHON OIL COOLER

NC
DRAIN RCB-D

OO

10
TEST POINTS P, Q, R, S, T

10

OIL DRAIN RCB-A


RELIEF DRAIN RCB-B

RCB-X-6

RCB-X-5

RCB-X-7

IN LINE
STRAINER
(BETWEEN
FLANGES)

DRAIN RCB-E

CAD FILE: OIL SCHEM-RCB

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 28 of 30

Procedure

(RED) RC-U
S

+12F
SUCTION

OIL SCHEMATIC FOR


HIGH STAGE COMPRESSORS

NC

RC-N

SUCTION
STRAINER

RC X-2

(TYPICAL RC-5, RC-6, RC-7)

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

1 FPT PUMP OUT-PLUGGED

RC-EE

RC-Z

THERMOMETER
RC-H

RC-J

OIL FILL RC-M

DUAL RELIEF VALVES RC-X-12


NC

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

HIGH PRESSURE LIQUID


AMMONIA
INLET RC-X-3

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

THERMOSIPHON OIL COOLER

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)

CAD FILE: OIL SCHEM-RC

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 29 of 30

Procedure

Ammonia Pipe Labeling


Pipe Jacket / Label Colors
High Pressure Liquid

70 PSIG

-30 Pumped Liquid Supply

70 PSIG

-30 Pumped Liquid Return

70 PSIG

-40 Pumped Liquid Supply

70 PSIG

-40 Pumped Liquid Return

70 PSIG

+30 Suction/Defrost Relief

70 PSIG

Hot Gas

70 PSIG

Booster Discharge

70 PSIG

Valve Tag Colors


Hot Gas
Liquid
Suction (Liquid Or Gas)
Misc. (Regulators, Controls And Service)

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 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.

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