Grasso Conversion Kit Training

{Name of CSO Trainer for GCK}

{Name of CSO}

GEA Refrigeration Technologies

Grasso Conversion Kit Training

At the end of this training you should:

• Understand the GCK concept

• Be able to recognise a sales opportunity
• Understand the support we can offer you
• Understand the information we require from you
• Be able to explain USPs to your customers
• Be able to offer a fixed (budget) price without delay
• Sell GCKs!

2 GCK Training for CSO Service GEA Refrigeration Technologies

Grasso Conversion Kit Training

• INTRODUCTION
• What are our customers’ choices without GCK
• Introduction of GCK concept
• GCK – what do we sell?

• PRICING & STANDARDS

• Budget pricing
• Site survey & design drawing
• Site survey and final pricing

• SALES
• Unique Selling Points for GCK
• Sales opportunities – what are we looking for?

• WHAT WE NEED FROM YOU TO GIVE YOU SUPPORT?

3 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Introduction

Industrial Screw compressor packages have been used at the heart of

refrigeration systems for over 50 years.
Screw compressor packages include the following items:

•Screw Compressor

•Drive Motor

•Oil Separator

•Oil Cooler

•Oil Distribution System

•Control system

4 GCK Training for CSO Service GEA Refrigeration Technologies

Screw Compressor Package

One example of our competitors’ package units

Screw
Drive Motor
Compressor

Control system Oil distribution

system

Gram GST41
Grammatic Control
Oil cooler
Oil separator

5 GCK Training for CSO Service GEA Refrigeration Technologies

 GEA Grasso Screw Compressor Package

Oil Separator

Control System
Drive Motor

Screw Compressor

Oil Cooler

Oil Distribution
System

GCK Training for CSO Service GEA Refrigeration Technologies

Major Overhaul – Customer Options

When a major overhaul of the compressor is required the end-user has

several options:
• Overhaul the existing compressor.
• Replace the compressor with a new or remanufactured one of the
same type.

• Replace the entire compressor package unit with a new one.

• Replace the compressor with one from another manufacturer.

7 GCK Training for CSO Service GEA Refrigeration Technologies

Another manufacturer ???

Another manufacturer ???

This option is rarely considered because of:

• Loyalty to original supplier.

• No fixed prices.
• Lack of availability.
• Technical difficulty.
• Lack of support from manufacturer.

8 GCK Training for CSO Service GEA Refrigeration Technologies

Grasso Conversion Kit -GCK

Consists of 2 main components: 1. Compressor and

oil distribution
system mounted
on a single sub-
frame to suit
existing package.

2. Sub-frame to suit
existing drive motor
and existing
package.
Mounted onto Parallel beams

9 GCK Training for CSO Service GEA Refrigeration Technologies

Grasso Conversion Kit -GCK

1. Compressor and
oil distribution
system mounted
on a single sub-
frame to suit
existing package.

2. Sub-frame to suit
existing drive motor
and existing
package.

10 GCK Training for CSO Service GEA Refrigeration Technologies

 GCK – Reuse existing components

Providing the GEA compressor has a

similar swept volume to the original
compressor, then the remaining package
components:
•Drive motor
•Oil separator
•Oil Cooler
•Control system
Can all be re-used.

11 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Standard GEA Components

The beauty of the GCK is it employs standard design components

from GEA Grasso.

Some are specifically adapted to suit the existing package.

12 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Examples

13 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Before

14 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – After

15 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Before

16 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – After

17 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Before

18 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – After

19 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Pricing & Standards

• 1 Budget Price based on existing compressor and general information

• Compressor swept volume and GUD
• Standard Components
• Budget price for GCK from TC Berlin
• Scope of supply
• Budget price for installation

• 2 Site Survey
• Design drawing from TC berlin
• Final price to customer
• GCK Delivery & Installation

20 GCK Training for CSO Service GEA Refrigeration Technologies

Swept Volume Comparison

Be careful!!

21 GCK Training for CSO Service GEA Refrigeration Technologies

GEA Grasso screw compressor range

Swept volume (m³/h)

0 100 200 300 400 500 600 700 800 900 1000 2000 4000 6000 8000 9000

GEA Grasso MC
4 types, 471 – 870 m³/h

GEA Grasso LT
14 types, 805 – 8.560 m³/h

22 GCK Training for CSO Service GEA Refrigeration Technologies

GEA - Standard Components

Compressor OMC
subframe

Service
valves
Suction Filter and NRV
Suction Filter Combination for V to XA
SFC for P-T

23 GCK Training for CSO Service GEA Refrigeration Technologies

GEA - Standard Components

Motor subframe
GSC TP Control
Cubicle

4x

24 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Budget price for TC Berlin supply
(example)

Protected Excel File – restricted access for security

25 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Scope of supply (example)

26 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Scope of supply (example)

27 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Budget price for TC Berlin supply
(example)

Pricing Tool
Demonstration

28 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Example with common baseframe

Common
baseframe

29 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Example with common baseframe

30 GCK Training for CSO Service GEA Refrigeration Technologies

GUD - Check Motor Size

31 GCK Training for CSO Service GEA Refrigeration Technologies

GUD - Check Oil Pump and Filter size

32 GCK Training for CSO Service GEA Refrigeration Technologies

GUD - Check Valves for Suction

33 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Scope of supply

• Compressor subframe assembly to suit existing package:

• New, Fixed Vi, 28 bar, standard or booster compressor
• Suction filter
• Suction NRV (option for V-XA)
• Oil Management Centre (OMC)
• Oil pipework from OMC to compressor mounted

• Loose Supply items

• Coupling & guard, spare oil filter etc.

• Motor subframe assembly to suit

existing package
• Adjustable mounting bolts for motor

34 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Budget price for installation

Based on
experience
so far

35 GCK Training for CSO Service GEA Refrigeration Technologies

Example 1 - GCK Site Survey

36 GCK Training for CSO Service GEA Refrigeration Technologies

Example 1 - GCK Design Drawing

TC Berlin will not

proceed until the
design is approved
by you!

37 GCK Training for CSO Service GEA Refrigeration Technologies

Example 2 – GCK Site Survey (Berlin Training)

Represents
electrical cabinet
2m high

38 GCK Training for CSO Service GEA Refrigeration Technologies

Example 2 – GCK Site Survey (Berlin Training)

Note control voltage for GCK solenoid coils

Note all connection sizes for GCK
Confirm motor shaft diameter
Note size of existing small pipes/fittings for GCK
Anything to help ensure success!

39 GCK Training for CSO Service GEA Refrigeration Technologies

Example 2 - GCK Design Drawing (Berlin
Training)

3D pdf

40 GCK Training for CSO Service GEA Refrigeration Technologies

Example 2 – GCK P&ID (Berlin Training)

41 GCK Training for CSO Service GEA Refrigeration Technologies

GCK – Final price to customer

42 GCK Training for CSO Service GEA Refrigeration Technologies

GCK Delivery

• Compressor subframe assembly to suit existing package:

• New, Fixed Vi, 28 bar compressor
• Integrated suction filter
• Integrated suction NRV
• Oil Management Centre (OMC)
• Oil pipework from OMC to compressor mounted

• Loose Supply items

• Coupling & guard, spare oil filter etc.

• Motor subframe assembly to suit

existing package
• Adjustable mounting bolts for motor

43 GCK Training for CSO Service GEA Refrigeration Technologies

GCK Installed

44 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - What Information is required?

• GCK Checklist

Example of motor
nameplate marked
for one direction
only.

New cooling fan was

required!

45 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - USPs

• Future proof upgrade solution

• New, GEA compressor factory supported package

• Standard GEA solution utilising standard GEA components

• Fixed price solution

• Customer can budget for upgrade with no surprises

• Compact solution, quicker and less expensive than a new

compressor package
• Re-use existing components
• Installation within existing machinery space, no building alterations
necessary.

46 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - USPs

• Possibility to optimise system capacity and efficiency

• GEA Standard solution supported by your local GEA Service

organisation

• GEA components with standard warranty terms & conditions

• Obsolete compressor manufacturers are limited to a financial warranty

• Possible to re-use existing control system or upgrade to modern

control system optimised for energy efficiency

47 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - GEA Compressor USPs

• Utilises high quality, state of the art, GEA Screw compressor

designed and built in Germany:
• Higher efficiency with GEA 5/6 rotor profile
• Lower noise and vibration level
• Higher reliabilty with robust design

• Lower maintenance cost:

• 66% longer maintenance interval than most major compressor
manufacturers (30,000hr x 1.66 = 50,000hr)
• Sleeve bearings for Large Series Compressors designed for unlimited
lifetime
• Thrust bearings can quickly & easily be checked and/or replaced on all GEA
screw compressors
• Grasso Compressor Video

48 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Sales Opportunities

What are we looking for?

• Obsolete / Outdated / Worn screw compressors
• Compressors coming up for major servicing
• Compressors on the limits of capacity
• Failed or failing screw compressors
• Compressors with none or poor manufacturer’s support
• Customers with budgetary restriction (unable to invest in replacement
packages)
• Customers for whom downtime is important
• Existing or potential customers
• Opportunity for expanding service

49 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Example 1

• Outdated/worn compressors.
• Tight plant room and access
• Major works required even to change like-for-like or overhaul
• Cheaper alternative to upgrade/replace compressors than to replace
complete compressor packages.
• Extended maintenance intervals
• Easy maintenance checks

50 GCK Training for CSO Service GEA Refrigeration Technologies

 GCK - Example 2

• Slight increase of capacity required

• Good plant room and access
• Planned Annual Shut Down of 2 weeks
• Cheaper alternative to upgrade/replace compressor than to replace
complete compressor package.
• Extended maintenance intervals
• Easy maintenance checks

51 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Example 3

• Major overhaul due

• Slight increase in capacity required
• Good plant room and access
• Planned Annual Shut Down of 2 weeks
• Cheaper alternative to upgrade/replace compressor than to replace
complete compressor package.
• Extended maintenance intervals
• Easy maintenance checks

52 GCK Training for CSO Service GEA Refrigeration Technologies

GCK - Example 4

• Obsolete and failing compressors (noisy)

• Increase in capacity
• Very poor plant room access (maximum door opening 750mm)
• Much cheaper alternative to upgrade/replace compressor than to replace
complete compressor package
• Efficiency and reliability increases
• Compressor controller upgrade to GSC
• Extended maintenance intervals
• Easy maintenance checks

53 GCK Training for CSO Service GEA Refrigeration Technologies