REFRIGERATION PLANT SIMULATOR RPS 4000

REFRIGERATOR MODEL TRAINEE MANUAL

Transas Ltd. November, 2005

 2005 Transas Ltd. All rights reserved. The information contained herein is proprietary to Transas Ltd. and shall not be duplicated in whole or in part. The technical details contained in this manual are the best that are available at the date of issue but are subject to change without notice. Transas Ltd. pursues the policy of continuous development. This may lead to the product described in this manual being different from the product delivered after its publication. The names of actual companies and products mentioned herein may be the trademarks of their respective owners.

This document contains: Introduction ................................................................................................................3 Printing House Conventions.................................................................................3 Purpose of the Provision Cooling System ..............................................................4 System Components .................................................................................................4 Control Panel..............................................................................................................7 SW PUMP Group Control of Sea Water Supply ...............................................7 Group for the Control of Pipeline Cut-off Valves ..................................................8 Compressor Control Group ..................................................................................8 Control of Provision Storerooms Group .............................................................11 Alarm Signals ...........................................................................................................14 Safety System ..........................................................................................................15 System Faults Introduced by the Instructor .........................................................15 Directions for the Plant Operation and Maintenance...........................................16 Procedure for Starting the Plant in Manual Mode ..............................................16 Defrosting of Refrigeration Equipment in Manual Mode ....................................18 Replenishment of Liquid Refrigerant..................................................................18 Compressor Replenishment with Oil..................................................................19 Air Discharge......................................................................................................20 Replacement of Filter Drain ...............................................................................21 Compressor Breakdown.....................................................................................21

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Introduction

INTRODUCTION
The simulator is designed for the training of watch keeping personnel in the correct operation of the ships Provision Cooling System including: Preparation and putting into operation of machinery and systems; Monitoring of their operation by the measured parameters with the assistance of the alarm system; Troubleshooting procedures.

In addition to the training of practical skills, the simulator allows familiarisation with fundamentals of the structure, functioning and interaction of the elements and subsystems. The set of the simulated systems complies with the currently accepted ship standard. Parameters and performance characteristics of the modelled machinery and systems correspond to the actual ones, as the simulator models all the principal processes (thermodynamic, mechanic, gas and hydrodynamic, electrical) in their interrelation.

Printing House Conventions

Sample of notation Comments To highlight names of windows, pages, buttons, etc.

START/STOP

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Purpose of the Provision Cooling System

PURPOSE OF THE PROVISION COOLING SYSTEM

The automatic Provision Cooling System is intended for creating and maintaining the set temperature conditions for the storage of food in two groups of provision stores.

SYSTEM COMPONENTS
The system mnemonic diagram is shown in Fig. 1.

Fig. 1

The following components are included in the system and modelled in the simulator: Provision stores as a thermodynamic object; Refrigeration plants 1 and 2; Gas and liquid lines with valves as hydro- and gas dynamic objects; Cooling sea water pump.

The provision stores are divided into groups proceeding from the level of temperature maintained in them. The first group includes three provision storerooms for the storage of frozen foods: Butter storage of butter at a temperature of -2; Meat storage of meat at a temperature of -15; Fish storage of fish at a temperature of -15.

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

System Components

The other group includes three provision storerooms for the storage of chilled food: Fruit storage of fruit at a temperature of +2; Vegetables storage of vegetables at a temperature of +2; Dry prov. storage of dry provisions at a temperature of +8.

Each of the refrigeration plants operates for its group of consumers. However, the refrigeration performance of each refrigerator is sufficient for the supply of both storeroom groups if required. This capability is ensured by the availability of connecting lines with cut-off valves. Freon R134a has been selected for the main liquid refrigerant, there is a capability to switch to R401b. The sea water pump which is in the right bottom corner of the mnemonic diagram, supplies water for the cooling of condensers 1, 2.

Condensers 1 and 2 are located in the bottom part of the mnemonic diagram. Shown here is the liquid refrigerant level in the condenser collector. The sea water flow for the condenser cooling is controlled by using the condensing pressure governor (water control valves) installed on the water supply lines to condensers 1 and 2.

Fig. 2

Compressor 1 maintains the required temperature conditions in the frozen food stores (Butter, Meat, Fish), compressor 2 maintains the required temperature in the chilled product storerooms (Fruit, Vegetables, Dry prov.).

Fig. 3

When the compressors are operating, indicators of the compressor operation light up on the mnemonic diagram. Also shown here is oil level in the compressor case and the degree of openness of the compressor suction valve. Automatic adjustment of the compressor refrigeration performance is provided in two ways: compressor START/STOP and bypassing. Adjustment by bypassing is performed by using the performance suction pressure governor control. On the mnemonic diagram, the regulator is set on the compressor bypass line. The current position (extent of openness) is shown on the digital indicator of the performance regulator on the mnemonic diagram.

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

System Components

The sight glass located on the liquid line on the mnemonic diagram shows the state of the liquid refrigerant and moisture content.

The air temperature in the storerooms is maintained with the air coolers. The thermo switch monitors the temperature in the pertinent provision storeroom and controls operation of the solenoid valves in the refrigeration chamber, as well as the operation of the air cooler valve. As the solenoid valve is opened, its OPEN indicator lights up on the mnemonic diagram (above the air cooler). Operation of the air cooler fan is reflected on the mnemonic diagram.

Liquid refrigerant is supplied to the air cooler by the thermostatic expansion valve (above the air cooler on the mnemonic diagram). The current status degree of openness) is shown on the digital indicator of the thermostatic expansion valve on the mnemonic diagram.

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Control Panel

CONTROL PANEL
The control panel located in the right hand part of the screen page contains the following groups: Control of sea water supply; Control of pipeline cut-off valves; Control of compressors; Control of provision storerooms.

SW PUMP Group Control of Sea Water Supply

Fig. 4

The sea water pump is turned on/off by using ON/OFF button. When the pump is ON, the button indicator is backlighted, and the pump ON indicator lights up on the mnemonic diagram.

Fig. 5

Set above the buttons on the control panel is the digital pressure gauge, which shows the pumps charging pressure. To the right of the pressure gauge on the control panel, there are three temperature gauges showing sea water temperature at the system inlet INLET and temperature of the water after condensers 1 and 2 OUTLET 1 and OUTLET 2 respectively.

Fig. 6

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Control Panel

Group for the Control of Pipeline Cut-off Valves

POWER indicator shows that the system is powered. SHUT OFF VALVES button serves for the control of cut-off valves on the vapour and liquid connection lines on the mnemonic diagram. A press on the button opens the valves, thus ensuring the interchange ability of the compressors. When the valves are opened, the valve OPEN indicators light up on the mnemonic diagram and the button on the control panel is backlighted.

Compressor Control Group

Fig. 7

There are two tabs in the group: COMPRESSOR 1 and COMPRESSOR 2 which are used for selecting the parameter monitoring instruments and controls of the required compressor:

Fig. 8

Installed on the control panel are amperemeter (shows electrical current), vacuum gauge (shows suction pressure SUCTION), and two pressure gauges (shows charging pressure DISCHARGE, OIL pressure gauge shows pressure in the compressor lubricating system).

Fig. 9

With a high charging pressure in the compressor, an alarm is generated: appropriate lamps start flickering in the bottom part of the screen.

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Control Panel

The alarm is also generated in case of low pressure in the compressor lubricating system. In the centre of the control panel there are three temperature gauges for determining the liquid refrigerant temperature on the suction line SUCTION, on the charging line DISCHARGE, and in the condenser CONDENSER.

Fig. 10

With a high compressor discharge temperature, an alarm is generated, and appropriate lamp starts flickering in the bottom part of the screen. In the left hand part of the control panel, AUTO-MANUAL compressor operating mode switch is located. As the switch is set to AUTO position, control of the compressor motor operation and solenoid valves is exercised automatically. Adjustment of water control valves for maintaining the set condensing pressure value (0.6 0.7 MPa) is made on the control panel. In the left hand part of the control panel, there is PRESSURE SET COND. condensation pressure controller (the controller is shown in Fig. 11 to the right).

Fig. 11

The current condition of the condensation pressure control (degree of openness) is shown on the controller digital indicator on the mnemonic diagram. If the switch is set to MANUAL position, to turn the compressor on, it is first necessary to open the master solenoid by pressing MASTER SOLENOID button on the control panel. The button indicator is backlighted, and the valve open status indicator lights up on the mnemonic diagram. Then the compressor is turned on by using ON button on the control panel.

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Control Panel

OFF button serves for turning the compressor off.

The suction valve of the compressor is opened via SUCTION VALVE setter in the right hand part of the control panel.

Fig. 12

Adjustment of the compressor refrigeration performance is provided in two ways: compressor START/STOP and bypassing. The compressor is started and stopped automatically by the low pressure switch. The switch is adjusted by using PRESSURE analog setter. On OFF scale, set the suction pressure value whereupon the compressor cylinders will turn off.

Fig. 13

On ON scale, set the pressure value whereupon the compressor will turn on. System valve control buttons are in the bottom part of the group. The lighted button indicator corresponds to the valves open status. As a valve is opened, the valve OPEN indicator lights up on the mnemonic diagram. Button for the control of the shut-off valves on the liquid refrigerant drain from the condenser. Button for the control of the valve for the system replenishment with liquid refrigerant. Button for the control of the moisture eliminator shut-off valve.

Button for the control of the moisture eliminator bypass valve (used when the moisture eliminator is replaced). Button for the control of the valve for the supply of oil into the compressor.

Button for the control of the valve used in the procedure of releasing air from the system.

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REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Control Panel

Control of Provision Storerooms Group

Fig. 14

In the top part of the group there are tabs for switching monitoring tools and controls of different provision storerooms:

Fig. 15

Set to the left on the control panel is a thermometer showing the current temperature in the provision storeroom. With a high temperature in the cooled space (3 higher than the set value) an alarm is generated a lamp starts flickering in the bottom part of the screen indicating the pertinent provision storeroom, e.g. that for the storage of butter: High T Butter.

Fig. 16

To the right of the temperature gauge on the control panel, there is a digital controller of the thermoswitch monitoring the temperature in the pertinent provision storeroom and controlling operation of the solenoid valves in the refrigeration chamber, as well as the operation of the air cooler valve. As the solenoid valve is opened, its OPEN indicator lights up on the mnemonic diagram (above the air cooler).

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

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Control Panel

In the centre of the control unit, there is a pressure gauge showing the pressure and boiling point in the pertinent air cooler.

Fig. 17

To the right of the pressure gauge on the control panel for butter (Butter) and dry provisions (Dry prov.) storerooms, there is a setter of PRESS. evaporation pressure control. The controls current state is shown on the digital indicator on the mnemonic diagram (below the air cooler of the pertinent storeroom). Arranged in the bottom part of the control panel are buttons. Storeroom loading/unloading control button. It is first necessary to open the storeroom door by using DOOR button (see below). Then press LOADING button to open the following dialogue window on the screen:

Fig. 18

The window heading indicates which storeroom will be loaded/unloaded. The central part of the dialogue window displays an open storeroom door and the amount of goods in kg which is currently stored there. Enter the amount of products to be unloaded in MASS box in the left hand part of the dialogue window (UNLOAD) and press APPLY button. To load the storeroom, enter the required amount of goods in MASS box in the left hand part of the dialogue window (LOAD), enter temperature in T box and press APPLY. The procedure for loading provisions in the chamber can be performed from the instructor workplace as well. In Data Monitor window, enter the amount of goods in kg in the selected chamber. If there were no goods in the chamber at the loading time, the provisions which are being loaded will be stored in the chamber with the temperature equal to the refrigeration chamber temperature. If there were some goods in the chamber at the loading moment, the provisions which are being loaded will have a temperature of the provisions already stored in the chamber.

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REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Control Panel

Door control button. It is used for the loading and unloading of goods into/from the storeroom. When the door is opened, the button is lighted, and an open door is shown on the mnemonic diagram (in the bottom part of the storeroom). The door will not close as long as the light in the storeroom is on. Storeroom lighting button. The lighted button corresponds to ON status. The light cannot be turned on unless the storeroom door is open. In the right bottom corner of the control panel, there is DEFROSTER unit which includes AUTO MANUAL switch for the control of the refrigeration equipment defrosting system.

In the right bottom corner of the control panel, there is DEFROSTER unit which includes AUTO MANUAL switch for the control of the refrigeration equipment defrosting system.

Fig. 19

Button for the control of the evaporator defrosting process when the switch is in MANUAL position. During the defrosting the button is backlighted, and a red coloured indicator lights up on the mnemonic diagram (next to the air cooler).

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

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Alarm Signals

ALARM SIGNALS
High T Butter temperature setting in the storeroom exceeded (by 3 ); High T Meat temperature setting in the storeroom exceeded (by 3 ); High T Fish temperature setting in the storeroom exceeded (by 3 ); High T Fruit temperature setting in the storeroom exceeded (by 3 ); High T Vegetables temperature setting in the storeroom exceeded (by 3 ); High T Dry Provis. temperature setting in the storeroom exceeded (by 3 ); High Press. Compr. 1 Out high pressure at the outlet of Compressor 1; High T . Compr. 1 Out high temperature at the outlet of Compressor 1; Low Press. Compr. 1 Oil low oil pressure in Compressor 1; Low Level. Compr. 1 Oil low oil level in Compressor 1; Solenoid 1 Closed solenoid valve in Compressor 1 closed; Compressor 1 Shut Down Compressor 1 stopped automatically; High Press. Compr. 2 Out high pressure at the outlet of Compressor 2; High T . Compr. 2 Out high temperature at the outlet of Compressor 2; Low Press. Compr. 2 Oil low oil pressure in Compressor 2; Low Level. Compr. 2 Oil low oil level in Compressor 2; Solenoid 2 Closed solenoid valve in Compressor 2 closed; Compressor 2 Shut Down Compressor 2 stopped automatically; Low Press. Cool Water low pressure of cooling sea water; Man In Cold Store.
o o o o o o o o

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REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Safety System

SAFETY SYSTEM
Not available as an individually implemented subsystem, provided by the system automatics.

SYSTEM FAULTS INTRODUCED BY THE INSTRUCTOR

Ref. Power fault system power supply fault; SW Reg. Valve 1 Fault faulty sea water valve 1; SW Reg. Valve 2 Fault faulty sea water valve 2; Air in System 1; Air in System 2; Excessive moisture Filter 1; Excessive moisture Filter 2; Condenser 1 Fouling; Condenser 2 Fouling; Compressor 1 breakdown; Compressor 2 breakdown; Refrigerant leakage from System 1; Refrigerant leakage from System 2; Oil leakage from Compressor 1; Oil leakage from Compressor 2; Term. Exp. Valve Fouling (Fish) fouling of temperature valve in the storeroom; Term. Exp. Valve Fouling (Meat) fouling of temperature valve in the storeroom; Term. Exp. Valve Fouling (Butter) fouling of temperature valve in the storeroom; Term. Exp. Valve Fouling (Fruit) fouling of temperature valve in the storeroom; Term. Exp. Valve Fouling (Vegetables) fouling of temperature valve in the storeroom; Term. Exp. Valve Fouling (Dry Prov.) fouling of temperature valve in the storeroom; Snow Coat (Fish) growth of snow coat in the storeroom; Snow Coat (Meat) growth of snow coat in the storeroom; Snow Coat (Butter) growth of snow coat in the storeroom; Snow Coat (Fruit) growth of snow coat in the storeroom; Snow Coat (Vegetables) growth of snow coat in the storeroom; Snow Coat (Dry Prov.) growth of snow coat in the storeroom; Thermostat Fault (Fish); Thermostat Fault (Meat).

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

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Directions for the Plant Operation and Maintenance

DIRECTIONS FOR THE PLANT OPERATION AND MAINTENANCE

Procedure for Starting the Plant in Manual Mode
1. Turn on the sea water pump. Monitor its operation by the pressure gauge.

Fig. 20

2. Set the compressor operating mode switch to MANUAL position.

3. Open the shut-off valves on the liquid refrigerant circulation lines.

4. If the refrigeration plant is expected to operate for its own group of storerooms only, shut-off valves on the connecting steam and liquid pipelines are closed. If one of the refrigeration plants operates for both groups of consumers (the second plant is not turned on), the shut-off valves should be closed. 5. Adjust the low pressure switch. On OFF scale, set the pressure value whereby the compressor is turned off. By the moment of the compressor stop, the temperature in all the cooled storerooms should achieve the set value.

Fig. 21

On ON scale, set the pressure value whereby the compressor is turned on. By this moment, temperature in at least one room has grown to more than the set value.

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REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Directions for the Plant Operation and Maintenance

6. Adjust thermoswitches for each storeroom.

Fig. 22

7. For Butter and Dry. Prov. storerooms. Adjust the evaporation pressure control.

Fig. 23

8. Open the master solenoid valve.

9. Start the compressor.

10. 11.

Set the operating mode switch of the equipment defrosting system to AUTO position. Set the time interval (in hours) at which the defrosting of refrigeration equipment will be performed in each cooling space.

Fig. 24

12.

Set the defrosting system control switch to AUTO position.

13.

Monitor the plant operation parameters maintaining their values within the standard range. You will be advised about all the faults by the alarm system. As a monitored parameter reaches the maximum permissible value, the safety system is actuated: an appropriate alarm is turned on in the bottom part of the screen. Load (unload) as necessary the set mass of goods (products) into/from the storerooms.

14.

Fig. 25

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

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Directions for the Plant Operation and Maintenance

Defrosting of Refrigeration Equipment in Manual Mode

This is used in case of excessive growth of hoar frost on the surface of refrigerating units. If the thickness of the hoar frost layer is 5 mm or more, and the equipment defrosting process has not been started automatically, then it is necessary to: 1. Set the defrosting system control switch to MANUAL position.

2. Press ON button under the switch.

Replenishment of Liquid Refrigerant

This is performed if the refrigerating plant operating mode indicates the insufficiency of liquid refrigerant in the system (low level of liquid refrigerant in the condenser receiver part, gas bubbles in the sight glass, low suction pressure, extensive overheating on the suction line and high charging temperature): 1. Set the compressor operating mode switch to MANUAL position.

2. Close the shut-off valve on the liquid line after the condenser.

3. Open the make-up valve.

4. Monitor the liquid refrigerant level by using the sight glass on the receiver part of the condenser. 5. After the end of the process, close the make-up valve (the liquid refrigerant level on the condenser sight glass is 0.40.5 ). 6. Open the shut-off valve after the condenser. 7. Turn the compressor on.

8. Set the operating mode switch to AUTO. 9. Monitor the refrigerating plant operation parameters. In case of the system overfilling with liquid refrigerant, there may be damp compressor operation.

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REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Directions for the Plant Operation and Maintenance

Compressor Replenishment with Oil

This is performed if the oil level in the sight glass on the compressor sump has dropped to below mark. The oil should best be added with the compressor not running (the oil level is clearly visible in the sight glass): 1. Set the compressor operating mode switch to MANUAL position.

2. Close the compressor suction valve. 3. After the suction pressure (in the sump) has dropped to a value below the atmospheric pressure ( -0.5 bars), stop the compressor. 4. Open the oil make-up valve.

5. After the end of the process (oil level is not higher than 2/3 of the sight glass), close the valve. 6. Turn the compressor on.

7. Set the operating mode switch to AUTO position.

8. Monitor the refrigerating plant operating parameters. Where the compressor cannot be stopped (e.g. loading of a considerable amount of goods with rather high temperature) at the moment of oil replenishment, it is necessary: 1. To re-adjust the low pressure switch on OFF scale make -0.5 -0.3 setting.

Fig. 26

2. After the pressure has dropped below the atmospheric pressure, open the oil make-up valve. 3. After the end of the process, close the valve. 4. Re-adjust the low pressure switch to the operating mode. 5. Monitor the refrigerating plant operating parameters. If oil is added to the operating compressor, the replenishment will be either excessive or incomplete.

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

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Directions for the Plant Operation and Maintenance

Air Discharge
This is performed if the pressure gauge needle on the charging line makes jerking oscillatory motions, and the charging pressure exceeds the optimum value by 0.2 MPa and more: 1. Set the compressor operating mode switch to MANUAL position.

2. Turn the compressor off.

3. Turn the compressor off (on the right in Fig. 27).

Fig. 27

4. After the water temperature drops at the condenser outlet (OUTLET temperature gauge) down to the sea water temperature (INLET temperature gauge), open the valve for the discharge of air from the system. 5. As the charging pressure drops to the value corresponding to the optimum condensation temperature, i.e. as the temperature readings in DISCHARGE pressure gauge and DISCHARGE temperature gauge are equalised, close the air discharge valve. 6. Monitor the level of liquid refrigerant by using the sight glass on the condenser (there should be no lowering of the level). 7. Adjust the condensation pressure control for the maintaining of the set pressure value (0.60.7 MPa). 8. Turn the compressor on.

9. Set the operating mode switch to AUTO position.

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REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

Directions for the Plant Operation and Maintenance

Replacement of Filter Drain

This is done when the colour of the sight glass indicator changes. The indicator colour changes from green to yellow as the moisture penetrates in the liquid refrigerant system: 1. Open the bypass valve of the filter drain.

2. Close the shut-off valves of the filter drain.

As this is done, the indicator colour will change from the yellow to green, i.e. there will be an imitation of the filter drain replacement: 1. Open the shut-off valves of the filter drain. 2. Close the bypass valves of the filter drain.

Compressor Breakdown
In case of failure of one of the compressors, the other compressor will maintain the required temperature in all the six provision storerooms: 1. Re-adjust the low pressure switch of the operating compressor (N2) as required (in case of breakdown of compressor N1). 2. Set the operating mode switch of the stopped (broken) compressor to MANUAL position. 3. Close the master solenoid valve on the refrigerating plant which is not operating. 4. Open the shut-off valves on the steam and liquid connecting lines.

REFRIGERATION PLANT SIMULATOR RPS 4000. Refrigerator Model. Trainee Manual

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