GEA Grasso compressors, High COP Solution

• The new Grasso V series

challenges your Total Cost of Ownership

• Variable Speed Drive (VSD)

for reciprocating compressors

• Example COP analysis – Screw & Piston

• Example cost analysis – Screw & Piston

• Saving energy with Grasso SP & HR oil cooler

• Saving energy with Grasso BluAstrum chiller

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The new Grasso V series
challenges your Total Cost of Ownership

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Impression Chillventa Germany 2010

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Impression Chillventa Germany 2010

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Philosophy Grasso V series

The new Grasso V series challenges

your Total Cost of Ownership!

 Minimum energy costs

 Minimum maintenance costs
 Minimum investment costs
 Maximum reliability

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Grasso V series

Key-points for development:

1. Reciprocating compressor technology is solution for the future

2. Guaranteed quality
3. Lowest possible Total Cost of Ownership for end-user
4. On time maintenance
5. No design restrictions

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Minimum Energy Costs

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Minimum energy costs

New revolutionary housing design

 Optimized temperature separation.
 Less pressure loss in housing
 Large field of application without additional oil & cylinder cooling
 Large field of application under part load

Grasso 612 Grasso V-700

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Minimum energy costs

Best COP (suction side)

 Optimized inlet with better suction gas entry

 Huge suction chamber with low gas
velocities resulting in less pressure losses

 Unrestricted gas flow towards suction valves

 Minimized heat transfer between high and
low pressure side resulting in minimum
suction gas superheat

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Minimum energy costs

Best COP (compression cycle)

 Optimized suction sleeve holes for suction

valves

 Free flow discharge valves design

 Lightweight composite material suction
and discharge valves

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Minimum energy costs

Best COP (discharge side)

1 : Suction
2 : Discharge
Log P

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Minimum energy costs

Best COP (discharge side)

Less superheat
Lower discharge
temperatures 1 : Suction
2 : Discharge
Log P

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Maximum Energy Efficiency

• Measured oil temperature NH3 , -10/35 C, 1200 rpm.

V series

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Maximum Energy Efficiency

• Measured discharge temperature NH3 , -10/35 C, 1200 rpm.

V series

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Maximum Energy Efficiency

Measured Isentropic efficiency NH3 , 1200 rpm.

V series

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Minimum energy costs

Grasso V series (700 and on) versus Grasso 12 / 12E

 Lower discharge temperatures in full load : average 5K

 Lower discharge temperatures in part load : average 15K

 Lower oil temperature (in part load) : up to 30K

 Lower energy consumption compared to :

Grasso 12 : 4 - 6%
Grasso 12E : 2 - 4%

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Minimum Maintenance Costs

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Minimum Maintenance Costs

1. Extended maintenance intervals

 Best possible “running” parts
 Optimum/maximum speed chosen:
 NH3 refrigerant : 1200 rpm

 Synthetic refrigerants : 1000 rpm.

 Nominal service interval of 15.000 hrs. (top-end)

2. Flexible maintenance intervals with

Grasso Maintenance Monitor
 Monitoring online operating conditions
 Displays upcoming maintenance intervals
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Minimum Maintenance Costs

Flexible maintenance intervals with Grasso Maintenance Monitor

Every Grasso V series compressor is equipped with a GMM !!

Displays next Online measurement of

maintenance operation conditions
interval

Calculate next
maintenance interval

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Minimum Maintenance Costs
Technical specifications GMM
• Housing IP55
Measuring 5 parameters: • HALT (Highly Accelerated Life Test) tested
• Hot / cold
• Fast cycling temperatures
• 3x Temperatures •
•
Random vibrations
Combined steps
• Temperature Celsius - Fahrenheit
• Tdischarge
• Tsuction
• Toil
• RPM
• Start / Stops

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 Minimum Maintenance Costs

3 access configuration:
1. Connect GMM directly to computer or laptop
2. Connect GMM to closed company network (router), access with several computers
3. Connect GMM to company network with World Wide Web access. Possible access from
outside the company network

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Minimum Maintenance Costs

Web access

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Minimum Maintenance Costs

Convenient maintenance:

Easy access to wearing components

 O-ring seals instead of gaskets, no scraping & polishing required

 4 – bolt head cover gives direct access to valves & cylinder liner
 50% less fixing bolts all over compressor housing
 Easy removal of drive end main bearing housing for easy and accurate shaft
seal replacement
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Oil Consumption

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Oil Consumption

Packages with or without Oil separator?

 Increased distance between crankshaft and oil sump level

 Low pressure difference between crank casing and suction chamber
 Low gas velocities in the suction chamber
 Lower oil temperatures in part load

Result: - 50% compared with existing Grasso

compressors!

Laboratory results

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Oil Consumption

Laboratory measurements
refrigerant: NH3, running conditions: -10/35 oC

• Grasso612E n= 1200 rpm.

Oil carry over: After compressor : 46.4 cm3/h (20.4 ppm.)

After oil separator : 19.1 cm3/h (8.4 ppm.)

• Grasso V1100 n= 1200 rpm.

Oil carry over: After compressor : 10.0 cm3/h ( 4.4 ppm.)

(After oil separator : 4.1 cm3/h) ( 1.8 ppm.)

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Oil Consumption

Packages without Oil separator

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Oil Consumption

Packages without Oil separator

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Oil Consumption

2. Package with oil separator

 High efficient oil separator resulting in further improvement of lower

oil consumption (efficiency > 90%*)
 Lower discharge temperatures produce less oil vapor in discharge
gas what contributes to better oil separation

Result:
 Extreme low oil carry over to the installation
 Extended oil refill intervals and related costs

* Liquid drops

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Oil Consumption

3. Installation

 Extreme low oil carry over from compressor and efficient oil
separator prevents contamination of the installation.
 The isolating effect of oil in evaporators and condensers results in
more energy consumption
Oil film thickness

160 3.5

140 3.0

Oil film thickness [um]

120
2.5

dT-oil film [K]

100
2.0
80
1.5
60
1.0
40

20 0.5

0 0.0

Result: 0 200 400 600

Oil carry over [ppm]
800 1000

 More energy efficient installation due to low oil carry-over

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Sound level

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Sound

Sound power measurements at 1200 rpm, -10/35

110
Grasso V Grasso 12E
105
Sound power [dB(A)]

100

95

90

85

80
12 10 9 8 6 4
Number of cylinders

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Minimum Investment Costs

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Minimum Investment Costs

Lower price per kW cooling capacity!

Grasso V series standard fitted with:

• Build in counter pressure independent overflow valve (acc. EN
13136)
• Heavy duty axial roller bearing
• Grasso Maintenance Monitor

Additional arguments:
• 20% more cooling capacity
• Better project fit due to smaller capacity steps in the product range

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Maximum Reliability

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Maximum Reliability

Using best materials & proven components

Suction/discharge valves
Composite material valves

Shaft seal
Max. cooling by full oil

pump flow

Oil filter
high capacity oil filter

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Maximum Reliability

Crankshaft thrust bearing

Roller bearing construction

Main bearings
increased diameter

(90  112 mm)

Standard Warrantee period :

2 years

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Maximum Reliability

Oversized suction chamber

Oversized suction gas entry, and optimized filtering & distribution results in
increased resistance against liquid hammer.

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Total Cost of Ownership

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Total Cost of Ownership

Resume of improved TCO

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Total Cost of Ownership

Extra tool to strengthen the philosophy of the Grasso V series

The Grasso Sales force can provide you with a prediction of the total
running costs

Project
Comsel Quotation
input
Selection /
quotation
software Total
Additional
Running
TCO input
Costs

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Total Cost of Ownership

Required input
1. Refrigerant en running conditions (from Comsel)
2. Operating hours per year
3. Number of start/stops per 24 hrs
4. Inverter Yes / No
5. Speed (if inverter No, single speed compressors)
6. Average speed (if inverter Yes)
7. Average compressor part load
8. Energy cost in price per kWh
9. Labour costs in price/hr
10. Oil costs in price per liter

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Total Cost of Ownership

Example A : input Example B : input

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Total Cost of Ownership

Example A : output Example B : output

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The Product Range

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Product Range

Series Overview

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Last introduced models:
Grasso V 1400 ( 8 cylinder)
Grasso V 1800 (10 cylinder)
Available since January 2011

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V 1400

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V 1800

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Finalizing single stage range:
Grasso V 300 (4 cylinder)
Grasso V 450 (6 cylinder)
Grasso V 600 (8 cylinder)
(small block)
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3. The V300 – V600

• Available for sales from 01.01.2012

• Direct replacement for the Grasso 10
Grasso V Grasso 10 Cylinders Swept volume at 1.500rpm
(m3/h)
V300 410 4 290
V450 610 6 435
V600 810 8 580

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3. The V300 – V600

Design V300 – V450 – V600

• Housing design identical below centerline of crankshaft (same feet
width and shaft height) with existing V700, V1100, V1400 (big block)

Cylinders Small Big Intermediate Intermediate

block block Bearing Plate
4 V300 V700
6 V450 V1100 1
8 V600 V1400 1 1
10 V1800 2 1

• Oil pump capacity adapted to smaller bearing journals

• Suction strainer smaller in diameter

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3. The V300 – V600

Design V300 – V450 – V600

• Testing in progress

• Similar performance improvements expected

due to revolutionary crank case construction

Features V300 – V600 V700 – V1800

Max speed 1.500 rpm 1.200 rpm
Nominal service int. 12.000 hrs 15.000 hrs
GMM Included Included
Warrantee 2 year 2 year

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Grasso V series small block development

First prototype Grasso V450 in assembly

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Grasso V series small block development

First prototype Grasso V450 on test bench

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Product Range

Status development single stage V series replacing:

1. 4 & 6 cylinder Grasso 12/12E series Done

2. 9 &12 cylinder Grasso 12/12E series Done

3. 4, 6 & 8 cylinder Grasso 10 series 01.01.2012

4. Two stage models 01.01.2013

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TCO Comparison
Grasso V / Grasso 12(E)

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TCO comparison

Total cost Grasso V700 compared to Grasso 412

10.0% 1.000 rpm comparison in total cost per kWh

8.0%

6.0%
Deviation from 412 in percentage

4.0%

2.0% Break even at

2.000 hours
412
0.0% V700(1000)
0 10,000 20,000 30,000 40,000 50,000 60,000
-2.0%

-4.0%

-6.0%

-8.0%

-10.0%
Running hrs

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TCO comparison

Total cost Grasso V700 compared to Grasso 412E

10.0% 1.200 rpm comparison in total cost per kWh

8.0%

6.0%
Deviation from 412E in percentage

4.0%
Grasso V series
always better TCO
2.0%
412E(1200)
0.0% V700(1200)
0 10,000 20,000 30,000 40,000 50,000 60,000
-2.0%

-4.0%

-6.0%

-8.0%

-10.0%
Running hrs

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Conclusions

• Grasso V series has the best Coefficient Of Performance (COP)

• Grasso V series has the best TCO compared to Grasso 10, 12(E)

• Grasso V series has a lower TCO directly from the start than a
Grasso 12 and Grasso 12E (1200 rpm)

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Conclusions

• Grasso V series has the best Coefficient Of Performance (COP)

• Grasso V series has the best TCO compared to Grasso 10, 12(E)
• Grasso V series has a lower TCO directly from the start than a
Grasso 12 and Grasso 12E (1200 rpm)

• Grasso V series has a lower TCO after 9.000 hrs (<2 years) than a
Grasso 12E (1500 rpm)

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