Operation and Maintenance

7.
OPERATION AND MAINTENANCE
7. OPERATION AND MAINTENANCE

7.1. COMMISSIONING 7.1.1. Pressure Testing of Refrigeration Circuit 7.1.2. Vacuumising of Refrigeration Circuit 7.1.3. Charging of Refrigeration Circuit 7.1.4. Trial Run and Handing Over
7.2. OPERATION 7.2.1. Know about Air Conditioning System 7.2.2. Efficient Operation of Air Conditioning System 7.2.3. Important Feelers from Air Conditioning Plant 7.2.4. Inferences from Log Sheets
7. OPERATION AND MAINTENANCE

7.3. MAINTENANCE 7.1.1. Routine Maintenance 7.1.2. Periondical Maintenance 7.1.3. Maintenance Schedule for System, Chiller and Compressor
7.4. TROUBLE SHOOTING

7.5. CAPACITY MEASUREMENT & CHECK POINTS
PRESSURE TESTING OF REFRIGERANTION CIRCUIT

What should be the test pressure? Test pressures has a relation to the operating pressures. Generally the system is tested to 1.5 times the operating pressure. The operating pressure of an AC&R system is dependent on refrigerant used, ambient temperature, condensing pressure and suction pressure.
What is procedure adopted in pressure testing?

- Generally dry nitrogen is used for pressure testing. - We have to test the high side (the area which has high pressure from compressor discharge shut off valve to the inlet of expansion valve) to the high test pressure and low side (the area which has low pressure from the outlet of expansion valve to the suction service shut off valve on compressor) OPERATION AND MAINTENANCE

- Keep all the valves in the system are open. - First test the entire system to the low pressure and make sure there are no leaks. - Shut off the discharge service shut off valve and liquid line service valve - Apply high pressure to the high side only and test the system for leaks

- What are methods adopted to identify the leaks? - Use soap solution to detect the leaks - Use halide leak detector A burning flame which is generally blue in colour will turn green when any of the halogen gases (Fluorine, chlorine, bromine or iodine) come near the flame. This method is not suitable for Ammonia systems. Apply pressure up to 5 lbs into the system using R-12/R-22/R-11. Increase the test pressure to the desired level using nitrogen. Check for the leaks. - Electronic instruments are available to detect presence of halogen gases in the vicinity of the instrument. The instrument can be adjusted to monitor leaks of different magnitudes.

- What are methods adopted to identify the leaks? - Vacuum Standing Test Using a good quality vacuum pump, draw the desired vacuum within the entire system. Note down the date, time, temperature of surrounding air and the quantum of vacuum reached. Close the valves leading to the vacuum pump. On the next day at the same time, observe the vacuum in the system and temperature of air surrounding the system. Subject to slight variation in ambient temperature the vacuum in system should remain the same. If not, there are leaks to be detected and stopped.

DOs: - Have total patience while pressure testing. There should be no hurry whatsoever in doing pressure testing. - Do a through job of stopping all leaks. DONTs: - Do not rely on the work of new comer as he has not experience - Do not use Oxygen for pressure testing. You are bound to end up in accident of a big magnitude. -Do not test the system for a pressure higher than desired. - Do not use gas cylinders without proper pressure regulating valves. - Do not start the system while pressure testing even by chance. OPERATION AND MAINTENANCE
THE SYSTEM SHOULD BE THOROUGHLY LEAK TESTED BEFORE EMBARKING UPON THE EVACUATION PROCESS.
VACUUMISING OF REFRIGERATION CIRCUIT

- What is vacuumising? - Ensuring that the refrigeration circuit is without moisture and air at the time of charging oil and refrigerant is vacuumising. - Why should we have a vacuumised system? Air inside the system will a) prevent us from charging refrigerant fully. b) remain as a non condensible inside the condenser and reduce the condenser capacity and thus reduces the cooling effect. c) increases condensing temperature and temperature of parts inside the compressor. d) reduces the effective use of electric power consumed lower efficiency. OPERATION AND MAINTENANCE

- Why should we have a vacuumised system? Moisture inside the system will result in a) formation of acids inside the compressor due to heat, oil, gas and moisture. b) acids acting on the motor winding if it is a hermetic / semihermetic compressor. c) acids will act on the parts of the compressor resulting in corrosion.
d) breakdown of compressor either electrical or mechanical or both. e) blocking of expansion valve at the needle valve by formation of ice. f) poor operation of system.

What should be the extent of vacuum required? Unit of measurement of vacuum in AC&R industry is MICRON. One micron is one millionth part of a meter. 1 micron is 1/1000 mm, that is 0.001 mm. We can aim at 500 microns. What is the procedure adopted while vacuumising? - Firstly we need a good vacuum pump. Secondly we need a good system without leaks. -A good vacuum pump is one which can draw the required vacuum within a reasonable time - Do not use the system compressor for drawing vacuum. OPERATION AND MAINTENANCE

What is the procedure adopted while vacuumising? - Vacuum pump should have oil of proper quality and changing the oil is desired as the oil will be absorbing moisture continuously while in operation. - Connection between vacuum pump and the AC&R system should be minimum with two pipes, one leading to the high side and another to the low side. The pipes should be of at least 1/2 dia. - A non return valve between pump and system is desirable to avoid suction of oil into the compressor in the event of power failure. - One vacuum gauge has to be located at the farthest point from the pump and at the top most point on the system and this alone can be the one to establish the vacuum inside the system. OPERATION AND MAINTENANCE

How to check the exact vacuum inside?
Instruments used are

- Compound gauge - Vacuum gauge - McLloyd manometer - Electronic vacuum gauge Both compound gauge and vacuum gauge are susceptible for indicating incorrect readings, being a mechanical contrivance. McLloyd manometer can read even 100 microns. Even electronic vacuum gauges are very sensitive. OPERATION AND MAINTENANCE

How to improve vacuumising process?
- Heating the system: This is OK for small systems only. Heating the refrigeration circuit will drive moisture quickly.
- Triple evacuation: After vacuumising fully, charge the system with R-22 to 2 psig, revacuumise. Do this operation thrice. The gas let out drives the moisture quickly. - Use cold trap: Cold trap is an inter-cooler placed between the vacuum pump and the system. The intercooler provides a cold surface in the air stream from the system and the moisture in the air gets condensed on the cold surface.
CHARGING OF REFRIGERANT
Quality of refrigerant:
Refrigerant used must be of proper quality. Quality means both the chemical inside, the dryness, the contamination with air etc.
Quantity of refrigerant: Follow the manufacturer guideline.
What is the procedure adopted while charging refrigerant?
- Charging has to be done slowly.

- For charging of refrigerant, we should use a small dia pipe say dia. Copper pipe. - Initially charging of refrigerant has to be through only liquid line. Liquid can be let into the system. - Do not charge into the suction line, liquid refrigerant at any stage. - Final charging can be through suction line, but after making sure that only gas enters the system. Keep the cylinder of refrigerant vertical while charging into the suction line. OPERATION AND MAINTENANCE
What is the procedure adopted while charging refrigerant? - While charging refrigerant, keep a watch on the current drawn by the compressor. It should not exceed the full load amps. - There is need to check the super-heat on the suction after the system is fully charged. - System should be charged only to the extent required. - If the system is having partial load at the time of commissioning, the charge has to be supplemented later when the full load comes on. - Make sure that the safety control circuit is fully effective when the system is getting charged. OPERATION AND MAINTENANCE
TRIAL RUN AND HANDING OVER

Trial run period in the case of ACR plants, can extend to a few weeks even. During trial run, the following will have to be done: - tuning of the system as a whole i.e. air flow, water flow, refrigerant flow, safety control operation, temp / RH control operation. - taking all measurements over a reasonable period of time. - comparing the actual readings with design parameters. - training the clients mechanics on the job - establishing the log sheets. Before handing over, the following will have to be done: - turning down the impellers of the pumps to make sure that only correct quantity of water is flowing through - fitting the blowers with pulleys which will give desired air quantities only OPERATION AND MAINTENANCE
OPERATION
OPERATION OF THE AC SYSTEM COVERS:
Running of the plant in a satisfactory manner Recording the measurement done and also the events that have taken place in the log book Record the unusual behaviour of plant Inferences from the log sheets Efficient operation of the air conditioning system
OPERATION
Before operation of the plant, the concerned staff must have a clear idea of the air conditioning system KNOW THE FOLLOWING: The following information is essential to understand the air conditioning system / coordinate with service provider / analyse problems in future / undertake any modifications Basis of design - Maximum ambient DB / WB temperatures - Room designed DB / RH with the tolerance permitted - Occupancy - Equipment load, process load, product load - Lighting load - Fresh Air OPERATION AND MAINTENANCE
OPERATION
KNOW THE FOLLOWING: Designed Operating Parameters of various equipment: - Compressor (Suction & discharge temperatures / pressures) - Condensers (Water flow / air flow, pressure drop and temp. drop in water line) - Chillers (Water flow, pressure drop and temp. drop in water line) - Water circulating pumps (Pump head and flow rate) - Cooling / heating coils (Flow rates, temperature drops and pressure drops) - Air handling units ( Quantity of fresh air, return air, supply air; ADP; temperatures at air entry, after fan, after heaters, before & after cooling / heating coils ) OPERATION AND MAINTENANCE
OPERATION
KNOW THE FOLLOWING:
- Cooling towers (Air / water flow rates, temperature drop in water line and approach to cooling tower)
- Temperature / RH controls (cut in-out points, set points and sequence of operation) - Safety Controls (Set / cut in-out points sequence of operation) - Refrigeration system controls (Superheat and sub-cooling) - Control circuit (Sequence of operation) - Motors (RPM, HP, safety factor allowed white selecting the motor) OPERATION AND MAINTENANCE
OPERATION
KNOW THE FOLLOWING:
- Starters ( Type, overload setting and time delay

allowed) - Charge of oil, refrigerant, brine, etc. (Type, quality and quantity)
Data of various equipment Make, model, serial numbers and technical specifications
As built drawings hard and soft copies Plant layout, chilled water schematic, condenser water schematic, duct layouts with air quantities to various areas, AHU room layouts, electrical schematics, etc.
OPERATION
Operation and Maintenance manual by the vendor Operating instructions and preventive maintenance Operation / Maintenance / Service manuals from original equipment manufacturers of major equipment Spare parts manual for major equipment Details like type of refrigerant, compressor oil, bearings model, belt sizes, filter sizes Escalation chart from service provider with telephone numbers
OPERATION
The above information should be treated as typical example of the nature of information that are required to be collected.
This data varies from job to job. While operating the plant, the operators should obtain readings required for establishing important feelers from AC plants as also inferences from log sheet. Failure to record the unusual behaviour of the plant will make trouble shooting / preventive maintenance difficult. A careful study of the readings of the Log Sheets will forewarn of possible breakdowns in future. Such services can then be arranged so as to avoid the breakdowns. OPERATION AND MAINTENANCE
EFFICIENT OPERATION OF AIR CONDITIONING SYSTEM

Set the correct room temperature Normal tendency is to set lowest temperature to avoid complaints. Too low temperature is as uncomfortable as high temperature. Set correct DP value for secondary pumping system Set correct static pressure for VAVs Ensure proper chilled water and condenser water quality is maintained

Operate the system at high chilled water temperature during winter and monsoon seasons BMS will help
During the months when there is continuous partial load operations, let the chilled water temperature be 47 deg. F instead of 45 deg. F. This can be achieved by resetting the thermostat sensing the chilled water outlet temperature, which in turn operates the unloaders on the compressor. IKW/TR will be low at higher chilled water temperature.

Ensure that indoor venation blinds are closed as far as possible Avoid leakages in the air conditioning space to avoid infiltration of fresh air
Ensure toilet exhaust air and kitchen exhaust air is not mixed with air-conditioned air
Ensure that air conditioning equipment is running only when it is required Try and maintain high indoor temperature during lunch time, etc.
IMPORTANT FEELERS FROM AC PLANTS

FEELERS INDICATORS
Liquid line sweating behind strainer / catchall / capillary

Liquid line is hot and cold alternatively, periodical and continuous change Liquid line hot all the time Expansion valve has ice beyond the liquid inlet Evaporator coil has block of ice on it
Choke in refrigerant line just after the cold spot

Indicates improper liquid seal in the condenser / receiver OR shortage of gas in the system Shortage of gas in the system Power element of expansion valve has stuck leading to excessive pressure drop Condensing pressure is too low / pressure drop across the valve is inadequate or short of gas

FEELERS INDICATORS
Compressor crankcase oil portion Liquid flooding is indicated has excessive sweating or ice formation or excessive foaming in the oil
Compressor crankcase suction side is hot Condenser bottom as hot as top Compressor oil chamber too hot Suction line - hot Internal relief valve could have opened out / excessive superheat possible Liquid seal is missing OR the system is short of gas Crankcase heater may be ON even when compressor is working Excessive superheat OR system is short of gas

FEELERS Bearing surfaces - hot INDICATORS Improper lubrication
Electric cables / starters / switches / Overloading at that spot motors - hot Oil spots on any component of the refrigeration system Gas leak at that spot
INFERENCES FROM LOG SHEETS

Cooling Tower:
OBSERVATIONS PROBABLE REASONS FOR VARIATIONS BEING HIGHER THAN NORMAL Temp. (water in water out): normal is 8 to 10 deg. F Temp. (water out WB of air entering): normal is 7 deg. F - Inadequate air & / or water flow - Filling is not effective LOWER THAN NORMAL - Excessive air & / or water flow - Short cycling of air near cooling tower
- Water distribution is not No correction is desired uniform - Insufficient filling material - Inadequate air/water flow
Temp. (WB at entry WB at ambient): normal is nil
- Short cycling of air near cooling tower.
Not possible

Condenser:
OBSERVATIONS PROBABLE REASONS FOR VARIATIONS BEING HIGHER THAN NORMAL Temp. (water out water in): normal is 8 to 10 deg. F Temp. (Condensing water out): normal is 10 deg. F - Inadequate water flow LOWER THAN NORMAL - Excessive water flow - Fouled water tubes in condenser - Partial load on the plant - Partial load on the plant
- Air in system - Fouled water tubes

AHU:
OBSERVATIONS PROBABLE REASONS FOR VARIATIONS BEING HIGHER THAN NORMAL Temp. (water out water in): normal is 8 to 10 deg. F. Can be higher or lower too Temp. (Air DB after coil water out) depends on design - Low water flow - Increase in load LOWER THAN NORMAL - High water flow - Reduced load
- Filter / Coil chocked - Low air flow - Poor cooling
Low load
Temp. (Air DB before coil air DB after coil) Air (DB after fan DB before fan)
- Low load
- Filter / coil chocked - Short of gas - High super heat - Fan not working - Not possible
- Fan motor over loaded

AHU:
OBSERVATIONS PROBABLE REASONS FOR VARIATIONS BEING HIGHER THAN NORMAL LOWER THAN NORMAL
Temp. (DB at first SA grille - Reheaters on - Not possible DB after fan) - Supply air getting heated Temp. (Last supply grille DB First supply grille) - Duct insulation not effective / adequate - Not possible
Temp. (return grille supply grille DB) Temp. (DB before cooling coil DB return grille)
- Air flow not enough - Inadequate insulation on return duct - Fresh air leak into return duct / plant room
- Too much air flow at partial load - Leaky supply air ducts - SA air leak at diffusers / grilles due to improper fixing

Compressor:
OBSERVATIONS PROBABLE REASONS
Condenser normal and suction low

Condensing high and low suction
- System is short of gas

- Condenser not functioning effectively

Compressor and condenser:
OBSERVATIONS PROBABLE REASONS
Temp. (Condensing water out) is high and Temp. (Water out water in) is low
- Scaled condenser
MAINTENANCE
ROUTINE MAINTENANCE :
Involved in keeping the area clean Operation of the plant at the best efficiency
PERIODICAL MAINTENANCE:
Observing the performance of all the controls Locating the abnormality of plant performance Analysing the causes for the abnormal performance of plant Attending to rectifications of such defects which should be immediately set right
MAINTENANCE
PERIODICAL MAINTENANCE:
Helps in avoiding breakdowns which otherwise would occur after some time Taking note of the defects which have been coming up on the plant from time to time; of the feelers obtained from the plants with the help of the log book entries; reasons for malfunctioning of the plant action is to be taken to correct the malfunctioning
A VERY CAREFUL ANALYSIS OF THE LOG SHEET DATA, THE CHANGES THAT HAVE COME IN THE PERFORMANCE OF THE PLANT OVER A PERIOD OF TIME AND MINIMUM CORRECTIVE STEPS TO BE TAKEN ARE DESIRED
ROUTINE MAINTENANCE
Lubricate bearings Tighten belts Reduce water leaks Observe oil spots Observation vibrations and noise Observe hot / cold spots Clean filters Clean nozzles of cooling towers Clean the surfaces of equipment Observe water level in tanks Observe Amps, Volts, RPMs. Observe wear and tear on parts
ENTER DETAILS IN LOG BOOK REGULARLY AND IMMEDIATELY ASSIST THE GROUP DOING PERIODICAL AND PREVENTIVE MAINTENANCE
PERIODICAL MAINTENANCE
ESTABLISH DURING PREVENTIVE MAINTENANCE THE FOLLOWING: Temperature Differences - Water in to out at condenser, chiller, cooling coils, cooling tower, heat coil. - Cooling tower tank water to WB of entering air - Wet bulb of air entering cooling tower and ambient air WB - Condensing to water out from condenser Pressure Differences - Compressor (Pump oil to suction; pump oil to control oil; discharge to suction) - Evaporator (Coil outlet to suction on compressor) - Pump (Outlet to inlet) - Heat exchangers (inlet to outlet)
ESTABLISH DURING PREVENTIVE MAINTENANCE THE FOLLOWING: Hot spots - Electric cables, motors, starters. - Bearings of all moving parts. - Hot gas & liquid lines. Cold spots - Suction lines, liquid lines behind expansion valves, compressor body / crankcase. Oil spots - Refrigeration system
ESTABLISH DURING PREVENTIVE MAINTENANCE THE FOLLOWING: Satisfactory operation of safety / temperature / refrigeration controls - HP, LP cutouts, Oil safety switch, airstat, antifreeze thermostat, fire dampers, fire alarms, sequential operative circuits, overload releases - Super heat on expansion valves, liquid level controls
TAKE CORRECTIVE STEPS WHICH ARE TO BE TAKEN IMMEDIATELY
MAINTENANCE SCHEDULE - SYSTEM

Check Points Log parameters Daily X Weekly Monthly Quarterly Annually
Check water level in expansion tank

Check water level in make-up water tank Check quality of water Clean water line strainers Top up grease for all motors Clean air filters Apply thermal paste on the temperature sensors Check for any abnormal noise and vibration Clean equipment externally
X
X X X X X X X X
MAINTENANCE SCHEDULE - CHILLER

Check Points Log parameters Check for any refrigerant leaks Check / clean refrigerant strainer Check condition of refrigerant drier Daily X X X X Weekly Monthly Quarterly Annually
Clean air cooled condenser coils

Check healthy operation of safety devices Check tightness of all electrical terminations and connections Apply thermal paste on the temperature sensors
X
X X X
Check for any abnormal noise and vibration

Check liquid line sight glass / moisture indicator
X
X
Oil sample
Check suction superheat Check crank case heater Check maintenance schedule with OEM X X
MAINTENANCE SCHEDULE COMPRESSOR

Check Points Electrical Insulation Oil filter catridge Suction filter Oil level Oil Bearings Motor thermal protector Check maintenance schedule with OEM X - Check or Clean R - Replacement X X X X X X X X X X X X X R X X X R X X 1000 hrs 2500 5000 10000 hrs hrs hrs X X 15000 hrs 20000 hrs X X 25000 hrs 30000 hrs X X X X
Recommended Water Quality for Cooling Water

Test parameter Ph TOTAL HARDNESS (CACO3) PPM Make-up water quality standard 6.0 8.0 MAX. 50 Cooling water quality standard 7.2 8.5 MAX. 200
TOTAL ALKANITY (CACO3) PPM

CHLORIDE ION (PPM) TOTAL ION (Fe) PPM SILICA (SiO2) AMMONIUM ION (PPM) TDS (PPM)
Less than 80
Less than 50 Less than 0.3 Less than 30 Less than 0.2 Max. 250
Less than 100

Recommended Water Quality for Chilled Water

Test parameter Ph TOTAL HARDNESS (CACO3) PPM Make-up water quality standard 7.2 8.5 MAX. 80
TOTAL ALKANITY (CACO3) PPM

CHLORIDE ION (PPM) TOTAL ION (Fe) PPM SILICA (SiO2) AMMONIUM ION (PPM) TDS (PPM)
Less than 100

TROUBLESHOOTING
Trouble shooting is an art which can be developed by sincere effort Experience, taking guidance from the experienced seniors, analysing the data from the field, methodically going about establishing possible cause for the trouble will in the end shoot the trouble. Troubles can start on the day of commissioning the plant also Given below are the most common troubles and the usual root causes
TROUBLESHOOTING
NOT COOLING PROPERLY
Improper air distribution due to failure of insulation acoustic insulation inside the duct, filter chocking, cooling coil chocking, chocking of grille, blocking of grilles by curtains, cupboards. Changes in layout / location of equipment Dampers closed Fan belt broken Inadequate quantity of air flow.
Leakage of supply air and fresh air

Reheaters coming on abruptly Defective design of piping
TROUBLESHOOTING
NOT COOLING PROPERLY
Improper setting of temperature controls
Insufficient water through cooling coils

Water line valves are closed. 2way / 3-way valve is not functioning properly balancing valve is chocked Water balancing is disturbed
Air balancing is disturbed

Load is more in the air conditioned area
TROUBLESHOOTING
RH IS HIGH
Improper setting of humidistat
Cooling coil is dirty

Insufficient water through cooling coils Chilled water temperature is not maintained Leakage of fresh air in to conditioned area Dry bulb temperature is maintained low in the conditioned space
Re-heaters are not functioning properly

Low equipment load in the air conditioned space
TROUBLESHOOTING
SYSTEM NOISY
Noise generated from fan / belt / fan bearings / motor bearings
Misalignment of belts / driving and driven equipment

Noise generated by equipment due to lose joints, dampers, filters Air cutting noise at the grille due to improper air balancing External noise entry Lack of sound attenuators
Plant room walls not acoustically treated

Fan / AHU selection is improper
TROUBLESHOOTING
FOUL SMELL
Foul emanating from return air stream / fresh air intake
Dead rat in the return duct

Drain tray / filters / cooling coil are not clean Fresh air intake is less or nil Toilet exhaust air is mixing with air conditioned air
TROUBLESHOOTING
WATER DRIPPING
Leakage from a system other than of ACR
Failure of insulation on the chilled water pipe lines

Fresh air striking cold duct surface Inadequate insulation on the cold surfaces Leakage from pipe line Leakage from drain line
TROUBLESHOOTING
DISTURBING VIBRATIONS
Vibration isolators defective
Foundations of moving equipment touching the building reinforcements

Pipe and duct supports are touching the false ceiling, false ceiling supports, partitions, etc. Duct / pipe passing through walls / slabs / partitions with out any isolation Moving parts out of balance
TROUBLESHOOTING
DISTURBING CROSS TALK
Return duct / grilles / diffusers need sound attenuators
Partitions also should have sound attenuation properties
DUST LEVEL HIGH

Excessive dust generated at fresh air intake point
Filters are not doing their job properly

Dust generated with in the conditioned area
TROUBLESHOOTING
FIRE IN SYSTEM
Short circuit in electrical components
Waste cloth lying loose on heaters, etc. Safety controls are made inoperative Waste / inflammable material in the plant room Strict discipline by staff (smoking, etc.) not maintained
TROUBLESHOOTING
BREAK DOWN OF THE SYSTEM
Entries in the log book will generally indicate the most probable reason for the failure, malfunctioning of one or more components of the system including the controls
Failure to rectify defects noticed during earlier maintenance operations, etc.
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING
Check maintenance schedule with OEM
TROUBLESHOOTING
There could be around ten types of complaints, the most common one being NOT COOLING with more than 50 possible causes for it. The possible defects which are highlighted in each of the category are not to be assumed to be present till all the other simpler causes are examined. No point in assuming that the designer has made a mistake in establishing heat load or design, till all other causes are eliminated fully.
TROUBLESHOOTING
DO NOT BLAME ANYONE WHILE DOING TROUBLE SHOOTING NEITHER THE DESIGNER, NOR THE ERECTOR, NOR THE ELECTRICIAN, NOR THE DECORATOR, NOR ANY OTHER AGENCY. DO THE JOB OF RECTIFYING THE DEFECT SOON AND CLEAR THE PROBLEMS
CAPACITY MEASUREMENT
Capacity measurement of ACR plant at site:
DX Plant:
Refrigeration Capacity in TR = 4.5 x CFM x (H1-H2) / 12000
Where CFM = Air quantity in cubic feet per minute H1 = Enthalpy of air entering the coil in Btu/hr H2 = Enthalpy of air leaving the coil in Btu/hr
Chilled Water Plant:

Refrigeration Capacity in TR = gpm x (T1-T2) x sp.ht x sp.gr. / 24
Where gpm = Flow rate of water/brine in gpm T1 = Temperature of water/brine entering the chiller in deg. F T2 = Temperature of water/brine leaving the chiller in deg. F Specific heat expressed in Btu/lb./deg. F For water specific gravity / specific gravity = 1
Power consumption measurement of ACR plant at site:
Power consumed can be established from the electrical readings of ammeter, voltmeter and PF
Power Consumption in KW = V x I x PF
Where V = Voltage in Volts I = Current in amps. PF = Power factor
Capacity of evaporator / cooling coil:
Capacity of evaporator / cooling coil can be calculated by measuring air quantity and WB temperature of entering air & leaving air
Capacity of cooling coil in Btu/hr. = 4.5 x CFM x (H1-H2)

Where CFM = Air quantity in cubic feet per minute H1 = Enthalpy of air entering the coil in Btu/hr H2 = Enthalpy of air leaving the coil in Btu/hr
Capacity measurement - pumps:
To establish the pump performance, flow rate and head should be measured
Head can be measured by installing the pressure gauges on suction side and discharge side. Head is the difference between the discharge pressure and suction pressure.
Flow rate can be measured by installing the flow meter in pipe line. Flow rate can also be read from the characteristic curve corresponding to head measured as above at particular impeller diameter and RPM
Check Points - pumps:
- Gland leak. While few drops can be allowed to drip, excessive flow should not be allowed.
- Direction of rotation of pump is very important.

- Noise from the pump. - Pump motor current should be less than its rated full load current. - Bearings should get the quality of grease / oil for lubrication. - Air should not be there in the system.
Capacity measurement - fans:
To establish the fan performance, air flow rate and static pressure should be measured
Air flow rate can be calculated by multiplying the area and velocity of air. Air flow rate is generally measured at cooling coil or filters in the return air.
Velocity can be measured with a velameter / anemometer either vane type or electronic type. Static pressure developed by the fan can be measured by pitot tube or manometer.
Check points Fans & AHUs:
- Condition of belts (matched set essential). - Proper alignment of fan with motor desirable. - Lubrication of bearings. - Vibration isolators to be effective.
- Fan guard to be in position. Function of limit switch.

- Foreign material should not enter the fan. - Fresh air inlet should not hit fan / AHU OPERATION AND MAINTENANCE
Check points Fans & AHUs:
- With star-delta starters, the time for change over from star to delta to be adequate to avoid stalling / overloading of motor.
- Drain water should not be stagnated in the drain tray.

- Drain pipe should be checked for proper drain.
Capacity measurement cooling towers:
Water flow rate together with the temperature difference will give the heat dissipated by the tower to the atmosphere.
Heat dissipated = GPM x (T1-T2)
Where GPM = flow of water in USGPM T1 = Temperature of water entering cooling tower in deg. F T2 = Temperature of water leaving cooling tower in deg. F
Wet bulb approach is an important factor to be observed
Check points cooling towers: - Water pressure at the nozzle should not be more than specified by
the manufacturer. - Wet bulb temperature of air entering cooling tower should be the same as the wet bulb of ambient air. Increase in WB reading at the entry indicates short cycling of air from the tower.
- Spray loss, drift loss and wastage around the sump are to be minimised.
- Blow down rate of water is to be established - Fan motor speed, current, condition of belt drive, lubrication to fan and motor bearings are also to be noted - Condition of strainer on tower needs attention - Level of water in cooling tower sump shall be 3 above the suction pipe
TRIAL RUN AND HANDING OVER

Trial run period in the case of ACR plants, can extend to a few weeks even. During trial run, the following will have to be done: - tuning of the system as a whole i.e. air flow, water flow, refrigerant flow, safety control operation, temp / RH control operation. - taking all measurements over a reasonable period of time. - comparing the actual readings with design parameters. - training the clients mechanics on the job - establishing the log sheets. Before handing over, the following will have to be done: - turning down the impellers of the pumps to make sure that only correct quantity of water is flowing through - fitting the blowers with pulleys which will give desired air quantities only

Operation and Maintenance

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Operation and Maintenance

Caricato da

Copyright:

Formati disponibili

7.

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

7. OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

7. OPERATION AND MAINTENANCE

7.4. TROUBLE SHOOTING

OPERATION AND MAINTENANCE

PRESSURE TESTING OF REFRIGERANTION CIRCUIT

What is procedure adopted in pressure testing?

PRESSURE TESTING OF REFRIGERANTION CIRCUIT

OPERATION AND MAINTENANCE

PRESSURE TESTING OF REFRIGERANTION CIRCUIT

OPERATION AND MAINTENANCE

PRESSURE TESTING OF REFRIGERANTION CIRCUIT

OPERATION AND MAINTENANCE

PRESSURE TESTING OF REFRIGERANTION CIRCUIT

PRESSURE TESTING OF REFRIGERANTION CIRCUIT

OPERATION AND MAINTENANCE

VACUUMISING OF REFRIGERATION CIRCUIT

VACUUMISING OF REFRIGERATION CIRCUIT

VACUUMISING OF REFRIGERATION CIRCUIT

VACUUMISING OF REFRIGERATION CIRCUIT

VACUUMISING OF REFRIGERATION CIRCUIT

Instruments used are

VACUUMISING OF REFRIGERATION CIRCUIT

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

- Charging has to be done slowly.

TRIAL RUN AND HANDING OVER

OPERATION AND MAINTENANCE

- Starters ( Type, overload setting and time delay

OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

EFFICIENT OPERATION OF AIR CONDITIONING SYSTEM

EFFICIENT OPERATION OF AIR CONDITIONING SYSTEM

OPERATION AND MAINTENANCE

EFFICIENT OPERATION OF AIR CONDITIONING SYSTEM

IMPORTANT FEELERS FROM AC PLANTS

Liquid line sweating behind strainer / catchall / capillary

Choke in refrigerant line just after the cold spot

OPERATION AND MAINTENANCE

IMPORTANT FEELERS FROM AC PLANTS

OPERATION AND MAINTENANCE

IMPORTANT FEELERS FROM AC PLANTS

OPERATION AND MAINTENANCE

INFERENCES FROM LOG SHEETS

Temp. (WB at entry WB at ambient): normal is nil

- Short cycling of air near cooling tower.

OPERATION AND MAINTENANCE

INFERENCES FROM LOG SHEETS

- Air in system - Fouled water tubes

OPERATION AND MAINTENANCE

INFERENCES FROM LOG SHEETS

- Filter / Coil chocked - Low air flow - Poor cooling

- Fan motor over loaded

OPERATION AND MAINTENANCE

INFERENCES FROM LOG SHEETS

OPERATION AND MAINTENANCE

INFERENCES FROM LOG SHEETS

Condenser normal and suction low

- System is short of gas

OPERATION AND MAINTENANCE

INFERENCES FROM LOG SHEETS