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Operation and Maintenance
Operation and Maintenance
Operation and Maintenance
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
THE SYSTEM SHOULD BE THOROUGHLY LEAK TESTED BEFORE EMBARKING UPON THE EVACUATION PROCESS.
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.
OPERATION AND MAINTENANCE
- 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.
CHARGING OF REFRIGERANT
What is the procedure adopted while charging refrigerant?
CHARGING OF REFRIGERANT
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
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:
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
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 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.
OPERATION AND MAINTENANCE
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
Electric cables / starters / switches / Overloading at that spot motors - hot Oil spots on any component of the refrigeration system Gas leak at that spot
- Water distribution is not No correction is desired uniform - Insufficient filling material - Inadequate air/water flow
Not possible
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
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
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
OPERATION AND 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)
PERIODICAL MAINTENANCE
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
PERIODICAL MAINTENANCE
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
X
X X X X X X X X
X
X X X
X
X
Oil sample
Check suction superheat Check crank case heater Check maintenance schedule with OEM X X
Less than 80
Less than 50 Less than 0.3 Less than 30 Less than 0.2 Max. 250
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
OPERATION AND MAINTENANCE
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.
TROUBLESHOOTING
NOT COOLING PROPERLY
Improper setting of temperature controls
TROUBLESHOOTING
RH IS HIGH
Improper setting of humidistat
TROUBLESHOOTING
SYSTEM NOISY
Noise generated from fan / belt / fan bearings / motor bearings
TROUBLESHOOTING
FOUL SMELL
Foul emanating from return air stream / fresh air intake
TROUBLESHOOTING
WATER DRIPPING
Leakage from a system other than of ACR
TROUBLESHOOTING
DISTURBING VIBRATIONS
Vibration isolators defective
TROUBLESHOOTING
DISTURBING CROSS TALK
Return duct / grilles / diffusers need sound attenuators
Partitions also should have sound attenuation properties
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
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
CAPACITY MEASUREMENT
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 MEASUREMENT
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 MEASUREMENT
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
CAPACITY MEASUREMENT
Check Points - pumps:
- Gland leak. While few drops can be allowed to drip, excessive flow should not be allowed.
CAPACITY MEASUREMENT
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.
CAPACITY MEASUREMENT
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.
CAPACITY MEASUREMENT
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.
CAPACITY MEASUREMENT
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
CAPACITY MEASUREMENT
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