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An operation and maintenance manual usually includes such items like starting
and shut down sequences, equipment maintenance, etc. However, what is often
missed is the communication of the design intent of the Engineer/Consultant,
to the operating personnel. There had been instances of improper plant
operation, because the operating personnel had not been made aware of how
the systems were designed to operate. This Manual has been prepared to
eliminate such deficiencies.
DESIGN DETAIL
Design conditions
Internal Load :
No. of people :
Lighting load :
Equipment load :
Condenser water (inlet) Temp :
Condenser water temp range :
Compressor Sat. Suction Temp. :
Total plant capacity required (Tons) :
Total installed capacity (tons) :
No. of plants to be operated at maximum load :
conditions
No. of standby plants: :
Refrigeration plants :
Condenser water pump :
Chilled water pump :
*
Type of Plant :
Cooling coil : Direct Expansion Chilled
type. water type
PLANT DETAIL
Compressor
Compressor motor
Condenser
Chiller
Cooling tower
Cond. water pump
Chilled water pump
Cond. water pump motor
Chilled water pump motor
Cooling tower fan motor
Size
Quantity
Motor HP
Filters - Qty
510 x 510 x 50
635 x 405 x 50
635 x 510 x 50
E lectrical Panel
The term ‘Air Conditioning’ encompasses both cooling and heating. But,
heating will be needed only to a very limited geographical areas in our Country
and hence, this Manual deals with the cooling aspect of the Air Conditioning
Plant.
There must be a medium to absorb the heat at the evaporator (i.e. At the low
temperature level) and to reject this heat to the atmosphere. This medium is
called the Refrigerant, which is a volatile liquid having a low boiling point.
The refrigerant is fed into the evaporator in the liquid form at low pressure and
temperature, where in absorbing heat, it changes to its vapour state. To move
the heat laden refrigerant gas from the evaporator to the condenser (where the
heat is rejected to the atmosphere) and also to raise its pressure so that the
gaseous refrigerant can be converted to its liquid state (for reuse in the
evaporator), the COMPRESSOR is used. The refrigerant is at high pressure in
the Condenser, while in the evaporator it has to be at low pressure to enable to
absorb the heat at the low temperature level. For reducing the pressure of the
refrigerant from the high side to that of the low side and also to automatically
monitor the rate of flow of the refrigerant to meet the load requirements, we
have the THERMOSTATIC EXPANSION VALVE. In addition to the above
main components, there are the safety and operating controls and other
ancillaries to complete the system.
The air from the space to be cooled is circulated over the evaporator coil,
inside which the refrigerant is boiling and absorbing the heat from air. The
Evaporator Coil is fitted in the air handling unit which is located in the air
handling unit room and air is distributed to the area to be cooled by a network
of ducts. The Compressor-Condenser set (called the Condensing unit) is
located in a separate plant room. The two components of the refrigeration plant
i.e. the Condensing Unit and evaporator coil are interconnected by means of
the refrigerant piping.
DRAIN
AIR-CONDITIONED ROOM
COND.
DX SYSTEM
The Air-conditioning plant engineered and installed for you has the Chilled
Water System. Water is chilled in a Central Composite Refrigeration Plant and
the chilled water is circulated through the cooling coils in air handling units
located in various places or zones of the building. This system is adopted for
multi-story/large buildings, as it is not advisable and economical to run long
lengths of refrigerant piping from the condensing unit (Compressor-condenser
assembly) to the various evaporator coils located in different parts or zones of
the building. Further, this system will be more suited to take care of diversities
in load, inherent in large buildings.
CONTROLS :
HP/LP CUTOUT :
This stops the compressor either when the discharge pressure exceeds a
set safety point or when the suction pressure falls below a certain set
point.
To stop the motor when the current exceeds the rated full load current.
To stop the compressor whenever the oil pressure does not develop as
required.
ANTI-FREEZE THERMOSTAT :
Provided in the outlet of the chiller to protect the chiller against freeze-
up. It stops the compressor in chilled water system, when the leaving
water temperature falls below 380 F.
FAN EVAPORATO
SECTION R COIL
AIR FILTER
AIR-CONDITIONED ROOM
AIR-CONDITIONED ROOM
FAN EVAPORATO
SECTION R COIL
AIR FILTER
AIR-CONDITIONED ROOM
FAN EVAPORATO
SECTION R COIL
AIR FILTER
AIR-CONDITIONED ROOM
DRAIN
AIR-CONDITIONED ROOM
COND.
COND. WATER
PUMP
COMPRESSOR OIL :
This chapter deals with the day to day operation of the plant. Operation of the
plant is not just starting and stopping the plant, but also includes some routine
maintenance work- on a day to day weekly and short period basis.
The result of faulty operation (including the routine maintenance) may escape
the attention, because it is not as dramatic as a breakdown, but in the long run
can work out to be quite costly. Therefore, proper operation is an important
aspect.
OPERATING INSTRUCTIONS :
(c) Chilled Water Linesare open, except those of the standby items
of equipment.
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3. Check up water level in the cooling tower and ensure that the make up
water system is working satisfactorily-such as float ball is OK and float
valve is free in movement and there is water flow when the ball is
pressed down, etc., and there is regular make up water supply to
cooling tower.
4. In chilled water plants, check the water level in the expansion tank and
ensure that the make up water system is working and there is regular
water supply.
Water level in the chilled water system can fall down due to pump
gland drips. If the level in the expansion tank is not maintained, air can
enter the chilled water system affecting the system performance
substantially and can even lead to freeze up of the chiller.
5. Check all air filters and water strainers and clean whenever found dirty.
6. Ensure that all doors and windows of the air conditioned area are
closed.
7. Ensure that the crank Case of the Compressor is warm to the physical
touch. If it is not warm, check for defects in the Crank Case
heater/circuit. Do not start the compressor until the defect is rectified
and the Crank Case warms up. Otherwise, poor lubrication will result,
reducing the life of the bearings of the Compressor substantially.
2.3 Cooling tower fan/s Inspect the cooling tower fan guard/s
periodically and ensure that they are in
good condition.
2.4 Chilled water pump/s - where Correct pressure of the chilled water, the
chilled water systems are pressure built by the chilled water pump/s
installed. Confirm that sufficient will depend upon the length of piping,
pressure is built up by the fittings, chiller, etc. Here again the
pump/s. pressure observed at the time of handing
over the plant is the best guide.
2.6 Switch ‘ON’ the refrigerant Refrigerant solenoid valves are provided
solenoid valve or the pilot in the main liquid line usually where the
solenoid valve (whichever is plant size is small. Pilot solenoid valves
used). are generally provided for bigger plants.
2.7 Start the compressor motor. In The rotor circuit in a slip ring motor
the case of slip ring motors, starter is provided with number of
stator-rotor starters are used. resistances. At the point of starting,
After switching on the stator maximum amount of resistance is in
switch of the starter, turn the series with the rotor and as the rotor
Rotor Wheel or handle wheel is turned towards the full speed
gradually and move smoothly to (run) position, the resistances are
the full running position. progressively cut off and rotor windings
Caution : The movement of get connected in Star.
Rotor Wheel/Handle should be If the rotor wheel is kept in an
neither too fast nor too slow. intermediate position, the resistance wires
Never leave the wheel/handle in in the rotor starter can get burnt.
an intermediate position.
3.1 As the compressor is started the Since the oil in the Crank Case of the
compressor oil pressure should Compressor is subjected to the suction
build up. Check that correct net pressure, the NET OIL PRESSURE
oil pressure is build up. Once developed by the (compressor) oil pump
the oil pressure is built up, the is the difference between the reading
cylinders of the compressor will shown on the oil pressure gauge and the
R. Sharma (BSNL Electrical Zone Patna) 12
3.2 Check the oil level in the oil The oil level in the compressor oil sight
sight glass of the compressor. glass should be within 3/8 to 1/2 of the
The oil level should be 3/8 or glass.
3/8 of 1/2 the sight glass.
In operation, certain amount of oil gets
entrained in the refrigerant vapour in the
compressor and is carried away to the
system alongwith the refrigerant. It is
obvious that the oil carried into the
system should return to the compressor,
continuously and automatically, to
maintain sufficient oil level in the
compressor. While designing the system
and the refrigerant piping, it is ensured
that the oil return will be proper.
However, due to certain malfunctions of
the system that can develop due to
improper maintenance or shortage of
refrigerant in the system due to leakage,
etc., The oil return can get affected.
Hence, it is important to observe the oil
level in the compressor periodically. If the
oil level tends to go down, it is a sure
R. Sharma (BSNL Electrical Zone Patna) 13
happen, before starting the plant starting the plant. This is a wrong
again. If on restarting, the plant procedure. Resetting of oil safety switch
trips again, please get in touch should be the last item in the step by step
with maintenanca agency / procedure in finding the reasons for the
manufacturer immediately. sudden stoppage. The plant could have
stopped on the pressure switches, water
flow switches, antifreeze thermostat,
motor overload, etc. First check these. If
ultimately it is found that all these are OK
then try resetting the oil switch. If it is
established that the plant has tripped on
the oil safety switch, then a very close
watch on the oil pressure (net oil
pressure) is absolutely essential. If the net
oil pressure tends to go down it is sure
indication of a problem in compressor.
Immediately trace out the problem and
rectify. Otherwise, a major compressor
breakdown can occur. If in difficulty,
contact maintenance agency.
2.2 Check that the Crank Case The importance of the Crank Case electric
electric heater comes on as soon heater has been explained in detail, in
as compressor stops and heater is chapter 3. Ensure that the Crank Case
working. heater comes ‘ON’ when the compressor
is stopped.
1. Where standby plant/s, pump/s etc. are provided systematically change over
the work of the plants periodically say once in a week or even every day. This
will ensure uniform wear and tear of the plants. Further this also helps in
R. Sharma (BSNL Electrical Zone Patna) 17
ensuring that all the plants are in good repair and the standby is in good
condition should a necessity occur.
2. Never ‘SWITCH OFF’ the main switch on the main electrical board or switch
off any component of the system, when the plant is in operation, for ease in
shutting down the plant. There had been instances of operators doing this way.
Such an action will put a heavy strain on the isolating switch/es and they can
even get completely damaged.
3. All the water valves in the system can be kept open all the time and need not
be closed daily. But it is essential to close and open each valve periodically to
ensure that the valves work and do not get stuck by scale formation or dirt
accumulation.
4. Keep the plant room clean. Do not use the plant room, particularly the air
handling unit rooms, as lumber rooms.
R. Sharma (BSNL Electrical Zone Patna) 18
Amps.
PRESS. TEMP. PRESS. TEMP. PRESS. TEMP. PRESS. TEMP. PRESS.
Amps.
PRESS. PRESS. PRESS.
Amps.
Amps.
Amps.
Amps.
Amps.
D.P.
O.P.
D.P.
O.P.
S.P.
S.P.
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
Out
In
In
In
In
In
In
In
In
In
In
In
In
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MAINTENANCE
DAILY :
Check water level before starting the plant. Also ensure that the make-
up water system is working properly i.e. the float valve is working
satisfactorily and there is sufficient water in the make-up water tank for
the full day operation of the plant. As explained in Chapter 4, if this
step is not taken care of, the plant performance will be affected and the
compressor can stop on the High Pressure Switch.
The necessity of the crank case heater coming into operation during the
idle period of the compressor has been explained in Chapter 3.
This should be within 3/8 to 1/2 of the oil sight glass. If this level is not
maintained, it is a positive indication of a malfunction in the plant. If
the operating personnel cannot locate and rectify the problem, service
personnel should be informed immediately.
CAUTION :
6. LOG BOOK :
WEEKLY :
A dirty air filter can reduce plant capacity. More the dirt accumulation
on the air filter, greater will be the reduction in capacity of the plant.
Air filters, if not cleaned regularly will get saturated with dirt and
thereafter dirt will pass on to the cooling coil fins, which will affect
plant capacity much more and in extreme cases can even lead to liquid
flood back to the compressor, which is highly injurious to the
compressor. Cooling coils being wet, this dirt/dust will form a crust in
R. Sharma (BSNL Electrical Zone Patna) 22
the coil. Hence, air filters are to be cleaned regularly. Weekly cleaning
has been suggested here. But where plants are installed in dusty
environments, it may be necessary to clean the air filters more often.
For example after a dust storm in Northern India, it is a must to clean
the air filters.
Air filters should be changed, when it is found that cleaning does not
remove all the dust.
Check for excessive water leak through the gland (certain amount of
water drip through the gland is necessary to keep the gland cool).
However if the drip develops into a regular flow, it is an indication that
the gland is not holding well. The gland nuts can be tightened to reduce
the leak. When tightening the nuts does not improve the situation, the
gland packing has to be renewed. If this is not done in time, water
consumption will go up and in chilled water pump, a water leak means,
loss of refrigeration.
The gland nuts should be tightened evenly to avoid the gland flange
touching the shaft. Always check for heating of the gland after
tightening. If the gland gets heated, it is an indication of overtightening
of the nuts.
Check the tension of belts and tighten whenever found loose. A loose
belt will reduce transmission efficiency and its own life will be
reduced; further the drive pulleys can get heated up. Replace belt when
it is not possible to tighten them any further. In mullet-belt drives,
change the complete set of belts. Select the belts for a matched set. If
this is not done, the load will be taken only by the smaller length belts,
thereby affecting transmission efficiency and belt life.
8. Drain, clean and refill the cooling tower sump. Cooling towers, being
in the open, collect lot of dust and muck, hence it is necessary to clean
once in a week.
Analyse the pressure and temperature readings of the plant from the log
book and establish that the plant is working satisfactorily. Corrective
action should be taken promptly when readings show even a minor
malfunction
PREVENTIVE MAINTENANCE :
MAINTENANCE FREQUENCY
2.1 CONDENSER :
Note : The frequency of cleaning the condenser tubes will depend upon the quality of
water used. When water used is fairly soft, yearly cleaning will be found
satisfactory. The frequency of cleaning will have to be established by
observing the operation over a period of time.
Note : Do not dress the Contacts with emery or sand paper. The contacts have hard
wearing coatings. If emery or abrasive paper is used, this coatings may get
removed. The shape of the contact point surfaces are made slightly sloping so
that the moving contact surface slides on the surface of the fixed contact and
maintains a positive contact. Thus the initial points of contact where arcing
occurs on making and breaking (which causes the pitting of the contact
R. Sharma (BSNL Electrical Zone Patna) 26
surfaces) are not the areas through which current passes in operation. These
specially shaped surfaces can get out of proper shape if emery paper is used.
Therefore cleaning should be done only with cloth. Replace badly pitted
contacts.
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TROUBLE SHOOTING
Even with a well maintained and operated plant troubles can develop. When
trouble occurs, a systematic study of all symptoms (by taking temperature and
pressure readings) should be made to come to a conclusion as to the cause of
the trouble.
Many of the breakdowns are caused originally by simple faults. Hence, while
trouble shooting, look for simple points first. Never jump to conclusion from
some symptoms only. Analyse all symptoms and come to a logical conclusion.
A properly maintained log book will help to a great extent to pin point the
probable area of trouble. Breakdown or major malfunctioning generally will
not occur all of a sudden. A small defect will develop into a major one, if not
detected and rectified in time. For example, a very minute gas leak over a
period of time can lead to lot of problems, such as, insufficient cooling, poor
oil return, excessive heating of compressor head etc. If only regular leak test
was taken and the minute leak detected and rectified, all the major troubles
cited could have been avoided.,
3. Compressor (a) Too high an oil level causing Correct the oil level.
noisy liquid hammering
5. Low (a) Too much cooling water to Regulate the water supply.
Discharge the condenser.
Pressure
(b) Too much liquid being fed Adjust the expansion valve
through expansion valve.
R. Sharma (BSNL Electrical Zone Patna) 31
(i) Too much oil in the system. Drain the oil gradually
from compressor keeping
an eye on oil return.
10. Compressor (a) Expansion valve in correctly Recheck and set expansion
loading and adjusted . valve.
unloading
intervals too (b) Oil pressure erratic. Check compressor oil level
short stop oil foaming and clean
oil lines.
12. Compressor (a) Oil trapped in the system. Investigate reasons for
oil level poor oil return and rectify.
going own.
PUMPING DOWN
1. Close the liquid outlet valve on the condenser/receiver and start the
compressor. The compressor should be run until the suction pressure
gauge indicates a pressure of 2 psig. The compressor should then be
stopped and discharge/shut-off valve should be quickly closed.
moisture may settle on the system and causes heavy damage when the plant is
started up.
When reassembling the system, it is advisable that the liquid side should be
closed up. Before completely sealing the system, crack the liquid outlet valve
to purge air from the system. Close the valve immediately and make the final
joint. However, where the system has been kept open for a long time, it is
necessary to evaluate the system before charging gas.
Test the system for leaks with Halide torch. If everything is satisfactory the
compressor may be started in the following way :-
3. Open liquid outlet valve. This will build-up a pressure in the system
and cause the low pressure switch to function and start the compressor.
(Note : If the low pressure switch contacts were kept mechanically
‘closed’ during pump down cycle, this must be removed. Also, if the
liquid solenoid valve was manually opened, it should be reset for
automatic operation).
4. Check oil level in the crank case and the refrigerant charge. If
necessary, add oil and gas. In case of refrigerant shortage, bubbles may
appear on the liquid indicator in the refrigerant liquids line.
REFRIGERANT CHARGING :
If the system has lost refrigerant gas due to leaks, broken connections, etc., this
gas must be replaced in order to ensure proper operation. It is important that no
gas be added until all leaks have been repaired. Shortage of refrigerant may be
indicated by any of the following symptoms :-
2. Low suction pressure and low condensing pressure. This condition may
cause ‘short cycling’ of the system.
4. Presence of the oil at leaking joint, connection, bolt and head etc.
1. Back seat the compressor suction shut-off valve. Remove the plug
from the gauge port.
R. Sharma (BSNL Electrical Zone Patna) 36
2. Connect the charging line from the refrigerant drum to the gauge port
but before tightening the connections, ensure that all air is purged from
the line by cracking the outlet valve on the refrigerant drum.
4. Start the compressor. Crack the suction valve off the back seat and
open the refrigerant drum valve. Gas will start flowing into the system.
Charge the system slowly. Stop the charging every two or three
minutes. Allow the system to stabilize and check suction, pressure and
liquid indicator, etc. Repeat this process of charging until system is
fully charged.
5. Watch the liquid level indicator and the suction pressure gauge. When
the bubbles disappear and the suction pressure is normal, close the
drum valve, back seat the compressor suction shut-off valve, remove
the charging line and plug the gauge port.
A refrigerant system must be kept free from gases other than the refrigerant.
Listed below are several sources of non-condensable in a system :
3. System not properly evaluated after the system has been opened out for
repairs.
(Note : To avoid this, always get refrigerant from well established and
reputed suppliers).
Non-condensable gases will cause high condensing pressures This will reduce
the refrigeration capacity, increase the operating cost and cause erratic
operation of the system. It is necessary therefore that non-condensable gases
must be purged from the system as soon as their presence is evidenced. In
R. Sharma (BSNL Electrical Zone Patna) 37
Pump down the unit. Run the condenser water pump for approximately half an
hour to allow the condenser to cool down. Install a pressure gauge on the
discharge service valve. After the water has circulated in the condenser for
sometime, its temperature and the pressure in the condenser will both be about
steady. Determine the saturation pressure of the refrigerant corresponding to
the condenser water temperature, leaving and entering water temperature will
of course be the same. If the actual pressure in the condenser is much above
this saturation pressure, it is clear that non-condensable gasses are present and
the system should be purged through the purge valve provided on top of the
condenser.
3. Slowly turn the valve system off the back seat from one to two turns.
Air will blow off if this is done slowly.
If the crank case oil level is low, add oil to the system to bring oil to the
correct level. Use capella ‘D’ or equivalent lubricant oil. Oil must be taken
out only from sealed airtight tins. Do not use oil from open drums or
containers.