Cycle of Operation

Chapter 1 Cycle of Operation

Chapter Objectives What is Refrigeration ?
This chapter describes the working cycle of the vapour absorption chiller and the functions of its various components Refrigeration is defined as the process of extracting heat from a low temperature medium and transferring it to a high temperature heat sink. Refrigeration maintains the temperature of the heat source below that of its surroundings while transferring the extracted heat to a heat sink. The boiling point of water is directly proportional to pressure. At atmospheric pressure water boils at 100C. At lower pressure it boils at lower temperature. At 6mmHg absolute pressure the boiling point of water is 3.7C. To change water from liquid to vapour it has to be heated. The heat is absorbed by the water and its temperature starts rising. However it rises until it reaches a point where the temperature stays constant and it starts boiling, ie. the liquid water vapourises. This point is called the boiling point. At this point all the heat being absorbed by the water does not change its temperature but only its phase. This heat, required to change the phase of a liquid to vapour, is called the Latent of Vapoursation. Similarly the heat rejected by a vapour when it condenses is called the Latent Heat of Condensation. Lithium Bromide (LiBr) is a chemical similar to common salt (NaCl). LiBr is soluble in water. The LiBr water solution has a property to absorb water due to its chemical affinity. As the concentration of LiBr solution increases, its affinity towards water increases. Also as the temperature of LiBr solution decreases, its affinity to water increases. Further there is a large difference between vapour pressure of LiBr and water. This means that if we heat the LiBr water solution, the water will vapourise but the LiBr will stay in the solution and become concentrated.

Basic Principles

Absorption Cycle overview

Absorption systems use heat energy to produce a refrigerating effect. In these systems the refrigerant, ie. water, absorbs heat at a low temperature and pressure during evaporation and releases heat at a high temperature and pressure during condensation. A solution known as absorbent, ie. Lithium Bromide (LiBr), is used to absorb the vapourised refrigerant (after its evaporation at low pressure). This solution, containing the absorbed vapour is heated at a higher pressure. The refrigerant vapourises and the solution is restored to its original concentration for recirculation. In a double effect absorption machine, the latent heat of condensation of the refrigerant generated in the first stage generator, is used in a second stage generator to enhance the efficiency of the cycle When the refrigerant undergoes a series of evaporation, absorption, pressurisation, vapourisation, condensation, throttling, and expansion processes, absorbing heat from a low temperature heat source and releasing it to a high temperature sink, so that its state is restored to its original one, it is said to have completed a refrigerating cycle.

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Cycle of Operation

Schematic Diagram Individual Parts Evaporator

A schematic diagram of the absorption cycle is shown in the Fig. 1.1 The operation of the various parts of the absorption machine is described below. The evaporator consists of a tube bundle, an outer shell, distribution trays, and a refrigerant pan. The chilled water flows inside the tubes. A refrigerant pump circulates the refrigerant from the refrigerant pan into the distribution trays. From the trays the refrigerant falls on the evaporator tubes. The shell pressure is very low (6mmHg). At this pressure the refrigerant evaporates at a low temperature (3.7C) and extracts latent heat of evaporation from the water being circulated through the evaporator tubes. Thus the water being circulated through the tubes becomes chilled. The absorber consists of a tube bundle, an outer shell (common with the evaporator), distribution trays, and an absorbent collection sump. Concentrated absorbent solution (63.4%) from the low temperature generator is fed into distribution trays. This solution falls on the absorber tubes. Concentrated absorbent has an affinity to water and absorbs the vapourised refrigerant from the evaporator section. Hence the vacuum in the shell is maintained at a low pressure and ensures the correct chilled water temperature. The concentrated absorbent becomes diluted. During this dilution the 'Heat of Dilution' is generated. This increases the temperature of the absorbent solution. This heat is removed by the cooling water being circulated in the absorber tubes. As the absorbent solution loses it's heat to the cooling water, it is able to absorb more refrigerant vapour, and gets further diluted. The diluted absorbent (58.5%) collects in the bottom of the shell. The diluted absorbent is pumped to the high temperature generator by the absorbent pump. It first passes through the low temperature heat exchanger where it absorbs heat from the concentrated absorbent. It next flows through the heat reclaimer where it absorbs heat from the steam condensate. Then the diluted absorbent flows through the high temperature heat exchanger where it absorbs heat from the intermediate absorbent solution. The solution then enters the high temperature generator. The heat exchangers serve to heat up the cool absorbent solution before it enters the high temperature generator for reheating. This reduces the heat input required in the high tremperature generator. This increases the efficiency of the cycle. The high temperature generator (HTG) consists of a tube bundle, an outer shell and a set of eliminators. Steam is allowed to pass inside the tubes. The diluted absorbent flows around these tubes and is heated. The temperature of the solution increases until it reaches it's boiling point. The absorbed refrigerant boils out of the solution. The solution concentration increases (to 61%). This increased concentration is referred to as the intermediate concentration. The vaporised refrigerant generated passes through the eliminators and goes to the low temperature generator. The low temperature generator (LTG) and condensor tube bundles are enclosed in a shell and are separated by an insulation plate. The vaporised refrigerant flows into the LTG tubes. It heats the intermediate absorbent, flowing outside the tubes, and condenses. The condensed refrigerant flows into the condenser. Refrigerant vapourised from the intermediate absorbent passes through the eliminators to the condenser. Here it is cooled by cooling water being circulated inside the condenser tubes. The refrigerant vapour condenses on the outside of the condensor

Absorber

Heat exchangers

High Temperature Generator

Low Temperature Generator and Condensor

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Cycle of Operation
V U

tubes and collects in the bottom of the condensor. The condensed refrigerant from the LTG and the condensor mix and flows to the evaporator. The absorbent which has become concentrated in the LTG drains to the absorber to begin a new absorbent cycle.

Fig 1.1. Cooling Mode

F

H E

P P

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Chapter 2 Water Circuit Considerations

Chapter Objective
This chapter describes the effects of changes in the hot / cooling and chilled water specifications and other issues, on the performance and operation of the machine. The temperature at which the refrigerant vapour in the condenser condenses, goes down in proportion to the reduction in the temperature of hot / cooling water. Hence the temperature differences available in the absorber and condenser increase enabling the machine to deliver a higher than rated capacity. As the capacity increases for the same solution flow rate, the various inefficiencies of the heat exchange reduce, thereby increasing the efficiency of operation. LiBr solution crystallizes when it is cooled. As the LiBr solution concentration decreases, the crystallization temperature decreases. At a concentration of 65% the crystallization temperature is 42C, at a concentration of 60% the crystallization temperature is 17C and at a concentration of 55% the crystallization temperature is 5C. The cooling water cools the diluted LiBr in the absorber, which cools the concentrated LiBr in the low temperature heat exchanger (LTHE). If the concentrated LiBr is cooled so that it crystallizes in the LTHE, the LiBr stops flowing through the LTHE, and the machine cannot operate. Hence the temperature of cooling water is to be controlled to ensure that the LiBr does not crystallize. LiBr becomes hot when it absorbs vapourised refrigerant. As the temperature of LiBr solution increases its the absorption power decreases. Hot / cooling water removes heat from the LiBr and ensures maximum absorption of the refrigerant. If the hot / cooling water temperature increases, so does the LiBr temperature. Hence the absorption of refrigerant vapour is reduced and the pressure in the evaporator increases. The rated chilled water temperature cannot be maintained and steam is wasted. To prevent this, the maintenance of the hot / cooling water temperature is essential and hot / cooling water temperature should not be allowed to rise. If the chilled water flow to the machine stops for any reason, the hot / cooling water flow to the machine should also stop within one minute. If the hot / cooling water flow to the machine continues when the chilled water flow is stopped, the absorbent solution in the absorber continues to get cooled and creates a high vacuum in the lower shell. The refrigerant temperature drops sharply and the evaporator tubes may ice as the chilled water becomes stagnant. Ensure that the hot / cooling water pump stops by interlocking the chilled and hot / cooling water pump contactors so that the hot / cooling water pump stops if the chilled water pump is stopped. In case the hot / cooling water pump is not dedicated to the machine and the hot / cooling water pump cannot be stopped when the chilled water pump stops, provide a butterfly valve in the hot / cooling water inlet line to the absorption machine. Hook up the hot / cooling water stop signal from the control panel to the actuator of the butterfly valve so as to close the valve when hot / cooling water is not required.

The lower the temperature of hot / cooling water, the better.

Extremely low hot / cooling water temperature is not acceptable.

Capacity of the machine reduces when hot / cooling water temperature increases

Interlock between chilled and hot / cooling water flows

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Chapter 2

Water treatment of chilled and hot / cooling water

The water treatment of chilled and hot / cooling water is important for the machine performance and long life. If the water quality is bad and shows a scaling tendency, scale adheres to the inside of the heat transfer tubes of the evaporator, absorber and condenser. The heat transfer between the chilled water and the refrigerant, and the hot / cooling water and the LiBr solution and the condensing refrigerant reduces. This causes an increase in the LiBr and condensed refrigerant temperatures and increases the steam consumption. The chilled and hot / cooling water should be treated to prevent scaling inside the tubes. If the chilled or hot / cooling water becomes corrosive, it will corrode the inside of the evaporator, absorber and condenser tubes. Tube failure due to corrosion will occur. It is essential to fully treat the chilled and hot / cooling water to prevent corrosive tendency.

Water Quality

The standard for water in the chilled and hot / cooling water circuits is shown in the following tables. STANDARD WATER QUALITY (For Copper tubes)

Items

Hot / Cooling water One-pass or circulating 6.5~8.0 800 max 100 max 200 max 200 max 200 max 1.0 max Not detected 1.0 max 50 max 20 max 20 max Make-up water 6.5~8.0 200 max 50 max 50 max 50 max 50 max 0.3 max Not detected 0.2 max 30 max 5 max 5 max Below 160 Below 160

Heat source / Chilled water Circulating 6.5~8.0 500 max 100 max 100 max 100 max 100 max 1.0 max Not detected 0.5 max 50 max 10 max 10 max 10 max -

Tendency Corro sion Scal ing

pH 25C Electrical conductivity (25lS/cm) M alkalinity (ppm) Total hardness (ppm) Chlorine Ion (ppm) Sulphuric acid ion (ppm) Total Iron (ppm) Sulphur ion (ppm) Ammonium Ion Silica (ppm) Free Carbonic acid Turbidity (NTU) Suspended solids (mg/l) Biological Oxygen Demand (BOD) ppm Chemical Oxygen Demand (COD) ppm

NOTE : 1. Each item of the standard values has a strong bearing on the failure due to corrosion or scale formation, and if any value item deviates from the standard value, it will cause corrosion or scaling. Therefore, these should be controlled. The range of the quality of water which may be used differs depending on the chemicals used to treat the water, and is not given here. It is desirable to set the appropriate water quality control values under the guidance of a water processing specialist who will periodically control it.

2.

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Water Circuit Considerations STANDARD WATER QUALITY ( For Cupro Nickel 90:10 tubes ) Items Hot / Cooling water One-pass or circulating 6.5~8.5 200 max 4000 max 800 max 1.0 max Not detected 1.0 max 50 max 20 max 20 max Make-up water 6.5~8.5 50 max 1000 max 200 max 0.3 max Not detected 0.2 max 30 max 5 max 5 max Below 160 Below 160 Heat source / Chilled water Circulating 6.5~8.5 100 max 2000 max 400 max 1.0 max Not detected 0.5 max 50 max 10 max 10 max Tendency Corro sion Scal ing

pH 25C Total hardness (ppm) Chlorine Ion (ppm) Sulphuric acid ion (ppm) Total Iron (ppm) Sulphur ion (ppm) Ammonium Ion Silica (ppm) Turbidity (NTU) Suspended solids (mg/l) Biological Oxygen Demand (BOD) ppm Chemical Oxygen Demand (COD) ppm

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Liquids

Chapter 3 Liquids
Lithium Bromide (LiBr) absorbent
Lithium Bromide (LiBr) is chemical. It is made from lithium obtained from lithium ore, and bromide obtained from sea water. LiBr and Sodium Chloride (NaCl) have similar characteristics, because Lithium (Li) and Sodium (Na) are alkalis, while Bromide (Br) and Chlorine (Cl) are halogens. Sodium Chloride is table salt. Hence we can easily imagine the properties of LiBr. If table salt is left in a high humidity atmosphere, it becomes sticky. This is because it absorbes moisture from the atmosphere. LiBr has the same characteristics and its absorption power is stronger than the table salt. The higher the LiBr solution concentration and the lower its temperature, the stronger its power to absorb water vapour. . Chemical formula . Molecular weight . Components . Specific gravity . Melting point . Boiling point : : : : : : LiBr 86.856 Li - 7.99%, Br - 92.01% 3.464 at 25C 549C 1265C

Lithium Molybdate (Li 2MoO4) - Corrosion Inhibitor

Lithium Bromide has a corrosive action on steel in the presence of oxygen. As the absorption machine is a vacuum vessel, there is almost no oxygen in it. However, corrosion inhibitor is added in the absorbent and the absorbent alkalinity is adjusted. The corrosion inhibitor forms an inert protective layer on the inside surface of the machine and inhibits the metal corrosion by LiBr. The formation of the protective layer reduces the concentration of the inhibitor. Hence the absorbent composition should be controlled, that is the amount of inhibitor should be maintained by chemical analysing the absorbent and recharging inhibitor as required. Excess inhibitor should not be added as it causes the Lithium Bromide to precipitate and degrades the machine performance. Refrigerant used in the absorption machine is water. The water should be pure and free of contaminants. Distilled water or demineralised water is used as refrigerant. Specifications of the water which can be used as refrigerant are . Specific Resistance : 5 x 105 Ohm/cm . Ca, Mg, Cl, Na : 0.01 ppm max. . Sulphur and Ammonium shall not be detected.

Water (H2O) Refrigerant

Octyl Alcohol (2-Ethyl1-Hexanol) Additive

To increase absorption effect of absorbent, Octyl alcohol is added into the machine. Excess quantity of octyl alcohol should not be added into the machine as it could form a sludge in the heat exchangers and degrade machine performance. . Molecular weight . Specific gravity . Refractive index : 130.23 : 0.831 ~ 0.836 at 20C : 1.428 ~ 1.433

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Chapter 4 Machine illustration

Chapter Objective
This chapter includes the four views of the machine and indicates the positions of its various parts and components.

HTG Steam Inlet Condenser

Drain Outlet Evaporator Evaporator Cooling Water Inlet

Absorber

Sight Glass

Side View (Left)

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IV - 2 Sight Glass Refrigerant Level Electrode Refrigerant Blowdown Valve Control Panel Refrigerant service valve Cooling Water Inlet C2M S Refrigerant Pump Absorbent Pump Purge Pump

Chapter 4

Cooling Water Outlet

Chilled Water Inlet

Chilled Water Outlet

Steam Trap

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Front View

C2M S Sight Glass Drain Heat Exchanger Low Temperature Heat Exchanger Strong solution service valve High Temperature Heat Exchanger Drain Outlet IV - 3 Intermediate solution service valve

Generator Solution Level Electrode

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Steam Inlet

Heat Reclaimer

Machine Illustration

Rear View

Weak solution service valve

Chapter 4

Cooling Water Outlet Condenser

HTG

LTG Chilled Water Outlet

Evap

Absorber

Evap

Chilled Water Inlet

Purge Pump Steam Trap

Side View (Right)

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Chapter 5 Controls and Safeties

Chapter Objective Control Panel
This chapter describes the operational controls of the machine and the safeties provided. The control panel consists of the following components : . Programmable Logic Controller (PLC). . Operator interface. . Power circuit for pumps. . Panel mounted instruments. The cooling capacity of the machine is the total heat extracted from the chilled water. The chilled water flow rate to the machine is kept constant. Hence the capacity is proportional to the difference in the temperatures of the inlet and outlet chilled water. Load changes are reflected in the rise or fall of the temperature of the inlet chilled water. As the inlet chilled water temperature rises or falls the outlet chilled water temperature tends to follow the same pattern. A RTD sensor in the outlet chilled water senses this change in temperature. This signal is fed to the PLC. An inbuilt software PID control loop processes this signal with respect to the chilled water set point. A control output signal of 4 to 20 mA is sent to the I/P converter. The I/P converter converts the 4 to 20 mA electrical signal to a 0.2 to 1 kg/cm2g pneumatic signal. This pneumatic signal controls the position of the steam control valve. As the load increases the steam control valve opens, as the load reduces the steam control valve closes, and thus regulates the quantity of steam entering the machine.

Capacity Control

BLOCK DIAGRAM:

PT100 TEMP. SENSOR

PLC

I to P STEAM CONTROL CONVERTER VALVE

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Chapter 5

Safeties

Safety devices are provided to protect the machine from abnormal conditions and safeguard it from damage and ensure continued availability. Safety devices are Machine mounted safeties located on the machine, Panel mounted safeties in the control panel, and Field Interlocks passing signals from the field to the machine.

Machine mounted safeties

. Chilled water flow switch : Paddle type device mounted on the chilled water outlet nozzle. . Chilled water Differential Pressure (DP) switch : Connected to the inlet and outlet chilled water nozzles. . Chilled water Antifreeze thermostat : Capillary thermostat mounted on the chilled water owlet nozzle . Absorbent pump thermal cutout : A thermal cutout provided in the absorbent pump stator winding. . Refrigerant level electrodes : Mounted in the refrigerant level box. . Generator level electrodes : Mounted in the high temperature generator level box. . Generator level controller. . Refrigerant level controller. . Absorbent pump overload relay / AC Drive. . Refrigerant pump overload relay. . Purge pump overload relay. . Absorbent pump miniature circuit breaker. . Refrigerant pump miniature circuit breaker. . Chilled water pump interlock. . Cooling water pump / butterfly valve interlock. The safety functions of the machine protect it against abnormal conditions. The various safety functions are Thermal shock protection. Antifreeze protection. Crystallization protection. Cavitation protection of refrigerant pump. Cavitation protection of absorbent pump. Motor protection. To protect the machine from thermal shock, the steam control valve is opened gradually for first 10 minutes after machine start up, when the HTG temperature is less than 70C. After the slow opening duration is over, the control is switched over to chilled water temperature modulation automatically. To prevent the chilled water from freezing in the evaporator tubes, the safety functions below stop the machine if abnormal conditions leading to ice formation appear. If the chilled water outlet temperature drops below the L-cut setpoint, the refrigerant pump is switched off. The L-cut is set from the cool mode control loop screen. This safety prevents further temperature drop of the chilled water. The refrigerant pump will restart after the Chilled water outlet temperature rises above the L-cut setpoint plus the hysterisis set point.

Panel mounted safeties

Field Interlocks Safety Functions

Thermal shock protection.

Antifreeze protection.

L-cut :

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Controls and Safeties

Internal antifreeze :

Antifreeze thermostat : Chilled water pump interlock :

If the chilled water outlet temperature drops below the internal antifreeze set point, the machine trips and the TOTAL SHUTDOWN alarm sequence is carried out. The alarm will be reset only after the chilled water outlet temperature rises above the internal antifreeze set point plus the hysterisis set point. If the chilled water outlet temperature drops below the setting of thermostat, the TOTAL SHUTDOWN alarm sequence is carried out. Chilled water flow is essential for machine operation. A potential free contact is to be wired from the chilled water pump motor starter to VAM/c panel to sense chilled water pump ON / OFF / TRIP status. The machine starts only when the chilled water pump is ON. If the chilled water pump stops / trips during operation, the TOTAL SHUTDOWN alarm sequence is carried out. If the chilled water flow drops below 50% of the rated value, the TOTAL SHUTDOWN alarm sequence is carried out. If the chilled water flow drops below 50% of the rated value, the TOTAL SHUTDOWN alarm sequence is carried out. If the concentrated absorbent solution returning to the absorber from the low temperature generator is excessively cooled, it crystallizes in the low temperature heat exchanger and the operation of the machine is affected. Crystallization occurs either when the concentration of the absorbent (related to its temperature) goes too high or its temperature drops excessively. The following safety functions prevent the machine from crystallizing. When the HTG temperature exceeds the 159C, the steam control valve closes immediately. This prevents further increase in LiBr concentration. The valve control is returned to the chilled water temperature control loop when the HTG temperature drops below 155C. If the HTG temperature exceeds the HTG high temperature set point (160C), the DILUTION CYCLE alarm sequence is carried out and the machine goes into dilution cycle immediately. HTG high temperature alarm can be reset only when the HTG temperature drops below the set point minus the hysterisis set value (5C). If the cooling water inlet temperature drops below the cooling water low temperature set point, the DILUTION CYCLE alarm sequence is carried out and the machine goes into dilution cycle immediately. The alarm can be reset only when the cooling water inlet temperature rises above the cooling water low temperature set point plus hysterisis set value. If the refrigerant level in the evaporator pan falls excessively, the pressure in the refrigerant pump suction drops below the saturation pressure of the refrigerant and the refrigerant pump starts to cavitate. To ensure minimum acceptable suction pressure the level of refrigerant is not allowed to fall below a certain level. This is done by means of three level electrodes, RE1, RE2, RE3, and a level relay, 33RL. The three electrodes are mounted in the refrigerant level box assembly on the lower shell (Evaporator side). RE1 electrode is the smallest in length and RE3 is the longest. The level is maintained between RE1 and RE2. RE3 acts as a reference electrode. When the level reaches RE1, the pump starts and when the level goes below RE2, the pump stops and restarts only when the level reaches RE1 again. When the level goes below RE2, a delay of 20 seconds is provided before the pump is switched V -3

Chilled water flow switch : Chilled water DP switch Crystallization prevention

Valve control on HTG temperature

HTG high temperature safety

Cooling water low temperature safety:

Cavitation protection of refrigerant pump.

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Chapter 5 off. If the absorbent level in the absorber sump falls excessively, the pressure in the absorbent pump suction drops below the saturation pressure of the absorbent solution and the absorbent pump starts to cavitate. To ensure minimum acceptable suction pressure, the level of absorbent is controlled. Absorbent level in the HTG is not allowed to rise above a certain level. This prevents excess absorbent from being pumped out of the absorber sump. This is done by means of three level electrodes, AE1, AE2, AE3, and a level relay, 33AL. The three electrodes are mounted on the high temperature generator level box. AE1 is the smallest electrode and AE3 is the longest. The level is to be maintained below AE1. AE3 acts as the reference electrode. When the level reaches AE1, the pump stops after a delay of 5 seconds. When the level goes below AE2, the pump restarts.

Cavitation protection of absorbent pump.

Motor protection safeties Absorbent pump thermal cutout (ATHC)

A thermal cutout in the winding of the absorbent pump motor opens if the temperature of the winding rises above the permitted level. If this contact opens the DILUTION CYCLE alarm sequence is carried out. This alarm can be reset only when the ATHC contact closes after the winding temperature drops below the maximum permitted level. If the absorbent pump motor draws more than its rated current, this overload relay trips and the DILUTION CYCLE alarm sequence is carried out. The alarm is reset by resetting the overload relay / AC Drive. If the refrigerant pump motor draws more than its rated current, this overload relay trips and the DILUTION CYCLE alarm sequence is carried out. Resetting the overload relay resets the alarm. If the purge pump motor draws more than its rated current, this overload relay trips. Resetting the overload relay resets the alarm. Miniature Circuit Breakers (MCBs) are provided in the power circuits of the absorbent, refrigerant and purge pumps. If a short circuit fault occurs in the power supply to the pumps, the MCBs trips.

Absorbent pump overload relay / AC Drive Refrigerant pump overload relay Purge pump overload relay Short Circuit Protection

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Alarm sequences :

There are three alarm sequences which activate when the fault conditions occur . Dilution cycle alarm sequence. . Total shutdown alarm sequence. . Power failure alarm sequence. This alarm sequence protects the machine from crystallisation. Fault conditions which activate this alarm sequence are . High temperature generator temperature high. . High temperature generator pressure high. . All temperature sensor errors except chilled water outlet temperature sensor. . Cooling water inlet temperature low. The alarm action is as follows Steam control valve closes immediately. Refrigerant pump stops. Machine goes into dilution cycle for 20 minutes. After 1 minute the cooling water pump stops or shut-off valve closes. If the operator does not acknowledge the fault within 20 minutes, the machine stops completely.

Dilution cycle alarm sequence.

Total Shutdown Alarm Sequence

This alarm sequence protects the machine from freezing of the evaporator or any other damage. Fault conditions which activate this alarm sequence are . Chilled water flow switch trip. . Chilled water D.P. switch trip. . Chilled water pump interlock trip. . Chilled water antifreeze thermostat trip. . Chilled water outlet temperature sensor fault. . Antifreeze trip inbuilt in the PLC software. . Absorbent pump over current trip / AC Drive trip. . Absorbent pump thermal cutout trip. . Absorbent pump contactor / AC Drive not responding. . Refrigerant pump over current trip. . Refrigerant pump contactor not responding. . MCB1 (Absorbent pump) / MCB2 (Refrigerant pump) trip. The alarm action is as follows Steam control valve closes immediately. Refrigerant and absorbent pump stop. V -5

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Chapter 5 Machine shuts down. After the fault(s) is reset the machine goes into dilution cycle. If the machine is not restarted during the dilution cycle, the machine stops completely after the dilution cycle is over.

Power failure alarm sequence

This alarm is displayed when the machine is powered up after a power failure during operation. Acknowledge and reset the alarm and restart the machine.

Alarm acknowledgment and reset sequence

When an alarm sequence is initiated, the alarm screen will pop up, with an audio alarm. Unless and until the activated alarm is acknowledged the user will not be allowed access to any other screen. Currently activated alarm(s) will be displayed, with the date and time. Press ACK to stop the hooter (audio signal). If there is more than one alarm, pressing the ACK key will display the next active alarm. Use ACK key to scroll through all active alarms. After rectifying the fault condition, each alarm will have to be individually displayed on the ALARM screen, and then reset all the alarm conditions by pressing the alarm reset key i.e. K4 key.

Start the machine by pressing the key on the OPERATION screen.

Example

If the chilled water pump trips, three alarms will be triggered : Chilled water pump OFF / TRIP Chilled water flow switch TRIP Chilled water DP switch TRIP . The ALARM screen will pop-up and the hooter will start. CHILLED WATER PUMP OFF / TRIP will be displayed on the ALARM screen. . Pressing ACK key will stop the hooter, and CHILLED WATER FLOW SWITCH TRIPPED will be displayed on the ALARM screen. . Pressing ACK again will display the next active alarm i.e. CHILLED WATER DP SWITCH TRIPPED. . Once all the alarms have been acknowledged, go to the STATUS screen and monitor the current status of the concerned devices, i.e. Chilled water pump CHW PUMP OFF Chilled water flow switch FLSw TRIP Chilled water DP switch DPSw TRIP . After the chilled water pump has been started and the required flow is resumed, the STATUS screen display will be Chilled water pump CHW PUMP ON Chilled water flow switch FLSw HEALTHY Chilled water DP switch DPSw HEALTHY . Once this condition is achieved, press alarm reset K4 key to reset the alarms. The red LED will go off to indicate that the alarm has been reset. Start the machine by pressing the 'M/C START' key on the operation screen.

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Controls and Safeties

Set points

The field instruments and the components in the control panel are to be set as follows

S.NO. 1. 2. 3. 4. 5. 6.

Description Chilled water flow switch Chilled water D.P. switch Antifreeze thermostat Absorbent pump over current relay Refrigerant pump over current relay Purge pump over current relay

Set points 50 % of rated flow 50 % of rated flow 4.0C As per pump rating As per pump rating As per pump rating

OP 7 Set points

The operator terminal settings are as follows

S.NO. 1. 2.

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. C2M

Description Chilled water temperature control set point (CHWSP) Chilled water temperature modulation control settings: a) Proportional Band b) Integral Band c) Derivative Band L-cut set point L-cut hysterisis Internal PLC software antifreeze Internal PLC software antifreeze hysterisis Cooling water inlet temperature set point Cooling water inlet temperature hysterisis HTG trip set point HTG hysterisis HTG set point for controlling the steam control valve HTG temperature set point for AC drive for absorbent pump speed control Steam control valve maximum travel limit Data log sampling time Trip log sampling time Anti-chattering timer Dilution cycle timer

Set points -

Remarks Refer machine specs.

- 85 + 10 0 CHWSP - 1C 2C CHWSP - 1.5C 2C 20C 5C 160C 5C 159C 140 C As per capacity testing 60 min 1 min 2 sec 20 min

Not accessible Optional

Adjustable Adjustable Not accessible Not accessible V -7

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Chapter 5 18. 19. ON delay timer for absorbent pump ON delay timer for refrigerant pump 5 sec 20 sec Not accessible Not accessible

PLC Input/Output assignments Digital Inputs 24 VDC type Onboard PLC S7-200 CPU 226
Address I 0.0 I 0.1 I 0.2 I 0.3 I 0.4 I 0.5 I 0.6 I 0.7 I 1.0 I 1.1 I 1.2 I 1.3 I 1.4 I 1.5 I 1.6 I 1.7 I 2.0 I 2.1 I 2.2 I 2.3 I 2.4 I 2.5 I 2.6 I 2.7 Device Tag 52W 69W DPS2 26W SPARE ATHC MCB 1&2 88A 51A 88R 51R 51P 33AL 33RL 4Y1 SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE Description Chilled water pump interlock Chilled water flow switch Chilled water DP switch Antifreeze thermostat SPARE Abso pump thermal cutout MCB 1 & 2 on Abso pump contactor/AC Drive ON Abso pump overload Refrigerant pump contactor on Refrigerant pump overload Purge pump overload HTG level low Evaporator level low Remote start/stop SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE

Digital outputs 24 VDC type onboard PLC S7-200 CPU 226

Address Q 0.0 Q 0.1 Q 0.2 Q 0.3 V -8 Description Hooter Refrigerant pump on Purge pump on Remote machine on indication C2M

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Controls and Safeties Q 0.4 Q 0.5 Q 0.6 Q 0.7 Q 1.0 Q 1.1 Q 1.2 Q 1.3 Q 1.4 Q 1.5 Q 1.6 Q 1.7 Remote machine trip indication Chilled water pump start enable Cooling water pump start enable CT Fan start enable Absorbent pump / AC drive start * AC Drive preset speed 50 Hz * AC Drive inline contractor SPARE SPARE SPARE SPARE SPARE
* Only used if AC Drive is provided

Analog Input / Output

Analog Inputs RTD PT100 and Outputs 4 ma to 20 ma Module type EM235 2 Nos. in slot 0 and slot 2 Address AIW0 AIW2 AIW4 AIW6 QW0 AIW8 AIW10 AIW12 AIW14 QW4 Description Chilled water inlet temperature Chilled water outlet temperature Cooling water inlet temperature Cooling water outlet temperature Signal to I/P converter HTG temperature Dilute solution temperature Spray solution temperature HTG vapour temp. Modulation signal for AC Drive

OP7 Operator Interface:-

The entire operation of the VAM/c is controlled through the OP7 operator interface. OP7 consists of: 1. A LCD display 2. Function keys 3. 4. 5. 6. Arrow keys Numeric keys ENTER key ACK key 4-Lines * 20-characters. F1 to F4 and K1 to K4 Left, Right, Up, Down. 0 to 9 with decimal point. to enter set points. to acknowledge Hooter/Alarm.

K1 to K4 keys are global keys with functions K1 K2 K3

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MAIN MENU MACHINE PARAMETERS MACHINE STATUS

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Chapter 5

K4

FAULT RESET

The LCD display is programmed to show the interface screens. A screen consists of a combination of indications, and keys. Through these, the machine status is observed, and its operation can be controlled. Screen tree structure is given below MAIN MENU OPERATION STATUS SETPOINTS 'M/C PARAMETERS' 'UTILITY' ALARMS 'DATALOG 'NORMAL' 'TRIP' 'SERVICES' 'M/C OPERATION' 'HTG / COW SP' 'LCUT / HCUT SP' 'OFFSET ADJ' 'PID SETTINGS' 'A/C DRIVE SETTINGS' M/C/ COMM DATE' 'PLC DATE / TIME' 'PRODUCT INFO' 'M/C MODES' 'ALARM LOG

Product Info Screen

This screen is the startup screen and is displayed on power up. The first page of this screen displays the Product and Model number.

T H E R M AX L T P r o d u c t : S F V A P O U R A B S M A C H I N

D , I N D I A / H F O R P T I O N E

The second page is accessed by pressing the F4 key.

P L S F MM S F

C S o H F - P I S o H F - O

f L f P

t C t -

w O w 1

a P a .

r r 0

e 1 e -

: . : 0

0 - 0 2 0 1 2 0 1

The second page displays the software version loaded in the Programmable Logic Controller (PLC) and the Operator Interface (OP7) also called the Man Machine Interface (MMI). This screen can also be accessed from 'MAIN MENU' Press K1 to go to Main Menu.

Main Menu :
V - 10

This screen displays the names of all the other function and operation C2M

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Controls and Safeties screens.

Access - K1 Key

The first page of the 'MAIN MENU' screen shown the names of the 'OPERATIONS', 'STATUS', and 'SETPONTS' screens, and shows the keys to be pressed to activate them.

M A I O P E R A T S T A T U S S E T P O

N M E N U I O N [ F 1 ] [ F 2 ] I N T S [ F 3 ]

> >

The other pages of the MAIN MENU screen can be displayed by scrolling down using the F4 key. The second page shows the M/C PARAMETERS, and the UTILITY activation keys.

M / C P A R AM E T E R S [ F 1 ] U T I L I T Y [ F 2 ] < < > > The third page shows the ALARMS and the 'DATALOG screen activation keys. A L A R M S [ F 1 ] D A T A L O G [ F 2 ] < < > >

The fourth page shows the SERVICES and the 'PLC DATE/TIME screen activation keys. S E R V I C E S [ F 1 ] P L C D A T E / T I M E [ F 2 ] < < > >

The fifth page shows the PRODUCT INFO, 'M/C MODES' and the 'ALARM LOG screen activation keys. P R O D U C T I N F O [ F 1 ] M A C H I N E M O D E S [ F 2 ] A L A R M L O G [ F 3 ] < < Other screens can be displayed by pressing the function keys indicated by the name of each screen.

Use F3 (<<) and F4 (>>) Function keys for scrolling pages up and down respectively. Operation
Basic machine operations are carried out through this screen. This screen consists of 6 pages, viz. Machine start screen Refrigerant pump auto / manual selection screen Refrigerant pump manual operation screen C2M

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Chapter 5 Purge pump operation screen Concentration limit control activation screen Chilled water inlet temperature control override screen Machine start screen M / C R E AD Y M A C H I N E : O F S T A R T S T F 1 F T O F O P 2 S T A R T

> >

Start the machine by pressing F1 and stop the machine by pressing F2. If the machine is ready to start the following message will be displayed - " MACHINE READY TO START ". If there is any fault condition then the following message will be displayed " MACHINE NOT READY TO START ". At the same time the machine status is also displayed. The next page can be displayed by pressing F4 function key

Refrigerant pump auto / manual selection screen

R E F R A U T O F 1 P UM P : A U T O M A N F 2

< <

> >

This screen is used to select the mode of operation of the refrigerant pump. In order to start or stop the refrigerant pump irrespective of the evaporator level, (for e.g. during Blowdown cycle) the refrigerant pump has to be in MANUAL mode. Default position is AUTO. Refrigerant pump AUTO / MANUAL mode can be changed using the F1 and F2 keys. To operate refrigerant pump in AUTO mode press F1 key, To operate refrigerant pump in manual mode press F2 key. Present mode status is also displayed.

Refrigerant pump manual operation screen

R E F R S T A R T F 1 P UM P : O F F S T O P F 2

< <

> >

This screen is used to switch the refrigerant pump on or off manually. It works only when the refrigerant pump is in MANUAL mode. This screen action is disabled when the refrigerant pump mode is in AUTO mode. Default position is STOP. Refrigerant pump START / STOP operation can be done using the F1 and F2 keys. To start the refrigerant pump press F1 key. To stop the refrigerant pump press F2 key. The current pump status is also displayed. C2M S 0105_0

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**

Controls and Safeties

Purge pump operation screen

P U R G E S T A R T F 1 P UM P : O F F S T O P F 2

< <

> >

The Purge pump can be switched on or off from this screen. Default position is STOP. Current pump status is also displayed. Purge pump START / STOP operation can be done using F1 and F2 keys. To start the purge pump press F1 key. To stop the purge pump press F2 key.

Concentration limit control activation screen

C O N C O N F 1 L I M I T : O F F O F F F 2

< <

> >

Concentration control can be activated or deactivated using F1 and F2 keys. To switch ON concentration control press F2 key. To switch OFF concentration control press F1 key.

Chilled water inlet temperature control override screen

C HW O N F 1 I N O V E R R I D E : O F F O F F F 2

< <

Chilled water inlet temperature control override can be switched ON / OFF using F1 and F2 key. To activate the override, press F2 key. To deactivate the override press F1 key.

Status Access - K3 Key

This screen displays the current on-line status of the machine safeties, Interlocks, pumps, control valve, levels, temperature sensors, switches etc. To invoke this screen, press K3 key. (It can also be accessed from the 'MAIN MENU' screen.) This will display the first page of 'STATUS' screen. Other pages can be scrolled up by pressing F3 key and down by pressing F4 key. To return to "MAIN MENU" press K1 key.

Set points

This screen can be accessed from 'MAIN MENU' screen - page 1, by pressing the F3 key. Access the different set points by scrolling down. Here following set points can be changed. CHW OUT SP / HOTW OUT SP - On access of the 'SET POINTS' screen, the cursor blinks at this set point entry field. Type the required set point here and press ENTER key. To discard wrongly keyed entries press ESC

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Chapter 5 (escape) key. CHW OUT TEMP and COW OUT TEMP are also displayed. C HW C HW C OW O U T O U T O U T S P : 7 . 0 T E M P : 1 0 . 0 T E M P : 3 0 . 0 > > TRIP D'LOG TIME - During machine trip condition, the machine parameters are logged at the interval of specified time interval. To change this set point scroll down cursor at set point value, cursor blinks here, type required time interval in minutes and press ENTER key. NORMAL D'LOG TIME - This is the time interval at which PLC logs all machine parameters. To change this set point scroll down cursor at set point value, cursor blinks here, type required time interval in minutes and press ENTER key. N O R D ' L O G T I M E : 6 0 M T R I P D ' L O G T I M E : 1 M S C V O U T P U T L I M I T : 7 5 % < < > > VALVE LIMIT - As the steam control valves are selected for the range of machine models, the value of steam control valve opening at which the rated capacity is achieved has to be the limit for valve openings. This value determines the maximum limit on the steam control valve opening. To change this set point scroll down cursor to this set point value. When the cursor blinks here, type the required %, and press ENTER key. DIL. SOL TEMP S.P. FOR DECRYSTALISATION OR HOT DEGREASING This set point is used to control steam valve in the de-crystallization / hot degreasing mode. D I L . S O L T E M P S . P . F O R D E C R Y S T A L I S A T I O N O R H O T D E G R E A S I N G 1 2 3 . 4 < <

M/C Parameters Access - K2 Key Utility

This screen displays all measured temperatures in degree Centigrade, steam control valve status, and pump status.

In the first page of this screen, the number of hours the machine has run and the number of times the machine has tripped are displayed M / C M / C R U N H R S : 1 2 3 T R I P N O S . : 1 2 3 > > Go to the next page of the screen by pressing the F4 key P U R G E R U N H R S : L A S T P U R G E D O N 0 1 / 0 8 / 0 0 1 1 : 0 < 1 2 3 E O N 0 < > >

In the second page of this screen, the number of purge pump run hours is displayed. The date and time at which the purge pump was last run is also V - 14 C2M

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Controls and Safeties displayed Go to the next page of the screen by pressing the F4 key M / C C O MM I S I O N E D D A T E 0 1 / 0 8 / 0 0 M A I N [ F 1 ] O N

< <

On the page the machine commissioned date is displayed.

Alarms :

The 'ALARMS' screen is an auto popup screen that is triggered whenever an alarm condition is detected. The activated alarm text will be displayed, with date and time of occurrence, in the alarm window. Press the ACK; i.e. acknowledge Key, to acknowledge the alarm, and to stop the hooter. The operator can scroll through all the activated alarms by pressing the UP/DOWN arrow keys on the OP7. As soon as the alarm is acknowledged, the alarm screen disappears and screen displayed prior to alarm activation is displayed.

Datalogs

All the data logged in PLC can be displayed here. Where logged data of measured temperatures, percentage steam control valve opening, status of absorbent pump and refrigerant pump, machine status with date and time are displayed. N O R D ' L O G T R I P D ' L O G [ F 1 ] [ F 2 ] > >

Press F1 to display normal data log. Press F2 to display trip data log. Using F3 and F4 Keys scroll pages UP/DOWN.

Service Settings

The critical machine parameter settings can be edited through the SERVICE screen. To avoid access from unauthorized persons, these screens are password protected There are 7 pages of Service Settings 1. 2. 3. 4. 5. 6. 7. M/c OPERATIONS HTG / COW SP L-CUT / H-CUT SP OFFSET ADJ PID SETTINGS DRIVE SETTINGS M/C COMM DATE S E R V I C E S E T T I N G S M / C O P E R A T I O N S [ F 1 ] H T G / C OW S P [ F 2 ] > >

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Chapter 5 L - C U T / H - C U T O F F S E T A D J S P [ F 1 ] [ F 2 ] > > [ F 1 ] [ F 2 ] > > [ F 1 ]

< < P I D S E T T I N G S D R I V E S E T T I N G S < < M / C C O MM . D A T E

< < M/C OPERATIONS Machine operation (start / stop) mode can be changed from local to remote and vice versa using F1 and F2 keys. Press F1 key to operate machine locally, and press F2 to operate machine remotely. M A C H I N E L O C A L F 1 HTG / COW SP H T G T E M P T R I P : 1 2 3 . 4 H Y S T E R S I S : 1 . 2 > > HTG TEMP. TRIP SP - If actual HTG temperature exceeds this set point value, machine trips on 'HTG TEMP. HIGH ALARM'. HTG HYSTERISIS - This value determines the HTG temperature, below the HTG TEMP TRIP SET POINT, at which the HTG temp high alarm can be reset. The HTG temp high alarm can be reset only when the actual HTG temperature is less than 'HTG TEMP TRIP SETPOINT ' - 'HTG HYSTERISIS'. C OW C OW I N I N T R I P S P : 1 2 3 . 4 H Y S T : 1 . 2 < < > > : L O C A L R E M F 2

COOLING WATER IN TRIP SETPOINT - If cooling water inlet temperature drops below this value machine trips on "COW IN TEMP LOW" alarm. COW HYSTERISIS - This value determines the value of cooling water inlet temp at which the alarm can be reset. The alarm is reset at "COW IN TRIP SP" + "COW HYSTERISIS" CT FAN OFF SETPOINT - This value determines the temperature of COOLING WATER at which the cooling tower fan is to be switched off. CT HYSTERISIS - This value determines the actual cooling water inlet temp above the CT fan off setpoint at which the cooling tower fan would restart. V - 16 C2M

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Controls and Safeties L-CUT/H-CUT SP L C U T L C U T S P : 6 . 0 H Y S T : 1 . 2 < < > >

L CUT SP - This is one of the antifreeze safeties for chilled water temperature. If the chilled water temperature drops below this value the refrigerant pump stops. Set this value at 'CHILLED WATER OUTLET TEMPERATURE SP' - '1.O' (degree C). L CUT HYST This set point determines the value above the L CUT SP at which the refrigerant pump restarts. The refrigerant pump restarts when the chilled water outlet temperature becomes greater than or equal to L CUT SP + L CUT HYST. Unit is degree centigrade. ANTIFREEZE SP - If the Chilled water outlet temperature drops below this set point the machine trips on 'INTERNAL ANTIFREEZE ALARM'. Set this value at 'CHILLED WATER OUTLET TEMPERATURE SP' - 1.5 O C. ANTIFREEZE HYST - The antifreeze trip alarm can be reset only when the Chilled water outlet temperature exceeds ' ANTIFREEZE SP' + ANTIFREEZE HYST.' Unit is degree centigrade. AN T I F R E E Z E AN T I F R E E Z E M A I N [ F 1 ] : 4 . 5 H Y S T : 1 . 2 < < > >

H CUT SP - If the Chilled water outlet temperature goes above this value an alarm is activated. Value set is in O c. H CUT HYST - This value determines the actual temperature of chilled water outlet below the 'H CUT TRIP SP at which the chilled water outlet temp. High alarm can be reset. The alarm will only reset when the outlet temp value is less than ' H CUT TRIP SP' - 'H CUT TRIP HYST'

H C U T H C U T

S P : 1 2 . 3 H Y S T : 1 . 2 < <

M A I N [ F 1 ] PID SETTINGS S V : 1 2 . 3 P V : 1 2 . 3 C V : 0 1 2 P = - 8 5 I = + 1 0 D = 0

> > S C V : A U T O A U T O F 1 M AN F 2

< <

> >

S C V O P E N I N G M AN U A L M O D E C2M

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Chapter 5 O P E N F 1 C L O S E F 2 < <

PV (PROCESS VARIABLE) - Process variable in this case is the Chilled water temperature. This PV numeric display is the Chilled water outlet temperature. NUMERIC ENTRIES: SV (SET VALUE): This is the Chilled water outlet temperature set point. The chilled water outlet temperature set point can be changed from here as well as from the SETPOINTS screen. In this screen the entry for chilled water outlet temperature set point has no function key assigned to it. To change the set point from this screen just type in the new set point & press the ENTER key. Unit is C. CV (CONTROL VALUE): This is the PID controller output or the Steam control valve opening in terms of % age. (0 to 100%). P (PROPORTIONAL GAIN): This value is the proportional gain of the PID control loop. It is a factor that is multiplied to the scaled error (scaled SV scaled PV) in the PID equation. This value provides a continuous, linear relationship between the deviation and the correction signal. I (INTEGRAL GAIN): This is the integral gain value of the PID control loop. This value adjusts the output signal based on both the size of the deviation and its duration (reset time). It eliminates the offset effect of the proportional action. D (DERIVATIVE TERM): This value determines the rate of change of the PID control loop output with respect to rate of change of actual Chilled water temperature. SCV AUTO/MANUAL CONTROL - To control the valve manually, put the Chilled water temperature PID control loop into MANUAL mode by pressing the MANUAL (F2) key again by pressing AUTO (F1) key SCV can be put in AUTO mode. Controlling the steam control valve manually is not recommended for normal operation of the machine OPEN (F1) This key lets you open the STEAM CONTROL VALVE by increments of 1% when the chilled water PID loop is in manual mode. CLOSE (F2) - This key closes the STEAM CONTROL VALVE by decrements of 1% when the chilled water PID loop is in manual mode. HTG TEMP LOW LIMIT - This set point is used to start the AC drive modulation at minimum frequency (35 Hz). HTG TEMP LOW LIMIT - This set point is used to stop the AC drive modulation at maximum frequency (50 Hz). A/C DRIVE SETTINGS A C D R I V E MO D U L A T I O N H T G T E M P L OW L I M : 1 2 3 . 4 H T G T E M P H I L I M : 1 2 3 . 4 > > A C D R I V E : I N L I N E I N L I N E [ F 1 ] B Y P A S S [ F 2 ] V - 18 C2M

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Controls and Safeties < < Depending on the HTG temperature AC Drive frequency modulates in the range 35 Hz to 50 Hz. AC Drive INLINE (F1) & BYPASS (F2) can be done using F1 & F2 Keys. M/C COMM DATE: O V E RW R I T E M / C C O MM D A T E : 0 1 / 0 1 / 0 1 R E T U R N [ F 1 ] > > Machine commissioned date is over written by pressing this key.

PLC date / time

This screen displays the current DATE and TIME of the PLC P L C D A T E & T I M E D A T E - 0 1 / 0 1 / 0 1 T I M E - 1 2 : 0 0 : 0 0 > > Current DATE and TIME of PLC can be changed in this screen. Types each field of DATE and TIME and press ENTER key on OP7 and to write this to PLC - press ENTER (F1) key. C D T E H A I N A T M T N E E E G R E D A Y ( 1 - 7 ) : 1 0 1 / 0 1 / 0 1 1 2 : 0 0 : 0 0 [ F 1 ]

< <

To synchronize the time setting of the PLC and the OP7, switch off power to PLC panel, and then switch it on again.

Machine Mode

Machine "COOL" mode (F1) / "SIM" mode (F2) can be changed from this screen. M A C H I N E M O D E S T A T U S : C O O L C O O L S I M F 1 F 2 D E C R Y S T A L I S A T I O N O R H O T D E G R E A S I N G : O F F S T A R T [ F 1 ] S T O P [ F 2 ] < < > > DECRYSTALISATION - By pressing F1 key machine can be operated in de-crystallization mode. If the machine was in operation prior to pressing the de-crystallization key then machine carries out dilution cycle of 20 minutes and then goes to decrystallization mode. The machine operates in de-crystallization mode for the time set from OP7. After the timing is over de-crystallization mode is stopped and absorbent pump continues to run for 20 minutes. In de-crystallization mode if machine trips on any alarm then decrystallization machine carries out dilution cycle. De-crystallization mode

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Chapter 5 can be switched off by pressing F2 key. Machine can not be started in decrystallization mode. In de-crystallization mode a. Chilled water pump is off. b. Cooling water pump is off. c. Cooling Tower fan is off d. Refrigerant pump is off. e. Absorbent pump is on. g. Steam control valve is open Steam control valve opening is controlled on Dilute solution temp and HTG temp. If dilute solution temp exceeds 90C or HTG temp exceeds 130C Steam control valve is closed, and is opened only when the respective temperatures drop below their hysterisys values.

Alarm Log

In this screen, the last six alarms logged in PLC are displayed. By pressing F3 and F4 keys all six alarms can be scrolled. 1 . H T G T E M P 0 1 / 0 1 / 0 1

H I G H A L A R M 1 2 : 0 0 < < > >

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Operation of the Machine

Chapter 6 Operation of the Machine

Chapter Objective Pre - start checks
This chapter describes the pre-start checks, starting procedure and the stopping procedure. . Switch on the input power supply to the control panel. . Check and maintain the vacuum in the machine. . Check all the set points on the operator panel. ( Refer list of set points ) . Set the position of all the function keys on the operator panel, as follows : MACHINE status. PURGE key. REF. PUMP key. AUTO/MAN key OFF STOP AUTO AUTO

Note : - These settings are default and should appear when the machine is powered up.

Starting Procedure

. Start the chilled water pump and maintain the required P across the machine. If the flow rate is less than minimum rated flow, CHILLED WATER FLOW LOW status will be displayed on the STATUS screen of the operator panel. After setting right the flow, the DP switch and the flow switch will indicate HEALTHY indication. . Start the hot / cooling water pump / flow and maintain the required P across the machine. . Start the air-compressor and / or maintain the required air pressure (oil and moisture free air) supply to the air filter regulators. . Open the isolating valve before the steam control valve and maintain the required dry and saturated steam pressure before the steam control valve. . Give machine START command on the operator panel. Machine ON indication is displayed on the STATUS screen. . Absorbent pump contactor 88A is energized. Absorbent pump ON/OFF is controlled by the level controller 33AL. Absorbent pump ON/RUN indication is displayed on the STATUS screen. . Refrigerant pump contactor 88R is energized. Refrigerant pump ON/OFF is controlled by the level controller 33RL. The refrigerant pump ON/RUN indication is available on the STATUS screen. . Slow opening of steam control valve starts and opens from 0-100% in 10 minutes, when the high temperature generator temperature is below 70C. The steam control valve slow opening indication is available on the STATUS screen. . After 10 minutes the control valve is put into modulation control. The valve opening is controlled according to the chilled water PID temperature control and the valve status will be displayed accordingly. When the potential free contacts of the PLC are used to start or stop chilled water pump and hot / cooling water pump or shut off valve, the machine start command automatically starts the chilled water pump and the hot / cooling water pump or opens the cooling water shut off valve in proper sequence. Siemens (1.0) VI - 1

Chapter 6

Stopping Procedure

. Press the M/C STOP switch into the OFF position on the operator panel. . Steam control valve closes immediately. . The contactor 88R is de-energized and the refrigerant pump stops. . Machine goes into dilution cycle and the indication DILUTION CYCLE ON on the STATUS screen. . Hot / Cooling water pump stops or shut off valve closes after 1 minute. . The status screen will indicate hot / cooling water pump / shut off valve DISABLED. . After 20 minutes, dilution cycle completes and the absorbent pump stops. . STATUS screen indicates MACHINE : OFF. . Stop the chilled water pump / flow. . The machine stops completely. When the potential free contacts of the PLC are used to start and stop the chilled water pump and hot / cooling water pump / shut off valve, the machine stop command automatically stops the chilled water pump and the hot / cooling water pump or closes the cooling water shut off valve in proper sequence.

VI - 2 Siemens (1.0)

Chapter 7 Operational Activities

Chapter Objective
This chapter describes the operational activities required to keep the machine in best condition. These activities are Air purging Blowdown of refrigerant Maintenance of operating log These should be carried out as per the Operational Activity Schedule Air purging is the activity by which non condensable gases are removed from the machine. This is done by operating the vacuum pump and opening the manual air purge valves. After purging is completed the valves are closed and the vacuum pump is stopped. The air purging system (see Figure 7.1) consists of Non condensable gases and water vapour are drawn from the absorber into the purge unit by a venturi action using absorbent bled off the absorbent pump discharge. The gases are bubbled through LiBr collected at the bottom of the storage tank to remove water vapour. The non condensable gases collect to a maximum pressure of 50mmHg. This consists of an arrangement of three diaphragm valves that enable the operator to connect the vacuum manometer to different parts of the machine by closing and opening the valves. A mercury in glass vacuum manometer capable of reading vacuum from 0mmHg absolute to 100mmHg absolute. One service valve provides access for the manometer to the machine and the other provides access for maintenance procedures like N2 charging and sampling. A double stage oil sealed vacuum pump for evacuating the machine and carrying out maintenance procedures. Three different vacuum measurements are carried out. The positions of the manual purge valves for these measurements are described in the table below. Position of Manual Purge Valves Valve no. 2 Valve No. 3 Closed Closed Open Closed Closed Open

Air Purging

Air Purging System

Purge unit

Valve assly

Manometer Service valves

Purge pump

Measuring vacuum

Vacuum reading Ultimate (No Load) Vacuum Pressure in the storage tank Pressure in the shell

Valve no. 1 Open Closed Closed

Reading the manometer

The manometer (see Figure 7.2) consists of a glass tube fitted into a casing with a graduated scale. One end of the glass tube is sealed and the other end is connected to the vessel whose degree of vacuum is to be measured. Mercury fills the glass tube from the sealed end to the bottom of the graduated scale. When the manometer is connected to a vessel at a vacuum of 100mmHg or greater, the mercury drops in the sealed leg of the glass tube. The degree of vacuum is the difference in the level of mercury in the two legs. This is read off the graduated scale. The level of mercury in the sealed leg of the manometer should always be higher than the other leg. Otherwise the reading is wrong and the manometer has to be repaired. VII-1

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Chapter 7 When the manometer is connected to the atmosphere the mercury should rise to the top of the sealed leg. If there is a gap between the mercury and the top of the sealed leg of the manometer, it is faulty and should be repaired.

Kinds of air purging

The two types of air purging are Purging from the storage tank, and Purging from the shell. The procedure followed for the two types of purging are the same except for the position of the manual purge valves (shown in the earlier table) . Power on the machine panel if it is off. . Start the purge pump. . Check that the purge pump is running well. . Open Manual purge valve No. 1. . Check that the ultimate (no load) vacuum developed by the vacuum pump is 4mmHg or less. . Open Manual purge valve No. 2 - for purging storage tank. Manual purge valve No. 3 - for purging from shell. . Continue operation of purge pump till purging is completed. . Close Manual purge valve No. 2 - when purging storage tank. Manual purge valve No. 3 - when purging from shell. . Continue operation of purge pump for 30 minutes to remove water vapour from pump oil. . Close Manual purge valve No. 1. . Stop the purge pump.

Air purging procedure

Precautions . Check that the ultimate vacuum of the purge pump is 4mmHg or less
before air purging. . Carry out air purging at least once a week. Purging may be required at more frequent intervals. . Always keep the gas ballast valve open while purging to prevent water from contaminating the purge pump oil. . Carry out purging from storage tank before the storage tank pressure reaches 50mmHg.

Blowdown of refrigerant

During operation, a small amount of absorbent disperses in the refrigerant and accumulates over time, resulting in a reduction in cooling capacity. Blowdown is carried out to purify the refrigerant. Contaminated refrigerant collected in the refrigerant pan is transferred to the absorber sump. Pure, fresh refrigerant collects in the refrigerant pan.

Procedure . Put the refrigerant pump switch into auto mode if it is not so
already. . Confirm that the refrigerant pump is running and refrigerant is visible in the sight glass. . Open the refrigerant blowdown valve completely. Refrigerant starts being pumped to the absorber sump. . Wait till the refrigerant pump stops due to low level signal from the refrigerant level relay (about 15min), and close the refrigerant blowdown valve completely. . Refrigerant will start building up and the refrigerant pump will start when the refrigerant level reaches the center of the evaporator sight glass. (About 20 min)

VII - 2

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Operational Activities . Repeat the procedure two or three times for complete purification of refrigerant.

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VII - 3

Chapter 7

Purge System
Manual purge valve No. 2 Vacuum Manometer Manual purge valve No.3

Service valve

Manual purge valve No.1

Purge Check valve Purge tank

Purge pump Figure 7.1

50 40 30 20 10 0 10 20 30 40 50

MANOMETER
Figure 7.2

VII - 4

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Operational Activities

Precautions . Outlet chilled water temperature goes up during the blowdown

procedure and will go down when the refrigerant restarts. Blowdown operation is carried out when chilling requirement is not critical. . Carry out refrigerant blowdown once a week.

Operating log

Re. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Record readings in accordance with the operating log at frequent intervals. These aid the operator to recognize both normal and abnormal machine conditions and also aids in planning the preventive maintenance schedule and in diagnosing machine problems. A typical operating log sheet is shown below. Items Unit Date : / / : : : : Time C Ambient temp. m3/hr Chilled water flow rate C ( / ) / / / Chilled water inlet & outlet temp. 2 kg/cm g / / / Chilled water inlet & outlet pressure m3/hr Hot / Cooling water flow rate C ( / ) / / / Hot / Cooling water inlet & outlet temp. 2 kg/cm g / / / Hot / Cooling water inlet & outlet pressure C Generator temp. mmHg Generator pressure kg/cm2g Absorbent pump pressure O Generator fluid level O Absorber fluid level O Evaporator fluid level kg/cm2g Supply steam pressure kg/hr Steam flow rate % Steam control valve opening mmHg Pressure in storage tank mmHg Pressure in shell mmHg Attained vacuum of purge pump % Concentration of diluted absorbent % Concentration of intermediate absorbent % Concentration of conc. absorbent % Concentration of refrigerant This section lists the operational activities in a schedule to be carried out on a daily, weekly, monthly, and quarterly basis.

Operational activity Schedule

Daily . Check chilled water and hot / cooling water flow rates.
. Check steam inlet temperature and pressure. . While the machine is in operation the following may be observed . No abnormality in the steam control valve. . No abnormal sound in the absorbent, refrigerant and purge pumps. . No other abnormality.

Weekly . Check oil in vacuum pump.

. Air purging . Blowdown refrigerant. . Check pH and hardness of chilled and hot / cooling water.

Monthly . Check and record TRG readings of Absorbent and refrigerant pumps Quarterly . Measure and record current drawn by absorbent, refrigerant and
purge pump. C2M

*** 0007_0

VII - 5

Chapter 7 . Analyze and control chilled and hot / cooling water quality.

VII - 6

C2M

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Dos and Don'ts

Chapter 8 Dos and Don'ts

Chapter Objective
This chapter describes various activities which are to be carried out in the operation of the machine and others which should not be done. Blowdown refrigerant once a week. Purge non condensable gases from the purge unit, if the storage tank vacuum is more than 15 mm Hg. Close the main steam isolation valve after switching off the machine. Maintain inlet steam pressure constant at rated value. Check the presence of octyl alcohol and corrosion inhibitor periodically. Analyse chilled and hot / cooling water every three months and maintain the quality of chilled and hot / cooling water. Ensure that hot / cooling water flow stops one minute after the stopping the machine. Change the vacuum pump oil, if it is contaminated (white misty colour) . Charge nitrogen gas upto 0.3 kg/cm2(g) in the system for long shutdown of the machine (i.e more than a month). If the shutdown is for a shorter period, purge the machine for 20 minutes, twice a week. Ensure that the rated electric supply (3 phase) is available. Always start the chilled water pump first and then the hot / cooling water pump. Ensure that the rated chilled water and hot / cooling water flows are passing through the machine. Ensure that the steam is available at rated inlet condition. Dont open any of the valves of the purge unit without running the vacuum pump. Dont disturb the setting of any instrument or safety provided on the machine. Dont put the refrigerant pump switch or the steam control valve operational switch in MANUAL, during normal operation of the machine. Dont increase the overload setting of any motor, even if the overload alarm trips. Do not run the vacuum pump continuously. Do not let the temperature of hot / cooling water fall below 22 deg.C. Maintain it by stopping the cooling tower fan or by bypassing the cooling water into the cooling tower basin by installing a 3 way valve. Dont decrease the chilled water flow below the specified value. Dont remove the bulb of the antifreeze thermostat from the thermowell provided. Ensure that the thermowell is always full of oil. Dont run the hot / cooling water pump if chilled water pump is not running. Do not by pass or change setting of any safety devices or instruments

Dos

Donts

VIII - 1

Preventive Maintenance

Chapter 9 Preventive Maintenance

Chapter Objective
This chapter details the schedule of the various preventive maintenance procedures to be carried out. Preventive maintenance ensures best performance and long life of the machine. Following activities are to be carried out every three months . Check and record working of all the safeties and their settings . Reset or replace the safety device ,as required. . Check all the set point values on the control panel . . Check and record the TRG reading of the absorbent and refrigerant pump. . Check and record the current drawn by absorbent, refrigerant and purge pump. . Analyse the Lithium bromide solution and maintain the corrosion inhibitor level and alkalinity. Charge corrosion inhibitor, if required. Charge alkali or acid, if required to maintain the desired parameters of lithium bromide. . Check for the presence of octyl alcohol. Charge octyl alcohol, if required. . Check and maintain the hot / cooling and chilled water quality. Following activities are to be carried out once in a year . External visual inspection of the machine for any damage. If any safety device is missing / damaged , replace the same. . Conduct nitrogen leak test on the machine. If any leak is detected, rectify the leak point. . Replace all the diaphragms on the diaphragm valves. . Check for any scaling / slime in the absorber, condenser and evaporator tubes. Carry out the tube cleaning , if required. . Overhaul the absorbent and refrigerant pump. . Clean the steam trap on the machine. . Check and record the working of all the safeties. Reset or replace the safety device , as required. . Check all the set point values in the control panel. . Check and record the insulation resistance. . Overhaul the purge pump and clean the moisture trap on the purge line. . Conduct bubble test on the machine. . Clean the seat of the steam control valve. This section describes the activities to be carried out during the long-term shut down of the machine . . Make sure that the steam control valve is closed and there is no circulation of hot / cooling and chilled water through the machine. . In case the shutdown is for one week or more, perform either : A. Perform air-purging once a week, to maintain the required vacuum in the machine. B. If the shutdown is for a period more than three weeks charge nitrogen gas into the machine upto a positive pressure of 0.2 kg/cm2g. No air-purging required in this case.

Quaterly maintenance procedures

Annual maintenance procedures

Maintenance for long term shut down

IX - 1

Preventive Maintenance

Water circuit preparation for long term shutdown

Water circuit preparation is done for Absorber and condenser section and Evaporator section. The absorber and condenser tubes should be kept dry. . Drain out all the water from the absorber and condenser from the drain port of the absorber header. . Carry out tube cleaning to remove any scale or slime in the absorber and condenser tubes. . Clean the tubes with water. . Add anti-corrosion chemicals to water and circulate it in the absorber and condenser circuit. . Drain the water from the tubes. . Dry the inside surface of the tubes. The evaporator tubes should be kept full with water. If the machine is located at a site where the ambient temperature will be below freezing point of water, drain out all the chilled water and dry the evaporator tubes.

Absorber and condenser section

Evaporator section

IX - 2

Chapter 10 Procedures
Chapter Objective List of Procedures
This chapter describes the various procedures to be carried out during the maintenance of the machine. Charging solutions (absorbent and refrigerant). Sampling absorbent. Measuring absorbent concentration. Absorbent analysis. Charging inhibitor (Li 2MoO4). Charging alkali (LiOH). Charging acid (HBr). Checking and adding Octyl alcohol. Charging Nitrogen gas. Expelling Nitrogen gas. Bubble test.

Electrical and Instrumentation

Checking insulation resistance. Checking safety device operation.

C M

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X-1

X-2 Method of Charging solution at the bottom of the container Figure 10.1

Chapter 10

Bending of Vacuum rubber hose

C M

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Procedures

Charging solutions (absorbent and refrigerant) Equipment used

This section describes the procedure for charging absorbent and refrigerant into the machine. (See Figure 10.1) . Solution container (absorbent and refrigerant). . Vacuum rubber hose with hose clamps. . Copper tube . Place solution containers near the service valve to be used for charging. . Operate the vacuum pump and ensure vacuum level of 35mmHg(abs) or less inside the machine. . Clean the equipment. . Connect the equipment as shown in the figure. . Fill the rubber tube with distilled water to avoid air ingress into the machine. . Insert the copper tube on the end of the vacuum rubber hose into. the liquid container (keep the end of the copper tube slightly above the bottom of the container) . Open the service valve using the slot in the cap. . When solution starts being sucked into the machine, watch carefully to ensure that air does not leak into the machine. . As the container starts becomes empty, tilt it so that air does not enter the tube as shown in the figure. . Before the container become fully empty, bend the rubber vacuum hose with both hands to ensure that air does not leak in, and quickly insert it into the next container. . Repeat the above steps till all the solution has been charged into the machine. . Once the required amount of solution has been charged, close the service valve. . Remove the rubber vacuum hose from the service valve and put the cap back on the service valve. . Stop the vacuum pump. . Wash all the equipment with water and store carefully. . When charging solution, be careful to prevent spillage. . Because vacuum exists inside the machine, be careful to prevent air leaking in during the above work. . Carefully wash the hose used in the above work with water so as to prevent dirt ingress. . Wear rubber gloves (Do not handle equipment or solution with bare hands.) and thoroughly wash off any absorbent which gets on hands, skin or clothes. Take care to prevent absorbent entering the eyes or mouth. . If any absorbent should spill, thoroughly wash it off with water.

Procedure (to be carried out when the machine is off)

Precautions

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X-3

X-4 Manual purge valve No.2 Manual purge valve No.3 Service valve Sampling Tool Purge Check valve Sampling Tool Purge pump Figure 10.2

Chapter 10

Vacuum Manometer

Manual purge valve No.1

Purge Tank

C M

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Procedures

Method of sampling absorbent Equipment used Procedure

This section describes the procedure for sampling small amounts of absorbent.(See figure 10.2) . Sampling Tool. . Rubber hoses for vacuum with hose clamp. . . . . . . . . . . . . . . . . . . . . Operate purge pump. Open manual air-purge valve No.1. Check vacuum less than 4mmHg Connect the sampling tool to the service valve on the purge system as shown in figure. Open up the service valve connected to the sampling tool. Open up the service valve of the sampling tool. When pressure drops below 4mmHg, close service valve of the sampling tool. Close the service valve of the purge system connected to the sampling tool. Close Manual purge valve No.1. Remove the sampling tool from the purge system. Connect the sampling tool to the service valve from which sample is to be extracted as shown in figure (ensure that the sampling bottle is held tilted downwards). Open the service valve of the sampling tool. Open the service valve from which sample is to be extracted. When sampling flask becomes full of the sample (find by feeling the temperature near the mouth) Close the service valve from which sample was extracted. Remove the sampling tool, open the cap and transfer the contents as required. Wash all equipment with water before reuse. Upon completion, refit caps and gasket on all service valves. Purge the machine for 15 minutes after sampling is over. Stop purge pump.

Precautions

Vacuum exists inside the machine. Take care to ensure that air does not leak into the machine. Handle all valves carefully so as not to damage them. Carefully wash equipment and rubber hose with water to remove dirt before using it in the above work. Do not discard the solution after measurement. Store it in an empty bottle and when it becomes full recharge the solution into the machine. (See procedure for charging solution )

Measuring absorbent
C M

This section explains the procedure to measure the concentration of absorbent and refrigerant. (See Figure 10.3) X-5

* *** 0010_0

Chapter 10

concentration. Equipment used

. Sampling cylinder . Gravimeter (Scale of 1.6 to 1.8 for absorbent and 1.0 to 1.2 for refrigerant). . Thermometer . Concentration Diagram of Lithium Bromide Solution (Figure 10.4) . Absorbent or refrigerant (solution to be checked) . Take sample of solution to be checked (Refer method of sampling). . Fill sampling cylinder to about 80% with solution to be checked. . Maintain sampling cylinder vertical and insert the thermometer into the cylinder and stir the solution thoroughly. . When the temperature stabilizes, read the indication on the thermometer. . Remove the thermometer and insert gravimeter. . When the gravimeter stops moving up and down, read the indication on the scale. . Remove the gravimeter from the measuring cylinder. . Store the solution in an empty bottle. . Read the concentration of Lithium Bromide Solution, using the Concentration Diagram (Figure 10.4). . Upon completion of measurement, wash the gravimeter, thermometer, and sampling cylinder with water, and then store them carefully. In the concentration diagram the horizontal axis represents temperature and the vertical axis specific gravity. The lines going down from left to right represent fixed concentration. If the specific gravity is 1.76 and the temperature is 60C, the concentration given by the point of intersection of lines projected from these valves will be 63.0%. Do not damage the gravimeter and thermometer. Do not spill any solution. Do not fill the sampling cylinder more than about 80%. Perform specific gravity and temperature measurements quickly.
60

Procedure

Example

Precautions

1.76 1.75

Figure 10.3 X-6 C M

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Procedures
0 1.95 94 93 92 91 1.90 89 88 87 86 85 84 83 82 81 68 1.80 79 78 77 76 66 67 69 70 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

SPECIFIC GRAVITY LITHIUM

75 74 73 72 71 64 1.70 69 68 67 66 65 64 63 62 61 1.60 59 58 57 56 55 54 53 52 51 1.50 .49 0 1.20 19 18 17 16 15 14 13 12 11 110 09 16 08 07 06 05 04 03 02 01 100 99 98 97 96 095 0 10 20 30 40 50 TEMPERATURE (C) CONCENTRATION DIAGRAM OF LITHIUM BROMIDE SOLUTION 60 70 80 90 100 2 1 0 6 4 10 8 12 14 18 20 TEMPERATURE (C) 22 10 20 30 40 50 .48 1.47 .46 60 70 80 90 100 110 51 .45 .44 1.43 120 130 140 150 160 170 180 50 52 53 55 54 56 57 58 59 60 61 62 63 65

CONCENTRATION (\)

CONCENTRATION (\)

Figure 10.4 X-7

C M

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Chapter 10

Absorbent (LiBr) Analysis

Analysis of the absorbent solution is done to determine the following . Concentration of inhibitor (Lithium Molybdate). . Alkalinity of the solution. . Copper concentration. . Iron concentration. Inhibitor 50 ~ 300ppm Alkalinity 0.03N ~ 0.07N Copper 20 ppm maximum Iron 10 ppm maximum The concentration of the Lithium Molybdate can be checked by "Atomic Absorption Spectrochemical Analysis". A sample of the absorbent solution made in following procedure is to be sent to a laboratory for analysis. If the concentration of Lithium Molybdate is less than the standard refer to procedure for adding inhibitor.

Standard values

Concentration of inhibitor

Procedure

This procedure decides the sequence for preparing the sample for checking the concentration of inhibitor . Take solution sample (Refer solution sampling procedure). . Pour the solution sample into a bottle. . Stand the bottle for about 24 hours. After 24 hours, solids will settle at the bottom of the bottle . Collect 5ml of absorbent solution from the top of the bottle by the pipette. . Pour the absorbent solution by above work into the beaker. . Mix 4ml of Aluminum nitrate and 1ml of 50% Hydrochloric acid solution in another bottle. . Add 1ml of solution made above into the beaker by another pipette. . Pour 94ml of pure water into the beaker by the burette. Total quantity of the solution in the beaker is 100ml.This means that absorbent solution is diluted to 1/20. Send this sample for inhibitor analysis. Before sampling, It is recommended to perform Decrystallisation cycle for 8 hours. Analysis of Alkalinity is done by phenolphthalein and acid titration method. Standard Concentration of the alkalinity : 0.03 N ~ 0.07 N . Take solution sample (Refer solution sampling procedure). . Pour the solution sample into a bottle. . A sample of absorbent is allowed to stand in a bottle for about 24 hours to decant the solution. (After 24 hours, solids will settle at the bottom of the bottle.) . Take 10 ml of absorbent solution from the top of the bottle using a pipette. . Pour the sample absorbent solution into a beaker. . Pour 50 ml of pure water into the beaker. . Add Phenolphthalein (2~3 drops) into the beaker. (Absorbent solution turns pink). .Add N/10 Hydrochloric acid (HCl) solution drop by drop into the absorbent solution using a burette till the absorbent solution becomes colourless .Calculate the Alkalinity using the following formula N = A x 0.01 Where N: Alkalinity of the sample. A : Quantity of HCl acid solution added (ml)

Alkalinity of the solution

Procedure

X-8

C M

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Procedures Action to be taken based on the alkalinity result (adding chemicals) a. b. c. Alkalinity is 0.03 N~0.07 N: Alkalinity is less than 0.03 N : Alkalinity is more than 0.07 N : No addition. Add LiOH. Add HBr

Refer to the procedure for adding LiOH or HBr. as applicable.

Concentration of Copper
and Iron.

The concentration of Copper and Iron can be checked by "Atomic Absorption Spectrochemical Analysis". A sample of the absorbent solution is to be sent to a laboratory for analysis. Standard of concentration of the All Copper : 20 ppm maximum Standard of concentration of the All Iron : 10 ppm maximum If concentration of the Copper and Iron are more than the standard valves, absorbent solution in the machine is to be filtered. Please contact service company.

Procedure

This procedure decides the sequence for preparing the sample for analysing the concentration of all Copper and all Iron . Take solution sample (Refer solution sampling procedure). . Pour the solution sample into a bottle. . Shake the bottle before collecting the absorbent solution. . Collect 1ml of absorbent solution from the top of the bottle by the pipette. . Pour the absorbent solution by above work into the beaker. . Add 1ml of N/10 Hydrochloric acid solution into the beaker by another pipette. . Pour 98ml of pure water into the beaker by the burette. Total quantity of the solution in the beaker is 100ml.This means that absorbent solution is diluted to 1/100. Send this sample for analysis. In case that crystallization of the absorbent solution occurs, decrystallise the machine and carry out the above procedures. In case that all Copper and all Iron are analyzed, wait for a while after adding HCl solution into the absorbent solution.

Note

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X-9

Chapter 10

Adding Inhibitor

This section describes the procedure to add inhibitor into the machine to prevent corrosion. Target concentration of inhibitor : 300 ppm . Inhibitor : Li 2MoO4 H2 O (20 w% solution) . Container . Rubber gloves . Pure water (DM water/Distilled water) . Vacuum rubber hose. . Copper tube . Hose clips. . Contact the service company for dosage of Inhibitor. . Put pure water into the rubber hose and replace the air it with the pure water. . Connect the rubber hose to the refrigerant service valve using the hose clip and push the copper tube into the other end of the rubber hose and secure it with a hose clip. . Pour inhibitor into a container. . Put on rubber gloves. . Insert the copper tube on the end of the vacuum rubber hose into the inhibitor container. . Perform air purging from the shell side of VAM. . Open up the refrigerant service valve. . When solution starts being sucked into the machine, watch carefully to ensure that air does not leak into the machine. . Close the service valve after completely charging the calculated amount of inhibitor. . Remove the rubber hose. . Place the cap on service valve after checking the packing inside. . Wash the equipment with water. . Perform refrigerant blow-down twice or thrice after these procedures are completed to circulate the inhibitor in the machine. . Perform air purging from the shell side of VAM for 30 minutes after completion of the above steps. Carry out this procedure while the machine operates. Wear rubber gloves while working. Thoroughly wash off any inhibitor which gets on hands, skin and clothes. Take care to prevent inhibitor entering the mouth. Don't spill inhibitor on the floor. All excess quantities of the solutions and waste fluids are to be disposed properly as per local laws and regulations. In case that machine is operated for 18 hours or more per day, add 650 cc of inhibitor ( Li 2MoO4 H2 O, 20 w% solution) every two months in spite of analyzing result of inhibitor.

Equipment used

Procedure

Precautions

X - 10

C M

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Procedures

Adding Alkali (LiOH)

This section describes the method of adding Lithium Hydroxide (LiOH) into the machine when the measured alkalinity is less than 0.03N. . Solution container 25 litre capacity . LiOH powder. . Rubber gloves . Pure water (DM water/Distilled water) . Vacuum rubber hose. . Copper tube . Hose clips . Contact service company for dosage and method of adding alkali - LiOH. . Perform air purging from the shell side of VAM continuously throughout the process. . After completing the process, Remove the rubber hose and wash the inlet port of service valves with water. . Replace the cap on the service valve after checking the packing inside. . Wash all equipment used with water. . Perform air purging from the shell side of VAM for 30 minutes after completion of the above steps. Perform this procedure while machine is in operation. Wear rubber gloves while carrying out the above procedure. Thoroughly wash off any LiOH which gets onto hands, skin and clothes. Don't spill LiOH. All excess quantities of the solutions and waste fluids are to be disposed properly as per local laws and regulations.

Equipment used

Procedure

Precautions

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X - 11

Chapter 10

Adding Acid (HBr)

This section describes the method of adding Hydrogen Bromide (HBr) into the machine when the measured alkalinity is more than 0.07N. . Solution containers . HBr solution (Concentration: 47 w%). . pH test paper . Rubber gloves . Mask . Pure water (DM water/Distilled water) . Vacuum rubber hose. . Copper tube . Hose Clips. . Contact service company for dosage and method of adding acid HBr. . Perform air purging from the shell side of VAM continuously throughout the process. . After completing the process, Remove the rubber hose and wash the inlet port of service valves with water. . Replace the cap on the service valve after checking the packing inside. . Wash all equipment used with water. . Perform air purging from the shell side of VAM for 30 minutes after completion of the above steps. Perform this procedure while machine is in Cooling operation. Wear rubber gloves and mask while carrying out the above procedure. Thoroughly wash off any HBr which gets onto hands, skin and clothes. Do not spill HBr. All excess quantities of the solutions and waste fluids are to be disposed properly as per local laws and regulations. In case that machine is operated for 18 hours or more per day, be sure to check and adjust alkalinity every two months.

Equipment used

Procedure

Precautions

X - 12

C M

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Procedures

Adding Octyl Alcohol

Octyl alcohol is charged in small quantities to enhance the performance of the machine. As there are chances of losing Octyl alcohol, it is necessary to top up the quantity of Octyl alcohol. This section describes the procedure for checking and the method of adding Octyl Alcohol (2-Ethyl 1-Hexanol) into the machine. . Solution containers . Octyl Alcohol . Rubber gloves . Mask . Pure water (DM water/Distilled water) . Vacuum rubber hose. . Copper tube . Hose Clips. Charging quantity is very critical, as excess decrements the performance of the machine. quantity

Equipment used

Procedure

. Take a sample of absorbent solution from the service valve at the absorbent pump outlet. The presence of Octyl Alcohol can be found out by its pungent smell from the absorbent solution. If there was no smell while purging, then topping-up is required. . For charging and dosage please contact the service company.

Precautions

Perform this procedure while machine is in Cooling operation. Wear rubber gloves and mask while carrying out the above procedure. Thoroughly wash off any Octyl alcohol which gets onto hands, skin and clothes. Do not spill Octyl alcohol. All excess quantities of the solutions and waste fluids are to be disposed properly as per local laws and regulations.

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X - 13

Chapter 10

Charging Nitrogen Gas

This section deals with the method of charging the machine with N2 gas. (See Figure 10.5)

Manual purge valve No.2 Vacuum Manometer Manual purge valve No.3

Service valve

Manual purge valve No.1

Purge Check valve

Purge tank

Purge pump

Equipment used

Figure 10.5 . N2 gas cylinders required for one complete charge. . Pressure regulator for N2 cylinder . Valve key (for nitrogen cylinder) . Pressure resistant rubber hose . Hose band . Pliers . Wire . Compound Pressure Gauge( -1 to 7 kg/cmg) with rubber hose and clips. The charging pressures are as follows : (a) For storage of machine : 0.3 Kg/cm2g (b) For leakage test : 1.0 Kg/cm2g (c) For equipment replacement : 0.1 Kg/cm2g . Connect the pressure gauge to the service valve al the absorbent pump outlet. . Prepare N2 cylinder and attach N2 gas pressure regulator . Close the service valve connected to the manometer. . Connect the pressure resistant rubber hose to the outlet of the pressure regulator, then open the valve on the cylinder to release a small quantity of N2 gas and purge the air in the C M

Standard

Procedure

X - 14

* *** 00 10_0

Procedures hose. . Connect the other end of the hose to No.1 service valve and fix it by means of the hose band. . Check that No1. No2 and No3 manual air-purge valves and also No1 service valve are fully closed. . Open No.2 manual air-purge valve. . Open No.1 service valve. . Using the pressure regulator, release a small amount of N at a 2 time into the chamber. . Charge N2 gas while watching the pressure gauge of the absorbent pump. . When the specified pressure is reached, close No.1 service valve and No.2 manual valve and also close valve on the outlet of the cylinder. . Remove the rubber hose from No.1 service valve, and place the cap on No.1 service valve. . Remove the pressure regulator, and neatly arrange the N cylinder 2 and rubber hose.

Precautions

The N2 cylinder is pressurised to 150 kg/cm2g. Take care when handling it. Do not suddenly raise the primary or secondary pressure of the pressure regulator on the N2 cylinder. Fix the N2 cylinder so that it does not fall over. On no account open No.1 and No.3 manual air-purge valve during N2 charging. This section describes the procedure of expelling nitrogen from the machine. . None Shell pressure to equal atmospheric pressure, (0 kg/cm2g) based on reading of absorbent pump pressure gauge. . Open No.3 manual air purge valve. . Remove the cap from service valve and open the valve using the slot on the valve cap so as to discharge the N2 until the internal pressure becomes equal to atmospheric pressure. . When the reading on the absorbent pump pressure gauge becomes atmospheric pressure (0 kg/cm2g), close the service valve. . Do not on any account open No.1 and No.2 manual air-purge valve while N2 gas is being discharged from the machine . When expelling N2 gas, adequately ventilate the surrounding area.

Expelling Nitrogen Gas

Equipment used Standard Procedure

Precautions

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X - 15

Chapter 10

Manual purge valve No.2 Manual purge valve No.3

Manual purge valve No.1

Purge Check valve

Purge Tank

Purge pump

Figure 10.6

X - 16

C M

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Procedures

Bubble test Equipment used

This section describes the procedure for carrying out the bubble leak test. (see Figure 10.6) Graduated cylinder Vinyl hose (2m) Bucket Putty Stop watch Leak test shall be performed during shutdown of the machine. Average of three measurements should be less than 15 cc in 10 minutes. . Perform air-purging until the inside pressure of the machine reaches the allowable degree of vacuum, and then continue airpurging at least for one hour. . Make sure that the no load vacuum of the purge pump is under 4 mmHg. . Connect the vinyl hose to the exhaust port of purge pump and put its other end into the bucket filled with water as shown in the figure . Diaphragm valves should be set as follows Valve No.1 Open, Valve No.2 & 3 Close . Operate purge pump for about one minute and then measure the bubble volume. . While measuring keep the vinyl hose within a depth of 10mm from the water surface. . If bubbles are collected, inspect and tighten downstream connections from the diaphragm valves. . If bubbles are still collected in spite of the above tightening, measure the volume of bubbles collected in 10 minutes. . Call this volume A . Then set the diaphragm valves as follows Valve No.1 & 3 Open, Valve No.2 Close . Gas ballast valve and oil delivery valve should be kept closed. . Continue operation of purge pump under the above conditions. . Measure the volume of bubbles in 10 minutes. And call this volume B. . While measuring keep the vinyl hose within a depth of 10mm from the water surface and wait until the first bubble to come out before starting the timer. . Measurement should be performed at least three times. . Between measurements, check that the no load vacuum of purge pump is under 4mmHg. . The value of (B-A) is the result of the bubble leak test. . If the oil is contaminated with water, replace oil. . As part of the leak test after assembly work at site. . As part of the periodical inspections. . After carrying out site procedures that break vacuum tightness and after N2 leak test. . Ensure that the no load vacuum attained by the vacuum pump is less than 4mmHg. If the no load vacuum of purge pump is above 4mmHg carry out maintenance of the purge pump.

Standard

Procedure

When is bubble leak test performed?

Precautions

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X - 17

Chapter 10

Measuring Insulation Resistance Standard Equipment used Procedure

This section describes the procedure of inspecting the insulation resistance of power and control circuit. a. b. Power circuit Control circuit : Above 10 M : Above 10 M

. Megger DC 500 V Driver . Do not supply electricity power during this measurement. . Disconnect green earth wire between terminal E on terminal base and earth terminal in control panel. . Make sure that MCB is not put on. . Connect earth wire of Megger to earth terminal in control panel. . Measure insulation resistance at terminals of R, S, T, U1, U2, U3, V2, V3, W1, W2, and W3. . Measure insulation resistance at terminals of "No.0". . Record the above measured valves. . This measurement is to be performed after replacement of electrical components and inspection of solution pumps. . This section describes the procedure to inspect the functioning of safety devices independently. These are Chilled water flow switch and DP switch. Chilled water freeze protection thermostat. . Continuity Tester . Bucket (about 5 liters capacity) . Ice Blocks . Hot water (80 - 90C) . Thermometer (0 - 100C) . Disconnect two wires connected to terminals strip in the control panel from the flow switch and DP switch. . Connect the tester between the above disconnected two wires. . Set the tester to measure resistance. . Operate chilled water pump(s). . Close the valve furnished at delivery piping of chilled water pump gradually to reduce chilled water flow rate. . Inspect that the indication of the tester becomes infinity at 50% of the specified chilled water flow rate. . If the setting was disturbed, re-adjust the flow switch and (or) DP switch. After completion of the test, reconnect the wires. . If flow switch/ DP switch is broken, replace it. . Disconnect two wires connected to terminal strip in the control panel from the chilled water freeze protection thermostat. . Connect the tester between the above disconnected two wires. . Set the tester to measure resistance. . Pour water in the bucket till it is about half full, Dip the sensor of the thermostat into the water, put the ice blocks into the water. . Read the temperature on the thermometer when the tester indicates infinity due to the reduced temperature of the water. . Set point : 3.5C . Take out ice blocks from the water. . Pour hot water in the water. . Inspect that the indication of the tester becomes [0] due to the rising temperature of the water. . If the setting was disturbed, re-adjust the thermostat. . After completion of the test, reconnect the wires. . If thermostat is broken, replace the thermostat. Stir the water to get the average temperature in the bucket during measurement. C M

Precautions

Inspection of safety devices Equipment used

Chilled water flow switch and Differential Pressure switch.

Chilled water freeze protection thermostat

Precautions

X - 18

* *** 00 10_0

Procedures

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X - 19

Troubleshooting

Chapter 11 Troubleshoting
Chapter Objective Trouble shooting categories
This chapter describes how to troubleshoot the machine. The various types of problems encountered during machine operation can be classified as below Problems without alarm indication - The problems without alarm indication are Operator terminal does not light up. Machine does not start. Leaving chilled water temperature does not reach setpoint. Leaving chilled water temperature is rising day by day. Large fluctuation in the chilled water outlet temperature. Steam control valve does not close when the desired chilled water outlet temperature is achieved. Problems with alarm indication - These problems occur when the machine is in operation. In case any of the following problems occur, the machine exectutes the appropriate alarm sequence with audio-visual indication. Chilled water pump put off / tripped. Chilled water flow switch tripped. Chilled water DP switch tripped. Chilled water pump put off / tripped. Chilled water flow switch tripped. Chilled water DP switch tripped. Chilled water temperature very low (Internal antifreeze). Antifreeze thermostat tripped. Chilled water inlet temperature sensor error. Chilled water outlet temperature sensor error. Hot / Cooling water inlet temperature sensor error. Hot / Cooling water outlet temperature sensor error. HTG temperature sensor error. Dilute temperature sensor error. Sprayed temperature sensor error. HTG temperature high. HTG vapour temperature high. Hot / Cooling water inlet temperature very low. Refrigerant pump tripped. Absorbent pump tripped. MCB 1 / MCB 2 tripped. Purge pump tripped. Absorbent pump not responding. Refrigerant pump not responding. PLC fault. Action in case of interrupted power supply. Jamming of purge pump Decrystallisation PLC troubleshooting.

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Troubleshooting

Problems without alarm indication Operator terminal does not light up. Machine does not start.

These problems may occur either when the machine starts or during operation of the machine.

Check if the main circuit breaker is turned on. If not, switch it on. Check if all the MCB's are on. If not, switch them on. In case the machine does not start up, check the following : Are the chilled water and hot / cooling water pumps running? If not, operate the pump(s). Are the inlet and outlet valves of the chilled water and hot / cooling water on the machine open? If not, open the valve(s). Check if the chilled water flow rate sufficient. If not, check the following : If the strainer in the chilled water circuit is clogged, clean the strainer in the chilled water circuit. Is air accumulated in the chilled water circuit? If yes, vent out the air from the chilled water circuit. Maintain the proper chilled water flow across the machine.

Chilled water temperature is not dropping.

In case the leaving chilled water temperature is not dropping, check the following Are the auxillary equipments ON ? Is the steam control valve select key in AUTO position? If not, put the steam control valve in AUTO mode. Is the refrigerant pump in AUTO mode? If not, put the refrigerant pump in AUTO mode. Other causes for not achieving the desired chilled water temperature are Insufficient vacuum. Insufficient steam supply. Insufficient hot / cooling water supply. Hot / Cooling water inlet temperature is higher than the design temperature. Refrigerant pump not operating. Chilled water flow rate higher than rated. In case the chilled water temperature is rising over a period of time, confirm that all the inlet parameters to the machine are being maintained in accordance with the specified values. Check the following causes -

Leaving chilled water temperature is rising day by day Fouling of hot / cooling water and / or chilled water circuit

Fouling in the hot / cooling water and / or chilled water circuit accumulates in proportion to the operating hours of the machine, and the capacity decreases in proportion to the fouling. Occurrence of fouling can be observed by noticing the pressure difference across the evaporator for chilled water circuit and across the absorber and condenser for hot / cooling water circuit of the machine. If the pressure difference across the respective heat exchanger has increased compared to the original value with the chilled water and hot / cooling water flows remaining constant, it indicates scaling in the respective circuit. Fouling in the hot / cooling

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Troubleshooting water tubes can also be confirmed by comparing the temperature difference between the hot / cooling water outlet and condensed refrigerant . If the difference is more than 3C, it indicates scaling in the hot / cooling water tubes. Fouling in the chilled water tube can be confirmed by observing the temperature difference between the chilled water outlet temperature and the refrigerant temperature on the outlet of the refrigerant pump line. In case the temperature difference exceeds 3C, it indicates fouling in the chilled water tubes. Perform tube cleaning of the chilled water and / or hot / cooling water tubes as required.

Mixing of absorbent solution in the refrigerant

A very small quantity of absorbent may be dispersed in the refrigerant and accumulate during the operation of the machine. It causes reduction in the capacity of the machine. Perform refrigerant blowdown to generate fresh refrigerant.

Insufficient octyl alcohol

Insufficient quantity of octyl alcohol in the machine will cause a reduction in the capacity of the machine. If there is no smell of octyl alcohol in the exhaust from the purge pump, octyl alcohol is insufficient. Charge the required quantity of octyl alcohol into the machine. The charge volume of octyl alcohol is 1.1 litres / 1,000 kgs of LiBr ( 55 % by weight ). Excessive addition of octyl alcohol will affect the absorbent circulation. Hence charge octyl alcohol in small quantities and observe the change in capacity of the machine. Do not charge excess quantity of octyl alcohol into the machine.

Very small amount of air leakage in the machine

If the machine is operating with a very small amount of air leakage, the capacity of the machine will reduce slowly over a period of time . Check the corrosion inhibitor level in the machine and maintain it as per the standard requirements. Perform the nitrogen leak test on the machine. Check for any minor leakage points, specifically at the sight glasses, solution level electrodes, refrigerant level electrodes, connections of manometer, diaphragm valves, absorbent pump pressure gauge and generator pressure gauge. Rectify the leak point and conduct nitrogen decay test for 24 hours and confirm there is no drop in the nitrogen pressure in the machine.

Large fluctuation in the chilled water outlet temperature

The reasons for large fluctuation in the chilled water outlet temperature are Variation in chilled water flow Variation in load Incorrect setting of PID values .Check and maintain the required flow. .Check and maintain a constant load on the machine. .Check and correct the required PID values as per the setpoint datasheet.

Steam control valve does not close when the hot or chilled water outlet temperature crosses the set temperature

If the steam control valve does not close when the desired temperature of hot or chilled water is achieved, check and correct the hot or chilled water set points.

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Troubleshooting

Problems with alarm indication

If the machine is in operation and any of the following problems occur, the machine stops with an audio alarm and a suitable visual alarm on the panelview operator terminal screen. The probable cause and remedy for the warning stop are as follows -

Description of alarm
Chilled water pump put off / tripped. Chilled water flow switch tripped. Chilled water DP switch tripped.

Probable cause
Chilled water pump stopped / tripped. Chilled water pump stopped / tripped.

Remedy
Check the chilled water pump for mechanical and electrical faults. Rectify the same and maintain the required flow. Check the chilled water pump for mechanical and electrical faults. Rectify the same and maintain the required flow. Check the strainer in the chilled water circuit, and clean if necessary. Check that the chilled water inlet and outlet valves are open. Replace / rectify the flow switch / DP switch Perform air-venting from the chilled water circuit. Change the steam control valve key to AUTO mode.

Inadequate chilled water flow rate.

Chilled water temperature very low (Internal antifreeze). Antifreeze thermostat tripped (*).

Malfunction of chilled water flow switch / DP switch. Accumulation of air in the chilled water circuit. (*) Steam control valve in MANUAL mode and in OPEN position. (*) Sudden reduction of chilling load. (*) Inadequate chilled water flow rate.

Chilled water inlet temperature sensor error. Chilled water outlet temperature sensor error. Hot / Cooling water inlet temperature sensor error. Hot / Cooling water outlet temperature sensor error. HTG temperature sensor error. Dilute temperature sensor error. HTG vapour temperature sensor error. Sprayed solution temperature sensor error.

Main setpoint of chilled water is too low. (*) Malfunction of antifreeze thermostat. Setpoint of L cut is too low. Sensor cable is open / short. Loose connection of sensor cable. Faulty temperature sensor.

Do not reduce the chilling load suddenly. Check the strainer in the chilled water circuit, and clean if necessary. Check that the chilled water inlet and outlet valves are open. Reset the chilled water set point to a higher value. Replace antifreeze thermostat. Reset the L cut setpoint to a higher value. Replace the sensor cable. Check the tightness of the cable connections. Replace the temperature sensor.

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Troubleshooting HTG temperature high. HTG vapour temperature high. High cooling water inlet temperature. (Cooling Mode) Check the setting of cooling water tower fan thermostat, and reset if required. Check the feed water system of cooling tower. Check and clean the cooling tower. Check and adjust the supply steam pressure. Check the opening of steam control valve. Check the operation of steam control valve. Check for fouling in the absorber and condensor tubes, and carry out tube cleaning if required. Check and reset the settings.

Excessive steam supply.

Fouling in the absorber and condenser tubes. Setpoint of HTG temperature / vapour temperature is not correct. Steam control valve select switch is in MANUAL mode and in OPEN position. Air leakage into the machine. Inadequate hot / cooling water flow rate.

Turn the steam control valve select key to AUTO mode. Perform nitrogen leak test and rectify the leak point. Check the operation of the hot / cooling water pump. Check that the hot / cooling water inlet and outlet valves are open. Check and vent out the air in the hot / cooling water line. Check and clean the strainer in the hot / cooling water line. Check and maintain the hot / cooling water flow rate. Reprogram the AC Drive. Check, and replace if necessary.

Cooling water inlet temperature very low. (Cooling mode only)

Refrigerant pump tripped. Absorbent pump tripped. MCB 1 / MCB 2 tripped.

Wrong AC Drive program. Malfunction of cooling water tower fan cutout thermostat. Setpoint of cooling water tower fan cutout switch is too low. Pump drawing overcurrent because of either Single phasing. Severe crystallisation. Setpoint of overload relay is too low. Malfunctioning of overload relay. High TRG reading.

Reset the set point of the cooling water fan cutout thermostat to a higher value.

Check and ensure proper power supply Decrystallise the machine Reset the set point to a higher value. Check, and replace the overload relay if required Replace the bearing.

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Troubleshooting Purge pump tripped. Pump drawing overcurrent because of Single phasing. Contamination of oil. Setpoint of overload relay is too low. Malfunctioning of overload relay. Loose connection on the contactor. Contactor stuck. Contactor coil burnt / open. Loose connection on the contactor Contactor stuck. Contactor coil burnt / open.

Check and ensure proper power supply. Replace the purge pump oil. Reset the set point to a higher value. Check, and replace the overload relay if required. Tighten the loose connection. Replace the contactor coil. Recycle the power to the AC Drive. Tighten the loose connection. Replace the contactor coil.

Absorbent pump not responding.

Refrigerant pump not responding.

PLC fault.

Refer to PLC fault troubleshooting.

Restart the machine only after the fault has been rectified. Whenever any safety device is replaced, make sure that the electrical connections are done correctly. Check and tighten any loose connection in the control panel and on the safety device.

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Troubleshooting

Action in case of interrupted power supply during operation

If the power supply to the machine is interrupted, switch off the machine immediately. Make sure that the steam control valve is closed. If the power supply is resumed within half an hour, immediately start the machine and maintain the appropriate inputs to the machine. If the power is interrupter for longer then half an hour, carry out the following activities . Start the machine and stop it, to put the machine into dilution cycle. . Start the machine and check for crystallisation. If there is no indication of crystallisation, operate the machine. . If there is any indication of crystallisation, perform decrystallisation, and then operate the machine.

Power cut during purging operation of the machine

If the power is interrupted when the air-purging of the machine is in progress, immediately close manual purge valve no.1, and then close the other manual purge valves. As soon as the power is resumed, operate the purge pump and continue air-purging. If the absorbent solution is forced into the purge pump by the incorrect operation of charging or discharging nitrogen gas, the absorbent solution causes jamming of the purge pump. If the quality of purge pump oil is not proper and contains too much contamination, the purge pump may become jammed. Charge fresh oil in the purge pump as below. . Drain out the contaminated oil from the purge pump. . Charge kerosene oil in the purge pump and operate it for a few seconds. . Drain the kerosene oil from the purge pump. . Charge purge pump oil in the purge pump and operate the purge pump for some time. . Drain the oil and recharge fresh purge pump oil. Now the pump is ready for usage.

Jamming of the purge pump

Precautions for operation of purge pump.

Always charge fresh purge pump oil in the purge pump for long term shut down. After a long term shut down or in the cold season, rotate the pulley of the purge pump manually several times before starting the purge pump.

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Troubleshooting This section describes the decrystallisation procedure.

Decrystallisation What is crystallisation ?

Crystallisation is the condition when lithium bromide solidifies. This occurs when the temperature of LiBr solution goes below the crystallisation temperature. (Refer to the concentration diagram of LiBr solution.) The crystallisation line for LiBr solution with reference to various temperatures and concentrations can be seen. If the concentration of LiBr solution is 68.5% , then the crystallisation temperature is 85C, i.e. if the temperature of LiBr solution with 68.5% concentration falls below 85C, then LiBr tends to form solid crystals. Similarly , if the concentration of LiBr is 63%, the crystallisation of LiBr will occur if the temperature of LiBr falls below 32C. LiBr flows through various pipes of the machine at different concentrations and temperatures. If the solution condition goes beyond the crystallisation line, then crystals formed will block the flow of the solution, thereby affecting the performance of the machine. Crystallisation usually occurs at the concentrated absorbent solution outlet of low temperature heat exchanger .

Causes of crystallisation

Crystallisation occurs when the following conditions occur together : Hot / Cooling water inlet temperature too low. Insufficient vacuum in the machine. Excessive steam supply. Insufficient absorbent flow rate. Hence it is of utmost importance that the input conditions to the machine are maintained in accordance with the design parameters.

Symptoms of crystallisation

When crystallisation occurs, the following can usually be observed : Absorbent level drops rapidly. This can be observed from the absorber sight glass. Evaporator level increases. This can be observed from the evaporator sight glass. Overflow of refrigerant from the refrigerant pan to the absorber sump takes place. Overflow of concentrated absorbent takes place from the low temperature generator to the absorber, bypassing the low temperature heat exchanger and the overflow line becomes hot. Temperature of dilute solution delivered from the absorbent pump increases. Chilled water outlet temperature rises. The outlet line of concentrated solution from the low temperature heat exchanger becomes cold. Change the position of steam control valve select key from AUTO to MANUAL. Set the steam control valve opening at 0%, stopping the steam flow into the machine. Change the position of refrigerant pump select key from AUTO to MANUAL and put it ON. Open the refrigerant blowdown valve, and transfer the refrigerant in the refrigerant pan, directly to the absorber sump. When the refrigerant pump gives abnormal noise, switch off the refrigerant pump by pressing the ON / OFF button. Put the machine operation key into the STOP position. After 20 minutes of dilution cycle is over, stop the chilled water and hot / cooling water flow through the machine.

Procedure for decrystallisation

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Troubleshooting Switch off the (MCB)incoming power supply to the control panel of the machine . Supply power to the machine control panel. Start the chilled water flow through the machine. Start the machine and operate it by manually controlling the input steam. Raise and maintain the temperature of dilute lithium bromide solution from the absorbent pump to around 50 - 60C. Continue this operation for about 2 - 3 hours. If required the duration should be extended.

During the above process , the HTG pressure should be monitored continuously, and maintain the pressure of the HTG below the safety set point of the HTG pressure switch. In case the crystallisation is intense, perform the following activities along with the above steps. Charge pure water from the service valve furnished at the concentrated absorbent side of low temperature heat exchanger. Heat the portion where crystallisation has occurred and the surrounding area externally, with a gas or oil torch.

Confirmation for decrystallisation

Check if the decrystallisation is successful by observing the following No flow of concentrated absorbent through the overflow pipe. This can be confirmed if the temperature of overflow pipe goes down. LiBr level in the absorber rises. This can be observed from the absorber sight glass. Temperature of concentrated absorbent at the outlet of low temperature heat exchanger rises.

After decrystallisation is successful

After the decrystallisation is successful carry out the following Change the position of machine operation key to STOP . After 20 minutes of dilution cycle is over, the machine and the chilled water flow are stopped completely. Change the position of refrigerant pump select key from MANUAL to AUTO. Change the position of steam control valve select key to AUTO. Locate and remove the cause of crystallisation and run the machine. Observe the operating condition of the machine for sometime, after restarting the machine, so as to confirm that decrystallisation process was successful. In case water was added during the decrystallisation work, remove the water from the machine. Water is removed from the service valve furnished on the refrigerant outlet piping, by using a small pump. However, in case only a small amount of water has been added, it has no affect on the capacity of the machine and the removal of water is not necessary.

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Troubleshooting

Precautions to be observed while troubleshooting the PLC

Never ever remove / insert any of the PLC cards under powered conditions. Prior to power up always confirm that all the PLC cards are in their respective slots as per the machines electrical drawing. Always keep the slelector switch on the CPU in RUN position. Ensure perfect earthing for the machine panel. Before interchanging / replacing any of the cards ensure that they are exactly as per the card specifications mentioned in the machine manual (I/O list).

Do not change the jumper settings on any of the cards. Ensure that they are as per the notes in the machines electrical drawing

Correction ProcedureExternal signal error (S*)

This fault deals with the temperature control software loop. Confirm that the P, I and D values and chilled water outlet temperature setpoint, are not negative, zero, or out of range. If found so, correct the values.

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