TC Manual Water Cooled Chillers

Page 1 of 24
Temperature Control Manual Water Cooled Chillers
Version 0.1 Date: 1/02/2007 Prepared By: Justin Day Engineering Department
Temperature Control Manual
WATER COOLED CHILLERS
TC Manual Water Cooled Chillers.doc
Aggreko Australia Pacific
Page 2 of 24

TABLE OF CONTENTS
Section
Page
IMPORTANT INFORMATION............................................ ERROR! BOOKMARK NOT DEFINED. 1 1.1 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.4 2 3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.2 3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.4 3.4.1 3.4.2 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.9 3.7 4 INTRODUCTION................................................................................................................3 Description........................................................................................................................4 Equipment .........................................................................................................................4 Compressor ..................................................................................................................5 Oil Separator ................................................................................................................6 Condenser ....................................................................................................................6 Expansion Valve ..........................................................................................................7 Evaporator....................................................................................................................7 Control Devices ...........................................................................................................7 Applications ......................................................................................................................8 TECHNICAL DATA ...........................................................................................................9 INSTALLATION, OPERATION AND MAINTENANCE (IOM)................................15 Installation.......................................................................................................................15 Handling.....................................................................................................................15 Foundation .................................................................................................................15 Clearances..................................................................................................................15 Ventilation .................................................................................................................15 Drainage.....................................................................................................................15 Water Piping ..............................................................................................................15 Water Treatment ........................................................................................................16 Commissioning ...............................................................................................................16 Unit Start-up ..............................................................................................................16 Seasonal Unit Start-up ...............................................................................................16 Operation.........................................................................................................................17 Temporary Shut Down and Restart............................................................................17 Emergency Stop.........................................................................................................17 Final Check ................................................................................................................17 Principal of Operation................................................................................................17 Decommissioning ...........................................................................................................18 Daily Unit Shutdown ......................................................................................................18 Seasonal Unit Shutdown .................................................................................................18 Maintenance Procedures .................................................................................................18 Daily Maintenance Checks ........................................................................................18 Weekly Maintenance Checks.....................................................................................18 Monthly Maintenance and Checks.............................................................................18 Annual Maintenance ..................................................................................................19 Maintenance Schedules..............................................................................................20 Troubleshooting ..............................................................................................................22 ELECTRICAL ...................................................................................................................23
Page 3 of 24

IMPORTANT INFORMATION
Fluid Flow through the chiller: Fluid pump MUST always feed into the Chiller Proper flow MUST be established for optimum operation The pressure across the chiller barrel is set to 40kPa delta p (delta p = fluid press entering the chiller minus fluid leaving the chiller) Correct Pump size Installation: Have technical information with you at all times to refer to
Position equipment on a level surface and leave room for air intake and room to work Keep hosing lengths as short as possible and tidy Complete a commissioning report Chiller Settings:

Leaving fluid temperature setting (Set Point) Cut in / Cut out temperature settings (Range / Dead Band) Low water temperature cut out setting Low refrigerant cut out setting Fluid Flow (delta p) Chiller Safety:

Contamination of chiller barrels Proper fluid flow Correct Power Supply Correct Phase Rotation PRE HEAT CHILLERS (minimum 24 hrs) Service valves Follow manufacturers recommendations Install strainers
Page 4 of 24

1 INTRODUCTION
This manual contains directions regarding the descriptions, installation, and operations of the Aggreko Water Cooled Fluid Chillers.
1.1
Description
The units are intended for the cooling of water or non corrosive fluids. They are designed to be located outside (rooftop or ground), not in an enclosed plant room or sealed building. They are used for a wide variety of applications in the mining, process, HVAC, Food, Industrial, and Manufacturing industries. The outlet temperatures for the chillers vary from our standard 6C water mixture to the lower temperatures of -19C (50% water / glycol mixture).
1.3
Equipment
The chiller is a pre-fabricated unit and consists of a number of important components.
Page 5 of 24
1.3.1
Compressor
The helical rotary chiller uses 2 screw like rotors to perform the compression process. The male rotor is driven by the compression motor. In the operation of the compressor, refrigerant vapour enters the compressor housing through the intake port. The refrigerant vapour is at a low, suction pressure and fills the grooves or pockets formed by the lobes of the rotors. As the rotors turn, they push the pockets of refrigerant toward the discharge end of the compressor.
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1.3.2 Oil Separator
The oil leaves the compressor entrained within the discharged refrigerant vapour, and it is the oil separator that recovers this oil. The separator consists of a vertical cylinder surrounding an exit passageway. As the refrigerant and oil mixture is discharged into this passageway the oil is forced outward by centrifugal force, collects on the walls of the cylinder and drains to the bottom. This accumulated oil drains out of the cylinder and collects in the oil sump located near the bottom of the chiller. The oil sump is heated to ensure proper lubrication and minimise refrigerant condensation in the sump.
1.3.3
Condenser
The water is pumped through the tubes of the shell and tube heat exchanger while refrigerant vapour fills the shell space surrounding the tubes. The condenser has a baffle plate that helps distribute the refrigerant evenly within the shell. As heat is transferred from hot, high pressure refrigerant vapour to the water, refrigerant condenses on the tube surfaces. The condensed liquid refrigerant then collects in the bottom of the shell where the lower tubes are now submerged, resulting in further cooling, or subcooling of the refrigerant.
refrigerant vapor condenser water water-cooled
tubes
liquid refrigerant
TC Manual Water Cooled Chillers.doc Aggreko Australia Pacific
Page 7 of 24

1.3.4 Expansion Valve
The expansion valve is used to maintain the pressure difference between the highpressure (condenser) and the low pressure (evaporator) sides of the system, as established by the compressor. This pressure difference allows the evaporator temperature to be low enough to absorb heat from the water being cooled, whilst allowing the refrigerant to be at high enough temperature in the condenser to reject heat to water at normally available temperatures. High pressure liquid refrigerant flows through the expansion device, causing a large pressure drop that reduces the refrigerant pressure to that of the evaporator. This pressure reduction causes a small portion of the liquid to boil off, or flash, cooling the remaining refrigerant to the desired temperature.
1.3.5
Evaporator
In the flooded shell and tube evaporator cool, low pressure liquid refrigerant enters the distribution system inside the shell and is distributed uniformly over the tubes, absorbing heat from relatively warm water that flows through the tubes. This transfer of heat boiled the film of liquid refrigerant on the tube surfaces and the resulting vapour is drawn back to the compressor. The cooled water can now be used in a variety of applications.
1.3.6
Control Devices
A microprocessor based control panel provides actual chilled water control as well as monitoring, protection, and adaptive limit functions. These controls monitor the chillers operation and prevent the chiller from operating outside its limits. They can compensate for unusual operating conditions while keeping the chiller running by modulating system components, rather than simply tripping off due to a safety setting. It not only provides accurate, optimised control and protection for the chiller, but permits interfacing for integrated system control. In a chiller water system, optimal control is a system wide issue, not just a chiller issue. The control device provides a wide range of features including: a. Access to all available chiller data; b. Set points Start up times Configuration items Service information Chiller report; Refrigerant report; Compressor report; and Custom report (include all information that the user wants to see).
Reporting; -
c.
Alarm and diagnostic capability
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-
100 different diagnostic messages (including a log of the past 20) Indicator to inform when an alarm is present Expanded help messages for each alarm for actioning Operator security
1.4
Applications
The water cooled chiller can be used in a wide variety of applications. From underground mine shaft cooling to air conditioning. The chiller is often used in conjunction with other Aggreko equipment such as cooling towers, fluid pumps, and heat exchangers.
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2 TECHNICAL DATA
aggreko
Prepared by: Discipline: Section: Date: Revision:
Page 9
of 24
Fluid Chiller
Document number
WATER COOLED US FC1200
a1.5
1.
INTRODUCTION The Aggreko water cooled fluid chillers are designed for water or water-Glycol cooling. The units are completely assembled with all interconnection refrigerant piping and internal wiring, ready for installation. The large capacity on a small foot print makes this unit excellent for large size application. If required Aggreko can supply a cooling tower to accommodate the chiller. This cooling tower can be placed on top of the chiller if space is a concern. A reliable screw compressor with V.I. control ensures an optimum performance over a wide temperature range. The unit is build in a standard 20 ft. container.
2.
KEY-DATA Cooling Capacity Absorbed Power Temperature Range Maximum ambient temp. Dimensions length width height weight 1200 kW at 6 degrees leaving water temperature 325 kW 3 C to 15 C 45 C standard ISO 20ft. Container. 6.0 metres 2.4 metres 2.4 metres 12000 kg approx
Page 10 of 24
aggreko
Page 10
of 24
Fluid Chiller
Document number

TECHNICAL SPECIFICATIONS
UNITS kW C / C C / C C / C VALUE 1200 11 / 6 +3 / +15 0 / +45 Screw Semi Hermetic 1 10 / 100
a1.5
4.
ITEM
Performance Data Design Capacity Design Operation Fluid Temperature IN / OUT Minimum / Maximum Outlet Fluid Temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Evaporator Data Evaporator Type Evaporator Material Design Flow Minimum / Maximum Flow Evaporator Barrel Capacity Evaporator Barrel Maximum Working Pressure Design Evaporator Barrel Pressure Drop Recommended System Water Volume Condenser Data Condenser Type Condenser Material Design Condenser Water temperature IN / OUT Minimum / Maximum Condenser Water Outlet Temperature Design Flow Minimum / Maximum Flow Condenser Barrel Capacity Condenser Barrel Maximum Working Pressure Design Condenser Barrel Pressure Drop Recommended System Water Volume Refrigerant Data Refrigerant Type Number of Circuits Design Refrigerant Charge Type Of Compressor Oil Oil Charge circuit Electrical Data Design Electrical Supply Voltage Design Electrical Rating Nominal Operating Current Starting Current Pre-Heating Supply Recommended Generator Set Required Cable Size per Phase Electrical Connection Noise Data Sound Pressure Level at 10 metres - Lp(A) Sound Power Level - Lw(A) Physical Data Overall Length Overall Width Overall Height Weight Fluid Coupling Size Condenser / Evaporator
l/s l/s / l/s litres kPa kPa litres
Shell & Tube Steel & Copper 57 26 / 96 263 1000 40 1500 Shell & Tube Steel & Copper 29 / 34 16 / 48 72 31 / 113 217 1000 35 1000 R22 1 370 15 38
C / C C / C l/s l/s / l/s litres kPa kPa litres
kg litres
Volts/Hz kVA Ampere Ampere Volts / kVA kVA mm
415/ 50 406 533 972 240 / 5 750 3 x 240 Busbar M12 70 98 6.0 2.4 2.4 12000approx 2 x 100 (4") with adaptor.
dB(A) dB(A) metres metres metres kg mm / inch
NOTE: Contact Technical Department If Application Conditions Differs From Design Conditions
Page 11 of 24
aggreko
Page 11
of 24
Fluid Chiller
Document number
a1.6
INTRODUCTION The Aggreko water cooled fluid chillers are designed for water or water-Glycol cooling. The units are completely assembled with all interconnection refrigerant piping and internal wiring, ready for installation. The large capacity on a small foot print makes this unit excellent for large size application. If required Aggreko can supply a cooling tower to accommodate the chiller. This cooling tower can be placed on top of the chiller if space is a concern. A reliable screw compressor with V.I. control ensures an optimum performance over a wide temperature range. The unit is build in a standard 20 ft. container. 2. KEY-DATA Cooling Capacity Absorbed Power Temperature Range Maximum ambient temp. Dimensions length width height weight 1300 kW at 6 degrees leaving water temperature 325 kW -12 C to 15 C (use 12 C with caution, please contact Technical Dept) 45 C standard ISO 20ft. Container 6.0 metres 2.4 metres 2.4 metres 12000 kg approx
Page 12 of 24
aggreko
Page 12
of 24
Fluid Chiller
Document number

TECHNICAL SPECIFICATIONS
UNITS kW C / C C / C C / C VALUE 1300 11.5 / 6 -12 / +15 0 / +45
a1.6
4.
ITEM
Performance Data Design Capacity Design Operation Fluid Temperature IN / OUT Minimum / Maximum Outlet Fluid Temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Evaporator Data Evaporator Type Evaporator Material Design Flow Minimum / Maximum Flow Evaporator Barrel Capacity Evaporator Barrel Maximum Working Pressure Design Evaporator Barrel Pressure Drop Recommended System Water Volume Condenser Data Condenser Type Condenser Material Design Condenser Water temperature IN / OUT Minimum / Maximum Condenser Water Outlet Temperature Design Flow Minimum / Maximum Flow Condenser Barrel Capacity Condenser Barrel Maximum Working Pressure Design Condenser Barrel Pressure Drop Recommended System Water Volume Refrigerant Data Refrigerant Type Number of Circuits Design Refrigerant Charge Type Of Compressor Oil Oil Charge circuit Electrical Data Design Electrical Supply Voltage Design Electrical Rating Nominal Operating Current Starting Current Pre-Heating Supply Recommended Generator Set Required Cable Size per Phase Electrical Connection Noise Data Sound Pressure Level at 10 metres - Lp(A) Sound Power Level - Lw(A) Physical Data Overall Length Overall Width Overall Height Weight Fluid Coupling Size Condenser / Evaporator
Screw Semi Hermetic 1 10 / 100
Shell & Tube Steel & Copper 57 26 / 96 263 1000 40 1500 Shell & Tube Steel & Copper 29.5 / 34 16 / 48 72 31 / 115 217 1000 35 1000 R22 1 463 15 36.5
kg litres
Volts/Hz kVA Ampere Ampere Volts / kVA kVA mm
415/ 50 406 412 935 240 / 5 750 3 x 240 Busbar M12
dB(A) dB(A) metres metres metres kg mm / inch 6.0 2.4 2.4 12000approx 2 x 100 (4") with adaptor.
Page 13 of 24
aggreko
Prepared by: Discipline: Section:
Adam Hentschel
Date:
12.02.2001
Revision:
Page 13 of 24
Document number
Fluid Chillers
WATER COOLED SCREW WCW FC1500A
au.1.4
1.
INTRODUCTION
The Aggreko water cooled fluid chillers are designed for water or water-Glycol cooling. The units are completely assembled with all interconnection refrigerant piping and internal wiring, ready for installation. The large capacity on a small foot print makes this unit excellent for large size application. If required, Aggreko can supply a cooling tower to accommodate the chiller. This cooling tower can be placed on top of the chiller if space is a concern. A reliable screw compressor with V.I. control ensures an optimum performance over a wide temperature range. The unit is built in a standard 20 ft. container. 2. KEY-DATA 1500 kW at 6 degrees leaving water temperature 240 kW +15 C to -12 C 40 C standard ISO 20ft. Container. 6.0 metres 2.4 metres 2.4 metres 12,640 kg
Cooling Capacity Absorbed Power Temperature Range Maximum ambient temp. Dimensions length width height weight 3. LAYOUT
aggreko
Page 14 of 24

Prepared by: Discipline: Section:
Adam Hentschel
Date:
12.02.2001
Revision:
Page 14 of 24
Document number
Fluid Chillers
WATER COOLED SCREW WCW FC1500A

UNITS kW C / C C / C C / C
au.1.4
4. TECHNICAL SPECIFICATIONS
ITEM Performance Data Design Capacity Design Operation Fluid Temperature IN / OUT Minimum / Maximum Outlet Fluid Temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Evaporator Data Evaporator Type Evaporator Material Design Flow Minimum / Maximum Flow Evaporator Barrel Capacity Evaporator Barrel Maximum Working Pressure Design Evaporator Barrel Pressure Drop Recommended System Water Volume Condenser Data Condenser Type Condenser Material Design Condenser Water temperature IN / OUT Minimum / Maximum Condenser Water Outlet Temperature Design Flow Minimum / Maximum Flow Condenser Barrel Capacity Condenser Barrel Maximum Working Pressure Design Condenser Barrel Pressure Drop Recommended System Water Volume Refrigerant Data Refrigerant Type Number of Circuits Design Refrigerant Charge Type Of Compressor Oil Oil Charge circuit Electrical Data Design Electrical Supply Voltage Design Electrical Rating Nominal Operating Current Starting Current Pre-Heating Supply Recommended Generator Set Required Cable Size per Phase Electrical Connection Noise Data Sound Pressure Level at 10 metres - Lp(A) Sound Power Level - Lw(A) Physical Data Overall Length Overall Width Overall Height Weight Fluid Coupling Size Condenser / Evaporator VALUE 1500 11.2 / 6 -12 / +15 0 / +45 Screw Semi Hermetic 1 30 / 100 Shell & Tube Steel & Copper 70 30 / 100 602 1000 70 2000 Shell & Tube Steel & Copper 29 / 34 16 / 48 75 45 / 164 367 1000 35 1000 R134A 1 386 39 415/ 50 277 382.4 960 240 / 5 500 240mm2 Busbar M12 70 98 6.0 2.4 2.4 12,640 2 x 100 (4")
kg litres Volts/Hz kVA Ampere Ampere Volts / kVA kVA mm
dB(A) dB(A) metres metres metres kg mm / inch
Page 15 of 24

3 3.1
INSTALLATION, OPERATION AND MAINTENANCE (IOM) Installation

Installation of the Chillers is of utmost importance. The operating life will be improved with the correct installation of the equipment.
3.1.1
Handling
The fluid chiller can be handled by a forklift or slings. Ensure that the weight of the fluid chiller does not exceed the maximum allowable lifting capacity of the crane, slings or forklift. Ensure all doors are closed and locked before moving.
3.1.2
Foundation
A solid foundation is required for the positioning of the unit, and must be flat, level and able to withstand the weight of the unit.
3.1.3
Clearances
Ensure there are sufficient clearances around the unit to allow maintenance operations to take place without obstruction. The following minimum distances are required: a. b. c. d. Front clearance of 1.5m Side and rear clearance of 1.5m Clearance above unit of 10m Distance between adjacent units of 3m.
3.1.4
Ventilation
The unit produces heat even through the compressor is cooled by the refrigerant. Provisions should be made to ensure the heat is removed. Ventilation must be adequate enough to maintain an ambient temperature lower then 50C. It is also important to vent the evaporator, condenser, and compressor pressure relief valves.
3.1.5
Drainage
The unit should be located near a large capacity drain for water vessel drain-down during shutdown or repair. The condensers and evaporators are fitted with drain connections.
3.1.6
Water Piping
All piping from evaporator and condenser should be isolated and supported to prevent stress on the unit. All piping components for the Evaporator and Condenser should be between the shut off valves so that isolation can be achieved.
Page 16 of 24

3.1.7 Water Treatment
Using untreated or improperly treated water may result in inefficient operation and possible damage. Consult a water treatment specialist if uncertain.
3.2 3.2.1
Commissioning Unit Start-up

a. b. c. d. e. Start water pump, adjust flow rate with flow valve if necessary Verify that the slide valve control switch is set at Auto Check the chilled water set point and adjust if necessary If necessary adjust the current limit set point Adjust the 3 position chiller switch from STANDBY/RESET to AUTO/LOCAL or AUTO/REMOTE
3.2.2
Seasonal Unit Start-up

a. b. c. d. e. Close all drain valves and re install the drain plugs in the evaporator and condenser headers Service the auxiliary equipment Vent and fill cooling tower, if used, as well as the condenser and piping. Air must be removed from this system Open all of the valves in the evaporator chilled water circuits If evaporator was previously drained, vent and fill the evaporator and chilled water circuit. When all air is removed, install vent plugs in the evaporator water boxes Check the adjustment and operation of each safety and operating control Close all disconnect switches Start the chilled water pump. While the chiller switch is set at STANDYBY/RESET, the UCM checks for closure of the chilled water flow switch Verify that the slide valve control switch is in AUTO position Check chilled water set point and adjust if necessary If necessary adjust the current limit set point Adjust the 3 position chiller switch from STANDBY/RESET to AUTO/LOCAL or AUTO/REMOTE
f. g. h.
i. j. k. l.
Page 17 of 24

3.3 3.3.1 Operation Temporary Shut Down and Restart
b. c. Press the stop tab on the control panel, compressors will stop To restart the unit, press the Auto Tab
3.3.2
Emergency Stop
A push button located on the unit causes the unit to stop immediately. To restart the unit after an emergency stop, pull out the stop button and reset the alarm on the touch screen.
3.3.3
Final Check
After start up, leave the unit in operation for at least 15 minutes, to ensure that the refrigerant pressures are stabilised. The following must then be checked: a. Both suction and pressure / temperature gauges must show approx 2 - 5C below leaving liquid temperature. (When running at low temp applications, this value can be higher) b. Both discharge pressure / temperature gauges must be approx 15C above ambient air temperature c. The sight glass in expansion valve must be clear d. Check for any noise and vibrations
3.3.4
Principal of Operation
Page 18 of 24

3.4 3.4.1 Decommissioning Daily Unit Shutdown
a. b. Turn the chiller switch to STANDBY/RESET If desired, turn off the chilled water pump
3.4.2
Seasonal Unit Shutdown

a. Turn the chiller switch to STANDBY/RESET Do not open the starter panel disconnect switch (This allows oil sump heater operation and prevents refrigerant migration into the compressor oil) b. c. d. e. Stop the chilled water pump at the pump push button station Drain condenser piping and cooling tower, if used. Remove the drain and vent plugs from the condenser headers to drain the condenser Once the unit is secured, perform maintenance procedures
3.6 3.6.1
Maintenance Procedures Daily Maintenance Checks

The following checks should be made on a daily basis: a. Log the chiller Condenser pressure is dependant on condenser water temperature. Evaporator pressure is dependant of evaporator water temperature b. c. Inspect refrigerant filter. Frost formation indicates a restricted filter element, and can also cause improper evaporator pressure Visually inspect oil filter pressure drop indicator. Replace oil filter if required.
3.6.2
Weekly Maintenance Checks

The weekly maintenance requirements are to review the operating log.
3.6.3
Monthly Maintenance and Checks

On a monthly basis, the following should be done: a. b. c. d. e. f. Review the operating log Clean all water strainers in both chilled and condensing water piping system Measure the oil filter pressure drop. Replace oil filter if required Measure and log the sub-cooling and superheat If operating conditions indicate a refrigerant shortage, leak check the unit using soap bubbles and repair all leaks Trim refrigerant charge until the unit operates in accordance with settings.
Page 19 of 24

3.6.4 Annual Maintenance
Shut down the chiller once per year to check the following: a. b. c. d. e. f. g. h. Perform all weekly and monthly maintenance procedures; Check refrigerant charge and oil level; Perform oil analysis; Check pressure drop across the oil filter; Inspect all piping for leakage and damage. Clean strainers; Clean and repaint;
Test vent piping of all relief valves for presence of refrigerant to detect improperly sealed relief valves. Replace any leaking relief valves; and Inspect condenser tubes for fouling; clean if necessary.
Page 20 of 24

3.6.9 Maintenance Schedules
The following are the Maintenance Schedules for the Aggreko Fluid Pumps:
Maintenance Schedule for Aggreko's Water-Cooled Liquid Chiller Fleet Series No: FC1200 (RTHA), FC1300 (RTHB), and FC1500 (RTHC) with Helical Rotary (Screw) Compressors:
On Hire and Installation Monthly or at 750 Hours 6-Monthly or at 4300 Hours Completion of Hiring and Decomm. At 36 Cumulative Months of Operation
Item No.
Installation, Operation, and Maintenance Instructions
General: Check and record the following operational data, as much as possible, on Commissioning and Start-up Report Sheet and check monthly and at decommissioning time: 1. ambient air dry bulb and wet bulb temperatures ( C) 2. compressor suction and discharge pressures (kPa) o 3. compressor suction and discharge temperatures ( C) o 4. compressor suction superheat temperature ( C) o 5. low refrigerant temp safety cut out set point ( C) o 6. chilled water leaving temperature set point value ( C) o 7. chilled water return temperature ( C) o 8. low chilled water temp. safety cut out set point ( C) o 9. condenser water leaving temperature ( C) o 10. condenser water return temperature ( C) 11. condenser water return limit set point value (%) 12. power supply Voltage (V) and frequency (Hz) 13. FLC: full load current (Amps) 14. phase currents (Amps) 15. current limit set point value (%) Check and record pressure drops through chilled water recirculation system and condenser water recirculation, and compare with design specifications and the job site-specific chiller selection/ rating data. Check and record sump heater operation when unit is off. Check and expedite any undue vibrations on the chiller unit. Seek for solution(s) to rectify. Check and record oil pressure. Compare with the operating range in chiller manufacturer's IOM manual. Check liquid refrigerant flow in sight glass for presence of moisture or any shortage of refrigerant. Check the settings of the HP and LP safety switches and oil control functions and compare with the allowable limit values in the manufacturer's IOM Manual. Reset if necessary. Check motor and drive and record the rated running load current in Amps. Check the existence of any refrigerant leaks. Report the leaks for rectification. Prove solenoid operation, as applicable. Check the functionality of the flow switches on chilled water system and condenser water system, as applicable.
o
3 4 5 6
X X X X X X X
X X
8 9 10
X X X
X X X X X
11
Page 21 of 24

Item No. On Hire and Installation Monthly or at 750 Hours 6-Monthly or at 4300 Hours
Maintenance and Servicing Instructions
Completion of Hiring and Decomm.
At 36 Cumulative Months of Operation
12 13 14
Check the TX valve or electronic expansion valve and superheat, as applicable. Check operation and calibration of chilled water temperature controller to maintain the intended design temperature. Check setting and operation of chilled water, low temperature safety thermostat, and record trip temperature. Check the thermal insulation over the chiller components. Replace or repair if necessary. Re-establish vapour seal around the chiller unit. Inspect corrosion protection device, as applicable. Remove insulation and water boxes. Clean and fit new gaskets. Clean chilled water tubes, plates, bolts, grease threads, and reassemble. Slug dose chilled water upon refilling or replenishing CHW in the recirculation system. Check and clean in-line strainers and scale traps on both the chilled water and condenser water recirculation systems, as necessary, depending on the type of cooling application and quality of the chilled water. Check oil level and top up if necessary. Test oil for acidity. Flush oil sump and change oil, if necessary. Check driers and change if necessary. Check oil filters and change if necessary. Check and align coupling and report on rubber wear. Set unit to work, prove operation. Lubricate and grease all points and linkages. Repair and paint any corrosion, clean generally. Electrical: Check for signs of burnt, hot connections and burnt contacts on starters and relays. Clean, rectify, and tighten. Replace any faulty indicator lights. Examine general condition of conduits, connectors, switches, and wiring, especially when chiller installed in damp and outdoor areas. Check operation of each item of equipment. Check for proper operation of Voltmeter and Ammeter as applicable. Replace faulty meters. Inspect, clean, and replace contacts, as necessary. Inspect relays. Replace faulty relays, as necessary. Check overload ratings against motor nameplate. Check connections to compressor motors, control panel/ MCCB (Motor Control Centre Board), and at points where the equipment is subjected to vibrations. Examine external switches for possible damages to seals. Check all time delays. Check all fuses for correct rating. Replace any safety warning, instructional, and operational labels that have fallen off, damaged, or removed. Check and rectify condition of exposed cable insulation. Strictly follow safe power isolation procedures prior to cable repair works. X X X X X X X X X X
15 16 17 18 19
X X
X X X X
20
21 22 23 24 25 26 27 28 29
X X X X
X X X X X X X X X
X X X
1 2 3 4 5 6 7 8 9 10 11 12 13
X X X X X X
X X
X X X X X X
X X X X X X X X
14
Page 22 of 24

Item No. On Hire and Installation Monthly or at 750 Hours 6-Monthly or at 4300 Hours
Maintenance and Servicing Instructions
Completion of Hiring and Decomm.
At 36 Cumulative Months of Operation
15 16 17 18
Vacuum clean interior of the control panel/ MCCB. Check and ensure that conduits are securely fixed. Examine and rectify the seals on the control panel/ MCCB. Check for the existence of electrical wiring diagram inside the control panel/ MCCB. Check the consistency of the electrical wiring diagram with the actual wiring and the components of the chiller. Ensure that it is 'as-installed'. Report any inconsistencies. Report any required revisions on the electrical diagram as per electrical modifications done or planned. Lubricate all pivot points. Use pure petroleum jelly. Piping and Fittings Associated with Chiller Installation: X X
X X X X
X X X X
19
20 21
X X
X X
1 2 3 4 5 6 7 8
Check rigid and flexible CHW and CDW pipework and valve glands for leaks, and repair leaks. Clean rigid and flexible pipework, wipe flexible pipe connections with grease, as applicable. Check and ensure that all valves are in correct position and orientation. Check proper functioning/ operation of all valves. Check strainers and clean, as necessary, as applicable. Vent all high points in the system, as applicable. Check all vents or scale pockets, vent or drain as necessary. Check condition of pipe insulation, test pipe insulation, as applicable.
X X X X X X X X
X X
X X
3.7
Troubleshooting
Page 23 of 24
Chiller capacity
50 kw 157 kw 200 kw 500 kw 600 kw 1300 kw 1500 kw
Fluid pump 3 l/s 10 l/s 10 l/s 30 l/s 30 l/s 75 l/s 75 l/s
Page 24 of 24

4 ELECTRICAL

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Temperature Control Manual Water Cooled Chillers

Temperature Control Manual

WATER COOLED CHILLERS