1

AIR CONDITIONING
1.0 Definition Of Air Conditioning:
Air conditioning is defined as the process of treating air so as to control
simultaneously its temperature, humidity, cleanliness and distribution.
Plant capacity:
56 * 3 = 168 TR (per UCB)
One ton of refrigeration TR gives the same amount of cooling as you get
by melting one ton of ice at 32 F over a period of 24 Hrs. (1 TR = 3024 Kcal/Hr)
Refrigerant:
Freon 22
R 22 Mono chloro di fluro methane (CHCl F
2
)
Boiling point: - 40.8 C.
2.0 System Description: (Ref: Fig 1 & Fig 2)
In TS-II/Stage II, each UCB is provided with a direct expansion type air
conditioning system. The air conditioning system is as follows: -
There are three Accel make reciprocating compressors; of these one is
normally in service while the other is a standby and another one is idle. Each
compressor consists of four cylinders. Two cylinders get loaded directly when the
compressor is started while the other two cylinders can be loaded / unloaded as
per the system requirements through a solenoid valve ULSV 1.
The refrigerant vapor returning from the coils of the Air Handling Units flows
through the freon suction header and is compressed in the compressor .the
compressed vapour flows into the shell of the condenser and is condensed into
liquid at high pressure giving up latent heat to the circulating water flowing
through the tubes of the condenser, the high pressure liquid freon then flows
through the liquid freon header to the expansion valves of the AHUs where it is
throttled. This enables it to start boiling in the coils of the AHU causing the
refrigerating effect.
In the AHU, three double suction blowers draw the warm return air from the
air-conditioned area across two banks of coils. The air is thus cooled and the
cooled air is blown into a common air supply duct in which are fitted 24 micro
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3
4
vee filters and 3 sets of strip heaters. The micro vee filters remove all the dust
particles in the air and the strip heaters / dehumidifiers help to maintain the
relative humidity and temperature of the conditioned air close to the design
value.
An induced draught cooling tower having two cells, cools the warm
circulating water from the condenser. This cooled circulating water is again
circulated by the circulating water pumps through the tubes of condenser.
2.1 Freon Circuit:
The freon circuit consists of two independent buses (Bus A & Bus B)
through which flows the high pressure liquid freon and expands in the upper
and lower coils of the three AHUs through the respective expansion valves.
The compressors can be run in pairs under different combinations as shown
the table below:
TABLE I:
Compressor
Mode
Selection
Compressor
should be
taken
Bus for the
compressor
to be
operated
Valve condition in
in the common header
Open Close
I 1 & 2
1 A
2 B
L1
XS2, XD2
L3
XS1, XD1
II 2 & 3
2 A
3 B
XS1, XD1
L3
L1
XS2, XD2
III 1 & 3
1 A
3 B
L1
L3
XS1, XD1
XS2, XD2

2.2 Liquid line solenoid valve ( LLSV) :
Liquid line solenoid is a 3-way solenoid valve provided in each liquid
freon bus (Bus A & Bus B). During normal operation, the suction header will
be in communication with the expansion valve. (LLSV on condition). When
LLSV is switched off, the high-pressure liquid freon header will be in
5
communication with the expansion valve and hence the expansion valve is
forced closed.
LLSV operation for different combinations of compressors refer table
1
Under mode selection I:
LLSV in bus A will get energized for compressor 1 and LLSV in bus B
for compressor 2.
Under mode selection II:
LLSV in bus A will get energized for compressor 2 and LLSV in bus B
for compressor 3.
Under mode selection III:
LLSV in bus A will get energized for compressor 1 and LLSV in bus B
for compressor 3.
2.3 Expansion Valve:
The figure Expansion valve may be referred. The expansion valve is
provided in the high-pressure liquid freon line to the air handling unit. In the
expansion valve, throttling process takes place and the low pressure freon
liquid from the expansion valve evaporates in the tubes of the Air handling
unit by taking the latent heat from the warm air returning from control room.
There are three elements involved in the operation of expansion
valve. These are 1) Bulb pressure (P1), 2) Suction header pressure (p2) and 3)
Spring pressure (P3) as shown in the figure.
The bulb pressure (P1) acts on the top of the diaphragm tending to
open the valve. The bulb pressure (P1) depends upon the temperature of
freon gas at the outlet of the Air handling unit. The pressure of the brine in
the thermal bulb is directly proportional to the temperature of outgoing
freon gas. The suction header pressure (P2) acts on the bottom of the
diaphragm tending to close the valve and the spring pressure (P3) assists in
closing the valve.
When the liquid line solenoid valve (LLSV) is switched ON the
suction header pressure (P2) is communicated through liquid solenoid valve
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to the expansion valve. When it is switched OFF, high pressure liquid freon
gets communicated to the expansion valve forcing it close.
The spring pressure (P3) is constant. A variation in any one of the
other two pressure quantities (P1 / P2) changes the amount of opening of
the expansion valve. During normal operation of the valve, these two
pressure quantities (P1 / P2) tend to establish a point of equilibrium to
maintain a steady state evaporation of freon in the air handling unit.
CASE A:
Assuming that the expansion valve has attained a steady state
position, if the heat load now increases, the outlet freon gas temperature will
increase. This results in an increase of the bulb pressure tending to open the
expansion valve slightly. Thus the admission of more quantity of freon takes
place resulting in increased evaporation in the Air handling units tubes. This
leads to an increase in the suction header pressure, which tends to close the
valve. The valve finally attains an equilibrium position.
CASE B:
Assuming that the expansion valve remains in the same OPEN
position, if the hat load decreases, the outlet freon gas temperature
decreases. This results in reduction in bulb pressure of freon flow pads to
reduced evaporation and hence the suction header pressure decreases
tending to open the valve. The valve will finally attain an equilibrium position
again.
3.0 Air Conditioning Plant Logics:
3.1 Permissives For Start Up:
1) For starting the compressor it should be selected through the
selector switch.
2) There should be adequate flow of circulating water through the
condenser.
3.2 Protections:
The running compressor will trip on any one of the following causes: -
1) When the suction pressure drops to 45 PSI.
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2) When the discharge pressure increases beyond 260 PSI.
3) When the differential pressure between the oil pressure and
suction pressure is less than 45 PSI for duration of 60 secs.
4) When there is no circulating water flow through the condenser.


3.3 Interlocks:
1) Modulrol motor for AHU face and bypass inlet damper regulation
will operate only when the AHU is in service.
2) a) When AHU1 is in service only then the first bank of strip
heaters (Heater I 18 KW) with get energized.
b) When AHU2 is in service only, then the second bank of
strip heaters (Heater II 18 KW) will get energized.
c) When AHU3 is in service only, then the third bank of strip
heaters (For dehumidification Heater III 18 KW) will
get energized.
3) The crankcase heater will get switched off when the compressor
is started and vice versa, provided the heater toggle switch at
the gauge board is in ON condition.
3.4 Auto Operation:
A) Strip Heater Operation:
i) When the return air temperature drops to 22 C, Heater I
will get switched 0 and the same will get switched OFF at 24
C.
ii) When the return air temperature drops to 21.5 C, Heater
II will get switched ON and the same will get switched OFF
at 23.5 C.
iii) When the relative humidity of the return air drops to 45%.
The humidistat (Heater 3) will get switched OFF and the
same will get switched ON at 50% RH.
B) Compressor Loading / Unloading:
8
When return air temperature drops to 20 C, ULSV1 will get switched
OFF thus unloading two cylinders and the same will get switched
ON at 22 C.
C) AHU Damper Regulation:
When the temperature of the return air drops to 19 C, the modutrol
motor begins to regulate the face and bypass inlet damper (such
that the AHU coils get partially bypassed) up to a minimum
temperature of 13.5 C. These dampers will start to normalize when
the return air temperature starts increasing from 13.5 C.
4.0 Air Conditioning Plant Operation:
4.1 Pre-Starting Checks:
1) General:
i) Prior to start up of the AC plant, check whether all pending
safety permits (LC) have been returned.
ii) Check for 415 volt supply in the AC plant control panel.
iii) Check whether the modules of the equipment to be started
are in ON condition.
2) Cooling Tower:
iv) Check for adequate oil level in CT fan gear box.
v) Check for adequate water level in CT sump.
vi) Check for opening of gate valve in service water make up
line.
vii) Check for closing of gate valve in the quick fill line.
3) Circulating Water System:
A) Check for the opening of following valves: -
i) Gate valve on top of the cooling tower suction, which is to be
taken into service.
ii) Suction valve of circulating water pumps.
iii) Outlet valves of all the condensers.
B) Check for closing of following valves: -
i) Gate valve on top of the cooling tower section not in service.
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ii) Discharge gate valves of circulating water pumps.
iii) Inlet valves of all the condensers.
iv) Inlet and outlet valves in the cooling water jacket line of all the
compressors.
4) Air Handling Units:
i) Check for opening of the AHU outlet dampers.
ii) Check whether the modutrol motors position indicators are in
OPEN position.
5) Compressor:
i) Check whether crankcase heater has been switched ON at
least half an hour prior to start up of the compressor.
ii) Check for adequate oil level in compressor crankcase.
iii) Check whether the suction & discharge valves are in closed
condition.
6) Freon Circuit:
i) Check whether the valves in the freon circuit are as given
in table 1 for the compressor to be started.
ii) Check for opening of before and after valves of the Y type
strainers in bus A & B.
iii) Check for closing of before and after valve of the bypass line
filters of bus A & B.
iv) Check for opening of the isolation valves of AHUS.
4.2 Start Up Procedure:
1) Select the pump & the compressor to be started in the
respective selector switches.
2) Open the respective condenser inlet valve.
3) Open the inlet and outlet valves in the cooling water jacket line
of the respective compressor.
4) Start the selected circulating water pump, open the discharge
valve and check the spray in the cooling tower.
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5) Start the cooling tower fan and check for any abnormal noise or
vibration.
6) Start the three air-handling units and check for normal
operation.
7) Open the discharge valve of the compressor fully and keep the
suction valve in partial open (2 or 3 turns) condition.
8) Switch ON the main control supply in the compressor gauge
board and check for red lamp indication.
9) Switch ON LLSV.
10) Start the compressor and begin to open the suction valve
gradually to full open condition.
11) Check whether the compressor parameters are stable and then
load the compressor fully by switching ON ULSV-1.
12) Observe the normal operation of the compressor for at least 15
minutes after starting of the compressor and also check the
crankcase oil level.
13) Record all parameters of the system.
4.3 Shutdown Procedure:
1) Switch OFF LLSV and allow the compressor to trip on LP trip and
immediately close the suction and discharge valves fully.
2) Switch OFF ULSV-1 and the main control supply toggle switch in
the compressor, gauge board.
3) Stop the circulating water pump and close the condenser inlet
valve.
4) Stop the cooling tower fan.
4.4 Compressor Pump Down:
A) Complete Pump Down:
Before opening the compressor or any part of the freon circuit for
maintenance work, maximum quantity of freon has to be collected
and stored in the condenser to prevent its loss. This operation is
known as pump down operation.
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B) Procedure:
1) Use a piece of thin aluminium sheet to hold the spring loaded
arm UP inside the low pressure switch (suction) or put a
temporary jumper wire across the terminals to keep the switch
closed. This prevents the compressor from tripping on LP trip.
2) With the compressor in service on ULSV-1 (full load) close the
liquid line valve of the respective condenser (for compressor I
& III). For compressor II close both the isolation valve (XD1 &
XD2) in the liquid freon header.
3) The suction pressure will drop gradually, when the suction
pressure drops to 20 PSI stop the compressor manually and
switch off ULSV-1, LLSV and main control supply.
4) Immediately close both the suction and discharge valves of the
compressor.
5) Remove the bypass of the LP switch (Mechanical or Electrical).
C) PARTIAL PUMP DOWN :
When the compressor is being shut down, it is advisable to collect &
store the freon in the condenser. This is known as partial pump down.
Procedure:
1) Keep the compressor in service on ULSV-1 (full load).
2) Slowly close the liquid freon valve of the respective condenser
(For compressor I & II). (For compressor II close isolation
valves XD1 & XD2).
3) Allow the compressor to trip on LP trip.
4) Close the suction and discharge valves immediately.
5) Switch off ULSV-1, LLSV and main control supply.
4.5 Change Over Of Compressors:
1) Stop the running compressor by carrying out PARTIAL
PUMPDOWN OPERATION.
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2) With reference to Table-1 change over the valves in the liquid
freon header and suction header with respect to the
compressor which has to be started.
3) Follow the start up procedure for the incoming compressor.

4.6 Air Handling Unit Isolation And Stopping:
1) Close the inlet isolation valves (Two valves).
2) After five minutes close the outlet isolation valves (Two valves).
3) Close the outlet dampers fully.
4) Stop the AHU.

4.7 Starting Of Air Handling Units:
1) Start the AHU.
2) Open the outlet dampers up to the marking provided.
3) Open both the outlet isolation valves.
4) Finally open the inlet isolation valves.
5.0 Liquid Stroke:
The term liquid stroke refers to the state where an amount of wet
saturated or even liquid freon is taken in to the cylinder and is forced out by
the piston, the valve mechanism lifting from its seat audibly. This constitutes
an overload on the mechanism as liquid is not compressible and is harmful to
the compressor. In the event of liquid stroke stop the compressor
immediately.
6.0 Safety Rules For Freon :
Freon is a colourless and non poisonous, however when it comes in
to contact with hot surfaces harmful chemical reactions takes place. For this
reason leaks should never be traced when the operator is smoking as the
possibility exists that freon gas may be inhaled over the burning tobacco.
Thus introducing poisonous gases in to the body.
Full or empty freon cylinders should be kept in horizontal position in
order to avoid their falling over. Freon cylinders should be carefully handled,
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they should not be exposed to direct sunlight or to temperature exceeding
50
0
C lower than 10
0
C.
Freon is heavier than air and it escapes through even the smallest
aperture. As the gas is odourless, there is no immediate indication of
possible leaks, which may be result in serious loss of this very expensive
refrigerants. It is therefore desirable to check the plant regularly for signs of
any leakage by means of soap solution. While trying to detect possible leaks
to Air Conditioning Plants room should be thoroughly ventilated.




7.0 Important Note:
1) Compressor should be started only after starting the AHUs.
2) If any AHU trips, immediately close both the inlet isolation valves
of the cooling coil.
3) Before starting the compressor ENSURE cooling water flow
through cooling water jacket line, failing which the cylinder
heads will get overheated.
4) After stopping the compressor close the cooling water jacket
line inlet & outlet valves so as to prevent possible accumulation
of liquid freon in the cylinder heads which may lead to liquid
stroke during subsequent start of the compressor.
5) In the event of fire, the fire damper in the common outlet duct
will close. Hence immediately trip the compressor and stop the
air-handling units.
6) In the event of change over of the compressors, partial pump
down of the running compressor should be carried out.
7) If the compressor is to be kept in stopped condition for more
than 15 days then the partial pump down of the compressor
may be carried out.
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8) Whenever any valve in the freon circuit is operated it should be
checked for leakage with soap solution immediately.
9) The compressor should not be run in the partial loaded
condition (ULSV-1 OFF) for long durations, since under partial
load cylinders on one side alone will be loaded resulting in un-
balanced running of the compressor.
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8.0 Design parameters :

Sl.
No.
Parameter
UCB, relay & control
equipment room
DAS cabinets, UPS
control room
ESP control
room
DM Plant
laboratory.
01
Design outside
conditions.
38.2
0
C DB, 28.4
0
C
WB.
38.2
0
C DB
25.5
0
C WB
28.2
0
C DB
25.5
0
C WB
02
Inside conditions
to be maintained
22
0
C 2
0
C DB
RH not exceeding
50%.
24.4
0
C 1.5
0
C
DB RH not
exceeding 55%
24.4
0
C 1.5
0
C
DB RH not
exceeding 55%
03 Occupancy. 30 4 5
04 Lighting load (KW) 22 4 2
05 Equipment (KW) 142 40 5
06
Fresh air quantity
(KW)/ hr.
4650/hr. 700/hr. 425/hr.
07 Glass area (m
2
) --
NE SW
22.5 22.5
--
08
Other
constructional
details.
Roof is partly
exposed to sun, soffit
of roof insulated with
50mm thick.
Polystyrenes foam
insulation. Walls are
230mm thick, Roof
slab thickness is
100mm. All side wall
are not exposed to
sun.
NW SW
Walls are
exposed to sun.
Two walls are
exposed to sun.
Roof is exposed
to sun.
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9.0 TECHNICAL PARTICULARS OF DIRECT EXPANSION TYPE
CENTRAL AIR CONDITIONING PLANT FOR UCB:
9.1 COMPRESSOR :

01 Make Accel Sabore.
02 Model SMC 4 100.
03 Quantity 3 Nos. (1 No. stand by).
04 Capacity Each 56 TR.
05 Suction temperature 7.2
0
C.
06 Condensing temperature 40.5
0
C.
07 Refrigerant R 22.
08 Speed 1300 rpm.
09 BHP 48.31

9.2 MOTOR (COMPRESSOR) :

01 Make Crompton Greaves Ltd.
02 Type
TEFC (Squirrel cage
induction motor)
03 KW 45
04 Current 82 A.
05 Insulation Class B.
06 Power Supply 3 ph 415 V 50 C/S.
07 Speed 1475 rpm.

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9.3 CONDENSER :

01 Type.
Shell & tube integral finned
tubes.
02 Quantity. 3 Nos.
03 Shell dia. 14
04 Tube length. 8 feet 6 inch.
05 No. of tubes. 134.
06 No. of passes. 4
07 Water inlet temperature. 32
0
C.
08 Water outlet temperature. 36.4
0
C
09 Water flow rate (USGPM). 224

9.4 CONDENSER WATER PUMP :

01 Make. BEST & CROMPTON.
02 Type. Horizontal split casing.
03 Model. 3L3.
04 Power Supply. 3ph, 415V, 50 C/S.
05 HP. 10
06 Speed. 1450 rpm.
07 Capacity. 31 m
3
/hr.
08 Nos. 3

9.5 COOLING TOWER :

01 Make. PAHARPUR.
02 Type. Induced draft.
03 Model. 341 602.
04 Quantity. 1 No.
18
05 Capacity. 122 CMP.
06 Motor Type. TEFC.
07 Power Supply. 3ph, 415V, 50 Hz.
08 HP. 5.
09 Insulation. Class B

9.6 AIR HANDLING UNIT :

01 Type. MS Sheet metal casing.
02 Model. AHU 11.
03 Capacity CMH. 26,000.
04 Quantity. 3 Nos.
05 Speed. 760 rpm.
06 BHP. 9.
07 Motor make.
Crompton TEFC Squirrel
cage.
08 HP. 12.5
09 Power Supply. 3ph, 415V, 50 C/S.
10 Speed. 1465 rpm.
11 Insulation. Class B.

9.7 COOLING COIL :

01 Size 96 x 48 .
02 Capacity K. Cal/hr. 61600 X 2.
03 No. of rows. 6.
04 No. of fins / inch. 2 X 16.
05 Coil pipe size. 5/8 OD.

19
9.8 AIR FILTER (METALLIC GI WIRE MESH TYPE) :


01 Size. 25 X 20 X 2.
02 Nos. 18 per AHU.
03 Efficiency. 80% down to 20 microns.
04 Capacity. 1450.

9.9 MIRCOVEE FILTERS :

01 Size. 610 X 610 X 300 mm.
02 Nos. 24.
03 Capacity CMH. 3500.

9.10 HEATERS :

01 Make. Electro craft.
02 Type. Finned type strip heaters.
03 KW (Total). 55.5













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OFFICE OF THE GENERAL MANAGER
THERMAL STATION-II
TURBINE OPERATION & OPERATION SERVICES

03/ 12/ 2012
CIRCULAR
The Unit Control Rooms in Stage II (Unit IV to VII), TPS_II are provided
with a direct expansion type air conditioning system. The Freon circuit
consists of two independent buses (Bus A- Top Bus, Bus B- Bottom Bus)
through which the high pressure Freon flows and expands in the upper and
lower coils of the three Air Handling Units (AHU) through the respective LLSV
valves. The Freon Bus selection is based on the compressor selection
tabulated as below.
Compressor
Mode selection
Compressor
In service
Automatic Selection of Freon Bus
for the selection
I 1 & 2 1 TOP BUS through LLSV1 ON
2 BOTTOM BUS through LLSV2 ON
II 2 & 3 2 TOP BUS through LLSV1 ON
3 BOTTOM BUS through LLSV2 ON
III 1 & 3 1 TOP BUS through LLSV1 ON
3 BOTTOM BUS through LLSV2 ON
* LLSV-Liquid Line Solenoid Valve
Problem Identified:
Understanding the compressor and Bus combination selection gives
nightmare to the operators in the emergency conditions. The combination of
Compressor selection switch problem and LLSV Solenoid problems also
delays troubleshooting.
Modification:
Hence to simplify the operation, any compressor can be taken into
service after switching ON LLSV of the required Freon bus either TOP BUS
or BOTTOM BUS. To enable the same, the following modifications/
arrangements have been made.
1. Independent toggle switch is provided in the switchgear panel for each
Freon bus (TOP / BOTTOM).
2. Compressor Mode selection switch and related logics are removed.
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3. The Valves in Freon Bus (XS1, XS2, XD1& XD2) are presently arranged in
such a way to select the Compressor as below:

Running Compressor Solenoid valve to be
switched ON
Freon Bus will be in service
Compressor-1 LLSV-1 Top Bus
Compressor-2 LLSV-1 or LLSV-2 Based on the requirement
Compressor-3 LLSV-2 Bottom bus

NOTE:
In Unit 6, the arrangement is vice-versa. I.e Compressor 1 in Bottom Bus and
Compressor 3 in Top Bus.


DGM/B&T (O&OS)