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Maintenance for Energy Efficiency

Institute of Hospital Engineering, Australia (IHEA)


Seminar Asset Management & Energy Efficiency

Exclusive Trane distributor Australia/New Zealand.


The TRANE trade mark is used by Dalkia Technical Services Pty Ltd under licence from American Standard.

System Maintenance
Some interesting examples.

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

System Maintenance
Period One

Maintenance Considerations

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

FACILITY REQUIREMENTS

Think about your HVAC system and its


application?

How does the HVAC system contribute to the


success of your operation?

What are the short and


long term objectives for your facility?

How well does your


HVAC system meet
these objectives?

PROBLEM AREAS

What type of breakdowns do you experience?

When do you repair or replace failing equipment?

What if problems arent getting fixed the first


time?

What if you are experiencing excessive energy


consumption?

How can you tell if maintenance costs are


excessive?

AUSTRALIAN STANDARDS
AS3666.2-2002

Air Handling and Water Systems Of Buildings Microbial Control. Part 2:


Operation and Maintenance
Specifies the minimum requirements for the operation and maintenance of
air-handling and water systems of buildings for the purpose of microbial
control
Excludes room air-conditioners and non-ducted split-systems
Control of legionnaires disease, Pontiac fever, Hypersensitivity
Pneumonitis and Humidifier fever

AUSTRALIAN STANDARDS
AS1851-2005

Maintenance of Fire Protection Systems and Equipment


Supersedes AS1851.6-1997
Requirements for inspection, test, preventative maintenance & survey of
fire & smoke control features of HVAC. Covered by AS1668.1, AS1668.2
Section 18 Fire & Smoke Control Features of HVAC Systems
Functionality & Performance Testing

AUSTRALIAN STANDARDS
AS1851-2005

Exhaust Fans (Used in Day-Day Operation)


Exhaust Fans (Dedicated to Fire Duty Only)
Fire Dampers
Smoke Spill
Heater Bank (Duct or Unit Mounting)
Kitchen Exhaust Systems
Fire Isolated Exit Pressurisation Systems
System Changeover Under Fire Condition

AUSTRALIAN STANDARDS
SAA HB40.1- 2001

The Australian Refrigeration and Air-Conditioning Code of Good Practice.


Part 1. Reduction of Emissions of Flurocarbon Refrigerants in Commercial
and Industrial Refrigeration and Air-Conditioning Applications
Developed with the intent of reducing emissions into the atmosphere (CFC
R11, R12, R502. HCFCs R22, R134a, R407c)
Maintenance, Recovery, Handling, Storage, Alternatives

AUSTRALIAN STANDARDS
Web Site: - www.standards.com

The 5 Loops - Maintenance


Period Two

Application of Standards

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

maintenance considerations

The Yellow Loop Airside


Standard: -

AS3666.2-2000

Scope: -

Monthly inspection and cleaning of


cooling coils and condensate trays
Monthly inspection of return air filters
Annual inspection of moisture producing
equipment (cleaning where necessary)

Equipment: -

Air Handling Units


Fan Coil Units
Packaged Units
Split Systems Ducted
Split System High Wall

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

maintenance considerations

The Yellow Loop Airside


Standard: -

AS1851-2005

Scope: -

Requirements for inspection, test, preventative


maintenance & survey of fire & smoke control
features of HVAC. Covered by AS1668.1,
AS1668.2

Equipment: -

Exhaust Fans (Used in Day-Day Operation)


Exhaust Fans (Dedicated to Fire Duty Only)
Fire Dampers
Smoke Spill
Heater Bank (Duct or Unit Mounting)
Fire Control System
Fire Isolated Exit Pressurisation Systems
System Changeover Under Fire Condition

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

maintenance considerations

The Blue Loop Chilled Water


Standard: -

AS3666.2

Scope: -

Scale Prevention
Rust Inhibitor

Equipment: -

Chillers
D.X. Packaged Units

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

maintenance considerations

The Red Loop Heat Rejection


Standard: -

AS3666.2

Scope: -

Continuous Biocide (Control Organic Growth)


Monthly Total Bacteria Count (Additional Dosing)
Quarterly Legionella Testing
Scale Control
Rust Inhibitor

Equipment: -

Chillers
Cooling Towers
Evaporative Condensers

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

maintenance considerations

The Purple Loop Controls


No Standards Apply
Recommendations
Basic Computer Maintenance
Monthly Data Backup
Regular Virus Checks
Clearing of Fault History
Annual Rotating Service
Sensor Drift
Actuator Stroking
Wiring

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

The Green Loop


Chiller Maintenance
Period Three

Maintenance Considerations

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

maintenance considerations

The Blue Loop Refrigeration


Standard: -

HB40
ASHREA Guideline 3

Scope: -

Quarterly Leak Testing (over 50kgs per Circuit)


Chiller Logging

Equipment: -

Chillers
Split Systems
Packaged Units

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

operating log

ASHRAE Guideline 3
s
s
s
s
s
s

s
s

Chilled Water Inlet and Outlet


Temperatures and Pressures
Chilled Water Flow
Evaporator Refrigerant
Temperature and Pressures
Evaporator Approach
Temperature
Condenser Water Inlet and Outlet
Temperatures and Pressures
Condenser Water Flow
Condenser Refrigerant
Temperature and Pressures
Condenser Approach
Temperature

American Standard Inc. 1999

Oil Pressures, Temperature, and


Levels

Addition of Refrigerant

Addition of Oil

Vibration Levels

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

maintenance considerations

Mechanical Components
Additional Chiller Specific Considerations
Clean Heat Transfer Surfaces (Water & Air Cooled)
Change Oil when Oil Analysis Dictates
Replace Oil Filter As Required
Replace Filter Drier As Required
Inspect Safety Controls and Electrical Components
Tighten Electrical Connections

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

Manufacturers recommendations

Demand Flow service

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

Manufacturers recommendations

Demand Flow service

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

maintenance considerations

Heat Transfer Surfaces


Recommended maintenance
Use a qualified water treatment
specialist

Clean condenser tubes annually

Clean water-side strainers


Test tubes every 10 years (maximum)

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

Fluid Analysis
Oil Analysis

Conduct annual analysis to verify system


integrity

Measure oil pressure drop to determine if filter


needs changing

Measure charge

Refrigerant Charge
Conduct analysis of refrigerant

Inspect purge system

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

Oil Analysis
Why perform regular oil analysis?

Helps reduce maintenance costs

Detects problems without


disassembly

Extends service life of oil charge

Reduces environmental problems related to oil


disposal

Helps maintain compressor efficiency and reliability

Helps lower refrigerant emissions

American Standard Inc. 1999

compressor

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

Chiller Maintenance
Period Four

The Power Of Good Service

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

Centrifugal Water Chillers

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

95.58%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

95.58%

Design Efficiency:

0.160

L3 (RLA):

95.58%

Chiller % Max RLA:

100%
606Amps

Motor/Compressor Data
Consumed Power:

399kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

95.58%

Winding #2:

34.6C

Discharge Refrigerant Temp:

36.78C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage
AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.00C

Average

418

T:

5.5C

Percent Imbalance

0.4%

Refrigerant Temp:

36.78C

Approach Temp:

1.78C

Refrigerant Pressure:

38.50kPa

* Purge Unit Data Omitted

Chiller Running Normally

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

413kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

38.01C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage

634Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.03C

Average

418

T:

5.53C

Percent Imbalance

0.4%

Refrigerant Temp:

38.01C

Approach Temp:

2.98C

Refrigerant Pressure:

43.25kPa

* Purge Unit Data Omitted

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG1780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

413kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

38.01C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage

634Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.03C

Average

418

T:

5.53C

Percent Imbalance

0.4%

Refrigerant Temp:

38.01C

Approach Temp:

2.98C

Refrigerant Pressure:

43.25kPa

* Purge Unit Data Omitted

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

413kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

38.01C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage

634Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.03C

Average

418

T:

5.53C

Percent Imbalance

0.4%

Refrigerant Temp:

38.01C

Approach Temp:

2.98C

Refrigerant Pressure:

43.25kPa

* Purge Unit Data Omitted

Fouled Condenser Tubes


Fouled Condenser Tubes

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

412kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

37.93C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage

633Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.02C

Average

418

T:

5.52C

Percent Imbalance

0.4%

Refrigerant Temp:

37.93C

Approach Temp:

2.99C

Refrigerant Pressure:

53.00kPa

* Purge Unit Data Omitted

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

412kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

37.93C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage

633Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.02C

Average

418

T:

5.52C

Percent Imbalance

0.4%

Refrigerant Temp:

37.93C

Approach Temp:

2.99C

Refrigerant Pressure:

53.00kPa

* Purge Unit Data Omitted

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

412kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

37.93C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67KPa

Compressor Voltage

633Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.02C

Average

418

T:

5.52C

Percent Imbalance

0.4%

Refrigerant Temp:

37.93C

Approach Temp:

2.99C

Refrigerant Pressure:

53.00kPa

* Purge Unit Data Omitted

Non Condensables In System


Non Condensables In System

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

413kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

38.05C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage

634Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

36.52C

Average

418

T:

7.02C

Percent Imbalance

0.4%

Refrigerant Temp:

38.05C

Approach Temp:

1.53C

Refrigerant Pressure:

43.08kPa

* Purge Unit Data Omitted

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

413kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

38.05C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage

634Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

36.52C

Average

418

T:

7.02C

Percent Imbalance

0.4%

Refrigerant Temp:

38.05C

Approach Temp:

1.53C

Refrigerant Pressure:

43.08kPa

* Purge Unit Data Omitted

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.165

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

413kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

38.05C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

12.00C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

6C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

4.14C

Differential Oil Pressure:

108.3kPa

Approach Temp:

1.86C

Refrigerant Pressure:

-62.67kPa

Compressor Voltage

634Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

36.52C

Average

418

T:

7.02C

Percent Imbalance

0.4%

Refrigerant Temp:

38.05C

Approach Temp:

1.53C

Refrigerant Pressure:

43.08kPa

* Purge Unit Data Omitted

Low Condenser Water Flow


Low Condenser Water Flow

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.162

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

406kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

36.79C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

11.50C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

5.5C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

3.47C

Differential Oil Pressure:

108.3kPa

Approach Temp:

2.53C

Refrigerant Pressure:

-63.37kPa

Compressor Voltage

634Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.01C

Average

418

T:

5.53C

Percent Imbalance

0.4%

Refrigerant Temp:

36.79C

Approach Temp:

1.78C

Refrigerant Pressure:

38.93kPa

* Purge Unit Data Omitted

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.162

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

406kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

36.79C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

11.50C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

5.5C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

3.47C

Differential Oil Pressure:

108.3kPa

Approach Temp:

2.53C

Refrigerant Pressure:

-63.37kPa

Compressor Voltage

624Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.01C

Average

418

T:

5.53C

Percent Imbalance

0.4%

Refrigerant Temp:

36.79C

Approach Temp:

1.78C

Refrigerant Pressure:

38.93kPa

* Purge Unit Data Omitted

TRANE - SERVICE REPORT

CENTRIFUGAL CHILLER Model CVHG780

Chiller Name:

Chiller No 1

Compressor Current Draw

Refrigerant Type:

R123

L1 (RLA):

100%

Chiller Cooling Capacity:

2500kWr

L2 (RLA):

100%

Design Efficiency:

0.162

L3 (RLA):

100%

Chiller % Max RLA:

100%

Motor/Compressor Data
Power Consumed:

406kWe

Compressor RLA:

Number of starts:

1145

Motor Winding Temps

Compressor Run Time:

8653hrs

Winding #1:

34.7C

Current Draw:

100%

Winding #2:

34.6C

Discharge Refrigerant Temp:

36.79C

Winding #3:

34.5C

Compressor Bearing Temp #1:

54.49C

Evaporator Data

Compressor Bearing Temp#2:

40.44

EWT:

11.50C

Oil Temperature:

56.5C

LWT:

6.00C

Oil Pressure (Low Side):

-62.1C

T:

5.5C

Oil Pressure (High Side):

46.2C

Refrigerant Temp:

3.47C

Differential Oil Pressure:

108.3kPa

Approach Temp:

2.53C

Refrigerant Pressure:

-63.37kPa

Compressor Voltage

624Amps

AB

416

Condenser Data

BC

419

EWT:

29.50C

AC

418

LWT:

35.01C

Average

418

T:

5.53C

Percent Imbalance

0.4%

Refrigerant Temp:

36.79C

Approach Temp:

1.78C

Refrigerant Pressure:

38.93kPa

* Purge Unit Data Omitted

Low Refrigerant Charge

Low Refrigerant Charge


American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

Total Cost of Ownership


Period Five

The Impact Of Poor Maintenance

American Standard Inc. 1999

Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN

TOTAL COST OF OWNERSHIP


Maintenance/Repair Expense

Cost
Time

Total Cost of Ownership


A systems approach to
maintenance services: The cost of ownership is
additive
The cost of ownership is
manageable
The cost of ownership can be
reduced

Total Cost of Ownership


A systems approach to
maintenance services: Chillers contribute as much
as 30% of a buildings
energy cost
A system needs to work in
unison

Total Cost of Ownership


Scenario 1
Fouled condenser tubes
Increases energy
consumption by 1-5%
Measurable by deviations in
condenser pressure from
design

Total Cost of Ownership


Scenario 1
Condenser is an open system
that is exposed to the
surrounding elements
Contaminants settle in
condenser thus reducing heat
transfer
Reduction results in
increased energy use

Total Cost of Ownership


Scenario 1

The bottom line, it is costing you


money every minute of every
day...

COST PENALTY
Capacity
kW/kW
Hours of operation
Cost per kWh
Cost of Operation
Loss Co-efficient
Cost Penalty

2500
0.160
5000
0.06
$120,000.00
3.1%
$123,720.00

$3,720.00

Total Cost of Ownership


Scenario 2
Non condensable in the
chiller
Increases energy
consumption by 1-5%
Measurable increase in the
use of purge and an
increase amperage draw

Total Cost of Ownership


Scenario 2
Pressure variances and lack of
proper leak checking can lead
to the introduction of noncondensable gases in the
chiller
Non-condensable gases can
lead to larger problems

Total Cost of Ownership


Scenario 2
The bottom line, it is costing
you money every minute of
every day...

COST PENALTY
Capacity
kW / kW
Hours of operation
Cost per kWh
Cost of Operation
Loss Co-efficient
Cost Penalty

2500
0.160
5000
0.06
$120,000.00
3.1%
$123,720.00 $3,720.00

Total Cost of Ownership


Scenario 3
Low water flow and a lack of
condenser water temperature
control
Increases energy consumption
by 5-10%
Pressure drop deviates from
design, cooling tower does not
provide relief

Total Cost of Ownership


Scenario 3
Improper operation of chiller
from design causes
increased work by the
compressor
System performance is
impacted

Total Cost of Ownership


Scenario 3
The bottom line, it is costing
you money every minute of
every day...

COST PENALTY
Capacity
kW/kW
Hours of operation
Cost per kWh
Cost of Operation
Loss Co-efficient
Cost Penalty

2500
0.160
5000
0.06
$120,000.00
3.1%
$123,720.00

$3,720.00

Total Cost of Ownership


Scenario 4
Low refrigerant charge,
improper oil level, fluid
contamination.
Increases energy consumption
by 1-3%
Approach temperatures
indicate deviations from
design

Total Cost of Ownership


Scenario 4
Heat transfer and motor
lubrication are reduced
Chiller integrity is
compromised

Total Cost of Ownership


Scenario 4
The bottom line, it is costing
you money every minute of
every day...

COST PENALTY
Capacity
kW/kW
Hours of operation
Cost per kWh
Cost of Operation
Loss Co-efficient
Cost Penalty

2500
0.160
5000
0.06
$120,000.00
1.3%
$121,560.00 $1,560.00

Total Cost of Ownership


When you add it all up:

Condenser Fouling
Non-Condensable Gases
Water Flow Problems
Low Refrigerant Charge

TOTAL COST OF OWNERSHIP

Capacity

2500

kW/kW

0.160

Hours of operation

5000

Cost per kWh

0.06

Cost of Operation
Loss Co-efficient
TOTAL COST PENALTY

$120,000.00
10.60%
$132,720.00 $12,720.00

Total Cost of Ownership


A systems approach to
maintenance services: A small investment in the
chiller plant leads to real
cash flow for operating a
facility,
Think about the potential on
the airside...

TOTAL COST OF OWNERSHIP


Maintenance/Repair Expense

Cost
Time