Professional Documents
Culture Documents
System Maintenance
Some interesting examples.
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
System Maintenance
Period One
Maintenance Considerations
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
FACILITY REQUIREMENTS
PROBLEM AREAS
AUSTRALIAN STANDARDS
AS3666.2-2002
AUSTRALIAN STANDARDS
AS1851-2005
AUSTRALIAN STANDARDS
AS1851-2005
AUSTRALIAN STANDARDS
SAA HB40.1- 2001
AUSTRALIAN STANDARDS
Web Site: - www.standards.com
Application of Standards
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
maintenance considerations
AS3666.2-2000
Scope: -
Equipment: -
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
maintenance considerations
AS1851-2005
Scope: -
Equipment: -
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
maintenance considerations
AS3666.2
Scope: -
Scale Prevention
Rust Inhibitor
Equipment: -
Chillers
D.X. Packaged Units
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
maintenance considerations
AS3666.2
Scope: -
Equipment: -
Chillers
Cooling Towers
Evaporative Condensers
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
maintenance considerations
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Maintenance Considerations
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
maintenance considerations
HB40
ASHREA Guideline 3
Scope: -
Equipment: -
Chillers
Split Systems
Packaged Units
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
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
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Manufacturers recommendations
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Manufacturers recommendations
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
maintenance considerations
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Fluid Analysis
Oil Analysis
Measure charge
Refrigerant Charge
Conduct analysis of refrigerant
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Oil Analysis
Why perform regular oil analysis?
compressor
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Chiller Maintenance
Period Four
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
95.58%
2500kWr
L2 (RLA):
95.58%
Design Efficiency:
0.160
L3 (RLA):
95.58%
100%
606Amps
Motor/Compressor Data
Consumed Power:
399kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
95.58%
Winding #2:
34.6C
36.78C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
413kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
38.01C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
Chiller Capacity:
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
413kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
38.01C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
413kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
38.01C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
412kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
37.93C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
412kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
37.93C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
412kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
37.93C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
413kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
38.05C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
413kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
38.05C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.165
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
413kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
38.05C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
12.00C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
6C
46.2C
Refrigerant Temp:
4.14C
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
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.162
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
406kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
36.79C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
11.50C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
5.5C
46.2C
Refrigerant Temp:
3.47C
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
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.162
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
406kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
36.79C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
11.50C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
5.5C
46.2C
Refrigerant Temp:
3.47C
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
Chiller Name:
Chiller No 1
Refrigerant Type:
R123
L1 (RLA):
100%
2500kWr
L2 (RLA):
100%
Design Efficiency:
0.162
L3 (RLA):
100%
100%
Motor/Compressor Data
Power Consumed:
406kWe
Compressor RLA:
Number of starts:
1145
8653hrs
Winding #1:
34.7C
Current Draw:
100%
Winding #2:
34.6C
36.79C
Winding #3:
34.5C
54.49C
Evaporator Data
40.44
EWT:
11.50C
Oil Temperature:
56.5C
LWT:
6.00C
-62.1C
T:
5.5C
46.2C
Refrigerant Temp:
3.47C
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
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Air
Air Conditioning
Conditioning Clinic
Clinic TRG-TRC010-EN
TRG-TRC010-EN
Cost
Time
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
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
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
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
Condenser Fouling
Non-Condensable Gases
Water Flow Problems
Low Refrigerant Charge
Capacity
2500
kW/kW
0.160
Hours of operation
5000
0.06
Cost of Operation
Loss Co-efficient
TOTAL COST PENALTY
$120,000.00
10.60%
$132,720.00 $12,720.00
Cost
Time