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HPCL-Mittal Energy Limited

Guru Gobind Singh Refinery, Bathinda

Normal SOP of CPP


Configured Water Cooled Screw Chillers System
(NEW CHILLERS)

O&M By:

STEAG ENERGY SERVICES (I) PVT LTD

Ashish Srivastava Siddiqui MD Ghazunfer Ali


01 1-MAY-2019 IFI
(STEAG) (HMEL) (STEAG) (STEAG) (HMEL)
PREPARED/RE
REV DATE STATUS REVIEWED CHECKED APPROVED CONCURRED
VISED
This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of HPCL-MITTAL ENERGY LTD. The
copyright of this document is vested in HPCL-MITTAL ENERGY LTD. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system
or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner.

Format No. 9111-000-PCT-007-00006 Rev-00


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Normal SOP of CPP Issue Date 1-MAY-2019


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9112-575-OPR-704-00024

1. Purpose 03

2. Scope 03

3. Responsibility and Accountability 03

4. Safety, Health and Environment Consideration 03

5. Related documents and references 04

6. Definitions and Abbreviation 04

7. Detail Procedure 07

8. Operating limits, Water Quality & Alarm and Tripping. 11

9. Troubleshooting of Chiller 14

10. Pre-requisite for training and competency 19

11. Flow sheet / detail drawing 19

12. Pre-requisite condition of isolation valves check list 19

13. Checklist for SOP 20

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1. PURPOSE 9112-575-OPR-704-00024
The purpose of this document is to develop standard operating procedures for Ventilation and
Air Conditioning equipments of CPP and maintain stable Rack room/Control Room temperature
below 24°C.
2. SCOPE
The scope of this procedure is limited as below points

a) Operation Philosophy of CPP Air Conditioning


b) Procedure for startup/Shutdown of air handling unit.
c) Procedure for Refrigerant replacement
d) Procedure for Refrigerant sampling
e) Procedure for leak Test
3. RESPONSIBILITY AND ACCOUNTABILITY
a) The Operation Manager is responsible for the maintenance of this procedure.
b) The Asst. Shift In-charge is responsible for execute the procedure through Field Engineers.
c) Control Room Engineer is responsible for maintaining the pressure and temp.

4. SAFETY, HEALTH & ENVIRONMENT PRECAUTIONS


SAFETY

HAZARDS PRECAUTIONS ACTION BY

Use mandatory PPE’s as Helmet, hand


Noise induced hearing loss FIELD ENGINEER
gloves, goggle, safety shoe, coverall.
a) Check the ventilation to avoid
accumulation of refrigerant
Asphyxiation or explosion b) During filling of refrigerant or any
FIELD ENGINEER
maintenance work LEL should be
checked in time intervals.
Refrigerant spilling or splashing
Use safety goggles, coverall FIELD ENGINEER
into eyes

HEALTH
HAZARDS PRECAUTIONS ACTION BY
Noise induced hearing loss – Use hearing protection in the area FIELD ENGINEER
Prolonged exposure to noise >
85 Dba may cause deafness
ENVIRONMENT
HAZARDS PRECAUTIONS ACTION BY
Sound pollution Use ear plugs before entering the chiller FIELD ENGINEER
room.

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5. RELATED DOCUMENTS and REFERENCES


9112-575-OPR-704-00024
a) AHRI Standard 550/590
b) Configured Water Cooled Screw Chillers system Installation
c) Operation and Maintenance Manual

6. DEFINITIONS and ABBREVIATIONS:


LABELS
LABEL DEFINITIONS

DANGER:
DANGERS alert you to an immediate hazard that causes serious injury or death and
requires special Precautions to be taken

CAUTION:
CAUTION alert you to a potential hazards that causes serious damage to equipment/
Property under certain condition
WARNING:
WARNING alert you to a potential hazard that causes serious injury or death under
certain condition

NOTE:
Note emphasize or remind you of an important place of information

6.1 ABBREVIATIONS:
1) AHRI : Air Conditioning Heating And Refrigeration Institute
2) TR : Ton of Refrigeration
3) AHU : Air Handling Unit
4) HVAC : Heating Ventilation and Air Conditioning
5) CW : Cooling Water
6) ACW : Auxiliary Cooling Water
7) AC : Air Condition.
8) VAM : Vapour Absorption Machine
9) SFU : Switch fuse unit
10) MCCB : Molded Case Circuit Breaker
11) ACB : Air Circuit Breaker
12) PMCC : Power cum Motor Control Centre

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6.2 Building applications.


9112-575-OPR-704-00024

Chilling Capacity of Chiller System : 303 TR


Mode : LCW2 Series
Make : BLUE STAR

6.3 Backup Air Conditioning System


a) 1 Number of Vapour Absorption Machine (VAM) with capacity 255 TR as stand by air
conditioning system.
b) 13 Number of vapor compression air condition unit (tower AC Units) of 4.5 ton each (Total
58.5 ton) installed in CPP control and rack room as standby air conditioning system shall
be as started as backup as and when required.
c) 05 Number of vapor compression air condition unit (tower AC Units) of 4.5 ton each (Total
22.5 ton) installed in CPP UPS room as standby air conditioning system shall be as
started as backup as and when required.

6.4 Operation Philosophy


a) CPP air conditioning system consists with one chiller unit (VCRS) and one VAM (vapor
absorption refrigeration system) with redundant Control system and Utilities.
b) During CPP stable running or shutdown condition Chiller operation will be same as it runs
only on power supply.
c) During CPP Stable Operation cooling water is supplied through CPP ACW header however
standby Cooling tower and pump is used to full the cooling water requirement during total
CPP Shutdown
d) Chiller unit is having redundant Control system.
e) 03 Nos. 33000 CFM AHU units are installed and shall be operated as per temperature
requirement.

6.5 Chiller Unit or Vapour compression refrigeration unit


Central air conditioning system is envisaged for the control room panels. Central air
conditioning system consist chiller (VCRS) and air handling unit. Chiller shall produce
chilled water required, which is directed to individual AHUs by chilled water pump. Chiller
unit consist of 2 No. of refrigerant compressors, 2 nos. of chilled water pump (1W+1S) and
a cooling tower and 2 cooling water pumps (1W+1S) or supply of cooling water from ACW
header. Chiller room shall be provided with good ventilation.

6.6 Air handling unit


Air handling unit shall supply the conditioning air to respective rooms. AHUs shall be
decided based on required dehumidifier air quantity and AHUs models available. AHUs
shall be provided with backward curved blades fans.

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6.7 Features of Chiller


9112-575-OPR-704-00024
 Compressor - Chiller consist of 2 Nos. geared twin- Screw compressors
(type X05 and X06) with variable capacity slide valves for
continuous operation between minimum and maximum of full
load.
 Oil filter - Screw compressor has oil filter attached to oil separator.
 Refrigerant - 124 Kg and 141 Kg R134a refrigerant should be charged in
circuit 1 and 2 respectively.
 Lubricants - Screw Compressors is approved for use with Lubricant-Blue
Star HBR-B08. 32 ltrs oil is charged in each circuit 1 as well as
in circuit 2.

 Typical Properties HBR - B08 HANBELL (New oil)


Part Code - HBR - B08 Compressor oil
Viscosity (cSt) @40°C 120
Viscosity (cSt) @100°C 11.9
Specific Gravity 0.9753 (at 15°C)
Density 975.3 kg/m3 at 15°C
Moisture (ppm) 25 (maximum 50)
Flash Point, C.O.C.,°C 275
Pour Point °C -39

 Oil supply solenoid valve- SOV is installed in return oil line to isolate the compressor
from oil flow when compressor is not operating.
 Suction and economizer screens-It is provided to increase the reliability of
compressors.
 Capacity control system- It consist of the slide valve that permits changing of length of
screw used for refrigerant compression which results in loading
and unloading of the compressor.
 Evaporator - ¾” diameter copper Multi-tube evaporator contains water
inside the tubes and refrigerant on outer side in the shell.
 Condenser and Oil Separator - It is mounted in the upper part of the Condenser.
Compressor discharge gas passed through external muffler
discharge into oil separator. Vapour and oil is separated in oil
separator.
 High pressure safety -.Chiller consist of high pressure safety transducer with trip
setting at 175psig i.e. 12.3 K/cm2, located at discharge side of
each compressors.
 Electronic Expansion Valve (EXV)- The EXV is equipped with stepper motor that is
controlled by EXV board and sight glass is provided that

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permits the verification of the mechanism movement and the


9112-575-OPR-704-00024
presence of the liquid gasket.
 Moisture indicator - Located ion EXV, it permits the control of the unit charge
and indicates moisture in the circuit. The presence of bubbles
in sight glass indicates an insufficient charge or non-
condensable in the system. Presence of moisture will result in
change in colour of indicator paper in sight glass.
 Filter drier - Difference in temperature between the filter inlet and outlet
indicates the filet is dirty. Filter drier is used to keep the circuit
clean and moisture free.
 Sensors - It uses thermostats for temperature and transducers for
pressure measurement to control and regulate system.

7.0 DETAIL PROCEDURE


7.1 Procedure of Start-up of Configured Water Cooled Screw Chillers system
(VAM machine in running condition)

S ACTION BY
DESCRIPTION
No FE CRE ASIC SIC GIS
Crack open chiller Cooling water outlet valves according to the
1. √
required flow.
Open Cooling water to chiller inlet isolation valves (butterfly
2.
valves) on upstream and downstream of the Y-type strainer √
ensure strainer bypass valve is closed.
After proper venting, full open cooling water inlet and outlet
3. √
isolation valve.
4. Ensure the chilled water pump is in running condition. √
If chilled water pump is not running then- Start the chilled water
5.
pump and release air from Chilled water circuit by venting air √
from vent valve at located at Roof of the Control room.
Open makeup isolation valve of clarify water for filling Chilled
6.
water surge tank.
Close makeup isolation valve after ensuring level.

Ensure Chilled water circuit surge tank level is
normal
Crack open Chiller Chilled water inlet isolation valve and starts
7.
filling of line.

If Chilled water pressure drop, then start standby
chilled water pump manually from local panel.
8. Open Chilled water inlet butterfly valves present at the √

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upstream and downstream of the Y-Type strainer.


9112-575-OPR-704-00024
Open chilled water outlet globe valve and adjust the chilled
9.
water flow more than the flow switch set point.

Ensure chilled water inlet isolation valve is full open.
Oil heater should be ON for minimum 8 Hours and temp should
10. √
be above 850F/ 29.450C in local display (1-16).
Check Chiller Chilled water inlet/Outlet pressure is normal in
11.
local PG.

Ensure chilled water pump discharge pressure
should be above 2 kg/cm2.
Switch on the main power supply of individual chiller.
12.
Ensure turn on the SFU and all MCCBs located √
inside the chiller panel.
Individual ON/OFF power supply should be on condition in
13. √
inside the chiller panel.
To start chiller unit from local: Select selector switch key in
14.
local mode, chiller will start after 90 seconds.
To start chiller unit from DCS: Select selector switch key in
auto mode, give start command from DCS soft switch, chiller
will start after 90 seconds. √
First compressor will start in unloading, give the set
point of chilled water then compressor get loaded and observe
the difference in local.
Ensure Compressor-1 will get loaded till 100% and then
15.
according to the temperature difference and demand the √
second system is generated to meet further load.
16. Record all operating pressures & temperatures of the chiller. √

7.2 Shut down procedure of Configured Water Cooled Screw Chillers system
If the chiller is to be shut down for an extended period of time (for example, over the winter
season), the following procedures should be followed:

ACTION BY
S No DESCRIPTION
FE CRE ASIC SIC GIS
Record all operating pressures, temperatures, amperages and
1.
voltages at 100% load of the chiller before taken into √
prolonged shutdown
Carry out leak testing of all the joints in refrigerant line
2. √
(if required)
Selector switch key in auto mode, give stop command from
3. √
DCS.

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When Selector switch key in local mode, then stop/off


9112-575-OPR-704-00024
command from selector switch.
4. Switch off the main power supply of both chillers. √
Individual ON/OFF power supply off from inside the chiller
5. √
panel.
Disconnect the main 3-phase supply power from the user
6. √
feeder.
Turn off the SFUs and all MCCBs located inside the chiller
7. √
panel. (if required)
Close cooling water to chiller inlet isolation valves (butterfly
8.
valves) on upstream and downstream of the Y-type strainer √
and its bypass valve.
Close Chilled water inlet butterfly valves present at the
9. √
upstream and downstream of the Y-Type strainer.
Drain the chilled water and condenser water completely from
10. √
the tubes
Ensure to close the doors of chiller starters and display panels
11. √
located on the chiller tightly.
Record the ambient DBT (Dry Bulb Temperature) and
12. √
refrigerant pressure.
13. The unit must never be left shut down with the liquid
line valve closed, as liquid refrigerant can be trapped between
this valve and the expansion device

7.3 Procedure of Start-up of Configured Water Cooled Screw Chillers


(VAM machine stop condition)
S. ACTION BY
DESCRIPTION
No FE CRE ASIC SIC GIS
1. Crack open Auxiliary cooling water outlet isolation valve.

Ensure that vam side cooling water isolate condition.
After proper venting of line, full open Auxiliary cooling water outlet
2. √
valve.
3. Full open Auxiliary cooling water inlet isolation valve. √
Open makeup isolation valve of clarify water for filling Chilled
4. √
water circuit & surge tank.
Close makeup isolation valve of clarify water after ensuring level of
5.
surge tank.

Ensure Chilled water circuit surge tank level is normal
Crack open Chiller Chilled water inlet isolation valve and starts
6.
filling of line.

Ensure that vam side chilled water isolate condition.

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7. After proper venting, full open9112-575-OPR-704-00024


chilled water inlet isolation valve. √
8. Open Chiller chilled water outlet isolation valve.

Ensure chilled water inlet valve is full open.
9. Start the AHU unit
Ensure Chilled water inlet/ outlet valve open for AHU. √
Ensure AHU damper open condition.
10. Start the chilled water pump and release air from Chilled water
circuit by venting air from vent valve at located at Roof of the √
Control room.
Check Chiller Chilled water inlet/Outlet pressure in local PG, If
11. √
pressure is normal; Switch on the power supply of the chiller.
12. To start chiller unit from local: Select selector switch key in
local mode, chiller will start after 90 seconds.
To start chiller unit from DCS: Select selector switch key in auto
mode, give start command from DCS soft switch, chiller will start
after 90 seconds. √
First compressor will start in unloading, give the set
point of chilled water then compressor get loaded and observe the
difference in local.
13. Ensure Compressor-1 will get loaded till 100% and then according
to the temperature difference and demand the second system is √
generated to meet further load.
14. Carry out leak testing of all the joints in refrigerant line. √
(if required)
15. Record all operating pressures & temperatures of the chiller. √

7.4 Procedure for Start-up of VAM / CHILLERS cooling tower system


S. No DESCRIPTION FE CRE ASIC SIC GIS
1. Cooling tower inlet valve crack open according to the ACW √
discharge pressure. (Chiller outlet to ACW header line)
2. Cooling tower Sump level maintain by cooling tower inlet valve. √

Ensure sump drain valve close condition.


3. Start cooling tower fan from local panel. √
4. Cooling water pump suction and discharge valve full open. √
5. Release the air from Cooling water circuit from vent valve at √
located at Roof of the Cooling tower.
6. Press START Key and start the cooling water pump from local √

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panel. 9112-575-OPR-704-00024
7. Chiller inlet (ACW discharge header) isolation valve slowly- √
slowly full close.

Ensure Cooling water pump discharge pressure is


normal ( above 2 kg/cm2).
8. Cooling tower inlet valve open according to pump discharge √
pressure.
9. Chiller outlet (ACW outlet header) isolation valve slowly-slowly √
full close.
10. Maintain the Sump level ACW outlet header isolation valve. √

Don’t use clarify water.


11. Record all operating pressures & temperatures of the cooling √
water system.

7.5 Procedure for Start-up of Air handling unit


ACTION BY
S No DESCRIPTION
FE CRE ASIC SIC
1. Chilled water inlet/ outlet isolation valve open for AHU √
2. Suction filter should be in clean condition. √
3. AHU Damper should be open condition. √
4. PLC supply in on condition. √
5. Push the start button from AHU Local panel √

8.0 Operating limits, Water Quality & Alarm and Tripping.


8.1 Operating parameters-
Sl
Parameter Unit Desired Range
No.
1. Compressor Suction Pressure PSI 28-36
2. Compressor Discharge Pressure PSI 110-135
3. Oil Pressure PSI 105-130
4. Compressor Suction Temperature °F 42-55
5. Compressor Discharge Temperature °F 110-135

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6. Oil Temperature 9112-575-OPR-704-00024°F 90-130


7. PT1000 °F 65-120
8. Liquid Temperature °F 40-50
9. Compressor Suction Superheat °F 0-5
10. Compressor Discharge Superheat °F 15-20

8.2 Operating Limits of cooling water and chilled water.


Sl. Description Minimum Maximum
No.
1. Evaporator water entering temperature at startup - 350C
2. Evaporator water leaving temperature during operation 4.44 0C 12.78 0C
3. Evaporator entering/leaving temp difference 2.8 0C 11.1 0C
4. Condenser water entering temperature at startup 18.33 0C -

5. Condenser water leaving temperature during operation 23 0C 45 0C


6. Condenser entering/leaving temp difference 2.8 0C 11.1 0C

8.3 Recommended Water Quality Standards


Test items Chilled Cooling Tower Makeup
Water Quality Water Quality Water Quality
pH 7.2 - 8.5 7.2 - 8.5 6.0 - 8.0
Total hardness (CaCo3) ppm Max. 80 Less than 200 Max. 50
Total alkalinity (CaCo3) ppm Less than 100 Less than 100 Less than 80
Chloride ion (ppm) Less than 50 Less than 200 Less than 50
Total Iron ion (Fe) ppm Less than 0.3 Less than 1.0 Less than 0.3
Silica (SiO2) ppm Less than 30 Less than 50 Less than 30
Ammonium ion ppm Less than 0.2 Less than 1.0 Less than 0.2

8.4 ALARM & TRIPPING


ALARM
Sl. No. Set point Description Trip Delay Default Setting
(Seconds)
1. CW OUT TRGT ---- 450F
2. CTRL ZONE+ ---- 10F
3. CTRL ZONE- ---- 10F

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4. STEP DELAY 9112-575-OPR-704-00024 ---- 150


5. MAX ROC ---- -0.80F
6. MAX ROC ---- 0.80F
7. A–CYC OFF-ON ---- 900 sec
8. COMP MIN RUN ---- 4 min
9. STAR DELTA ---- 3 sec
10. LOW SUCTION UNLOAD ---- 1 psig
11. LOW SUCTION RELOAD ---- 3 psig
12. HI DISC UNLD ---- 15 psig
13. HI DISC RELD ---- 20 psig
14. HI DISCH TEMP UNLOAD ---- 80F
15. HI DISCH TEMP RELOAD ---- 90F
16. SAFETY HOLD ---- 180 sec
17. LO LQD UNLD ---- 10F
18. MOP TARG PSI ---- 50 psig

TRIPPING
Sl. No. Set point Description Trip Delay Default Setting
(Seconds)
1 Compressor Hi amperage 2 110 %
2 Compressor Low amperage 5 15 %
3 Compressor Low Suction 120 25 psig
4 Compressor Low gas / LLS FLT 10 15 psig
5 Compressor High discharge pressure 2 175 psig
6 Low Discharge SUPER HEAT 300 100 F
7 HI DISCHARGE TEMPS 2 1900 F
8 Low oil differential 180 30 psid
9 Unsafe oil 5 10 psid
10 HI Motor Temp. 2 1350 F
11 Dirty filter 30 20 psid
12 HI REFRIGERANT LVL 60 70%
13 Anti-freeze 2 380 F
14 Low LIQUID (refrigerant) temp. 10 320 F
15 HI EVAPORATOR DELTA T 5 20 0 F
16 OIL LEVEL SWITCH 30 ----

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9.1 Troubleshooting of Chillers


9112-575-OPR-704-00024

Sl.
No. Cause Probability Causes Remedy / Corrective Action

Low suction pressure causes


Install liquid injection to motor coil
low refrigerant flow rate

Refrigerant shortage Charge refrigerant

Suction filter clogged Clean filter


Sudden trip
of motor High suction temperature Install liquid injection to motor coil
1.
thermostat / High suction superheat Adjust the superheat less than 5°F
sensor
Unstable electricity system or
Check electrical power supply
failure
Motor overload
Bad motor coil causing
temperature to rise rapidly
Low ambient temperature or
Turn on the oil heater before compressor starts.
high oil viscosity.
Capillary clogged. Clean or replace capillary
Modulation solenoid valve Clean/purge solenoid valve core or replace the
Compressor clogged or solenoid valve solenoid valve coil
2. unable to Internal built-in oil line
unload. Check and clean the compressor oil circuit
clogged.
Piston stuck-up. Change piston or piston ring
Oil filter cartridge clogged. Clean oil filter (replace if needed)
Too small high-low pressure
Minimum pressure differential is 40 PSI.
differential.

Modulation solenoid valve


Clean or replace the solenoid valve
clogged or burnt.

Piston rings worn off or broken


Change piston (if cylinder damaged severely,
or cylinder damaged resulting
change the cylinder)
Compressor leakage.
3 unable to
unload. Check the oil level of the compressor if enough,
Lubrication oil insufficient.
add some oil if necessary

Leakages at internal discharge


Check or replace the gasket and tighten the bolts.
cover plate end side.
Solenoid valve voltage
Check the control voltage
misused.

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Change the piston set, and check the cylinder and


Piston9112-575-OPR-704-00024
stuck-up.
slide valves.
Capacity control logic
Check
unsuitable.

1. Bad compressor motor coil.

2. Motor power terminal or bolt


wet or frosty.
3. Motor power terminal or bolt
bad or dusty.
Poor 4. Bad insulation of magnetic
4 insulation of contactors. Check the coil or charge the motor stator
motor 5. Acidified internal
refrigeration system.
6. Motor coil running long time
continuously under high
temperature
7. Compressor restart counts
too many times.
5
Slide valve piston unable to go Check if the unloading SV is energized. once the
back to its lowest % original compressor has been shut down. Unload the
position. compressor before shutdown

Voltage incorrect. Check the power supply

Voltage drop too big when


Compressor starting the compressor or
starting Check the power supply and the contactor.
magnetic contactor failure or
failure or Y-
phase failure.
∆ starter
shifting Motor broken down Change the motor
failure Motor thermistor sensor trip. See “sudden trip of motor sensor” above
Incorrect supply power
Check and reconnect
connection.
Y-∆ timer failure. Check or replace.
Discharge or suction stop
Open the stop valve
valve closed.
Improper connection between
Check and reconnect the wiring
node terminals of Y-∆ wiring.
Rotor locked Check and repair

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Earth9112-575-OPR-704-00024
fault Check and repair
Protection device trip Check

Damaged bearings. Change bearing.

Phenomenon of liquid
Adjust proper suction superheat
compression.
Friction between rotors or
Change screw rotors or/and compression
between rotor and
chamber.
compression chamber.
Check the oil level of the compressor if enough,
add some oil if necessary.
Abnormal Insufficient lubrication oil.
vibration and Dismantle the compressor and change the
6 damaged parts.
noise of
compressor
Electromagnetic sound of the
Check
solenoid valve.
System harmonic vibration
Check the system piping and if possible
caused by improper
piping system. improve it using copper pipe.
External debris fallen into the Dismantle the compressor and check the extent of
compressor. the damage.
Friction between slide valve Dismantle the compressor and change the
and rotors. damaged parts.
Motor rotor rotation imbalance. Check and repair.
Motor line open Check
Compressor Tripped overload Check the electrical connection
7
does not run Screw rotors seized Replace screw rotors, bearings, etc.
Motor broken Change motor.
Check for leaks. Charge additional refrigerant and
Insufficient refrigerant.
adjust suction superheat to less than 5°F
Condenser problem of bad
Check and clean condenser
heat exchange.
Refrigerant overcharge. Reduce the refrigerant charge
High
8 discharge Air/moisture in the refrigerant
Recover and purify refrigerant and vacuum system
temperature system
Improper expansion valve. Check and adjust proper suction superheat
Insufficient lubrication oil. Check the oil level and add oil.
Stop the compressor and change the bearings
Damaged bearings.
and other damaged parts.
Improper Vi value. Change the slide valve.

Format No. 9111-000-PCT-007-00006 Rev-00


HPCL-Mittal Energy Limited Revision 04

Normal SOP of CPP Issue Date 1-MAY-2019


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Configured Water Cooled Screw Chillers System Page 17 of 20

9112-575-OPR-704-00024
No system additional cooling
Install additional system cooling (liquid injection or
oil cooling or both, based on working condition
(Liquid injection or oil cooler)
limitation)
Lack of refrigerant Check for leaks. Charge additional refrigerant.
Compressor Check and correct the piping or install an external
9 Improper system piping
loses oil oil separator
Refrigerant fills back Maintain suitable suction superheat at compressor
Lack of refrigerant Check for leaks. Charge additional refrigerant.
Evaporator dirty or iced Defrost or clean coil
Clogged liquid line filter drier Replace the cartridge
Clogged suction line or
Low suction Clean or change suction strainer
10 compressor suction strainer
pressure
Expansion valve
Check and reset for proper superheat
malfunctioning
Condensing temperature Check means for regulating condensing
too low temperature

9.2 Controller Troubleshooting Quick reference sheet

Sl .No.
Problem Potential Solution

 Indicates a possible shorted input sensor


 Remove all sensor terminal blocks.
1. No Sensor +5V DC  Wait about 30 to 60 seconds. If +5V DC returns, replace
one sensor wire at a time until the +5V DC is lost again.
This will be the shorted sensor.
This indicates an open sensor input signal or 5V DC
problem.
 Check sensor wiring for missing wire or poor
connection.
 Check sensor for bad sensor.
2. A sensor input reads -99.9  Check +5V DC on sensor input to ground. If less than
5V DC is on the sensor
 5V DC terminal block, the problem is with probably a
shorted sensor. (A polyfuse protects the board)
 Remove all sensor input terminals.
 Wait for 1 min. or until 5V DC is restored at sensor
input.

Format No. 9111-000-PCT-007-00006 Rev-00


HPCL-Mittal Energy Limited Revision 04

Normal SOP of CPP Issue Date 1-MAY-2019


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Configured Water Cooled Screw Chillers System Page 18 of 20

 Connect terminals one at a time until short reappears


9112-575-OPR-704-00024
and fix bad sensor.
This indicates a shorted sensor input signal.

3. A sensor input reads +999.9  Check sensor wiring for +5V DC shorted to signal, etc.

 Check sensor for bad sensor.


(The temperature and humidity sensors do not require
calibration.) This indicates the transducer sensor input
A pressure sensor is reading more
4. needs to be calibrated via the offset capability in the
than 1psi off
software. (Transducers by design need to be calibrated
based on construction and altitude.)

This indicates an input problem with one sensor.


5. Invalid reading on one sensor input.
 Verify jumper settings correct for that SI.

‘MCS Controller Initialization’ on LCD Indicates Micro in constant reset.


Display.
6.  Check incoming power >105V AC or 240V AC
Indicates bad connection.
7. LCD blank.  Connector J2 on MCS not on or offset on connector.
 Resistor adjustment VR1 out of adjustment.
Indicates communications problem.
 Verify RS485 LED is blinking.
 Verify termination jumper J6 only on at Magnum and
8. Lost I/O last I/O.
 Verify Magnum and I/O address set correctly.
 Verify wiring from Magnum to each I/O is correct.
 Check fuses 120V AC on I/O units

This indicates inability to write to chip U10.


Changes to MCS not being made
9.
from the unit’s keypad.  Verify ‘EEP WRITE ENABLE’ jumper W6 is on.
 Not authorized
This indicates an invalid authorization number.
Follow the steps below for proper authorization:
 Press SERVICE DIAGNOSTICS key until the
10. Invalid authorization authorization option appears
 Press the ENTER key
 From the “Display Status” press keys corresponding
to your authorization number.

Format No. 9111-000-PCT-007-00006 Rev-00


HPCL-Mittal Energy Limited Revision 04

Normal SOP of CPP Issue Date 1-MAY-2019


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Configured Water Cooled Screw Chillers System Page 19 of 20

 Press ENTER
9112-575-OPR-704-00024
This indicates a problem with this SI only.
11. SI from AMPS board 10 A low.  Jumper setting on this SI is in wrong position.
 Incorrect sensor type is used.
12. Invalid Config Ver Defective Program IC. Controller needs to be replaced
13. Invalid Config Type Defective Program IC. Controller needs to be replaced

14. Invalid Config Defective Program IC. Controller needs to be replaced

Verify Berg jumpers using Quick Reference Sheets


Sensor input believed invalid (Under
15.  Check board version number
Sensor Diagnostic Sub Menu)
 Check wiring of sensor

10.0 PRE-REQUISITE FOR TRAINING AND COMPETENCE

S Certification/
Job Role Qualification Experience Training Special Skill
No. Validation
1 Field Engineer ITI/Diploma/Degree 3-5 years On job training Yearly
Control Room
2 Degree/Diploma 3-7 years On job training Yearly
Engineer
Assistant Shift
3 Degree/Diploma 5-10 years On job training Yearly
Incharge
4 Shift Incharge Degree/Diploma 7-12 years On job training Yearly

11.0 FLOW SHEET/DETAIL DRAWING


N/A

12.0 PRE-CONDITION OF ISOLATION VALVES


S
Description of valve Tag No. of valve Status of valve
No.
Tag NA -Butterfly Valves(U/s &
1 Cooling Water inlet valve open
D/s of Strainer)
2 Cooling Water outlet valve Tag NA- Globe Valve open
Tag NA- Butterfly Valves (U/s
3 Chilled Water Inlet Valve open
& D/s of Strainer)
4 Chilled water outlet Valve Tag NA -Globe Valve open

Format No. 9111-000-PCT-007-00006 Rev-00


HPCL-Mittal Energy Limited Revision 04

Normal SOP of CPP Issue Date 1-MAY-2019


Next Review
Configured Water Cooled Screw Chillers System Page 20 of 20

9112-575-OPR-704-00024
13.0 CHECKLIST AS PER SOP

Startup Checklist

ACTION BY
S No DESCRIPTION
FE- CRE- GIS ASIC SIC
Oil level should be higher than the middle line √
1
of oil level in sight glass
Turn on the oil heater at least 8 hr prior to √
2
starting
3 System Value status should be OPENED √
Electricity voltage should be kept within ±10% √
to the rated voltage. Instant maximum voltage
4
drop while starting should be less than 10% to
the rated voltage
Control circuit should be 220V. Maximum √
5
voltage is 230V
Insulation resistance value should be 5 √
6 Mohms of the motor between phase to phase
and phase to ground
Setting of switches, sensors and controllers √
7
should be properly set.
Motor winding sensor & Discharge √
8
temperature sensor should be fixed properly.

…………………………………………..END OF CHECKLIST……………………………………….

Format No. 9111-000-PCT-007-00006 Rev-00