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9112-575-OPR-704-00024
1. Purpose 03
2. Scope 03
7. Detail Procedure 07
9. Troubleshooting of Chiller 14
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
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.
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
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
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 √
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.
panel. 9112-575-OPR-704-00024
7. Chiller inlet (ACW discharge header) isolation valve slowly- √
slowly full close.
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 ----
Sl.
No. Cause Probability Causes Remedy / Corrective Action
Earth9112-575-OPR-704-00024
fault Check and repair
Protection device trip Check
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.
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
Sl .No.
Problem Potential Solution
3. A sensor input reads +999.9 Check sensor wiring for +5V DC shorted to signal, etc.
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
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
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……………………………………….