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OPERATION AND MAINTENANCE MANUAL

CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266


(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

LIST OF CONTENTS

SECTION TITLE

1. System Overview
(A) Air Conditioning System
(B) Air-conditioning System — Split Air-cooled.
(C) Mechanical Ventilation System

2. Operation Procedure
(A) Air Conditioning System
(B) Air-conditioning System — Split Air-cooled.
(C) Mechanical Ventilation System

3. Operator's Knowledge

4. Maintenance
(A) Centrifugal Liquid Chillers
- Daily Maintenance
- Weekly Maintenance
- Annually Maintenance

(B) Chilled Water and Condensing Water Pumps


- Monthly Maintenance

(C) Cooling Towers


- Daily Maintenance
- Quarterly Maintenance

(D) Air Handling Units


- Quarterly Maintenance

(E) Chilled Water Fan Coil Units


- Quarterly Maintenance

(F) Switchboards, Control Panels


- Annually Maintenance

(G) Air-cooled Split Air-conditioning units


- Quarterly Maintenance

(H) Smoke Spill Fans


- Annually Maintenance

(I) Exhaust Fans


- Yearly Maintenance

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

5. Water Treatment
(A) Condensing Water
- Daily dosage
- Monthly water sample analysis

(B) Chilled Water


- Annually water sample analysis

6. List of Equipments (Appendix)


Appendix 1: York Chiller
Appendix 2: York Air Handling Units
Appendix 3: Ebsray Chilled Water Pumpsets
Appendix 4: Ebsray Condensing Pumpsets
Appendix 5: Nihon Spindle Cooling Tower
Appendix 6: Kruger Fans (Smoke Spill Fans)
Appendix 7: Kruger Fans (Exhaust Air Fans)
Appendix 8: Kruger Fans (Kitchen Exhaust Fans)
Appendix 9: York Fan Coil Units

7. Catalogue Of Main Equipment


(a) York Centrifugal Liquid Chiller (YK)
(b) York Screw Chiller (YEWS)
(c) York Air Handling Unit (YSM)
(d) York Ducted Fan Coil Unit (YSD)
(e) York Ducted Fan Coil Unit (YCF)
(f) York Ducted Fan Coil Unit (DCP)
(g) York Ducted Fan Coil Unit (CRBH)
(h) York Air-Cooled Wall Mounted Split Unit
(i) Nihon Spindle Cooling Tower
(j) Ebsray End Suction Pumps
(k) Kruger Fans (TDA)
(l) Kruger Fans (CCD)
(m) Kruger Fans (CFT)
(n) Winduct

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

System Overview

1. SYSTEM OVERVIEW

A. AIR CONDITIONING SYSTEM

1. a) The Mall Central Air-Conditioning System comprises of the following equipments: -

( i) 3 units of "York" Centrifugal Liquid Chiller.

(ii) 12 units "York" Modular Air Handling Units (AHU).

(iii) 255 units "York" Ceiling Concealed chilled-water Fan Coil Unit. (FCU).

(iv) 3 sets of "Ebsray" Chilled water pump.

(v) 3 sets of “Ebsray" Condensing water pump.

(vi) 3 sets of "NIHON SPINDLE" Cooling Tower.

(vii) 1 set of chemical dosing pump.

(vii) 1 set of Chiller's Main Switch Board (MSB).

(viii) 1 set of Chilled Water Piping from the Chillers to AHU(s) and FCU(s).

(ix) 1 set of Condensing Piping from the Chillers to Cooling Towers.

(x) Ducting for AHU(s) and FCU(s)

b) The Superstore Air-Conditioning System comprises of the following equipments: -

( i) 3 units of "York" Screw Chiller.

(ii) 12 units "York" Modular chilled-water Fan Coil Unit. (FCU).

(iii) 3 sets of "Ebsray" Chilled water pump.

(iv) 3 sets of “Ebsray" Condensing water pump.

(v) 3 sets of "NIHON SPINDLE" Cooling Tower.

(vi) 1 set of chemical dosing pump.

(vii) 1 set of Chiller's Main Switch Board (MSB).

(vii) 1 set of Chilled Water Piping from the Chillers to FCU(s).

(viii) 1 set of Condensing Piping from the Chillers to Cooling Towers.

(x) Ducting for FCU(s)

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

System Overview
2 Chillers Brief Description

a) The Mall Centrifugal Chillers are located at the Basement Chiller Plant Room, are controlled
by a Microcomputer Control Center that monitors its operation. It can be programmed to suit
job specifications. In operation, water flows through the evaporator, where boiling refrigerant
absorbs heat from the water. The chilled water is then piped to Air Handling units AHU(s)
and Fan Coil units FCU(s). The chilled water flows through the finned coil of the AHU(s)
and FCU(s), absorbing heat from the air. The warmed water is then returned to the chiller to
complete the chilled water circuit. The refrigerant vapor, which is produced by the boiling
action in the evaporator, flows to the compressor where the rotating impeller increases its
pressure and temperature and discharges it into the condenser. Water flowing through the
condenser tubes absorbs heat from the refrigerant vapor, causing it to condense. The
condenser water is supplied to the chiller from the cooling tower. The condensed refrigerant
drains from the condenser into the liquid return line, where the variable orifice meters the
flow of liquid refrigerant to the evaporator to complete the refrigerant circuit.

b) The Superstore Screw Chillers are located at the 2nd Floor Chiller Plant Room, are controlled
by a Microcomputer Control Center that monitors its operation. Its operation is similar to the
Mall Chillers

3. The oil heater operation is controlled by the Microcomputer Control Center. It is turned on
and off to maintain the oil temperature at 10 deg C (50 deg F).

4. The chilled water produced by the chillers is being circulated by 3 sets of Chilled Water
Pumps to all Air Handling Units (AHU) and Fan Coil Units (FCU) in the main building.
The Condenser water from the Chillers is being cooled by 3 sets of Condensing Water
Pump circulating to 3 sets of Cooling Tower.

5. AHU(s) and FCU(s), completed with cooling coil; fan motor, valves, strainer, thermostat,
filter, control panel (where necessary) and control wiring are installed at various locations
of the building to cool different areas of the building.

6. The ducting from AHU(s) and FCU(s) is installed to distribute the cooled Air from
AHU(s) and FCU(s) to cool the specific areas through Square Diffusers, Round Diffusers
and Linear Diffusers. The cool air supplying to the area is returned to AHU(s) and
FCU(s) through Return Air-Grilles. Two systems of return air are being implemented
depending on the design of the Air-conditioning system. There are ceiling return and
ducted return.

7. All AHU(s) rooms are equipped with sound proof. The wall of the AHU(s)'s rooms is
insulated with Rock Wool of 50mmX 40kg/m3 covered by the 3mm perforated sheet.

8. The chilled water piping is equipped with isolation valves and motorized zoning, valves.
The isolation valves are to isolate the flowing of chilled water to the equipments serving for
a particular area. This is to enable the repair or the maintenance of equipments for that
particular area. The motorized zoning valves are to isolate the flowing of chilled water to the
equipments of a particular zone. This is to enable the BMS control of shutting down the
supply of chilled water to the equipments in that particular zone.

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

System Overview

9. To achieve acceptable quality of condensing water, a treatment program should be


implemented. Sample of water will be taken and tested monthly. Based on the result, the
quantity of chemicals will be mixed and is injected into the condensing water system by
chemical dosing pump. These chemicals are to control the following parameters to
achieve the desired quality of condensing water.

PARAMETERS LIMITS MEANS of ADJUSTMENT


pH 7.2 to 8.5 Bleed-off to control
M-alkalinity 300max Bleed-off to control
(ppm CaCO3)
Total Hardness 400max Bleed-off to control
(ppm CaCO3)
T.D.S. 500Max Bleed-off to control
Molybedate (Mo04) 0.5- 1 ppm Add CL CL-4810-+-control

B. AIR-CONDITIONING SYSTEM — Split Air-cooled Air-conditioning unit

1. There is certain areas in the mall that are cooled by Air-cooled Split Air-conditioning
units. The Air-cooled Split Air-conditioning unit consists of a fan coil unit and condensing
unit. The Fan units installed are Wall mounted and Ceiling exposed type and all are wireless
control (Remote).

C. MECHANICAL VENTILATION SYSTEM

1. All mechanical rooms in the M&E building are installed with suitable fresh air fans and
exhaust Fans. All toilets, washrooms and specific rooms are installed with suitable
exhaust fan. Ducting is installed for all these Exhaust fans and fresh air Fans to supply and
extract air from the rooms or areas.

2. Smoke Spill Fans are installed with "winduct”. These fans are installed according to the
Bomba requirement.

3. Refer to Equipment schedule for list of fans and their details specification. These fans
were installed as per As-Built Drawing.

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

Operation Procedure

2. OPERATION PROCEDURE

A. AIR CONDITIONING SYSTEM

1. Check power supply to main Air-Con. Switchboard in the Air-Con Plant Room and
individual AHU control panels in their respective AHU Rooms.

2. Check the oil heater - It must be energized for 12 hours prior to starting the chiller.

3. Check the incoming water of the Expansion Tank installed at the roof level of the
Main Building. Check the water level of the Air-con Expansion Tank.. The water
level must be at least half full. The isolation valve of the Expansion Tank must be
open to ensure the chilled water piping system is completely filled up.

4. Check the incoming water to the Air-con Make-up Tank to ensure the continuous supply of
water. The water level of the Air-con Water Tank supplying to Cooling Towers must be at
least half filled to ensure continuous supply of water to the Cooling Towers.

5. The FCU(s) and AHU(s) must be switched on to provide sufficient load to the Chiller.
There are two ways of switching on the AHU(s). The selection switch on the control
panel can be switched to local (means manual - manually press the start or stop button) or
Auto (means by switch on by BMS at the main control room located at level 1).

6. The Chiller can be started in two ways. The selection switches on the MSB (Main Switch
Board) for Cooling Towers, Condensing Water Pumps, and Chilled Water Pumps can be
selected for Manual, Neutral or Auto. If the selection is manual, the Chiller can be started
manually by following the correct sequence of operation. If the selection is Auto (not
applicable to superstore air conditioning system, the chiller can be started by BMS at the
control room. The BMS will automatic calling the correct sequence of the operation
except the AHU(s).

(a) The correct sequence of the operation of the Chiller.

AHU(s) / FCU(s) operation


COOLING TOWER

CONDENSING WATER PUMP


CHILLED WATER PUMP


CHILLER

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

Operation Procedure

7. If it is in Auto operation, you can stop the Chiller's operation by BMS at the fire control
room, ground floor. The reverse sequence of the shutting down will be done
automatically. You have to stop the AHU(s) operation separately by BMS. If the
operation is in Manual, then the Chiller has to be shut down at the Chillers' Plant room
with reverse sequence.

8. The Condenser tube cleaner can only be done during the chiller shutdown.

B. AIR-CONDITIONING SYSTEM — Split Air-cooled Air-conditioning unit.

1. Switch on the Air-con switch for the power supply. Press ON/OFF on the remote controller
to turn on or off the Air-cooled Air-conditioning unit. The target room temperature can be set on
the Remote Controller. Other functions like timer, Fan speed, and other mode of operation can be
set on the Remote controller.

C. MECHANICAL VENTILATION SYSTEM

1. Check power supply for the control panels of the Fans (Fresh air and Exhaust).

2. START the fan by pressing start button on the control panel. Stop the fan by pressing
stop button.

3. For single-phase exhaust fans, turn ON/Off at lighting switch.

4. Smoke Spill Fans for the building can be tested from the Control Panels. If the selection
switch on the control panel is switched to manual, the fans can be switched on/off by
pressing the start/stop button. In normal operation, the selection switch is always in auto
mode. The fans will only be operational if the fire alarm signal is received.

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

Operator's Knowledge

3. OPERATOR'S KNOWLEDGE
Operator should be familiar with the following equipments: -

1. The function of each of the Air-Conditioning Equipment's

Namely a. Chiller
b. Cooling Tower
c. Chilled Water Pumps
d. Condensing Water Pumps
e. Air Handling Unit (AHU's)
f. Fan Coil Unit (FCU's)
g. Air-cooled Split Air-conditioning units.
h. Ventilation Fan and the area it serves.
i. Smoke Spill Fan and its function and the area it serves.

2. The powers supply to the following Switchboard and control panels.

a) Air-con Main Switchboard (MSB),


Power supply to:-
- Condensing water Pump,
- Chilled Water Pump,
- Cooling Tower,
- Chemical Dosing Pump,
b) Individual control panel of AHU(s),
c) Ventilation Fan Control Panel,
d) Smoke Spill Fan control panel,
e) Thermostat of the Fan Coil Units (FCU(s).

3. The sequence of system control for the equipments in manual and in automatic mode.

4. The location of the Isolating valves and motorized Zoning Valves for the chilled water
piping as indicated in the as-built drawing.

5. Location of all equipment's as listed in item (1) above and their control panels as described
in system overview and indicated in the as-built drawings.

6. Constant monitoring of the consumption of chemical solution into the condensing-water


system by Chemical dosing pump at the Chillers plant room.

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

Operator's Knowledge

4. MAINTENANCE
In general, daily Operation logbooks for all major equipments must be implemented to detect any
abnormality of the equipments. A good planned program of regularly scheduled maintenance is
recommended to maintain the good running condition of all the equipments. The following scheduled
maintenance for individual equipments are listed for implementation.

A. CHILLERS

An operating logbook for individual chiller is recommended. Daily record of system


operating conditions (temperatures and pressures) must be recorded at regular intervals
throughout the 24 hours operating period.

Daily maintenance
1. Check the Microcomputer Control Center display for any alarm. Rectify the problem
if any. Record the fault.
2. Check the bearing oil pressure on the SYSTEM Screen. Record it on the logbook.
3. Check the operating oil level. It should be between the upper and the lower sight
glass. Drain or add if necessary. Record it on the logbook.
4. Check entering and leaving condenser water pressures and temperatures. The
temperature can be checked on the SYSTEM Screen. Record it on the logbook.
5. Check the entering and leaving chilled water temperatures and evaporator 's pressure
on the SYSTEM Screen. Record it on the logbook.
6. Check the condenser saturation temperature on the SYSTEM Screen. Record it on
the logbook.
7. Check the compressor discharge temperature on the SYSTEM Screen. It should not
exceed 104 deg C (220 deg F). Record it on the logbook.
8. Check the compressor motor current on the SYSTEM Screen. Record it on the
logbook.
9. Check the temperature difference between the water leaving condenser and saturated
condensing temperature. It should not exceed by more than 2.2 deg C (4 deg F).
Record it on the logbook.

Weekly Maintenance
1. Check the refrigerant charge during shut down of the chiller. The refrigerant charge
level should be visible in the sight glass. This should only be done at least 4 hours
after shut down.
2. Check for any leakage of the entire chiller.

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

Operator's Knowledge
Annual Maintenance
1. Drain and replace the oil in the compressor oil sump.Inspect and clean water
strainers of the Evaporator and Condenser.
2. Inspect and clean tubes as required.

B. CHILLED WATER and CONDENSING WATER pumps.

Monthly Maintenance.

1. Checks pump glands/seal for leakage and bearings for excessive noise, wear and
temperature and lubricate with oil grease as and when necessary.
2. Check alignment and adjust as necessary.
3. Check lubrication.
4. Check all bolts and nuts for tightness and tighter as and when necessary.
5. Check pumps motor operation and measure running AMPERE adjust or rectify as
necessary.

C. COOLING TOWERS

Daily maintenance

1. Check the water level of the make-up tank. It should be at least half filled.
2. Check for abnormal vibration and noise, burning smell from the cooling tower.
Inspect the source and rectify immediately.
3. Check the incoming and outgoing water temperature If abnormal, inspect and rectify
the problem immediately.
4. Top up the chemical solution at the plant room and record the consumption daily.

Quarterly Maintenance.

1. Clean the hot water basin distribution holes and strainer to avoid clogging.
2. Check the fan bearings and replenish the grease if necessary.
3. Check the tension of the fan belt; adjust if necessary by shifting the fan motor
position. Replace the belt if the belt is worn-out or elongated.
4. Check fan blades for dust and other deposit. Clean the blades to avoid unbalance
operation of the fan.
5. Clean the louvers.

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

Operator's Knowledge

D. AIR HANDLING UNIT

Quarterly Maintenance

1. Check and clean filters, replace as necessary.


2. Check for abnormal bearing or moving components noise level, rectify or replace as
necessary.
3. Check alignment for belting and pulleys.
4. Check for wear and tightness of belting. Adjuster or replace as necessary.
5. Check coils and associated piping connections for leakage and purge air from coils.
6. Check drips trays and drains and cleans as necessary.
7. Check and clean strainers to the cooling coil.

E. CHILLED WATER FAN COIL UNITS

Quarterly Maintenance.

1. Check all filter, clean or replace as necessary.


2. Check cooling coil and strainer, clean as necessary.
3. Check for proper functioning of ON/OFF valve and thermostat, adjust or replace as
necessary.

F. SWITCHBOARDS / CONTROL PANELs

Annually maintenance

1. Record readings of all hour run meters, voltmeters and ammeters.


2. Check all starters, contactors and relays for bad contact, clean or replace as
necessary.
3. Check control sequence operation. Adjust sequential timing as necessary.
4. Check operation of all test switches and automatic devices and adjust as necessary.

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OPERATION AND MAINTENANCE MANUAL
CITY MALL COMMERCIAL DEVELOPMENT ON CL.015011266
(NEW DRAFT TITLE CL.015580355) AT JALAN LINTAS, KOTA KINABALU AC O&M CITY MALL version 1.0

Operator's Knowledge

G. AIR-COOLED SPLIT AIR-CONDITIONING UNIT.

Quarterly Maintenance

1. Clean air filter and replace whenever necessary.


2. Check the running ampere of the compressor.
3. Clean the condensing coil.
4. Check the function of the fan coil unit.
5. Check the pressure of the R22 Refrigerant. Top up the Refrigerant whenever
required.

H. SMOKE SPILL FANS

Yearly Maintenance

1. Activate the operation of the Fans once a month.


2. Check the running ampere of the Fan and recorded for reference.
3. Grease the bearings of the Fans whenever necessary.
4. Check the general running condition of the Fan. Rectify if any abnormality.

I EXHAUST FAN

Yearly Maintenance

1. Grease the bearings if necessary.

5. WATER TREAMENT

(A) Condensing Water

Daily dosage
-To top up the chemical mixture solution of the tank (located at the plant room)
based on the recommended dosage by the water treatment specialist.

Monthly water sample analysis


The appointed specialist will take water sample from the cooling tower for analysis.
A recommended dosage will be provided. If necessary, drain the water from the
basin of the cooling tower if it is required.

(B) Chilled Water

Annually water sample analysis


The appointed specialist will take chilled water sample from the plant room for
analysis. A recommended chemicals dosage will be added into the chilled water
system.

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