DIPLOMA PROFESSIONAL IN ELECTRICAL ENGINEERING

(PEEG)

NAME : MD RADZUAN A RAHMAN

IC : 730129-08-5135
DATE : 03/03/2022
LECTURER NAME : TUAN MOHD FIRDAUS BIN ABDULLAH

MARKS
QUESTION 1
Briefly explain the importance of Total Preventive Maintenance (TPM)
1. The major difference between TPM and other concepts is that the
operators are also made to involve in the maintenance process.
2. Avoid wastage in quickly changing environment.
3. Reduce Cost of Manufacturing.
4. Produce a low batch quantity at the earliest possible time.
5. Goods send to Customers must be “ non – defective”
(5 marks)
QUESTION 2
Root Cause Analysis (RCA) is not one well defined technique, but rather a
general philosophy. Identify the objective of RCA
1. Safety-based: accident investigation, health & safety
2. Production-based: quality control
3. Process-based: business processes outside of manufacturing
4. System-based: organizational culture, strategic management
(5 marks)
QUESTION 3
A chiller is a machine that removes heat from a liquid via vapor
compression. This liquid can then be circulated through a heat exchanger to
cool equipment, or another process stream (such as air or process water). As
a necessary by-product, refrigeration creates waste heat that must be
exhausted to the ambiance, or for greater efficiency, recovered for heating
purposes. Vapor compression chillers may use any of a number of different
types of compressors. Most common today are the hermetic scroll,
semi-hermetic screws, or centrifugal compressors. The condensing side of
the chiller can be either air or water-cooled. Even when water-cooled, the
chiller is often cooled by an induced or forced draft cooling tower.
Absorption and adsorption chillers require a heat source to function.
1. List down all possible maintenance work that needs to be done in terms
of equipment maintenance, housekeeping, and record-keeping.
Performing chiller maintenance is a must. Below are a few items to add to your general
maintenance checklist to ensure you don’t miss a step.

● Note refrigerant and oil levels

● Inspect fan control system

● Check evaporator water temperature differential

● Measure condenser fan motor volts/amps, where applicable

● Check water flow through evaporator

● Measure condenser and evaporator pressures

● Check operation of controls

● Leak-Measure and verify refrigerant, water, oil, etc.

● Check safety control settings

● Check operating control settings

● Inspect compressor motor operation

● Inspect compressor motor efficiency

● Check compressor motor volts/amps

● Secure all cap tubes from chafing

● Check crankcase heater operation

● Check cap control setting/operation

● Inspect condenser/evaporator controls air and water

● Inspect moisture indicator

● Check low/high and oil pressures

● Inspect fan and assembly rotations, etc.

● Check chill water temperature control

● Inspect belts, sheaves – tension and alignment

● Check fan speed controllers

● Listen and look for unusual noises/vibrations

● Check structural integrity of unit

 ● Compare tonnage being produced vs electricity being consumed

2. Prepare a detailed plan for 2 of the maintenance works that need to be

done.

KEEPING TUBES CLEAN

Tubes are the main path for heat transfer in chillers and can be largely responsible
for the performance of your industrial chiller. Contaminants and impurities can
increase thermal resistance. This would reduce heat transfer efficiency as the
resistance would affect the consistencies in approach temperatures in the chiller. It is
important to brush these tubes at least once per year. With a strong monitoring
system, you’ll be able to see problems before they occur. Giving you the opportunity
to clean the tubes before they become too much of a problem.

TREAT CONDENSER WATER

Keeping the condenser water clean is important for both boilers and chillers
maintenance for many of the same reasons. Corrosion and scaling both reduce
efficiency. Both of which, build up over time if the water is not well-treated. Untreated
can result in higher condenser pressures, impeded heat transfers and
inconsistencies in water temperature and water flow. Regular chemical treatments
can help keep the water clean and filters should be replaced often.

(15 marks)