RTHD

RTHD

OPERATION AND MAINTENANCE

 OPERATION
• MAIN COMPONENTS RTHD
• REFRIGERANT CYCLE
• LUBRICATING CYCLE
• LOAD/UNLOAD MANAGEMENT
• OPERATIONAL
 MAINTENANCE
• DAILY MAINTENANCE
• WEEKLY MAINTENANCE
• THREE MONTHLY MAINTENANCE
• SIX MONTHLY MAINTENANCE
• ANUALLY MAINTENANCE
• OTHER
- Compressor
- Condenser
- Evaporator
- Dual EXV
- Starter And Control panel
 Review—Period 1
oil supply compressor motor
system

oil separator

condenser
control
panel

starter
evaporator
 SCREW COMPRESSOR
• SEMI HERMETIC
SCREW COMPRESSOR
• MOTOR COMP COOLED
BY SUCTION GAS
• 3 PHASE MOTOR 380
VOLT, 50 HZ, 3000 RPM.
• 3 MOVING PART ( MALE
SCREW,FEMALE
SCREW AND SLIDE
VALVE )
Helical-Rotary (Screw)
Compressor
 Helical-Rotary Compressor

female rotor

male rotor

housing
 Slide Valve

discharge housing
port

rotors

slide valve
Helical-Rotary Compressor

discharge
meshing point port
Helical-Rotary Compressor

intake
port

pocket of refrigerant vapor

 EVAPORATOR
• FALLING FILM EVAPORATOR
• REFRIGERANT INSIDE SHELL, WATER
INSIDE TUBES
• REFRIGERANT SPRAYED AT ABOVE EVAP
TUBE BUNDLE
• REFRIGERANT ABSORB HEAT FROM
CHILLER WATER
• LIQUID REFRIGERANT CHANGE STATE TO
VAPOR
 Falling Film Evaporator
refrigerant vapor chilled
liquid water
refrigerant supply
tube bundle

chilled
water
return
liquid level
sensor
 Unit Components

Tube Land Area And Tube Support

 CONDENSER
• WATER COOLED,SHELL AND TUBE
CONDENSER
• WATER INSIDE TUBES, REFRIGERANT INSIDE
SHELL
• CT WATER ABSORB HEAT FROM
REFRIGERANT GAS
• HIGH PRESSURE AND TEMPERATURE VAPOR
CHANGE STATE TO LIQUID
 water-cooled
Condenser
refrigerant vapor
baffle

cooling
tower subcooler
water
liquid
refrigerant
tube bundle
 EXV
• DUAL ELECTRIC EXPANSION VALVE
• DRIVEN BY EXV MODUL TO MODULATING
DISCHARGE SUPERHEAT
• INPUT LIQUID REFRIGERANT LEVEL AND
REFRIGERANT SATURATED TEMPERATURE
• CREATE PRESSURE DROP EVAP SIDE AND
CONDENSER SIDE
Dual EXV
Oil Separator

refrigerant vapor
to condenser

refrigerant vapor
and oil mixture

oil return to sump

 REFRIGERANT CYCLE

• USED R 134a
• QTY 490 lbs
 Refrigerants
• Commonly used refrigerant :

CFC-11 HCFC-123

CFC-12 HFC-134a

HCFC-22
• Ozone Depletion Potential
• Global Warming Potential
 Refrigerant Operating Pressures

HCFC-22

HFC-134a
pressure

atmospheric
pressure HCFC-123

Vacuum Area

temperature
 LUBRICATING CYCLE

• Used Trane Oil 48

• QTY 6 Galon
 Oil Supply System
oil rotor bearings
separator

refrigerant rotor
vapor to
condenser

oil tank compressor

sump master
solenoid 2 1
valve

oil filter
 Oil Filter Replacement
• Annually
• At each oil change
• After major repair (unit Overhaul)
• Or if erratic oil pressure is
experienced during chiller operation
 Methods of Compressor
Unloading
• Reciprocating Cylinder Unloaders
• Scroll Cycle On and Off
• Helical-Rotary Slide Valve
• Centrifugal Inlet Vanes

Variable Speed
 Slide Valve Operation
high-pressure
refrigerant vapor load unload
valve valve

to low-
pressure
compressor
slide valve housing
operator
shaft
spring piston cylinder
 compressor...
Helical Rotors
Cut View
 Slide Valve

discharge
port

slide valve slide valve

(closed)
(open)
to suction

valve
opening
part
full load load
 compressor capacity control...
Unloading

compressor
discharge
slide valve
to suction
open
radial port

valve
opening
 START CHILLER
• RUNNING EVAP WATER PUMP ,CHECK PRESSURE DROP
CROSS EVAP
• RUNNING CONDENSER WATER PUMP , CHECK PRESSURE
DROP CROSS CONDENSER
• RUNNING COOLING TOWER FAN
• RUNNING LOAD (AHU OR FCU )
• CHECK CHILLER WATER SET POINT
• CHECK CURRENT LIMIT SET POINT
• IF ALL ITEM ABOVE STABLE PRESS AUTO CHILLER WILL
AUTO RESETING THAN START
• AFTER RUNNING STABLE TAKE LOG SHEET
 SHUT DOWN CHILLER
• PRESS BUTON STOP ONE TIME, CHILLER WILL
UNLOADING THAN STOP THE COMPRESSOR
• AFTER COMPRESSOR STOP, WAIT 1 MINUTE
BEFORE STOP EVAP AND COND WATER PUMP
 DAILY MAINTENANCE
• CHECK CHILLER WATER TEMP
• CHECK COOLING TOWER WATER TEMPERATURE
• CHECK EVAP AND COND REFRIGERANT PRESSURE
• CHECK EVAP AND COND REFRIGERANT TEMPERATURE
• CHECK SUCTION SUPERHEAT
• CHECK AMPERE AND VOLTAGE
• CHECK PRESSURE DROP EVAP AND COND WATER
• TAKE LOG SHEET
 POINTS

• EVAP PRESSURE ; 35-55 psig ( 240-380 kpa )

• COND PRESSURE ; 80-120 psig ( 550-850 kpa )
• LIQUID LEVEL -1 inch to +1 inch
• DISCHARGE SUPERHEAT 17 F
• SUBCOOLING 5-10 F
• EXV % OPEN 40-50 %
 WEEKLY MAINTENANCE

• DO DAILY MAINTENANCE
• ROLLING/ SQUENCING CHILLER
• ANALYSING LOG SHET LAST WEEK
 THREE MONTHLY MAINTENANCE
• TEST INSULATION MOTOR COMPRESSOR
• LEAK TEST
• CHECK ELECTRIC CONNECTION
• CLEAN CONTACTOR AND RE TIGHTENED
CONNECTION
• CHECK OIL LEVEL
• CLEAN PANEL FROM DUST
• CHECK AND TEST FLOW SWITCH
• CLEAN STRAINER EVAP/COND WATER PUMP
 POINTS

MEGAR READING MINIMUM 5

MEGA OHM, USE 500 VOLT MEGAR
OIL LEVEL MINIMUM 2 inch
NORMAL 2 - 5 inch
Max oil level 8 inch
SIX MONTHLY MAINTENANCE
• OIL ANALYSIS
• TEST INSULATION MOTOR
COMPRESSOR
• LEAK TEST
• CHECK AND CLEAN CONTACTOR
• RE TIGHTEN ALL ELECTRICAL
CONNECTION
• CHECK OIL LEVEL
• CHECK AND TEST FLOW SWITCH
• CHECK PARAMETER PROGRAM
 ANNUAL MAINTENANCE
• OIL FILTER REPLACEMENT
• OIL REPLACEMENT/ BASED ON OIL
ANALYSIS
• CLEANING EVAPORATOR TUBES
• CLEANING CONDENSER TUBES
• CHECK SENSOR ACURACY
• CHECK PARAMETER PROGRAM CHILLER
 HAL - HAL YANG PERLU
DIPERHATIKAN

– Condenser Entering Temperature = 30 0 C ( Min 270C )

– Condenser Leaving Temperature = 35 0 C
– Evaporator Pressure Drop = 0,2 bar
– Condenser Pressure Drop = 0,5 bar
– Oil Level Sensor ( Status ) Wet
– Evaporator Water Flow Flow
– Condenser Water Flow Flow
– Oil Differential Pressure Closed
 maintenance considerations
Mechanical Components
• Other design-specific requirements:
– Change oil when oil analysis dictates
– Replace oil filter periodically
– Replace oil return filter from evap periodically
– Vibration test analisis
 maintenance considerations
Heat Transfer Surfaces
• Recommended
maintenance
– Use a qualified water
treatment specialist
– Clean condenser and Evap
tubes as needed
– Clean water-side strainers
– Eddy Current Test tubes
every 3 years
Oil Sample Bottle

CAPS
 OIL SAMPLE MEASURED COMPONENT
Moisture : Leakage problem, contaminated oil or refrigerant
Acid : Result of chemical reaction between oil , rfgt, moisture
accelerated by heat
Aluminum : Impellers, seal
Chromium : Motor shaft
Copper : System piping, condenser, evaporator (followed by mois-
ture and acid)
Iron : Oil pump, stator lamination and rust
Tin : Main bearings, solder
Lead : Solder
Zinc : Sealing compound or eliminators
 Notice

• Do not jumper flow switch.

• Do not stop chiller by stop chiller water pump.
• Do not reset alarm by switch off power control.
• Do not press stop button twice in 3 second unit
will panic stop.
• Approach evap and condenser max 3 Celsius
near zero more better.
 Rule of Thumb
• Evaporator approach max 6 F
• Condenser approach max 6 F
• 1% oil in refrigerant: 2 % loss in efficiency
• 1F of additional lift :1,5% loss in efficiency
• 1 psi air in condenser : 3 % loss in efficiency