Saudi Chiller Commissioning

Man commissioning a chiller in Saudi wareing head gear

Saudi Chiller Commissioning

We arranged the trip to carry out Saudi chiller commissioning for our Company Director and overseas engineer Dave Thompson. 2x 500kw air cooled chillers had been positioned at high level on a gantry. These were at the back of a newly constructed building at a factory in Jeddah. The factory produces plastic water pipes used for buildings and industry. Their own pipework, produced onsite, was used for the water systems of the plant in this article.

Water System Check Valves

There are two underground water system reservoirs for the plant. A check valve is fitted below the water line on the inlet pipe feeding all of the pumps. This ensures that water is available to the pumps on start up, despite the reservoirs being below the pumps.

Saudi Chiller Commissioning of Chiller Pump Set

The chiller pump set sucks water from the underground chiller reservoir. It then discharges the water through a plate heat exchanger, then it flows up to the chillers. The chilled water then returns 5°C cooler back to the underground chiller reservoir.

Saudi Chiller Commissioning of PHE Pump Set

Another pump set sucks from the separate underground process reservoir and discharges through the other side of the above mentioned plate heat exchanger. The water is chilled by around 5°C which can be adjusted with a pressure regulating valve on the outlet of the PHE. This chilled water then returns to the underground process reservoir.

Saudi Chiller Commissioning of Process Pump Set

A third pump set also sucks from the above mentioned underground process reservoir. It then discharges up to a ring main which goes along the top of 6 lines. Then, it drains down into plastic extrusion moulding machines to cool the newly formed plastic pipe. It does this at just the right rate to prevent bending and distortion. After this, the chilled water drains at gravity pressure back into the underground process reservoir.

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Control Panels for Pump Inverters

All of the pumps run on inverter drives which saves a significant amount of electricity. These drives are located in three panels- one for each pump set. A spare inverter is available in each panel for easy switch over in the event of failure. A touch screen pump control display is fitted to each panel. Each display is wired into a PLC.

Touch Screen Central Control

The PLCs in each panel are in turn wired into a Schneider Electric touch screen central control interface. This is located on the front of the middle panel. All of the analogue sensor and transducer inputs are wired into this interface from around the plant. The underground process reservoir temperature sensor was found to be reading 4°C high, so an offset was put into the program. The digital outputs go from here to the various components around the plant.

3 Way Valve

One of these components is a 3 way valve on the plate heat exchanger. This valve regulates the percentage flow of water through the PHE, relative to the percentage of bypass to the chillers. In high load conditions, 100% of water is pumped through the PHE. With no load, 0% of water goes through the PHE with full bypass to the chillers. In a low load condition, the valve modulates at between 0% and 100%. All of these scenarios achieve a close control of 20°C in the underground process reservoir.

Saudi Chiller Commissioning of Filtration Systems

Chiller Evaporators

The chiller evaporators are protected by a ‘y’ strainer on each inlet.

PHE Chiller Side

The plate heat exchanger also keeps contaminants from the process reaching the evaporators of the chillers. This prevents the premature failure of the evaporators and also prevents heat exchange issues due to thermal insulation.

PHE and Process Bollfilter

Both of these water systems go through a Bollfilter back flush system. As the difference in pressure between filter inlet and outlet reaches a predetermined level, the back flushing operation is initiated with a green light being illuminated. This feature prevents the need to manually clean the filter at scheduled intervals. During the visit, however, these filters were overwhelmed by the residue left in the pipes and a narrow 100 micron filter size. The maximum difference in pressure was exceeded and the filtration system yellow warning light became illuminated. The filters were stripped down, cleaned and reassembled.

‘Y’ Strainer in Parallel

The factory engineer who had designed the system had the foresight to build a second filter into the water system. This ‘y’ strainer runs in parallel to the above Bollfilter and ensures seamless operation of the factory in the event of a blocked Bollfilter.

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Start Up during Saudi Chiller Commissioning

On first start up of the chillers, they were both found to be tripping on high pressure and not loading up. The chillers run on R134a which is a low pressure refrigerant in the UK. In Saudi Arabia, however, the ambient is around 40°C. This translates to an operating pressure of between 15 bar and 18 bar depending on loading and water temperature.

Loading Solenoids

Unloader switches are available on each system. These feed back to the PLC, from here the program energises the loading solenoids. They had been set to 14 bar which was the cause of the unloading issue. Our overseas engineer set the switches to 19 bar.

High Pressure Switches

He then changed the high pressure cut outs from 15 bar to 20 bar.

PRVs Checked during Saudi Chiller Commissioning

The pressure relief valves vent at 23 bar which is enough of a difference in pressure from the high pressure cut out.

Low Load Trips

Because only one line was running at the time of commissioning, one of the chillers was found to have tripped on a low temperature related trip. This fault had occurred the following morning when the water temperature had become too low due to the minimum run time of the compressors. The freeze up set point was also found to be too high at 7°C. Our overseas engineer entered a password into the front end of each chiller and modified the parameters to prevent this fault re occurring.

Full Load Testing

The water system temperature was allowed to build up to 30°C when production in the factory was offline. Then, the chillers were ran in anger until set point was achieved. An efficient superheat value of 3°C was recorded on all of the systems. This is due to electronic expansion valves being fitted. When the factory came back online, the systems were found to be off cycling or unloading to match the load.

Chiller Redundancy

Redundancy has been considered in the capacity of the chillers to allow for future factory expansion and systems being offline during repairs.

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400 kw white chillers with panels open during air cooled chiller maintenance

Air Cooled Chiller Maintenance

A nice day to carry out air cooled chiller maintenance at a new site we have taken over in the South East.

News Article No.6

Our engineer attended site at around 9am with the risk assessment method statement having been sent in advance. A site survey was carried out to see if there were any additional risks. Should there have been any changes- the RAMS have a section for the additional risks and control measures. After gaining a permit to work, our engineer was issued with a security pass to access the chiller compound. Three chillers are located in the compound which feed air handlers for a critical application. Two of the chillers are multiple system, scroll compressor, air cooled chillers. The other is a single system screw chiller.

Program Settings During Air Cooled Chiller Maintenance

A complete download of the program settings is available in our engineer’s phone. This is to cross reference the settings, should one of them be accidentally changed by the maintenance engineers. On site engineers are the first port of call for chiller trip outs, with the responsibility to get the plant up and running. We offer real time assistance, over the phone from our Technical Support Desk and can send user manuals in PDF form, direct to their computer. The settings were found to be nominal, so a detailed analysis of the alarm history was carried out:

Alarm History During Air Cooled Chiller Maintenance

In reverse date order, the alarm history of all the systems was interrogated. There had been several system shut downs to carry out the periodic maintenance by the onsite personnel. The electricity having been shut down, there was a subsequent oil pre heating timer in the history too. On Chiller 2, System 1 however, there had been several low pressure trip outs. Our engineer decided to start the maintenance with this system by carrying out a full diagnosis of the low side of the refrigerant system:

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Superheat During Air Cooled Chiller Maintenance

The system runs on R410a refrigerant. This refrigerant has higher operating pressures in comparison with other HFC refrigerants. It has an efficient temperature range which can be seen on a pressure enthalpy chart. Below or above this range- the refrigerant loses efficiency and so has a lower coefficient of performance. The most common saturation point for this refrigerant is 0°C which corresponds to a 7 bar suction pressure in the evaporator. Above this is the superheat of the refrigerant returning to the compressor. On this occasion there was found to be 26°C of superheat and a suction pressure of 4 bar- close to the low pressure trip out. After careful diagnosis, our engineer decided to focus his attention on the expansion valve:

Thermostatic Expansion Valve

There are 4 forces acting on a TEV:

Liquid line pressure coming from the condenser.
Versus
Suction pressure down the equalising line from the far side of the evaporator. This compensates for the pressure drop across the evaporator and shows the true compressor side pressure.

Spring pressure acting upwards and closing the valve.
Versus
Bulb pressure forcing the valve open.

To reduce the superheat, the bulb should have forced the valve open. The refrigerant charge in the bulb acts upon the bellows to achieve this. The reason for the malfunction, on this occasion, was found to be the failure of the expansion valve orifice. It had become jammed- causing a shortage of refrigerant in the evaporator and high superheat.

Latent Heat

Our engineer was carrying out the above fault finding with one compressor running and the other two being held off. This was to prevent a low pressure trip. Where chillers are left running with a high superheat condition, the reduced amount of latent heat causes a higher cost in electricity relative to refrigeration effect (COP) The refrigerant carries on superheating without absorbing latent heat- pointless and inefficient for a chiller.

Chiller Pump Down

For convenience, this chiller can be pumped down and valved off using the service valves. The evaporator can be worked on after breaking in procedures are carried out. Therefore, we have arranged for this to be carried out before fitting the new expansion valve parts. These chillers also have the ability to pump down the refrigerant on receiving a fault feedback from the electronic leak detector. This is an added measure to lower the environmental impact of refrigerant leaks.

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Subcooling During Air Cooled Chiller Maintenance

This is cooling the refrigerant vapour down, through the latent heat phase and then subcooling the liquid down further. On System 2 of the same chiller, a subcooling issue was identified. 21 bar/ 36°C saturation was normal for that system as defined by the fan speed controller. Now, the system pressure was higher at 28 bar/ 47°C saturation, so our engineer decided to work out the subcooling. A very high reading of subcooling was recorded at 28°C this was diagnosed to be due to non condensables in the refrigerant:

System Non Condensables

Non condensables are gases that will not condense, such as, air and nitrogen. If nitrogen is not vented properly and a deep vacuum then achieved, the gasses will remain in the refrigerant system. When calculating the subcooling, the readings work out incorrectly due the presence of the gasses. This can lead to false diagnosis. The remedy for the issue was to arrange a full refrigerant decant, pressure testing and dehydration, before charging with new refrigerant.

Efficiency

Having good subcooling values on a refrigerant system is critical to efficiency. Where there is no subcooling- the refrigerant has not fully rejected all the latent heat from the condenser. This can be seen when looking at a PH chart and plotting the pressures and temperatures. This heat remains in the refrigerant and adds to the system along with heat added from the compressor and heat from the process. This is another reason the coefficient of performance is reduced and so incurring increasing electricity costs for the plant.

Economizer

These chillers are also fitted with refrigerant economizers- one for each system. They work by diverting some of the refrigerant from the condenser, through a small expansion valve, then through a plate heat exchanger. The rest of the liquid refrigerant passes on the other side of the plate heat exchanger and so is further subcooled.

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Chiller compressor failure of blue Grasso in enclosure

Chiller Compressors

System Testing for Chiller Compressors

Chiller compressors fail often as a result of ineffective servicing and system testing. At Maximus Chillers, we carry out extensive tests during our visits to ensure that small problems are resolved before they become big problems. If we notice a reading starting to become abnormal, we can carry out the diagnosis and then remedy the problem. Some of the compressor readings we monitor are:

Temperature of Chiller Compressors

The suction, discharge, motor windings and bearing temperatures are recorded for comparison to previous visits. These are often available in the PLC for the chiller, or our engineer can take the readings with his test equipment. Problems with the oil cooler can be the cause of higher compressor temperatures, the system running outside of its nominal operating conditions is another reason. Magnetic drive systems have an advantage as they do not use oil.

Accelerometer

Portable vibration sensors are carried in of each of our company vehicles. This is an accelerometer to measure vibration. Along with other system readings, we keep an on going record of the vibration levels around the compressor. When internal components are coming out of alignment due to wear, this causes an out of balance condition in the compressor. This, in turn, causes a knock on effect- causing other components to go out of balance. Catching this condition early will prevent a compressor smash up resulting in the replacement of expensive internal components.

Oil Analysis for Chiller Compressors

Another way of preventing big problems from occurring is periodic compressor oil testing. Samples are taken, usually on alternate visits, which are sent off to a laboratory for analysis. The acid level is tested to provide pre warning of a potential compressor motor windings burn out. This is because acid in the compressor oil rots through the electrical insulation on the motor windings. The presence and quantity of white metal and yellow metal is analysed too. This is a window through to a component starting to wear inside the compressor.

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Screw

The compressor in the photo is a screw compressor. It operates with ammonia refrigerant. This refrigerant is usually used for low temperature applications, mainly associated with food production. This compressor, however, has a 1°C refrigerant saturation and is used to cool computer rooms. Common causes of compressor failure on this kind of compressor are:

Leaking Castings on Chiller Compressors

The various compressor components are sealed together using ‘o’ rings or paper gaskets. ‘O’ rings are especially prone to leaks due to work hardening and flattening of the sealing face. The system can be pumped down and the compressor valved off. Then, our lift and shift team can remove the compressor to our remanufacturing facility for strip down.

Leaking Shaft Seal

The mating surface of a shaft seal has a mirror smooth finish. This is to reduce friction and aid with a better seal. Over time, this starts to wear, causing an ineffective seal with a leak of refrigerant and oil. A service visit can be arranged to change the shaft seal on site. The shaft couplings can be split, the shaft seal can then be removed and replaced. A quick job, then the machine is up and running again.

Slide Valve Potentiometer

This is an electronic device with a slide attached to the moving compressor slide valve. The device has a start and an end position programmed into it during commissioning. The potentiometer converts the slide valve position, usually into a 4-20mA signal which is fed back to the chiller PLC. They are prone to reading out, or the reading being jammed in one position. This results in a trip out from the controls, as the controller is not able to determine the true position of the compressor slide valve. We have an off the shelf stock of slide valve potentiometers for the various compressor range. A service visit can be arranged to replace the part after diagnosis has been carried out. The controls operate the loading and unloading solenoid valves to change the position of the slide valve.

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Centrifugal

Centrifugal compressors are a very reliable kind of compressor but when they go wrong, they can go wrong in a big way. Compressor overhaul is expensive, this can be carried out onsite, or a better option is a lift and shift to our remanufacturing facility. Proximity sensors are usually fitted to monitor the distance between the impeller and the casting. This is an added protection along with the other sensors and transducers around the compressor.

MCS

We are on account with Micro Control Systems- an American company who specialise in building panels to order for specific chiller compressors. We easily fit this control system to any compressor to control the loading of the vanes in accordance to the available load from the process. The control panel has previously been fitted to other machines of the same model number, so any teething issues have already been ironed out. Maximus Chillers can achieve seamless operation of your plant.

Oil System for Chiller Compressors 

Newer centrifugal compressors are oil free so as to eliminate any of the service issues relating to oil. There are a substantial amount of compressors, however, that use oil to lubricate the bearings. This kind of compressor, if properly serviced, can last for 50 years. The oil system picks up impurities which are caught by various filters. These filters can be changed or cleaned according to the prescribed service schedule. Our engineers make sure that spares are ordered and kept onsite prior to a visit.

Cost Effective

Our visits and ongoing upkeep of your plant saves money. Money spent as a preventative measure saves so much more money in the long run. With competitive prices on specialist internal centrifugal compressor parts- Maximus Chillers completes the picture. When compressor failure occurs, you are in safe hands with years of industry experience invested in each of our engineers.

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Scroll

These are some issues affecting a scroll compressor:

High Discharge Pressure

With high discharge pressure, there is a corresponding increase in discharge temperature. This means that the compressor is operating beyond its recommended values. The cause of this is often a poorly maintained condenser. Especially on industrial chillers, there can have been gaps in the schedule where the condenser was not correctly serviced. This condition is often rectified easily by an onsite engineer by giving it a brush down. Where the fins are bent over- we carry a specialist tool to straighten them back out- how they came out of the factory. We also use different formulas of chemicals to rinse the various kinds of dirt from deep within the fins.

High Suction Pressure on Chiller Compressors 

Some chillers are used where very high water temperature can come back from the process if the chiller were to be off line for a short period. Usually, this happens in factories where certain industrial processes are being carried out. When the onsite engineers start the plant back up, the chiller experiences a high heat load to deal with.

MOP Expansion Valves

Maximum operating pressure expansion valves limit the pressure in the evaporator to a given level, regardless of the available heat load from the process. They do this by having a limited amount of liquid refrigerant in the bulb. When this runs out, the power element cannot push the orifice open any further- thus limiting the suction pressure. This is important to prevent scroll compressor failure as it prevents putting added strain on the compressor motor windings due to high suction pressure.

Oil and Refrigerant Shortage

Where there is a shortage in refrigerant, there follows a low oil level condition. The refrigerant mass flow rate carries the oil around the system and back to the compressor. This is greatly impaired when the chiller is short of gas. The oil cools the compressor and lubricates the shaft bearings. These bearings and other internal components wear down and seize causing failure. Maximus Chillers can put together a package to minimise chiller compressor failure.

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Carel controller and tick sheet during chilling plant maintenance visit

Chilling Plant Maintenance Visit

On this chilling plant maintenance visit, particular attention was made to compressor loading. This was to ensure that the compressors are capable of operating at 100%. With summer now here- we want the plant capable of running at full capacity.

Controller Loading Timer

On start up, the controller goes through a timer, this is to prevent the compressor from loading up too quickly, achieving set point and going off. With available load, the compressor would start back up and go into a short cycling condition. With 5 minute intervals, the controller brings System 1 screw compressor on at 25%. Then System 2 screw compressor on at 25%. In stages, the controller loads up the compressors until it matches the load.

Compressor Loading Solenoid Coils

These are 24vac. The controller sends out a run signal through the solenoid coil which magnetises the lift valve inside.

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Compressor Loading Solenoid Valves

As the valve lifts, discharge pressure oil passes through a channel and pushes the slide valve open a 25% stage. There are 4 valves for the 4 stages.

Chilling Plant Maintenance Visit at 100%

The chilling plant being maintained on this visit was now running at 100% on both systems. The system readings can easily be read by following the menu in the Carrel controller. Superheat and subcooling readings were found to be within normal operating limits. Also, a good read back was recorded on the water system.

Compressor Unloading

At the end of the day, the three way valves on the air handlers closed down according to the BMS schedule. This meant that the water was diverted away from the heat exchangers in the air handlers. This return water had not picked up any heat, so the controller started unloading the compressors. It did this through 75% to 50% then 25% until the water system was down to setpoint.

Off Cycle at Chilling Plant Maintenance Visit

The BMS stops the chiller with the remote start/ stop signal. Should the BMS malfunction, the chiller would stay off most of the night anyway. The water system pump adds heat into the water system. Therefore, every so often enough load would be available to bring one system on at 25% for a short while.

To read more about chiller compressor systems click the Tag at the top of the page.

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