Maintenance for Energy Efficiency

Transcription

1 Maintenance for Energy Efficiency Institute of Hospital Engineering, Australia (IHEA) Seminar Asset Management & Energy Efficiency Exclusive Trane distributor Australia/New Zealand. The TRANE trade mark is used by Dalkia Technical Services Pty Ltd under licence from American Standard.

2 System Maintenance Some interesting examples. American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

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19 System Maintenance Period One Maintenance Considerations American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

20 FACILITY REQUIREMENTS Think about your HVAC system and its application? How does the HVAC system contribute to the success of your operation? What are the short and long term objectives for your facility? How well does your HVAC system meet these objectives?

21 PROBLEM AREAS What type of breakdowns do you experience? When do you repair or replace failing equipment? What if problems aren t getting fixed the first time? What if you are experiencing excessive energy consumption? How can you tell if maintenance costs are excessive?

22 AUSTRALIAN STANDARDS AS Air Handling and Water Systems Of Buildings Microbial Control. Part 2: Operation and Maintenance Specifies the minimum requirements for the operation and maintenance of air-handling and water systems of buildings for the purpose of microbial control Excludes room air-conditioners and non-ducted split-systems Control of legionnaire s disease, Pontiac fever, Hypersensitivity Pneumonitis and Humidifier fever

23 AUSTRALIAN STANDARDS AS Maintenance of Fire Protection Systems and Equipment Supersedes AS Requirements for inspection, test, preventative maintenance & survey of fire & smoke control features of HVAC. Covered by AS1668.1, AS Section 18 Fire & Smoke Control Features of HVAC Systems Functionality & Performance Testing

24 AUSTRALIAN STANDARDS AS Exhaust Fans (Used in Day-Day Operation) Exhaust Fans (Dedicated to Fire Duty Only) Fire Dampers Smoke Spill Heater Bank (Duct or Unit Mounting) Kitchen Exhaust Systems Fire Isolated Exit Pressurisation Systems System Changeover Under Fire Condition

25 AUSTRALIAN STANDARDS SAA HB The Australian Refrigeration and Air-Conditioning Code of Good Practice. Part 1. Reduction of Emissions of Flurocarbon Refrigerants in Commercial and Industrial Refrigeration and Air-Conditioning Applications Developed with the intent of reducing emissions into the atmosphere (CFC R11, R12, R502. HCFC s R22, R134a, R407c) Maintenance, Recovery, Handling, Storage, Alternatives

26 AUSTRALIAN STANDARDS Web Site: -

27 The 5 Loops - Maintenance Period Two Application of Standards American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

28 maintenance considerations The Yellow Loop Airside Standard: - AS Scope: - Monthly inspection and cleaning of cooling coils and condensate trays Monthly inspection of return air filters Annual inspection of moisture producing equipment (cleaning where necessary) Equipment: - Air Handling Units Fan Coil Units Packaged Units Split Systems Ducted Split System High Wall American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

29 maintenance considerations The Yellow Loop Airside Standard: - Scope: - Equipment: - AS Requirements for inspection, test, preventative maintenance & survey of fire & smoke control features of HVAC. Covered by AS1668.1, AS Exhaust Fans (Used in Day-Day Operation) Exhaust Fans (Dedicated to Fire Duty Only) Fire Dampers Smoke Spill Heater Bank (Duct or Unit Mounting) Fire Control System Fire Isolated Exit Pressurisation Systems System Changeover Under Fire Condition American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

30 maintenance considerations The Blue Loop Chilled Water Standard: - Scope: - Equipment: - AS Scale Prevention Rust Inhibitor Chillers D.X. Packaged Units American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

31 maintenance considerations The Red Loop Heat Rejection Standard: - Scope: - Equipment: - AS Continuous Biocide (Control Organic Growth) Monthly Total Bacteria Count (Additional Dosing) Quarterly Legionella Testing Scale Control Rust Inhibitor Chillers Cooling Towers Evaporative Condensers American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

32 maintenance considerations The Purple Loop Controls No Standards Apply Recommendations Basic Computer Maintenance Monthly Data Backup Regular Virus Checks Clearing of Fault History Annual Rotating Service Sensor Drift Actuator Stroking Wiring American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

33 The Green Loop Chiller Maintenance Period Three Maintenance Considerations American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

34 maintenance considerations The Blue Loop Refrigeration Standard: - HB40 ASHREA Guideline 3 Scope: - Quarterly Leak Testing (over 50kgs per Circuit) Chiller Logging Equipment: - Chillers Split Systems Packaged Units American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

35 operating log ASHRAE Guideline 3 s s s s s s s s Chilled Water Inlet and Outlet Temperatures and Pressures Chilled Water Flow Evaporator Refrigerant Temperature and Pressures Evaporator Approach Temperature Condenser Water Inlet and Outlet Temperatures and Pressures Condenser Water Flow Condenser Refrigerant Temperature and Pressures Condenser Approach Temperature s s s s Oil Pressures, Temperature, and Levels Addition of Refrigerant Addition of Oil Vibration Levels American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

36 maintenance considerations Mechanical Components Additional Chiller Specific Considerations Clean Heat Transfer Surfaces (Water & Air Cooled) Change Oil when Oil Analysis Dictates Replace Oil Filter As Required Replace Filter Drier As Required Inspect Safety Controls and Electrical Components Tighten Electrical Connections American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

37 Manufacturers recommendations Demand Flow service American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

38 Manufacturers recommendations Demand Flow service American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

39 maintenance considerations Heat Transfer Surfaces Recommended maintenance Use a qualified water treatment specialist Clean condenser tubes annually Clean water-side strainers Test tubes every 10 years (maximum) American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

40 Fluid Analysis Oil Analysis Conduct annual analysis to verify system integrity Measure oil pressure drop to determine if filter needs changing Measure charge Refrigerant Charge Conduct analysis of refrigerant Inspect purge system American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

41 Oil Analysis Why perform regular oil analysis? Helps reduce maintenance costs Detects problems without compressor disassembly Extends service life of oil charge Reduces environmental problems related to oil disposal Helps maintain compressor efficiency and reliability Helps lower refrigerant emissions American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

42 Chiller Maintenance Period Four The Power Of Good Service American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

43 Centrifugal Water Chillers American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

44 TRANE -SERVICE REPORT CENTRIFUGAL CHILLER Model CVHG780 Chiller Name: Chiller No 1 Compressor Current Draw Refrigerant Type: R123 L1 (RLA): 95.58% Chiller Cooling Capacity: 2500kWr L2 (RLA): 95.58% Design Efficiency: L3 (RLA): 95.58% Motor/Compressor Data Chiller % Max RLA: 100% Consumed Power: 399kWe Compressor RLA: 606Amps Number of starts: 1145 Motor Winding Temps Compressor Run Time: 8653hrs Winding #1: 34.7 C Current Draw: 95.58% Winding #2: 34.6 C Discharge Refrigerant Temp: C Winding #3: 34.5 C Compressor Bearing Temp #1: C Evaporator Data Compressor Bearing Temp#2: EWT: C Oil Temperature: 56.5 C LWT: 6.00 C Oil Pressure (Low Side): C DT: 6 C Oil Pressure (High Side): 46.2 C Refrigerant Temp: 4.14 C Differential Oil Pressure: 108.3kPa Approach Temp: 1.86 C Compressor Voltage Refrigerant Pressure: kPa AB 416 Condenser Data BC 419 EWT: C AC 418 LWT: C Average 418 DT: 5.5 C Percent Imbalance 0.4% Refrigerant Temp: C Approach Temp: 1.78 C * Purge Unit Data Omitted Refrigerant Pressure: 38.50kPa

45 Chiller Running Normally American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

46 TRANE -SERVICE REPORT CENTRIFUGAL CHILLER Model CVHG780 Chiller Name: Chiller No 1 Compressor Current Draw Refrigerant Type: R123 L1 (RLA): 100% Chiller Cooling Capacity: 2500kWr L2 (RLA): 100% Design Efficiency: L3 (RLA): 100% Motor/Compressor Data Chiller % Max RLA: 100% Power Consumed: 413kWe Compressor RLA: 634Amps Number of starts: 1145 Motor Winding Temps Compressor Run Time: 8653hrs Winding #1: 34.7 C Current Draw: 100% Winding #2: 34.6 C Discharge Refrigerant Temp: C Winding #3: 34.5 C Compressor Bearing Temp #1: C Evaporator Data Compressor Bearing Temp#2: EWT: C Oil Temperature: 56.5 C LWT: 6.00 C Oil Pressure (Low Side): C DT: 6 C Oil Pressure (High Side): 46.2 C Refrigerant Temp: 4.14 C Differential Oil Pressure: 108.3kPa Approach Temp: 1.86 C Compressor Voltage Refrigerant Pressure: kPa AB 416 Condenser Data BC 419 EWT: C AC 418 LWT: C Average 418 DT: 5.53 C Percent Imbalance 0.4% Refrigerant Temp: C Approach Temp: 2.98 C * Purge Unit Data Omitted Refrigerant Pressure: 43.25kPa

47 TRANE -SERVICE REPORT CENTRIFUGAL CHILLER Model CVHG1780 Chiller Name: Chiller No 1 Compressor Current Draw Refrigerant Type: R123 L1 (RLA): 100% Chiller Capacity: 2500kWr L2 (RLA): 100% Design Efficiency: L3 (RLA): 100% Motor/Compressor Data Chiller % Max RLA: 100% Power Consumed: 413kWe Compressor RLA: 634Amps Number of starts: 1145 Motor Winding Temps Compressor Run Time: 8653hrs Winding #1: 34.7 C Current Draw: 100% Winding #2: 34.6 C Discharge Refrigerant Temp: C Winding #3: 34.5 C Compressor Bearing Temp #1: C Evaporator Data Compressor Bearing Temp#2: EWT: C Oil Temperature: 56.5 C LWT: 6.00 C Oil Pressure (Low Side): C DT: 6 C Oil Pressure (High Side): 46.2 C Refrigerant Temp: 4.14 C Differential Oil Pressure: 108.3kPa Approach Temp: 1.86 C Compressor Voltage Refrigerant Pressure: kPa AB 416 Condenser Data BC 419 EWT: C AC 418 LWT: C Average 418 DT: 5.53 C Percent Imbalance 0.4% Refrigerant Temp: C Approach Temp: 2.98 C * Purge Unit Data Omitted Refrigerant Pressure: 43.25kPa

49 Fouled Condenser Tubes Fouled Condenser Tubes American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

52 TRANE -SERVICE REPORT CENTRIFUGAL CHILLER Model CVHG780 Chiller Name: Chiller No 1 Compressor Current Draw Refrigerant Type: R123 L1 (RLA): 100% Chiller Cooling Capacity: 2500kWr L2 (RLA): 100% Design Efficiency: L3 (RLA): 100% Motor/Compressor Data Chiller % Max RLA: 100% Power Consumed: 412kWe Compressor RLA: 633Amps Number of starts: 1145 Motor Winding Temps Compressor Run Time: 8653hrs Winding #1: 34.7 C Current Draw: 100% Winding #2: 34.6 C Discharge Refrigerant Temp: C Winding #3: 34.5 C Compressor Bearing Temp #1: C Evaporator Data Compressor Bearing Temp#2: EWT: C Oil Temperature: 56.5 C LWT: 6.00 C Oil Pressure (Low Side): C DT: 6 C Oil Pressure (High Side): 46.2 C Refrigerant Temp: 4.14 C Differential Oil Pressure: 108.3kPa Approach Temp: 1.86 C Compressor Voltage Refrigerant Pressure: KPa AB 416 Condenser Data BC 419 EWT: C AC 418 LWT: C Average 418 DT: 5.52 C Percent Imbalance 0.4% Refrigerant Temp: C Approach Temp: 2.99 C * Purge Unit Data Omitted Refrigerant Pressure: 53.00kPa

53 Non Condensables In System Non Condensables In System American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

57 Low Condenser Water Flow Low Condenser Water Flow American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

58 TRANE -SERVICE REPORT CENTRIFUGAL CHILLER Model CVHG780 Chiller Name: Chiller No 1 Compressor Current Draw Refrigerant Type: R123 L1 (RLA): 100% Chiller Cooling Capacity: 2500kWr L2 (RLA): 100% Design Efficiency: L3 (RLA): 100% Motor/Compressor Data Chiller % Max RLA: 100% Power Consumed: 406kWe Compressor RLA: 634Amps Number of starts: 1145 Motor Winding Temps Compressor Run Time: 8653hrs Winding #1: 34.7 C Current Draw: 100% Winding #2: 34.6 C Discharge Refrigerant Temp: C Winding #3: 34.5 C Compressor Bearing Temp #1: C Evaporator Data Compressor Bearing Temp#2: EWT: C Oil Temperature: 56.5 C LWT: 6.00 C Oil Pressure (Low Side): C DT: 5.5 C Oil Pressure (High Side): 46.2 C Refrigerant Temp: 3.47 C Differential Oil Pressure: 108.3kPa Approach Temp: 2.53 C Compressor Voltage Refrigerant Pressure: kPa AB 416 Condenser Data BC 419 EWT: C AC 418 LWT: C Average 418 DT: 5.53 C Percent Imbalance 0.4% Refrigerant Temp: C Approach Temp: 1.78 C * Purge Unit Data Omitted Refrigerant Pressure: 38.93kPa

61 Low Refrigerant Charge Low Refrigerant Charge American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

62 Total Cost of Ownership Period Five The Impact Of Poor Maintenance American Standard Inc Air Conditioning Clinic TRG-TRC010-EN

63 TOTAL COST OF OWNERSHIP Maintenance/Repair Expense Cost Time

64 Total Cost of Ownership A systems approach to maintenance services:- The cost of ownership is additive The cost of ownership is manageable The cost of ownership can be reduced

65 Total Cost of Ownership A systems approach to maintenance services:- Chillers contribute as much as 30% of a buildings energy cost A system needs to work in unison

66 Total Cost of Ownership Scenario 1 Fouled condenser tubes Increases energy consumption by 1-5% Measurable by deviations in condenser pressure from design

67 Total Cost of Ownership Scenario 1 Condenser is an open system that is exposed to the surrounding elements Contaminants settle in condenser thus reducing heat transfer Reduction results in increased energy use

68 Total Cost of Ownership Scenario 1 The bottom line, it is costing you money every minute of every day... COST PENALTY Capacity 2500 kw/kw Hours of operation 5000 Cost per kwh 0.06 Cost of Operation $120, Loss Co-efficient 3.1% Cost Penalty $123, $3,720.00

69 Total Cost of Ownership Scenario 2 Non condensable in the chiller Increases energy consumption by 1-5% Measurable increase in the use of purge and an increase amperage draw

70 Total Cost of Ownership Scenario 2 Pressure variances and lack of proper leak checking can lead to the introduction of noncondensable gases in the chiller Non-condensable gases can lead to larger problems

71 Total Cost of Ownership Scenario 2 The bottom line, it is costing you money every minute of every day... COST PENALTY Capacity 2500 kw / kw Hours of operation 5000 Cost per kwh 0.06 Cost of Operation $120, Loss Co-efficient 3.1% Cost Penalty $123, $3,720.00

72 Total Cost of Ownership Scenario 3 Low water flow and a lack of condenser water temperature control Increases energy consumption by 5-10% Pressure drop deviates from design, cooling tower does not provide relief

73 Total Cost of Ownership Scenario 3 Improper operation of chiller from design causes increased work by the compressor System performance is impacted

75 Total Cost of Ownership Scenario 4 Low refrigerant charge, improper oil level, fluid contamination. Increases energy consumption by 1-3% Approach temperatures indicate deviations from design

76 Total Cost of Ownership Scenario 4 Heat transfer and motor lubrication are reduced Chiller integrity is compromised

78 Total Cost of Ownership When you add it all up: TOTAL COST OF OWNERSHIP Condenser Fouling Non-Condensable Gases Water Flow Problems Low Refrigerant Charge Capacity 2500 kw/kw Hours of operation 5000 Cost per kwh 0.06 Cost of Operation $120, Loss Co-efficient 10.60% TOTAL COST PENALTY $132, $12,720.00

79 Total Cost of Ownership A systems approach to maintenance services:- A small investment in the chiller plant leads to real cash flow for operating a facility, Think about the potential on the airside...

80 TOTAL COST OF OWNERSHIP Maintenance/Repair Expense Cost Time