Maintenance Considerations chiller trane 2

Maintenance  Considerations

chiller trane 2

chiller trane 2

maintenance considerations
Mechanical Components
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▲ Other design-specific requirements
◆    Change oil when oil analysis dictates
◆    Replace oil filter periodically
◆    Replace filter drier periodically
◆    Clean oil strainers annually
◆    Check shaft alignment annually
◆    Check coupling annually
◆    Replace shaft seal every 2 to 4 years
◆    Compressor teardown inspection every 5 to 10 years

Some centrifugal compressor designs do require periodic maintenance of mechanical system components. This includes oil and refrigerant filter changes, oil strainer changes, and a compressor inspection.
Open-motor compressor designs require shaft alignment, coupling inspection, bearing lubrication, and cleaning of the motor windings on a quarterly or annual basis.
In all cases, strictly follow the maintenance requirements and recommendations published by the manufacturer.

maintenance considerations
Heat Transfer Surfaces
 

▲ Recommended maintenance
◆    Use a qualified water treatment specialist
◆    Clean condenser tubes as needed
◆    Clean water-side strainers
◆    Test tubes every 3 years
To ensure optimum heat transfer performance, the heat transfer surfaces must be kept free of scale and sludge. Even a thin deposit of scale can substantially reduce heat transfer capacity. Engage the services of a qualified water treatment specialist to determine the level of water treatment required to remove contaminants from the cooling tower water.
Scale deposits are best removed by chemical means. During this process, the water-cooled condenser is commonly isolated from the rest of the cooling- tower-water circuit by valves, while a pump circulates cleaning solution through the condenser tubes.
Sludge is removed mechanically. This typically involves removing the water boxes from the condenser and loosening the deposits with a stiff-bristled brush. The loosened material is then flushed from the tubes with clear water. As part of this procedure, the strainers in both the chilled-water and cooling-tower- water circuits should be cleaned every year.
Every 3 years (more frequently in process or critical applications), a qualified service organization should perform nondestructive inspections of the evaporator and condenser tubes. The eddy-current tube test is a common method.

Rarely, problems may arise that cause refrigerant or water leaks. These must be repaired immediately.

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

Oil analysis is an important annual maintenance task required for centrifugal water chillers. It may be conducted more frequently for chillers that run continuously or more often than normal. This test, performed by a qualified laboratory, verifies the integrity of the refrigeration system by testing the concentrations of moisture, acidity, and metal. This analysis can determine where problems exist or could potentially develop. By taking oil samples on a regular basis, normal operating trends for the compressor and bearing metals can be analyzed. Instead of adopting a “change the oil once a year whether it needs it or not” approach, regular oil analyses can be used to determine proper oil change intervals and predict major problems before they occur.
Refrigerant analysis measures contamination levels and determines suitability for continued use. It can also determine if recycled refrigerant is suitable for reuse. Refrigerant analysis helps extend the life of the existing charge and ensures that the chiller is operating at peak efficiency.

Regularly logging oil and refrigerant charges, and examining the trends of this data, can help identify potential problems before they occur.

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

An oil analysis is a key preventive maintenance measure and should be conducted at least annually. It will help the compressor last longer while maintaining chiller efficiency and reducing refrigerant emissions.
A certified chemical laboratory can be contracted to perform the analysis for all types of compressors. Often the chiller manufacturer can provide this service.


 
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