kabul hvac survey report rev 03 30aug14

7/24/2019 Kabul Hvac Survey Report Rev 03 30aug14

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CONTRACT NO. SGE500-10-C-0012 30 August 2014

PROJECT NO. XJ-MC-0001

30 August 2014 Page 1of 39

EMBASSY OF THE UNITED STATES

KABUL, AFGHANISTAN

MECHANICAL ENGINEERING

EXISTING CONDITIONS SURVEY

HVAC SYSTEM REPORT

FINDINGSAND

RECOMMENDED SOLUTION SETS30 August 2014

QAVI ENGINEERS (PVT.) LTD

HERAT, AFGHANISTAN.


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Table of Contents

Building Mechanical Systems

A. Summary 3

B. Existing Conditions 4

C. Equipment Observations 11

D. Equipment Readings, Various Dates (note Delta-T values) 18

E. Other Observations 22

F. Corrective Suggestions 23

G. Suggested Statement of Work 27

H. Request for Proposal 33

I. Curriculum Vitae

Mr. Mohammad Amin 34


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A. Summary

This HVAC report has been developed by the Qavi Engineering, Ltd (QEL) staff mechanical

engineer Mr. Muhammad Amin after a site visit 19 through 21 August, 2014, to the U.S.

Embassy, Kabul, Afghanistan.

The visit was requested by the Facilities Engineer Office, U.S. Embassy, Kabul. Mr. Amin was

escorted and assisted on site by a Facilities Staff representative, Mr. Scott Biffle.

Request for Assistance Mission Statement:

1. Conduct an existing conditions survey, HVAC systems

2. Focusing on the three HVAC air chiller units.

3. Determine causes for the failure of four (4) compressor units in a short period of time.

Mr. Amins Curriculum Vitae is at Section H. He has more than 25 years experience in the

design, installation, testing, operations, maintenance, overhaul, and repair of Carrier, York,

Trane, Honeywell and similar large scale HVAC and refrigeration plants and their integrated

digital control systems. Proof of certification, training and experience is available on request.

This is an initial report. It is limited to the three days timeallocated on site and the directed

Mission Statement. A cursory technical analysis is offered as are various remedies.

Due to the advanced state of disrepair and system imbalance as a result of the questionableinstallation of the water sprayer contraption on air-cooled chillers, a greater degree of

remediation efforts will be required. These will include the removal, descaling, and re-

installation of the condenser coils. Lubrication oils and their correct amounts will need to be

checked and re-established per spec. Then the drawing down, vacuuming, and recharging of

the system.

With knowledgeable, timely maintenance, the deterioration of the system in general and the

specific replacement of four (4) York compressor units could all have been avoidable.


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B. Existing Conditions

The following system equipment was identified: Air-cooled chillers, Pumps, Air Handler Units, Building

Monitoring System

Chillers

Three air-cooled chillers have been installed on the roof top of the Utility Service Building.

o York , Model YCAS0953EB

o York , Model YCAS0953EB

o AirStack, Multi-module Chiller, Model ASP-30A (9 Modules)

All chillers feed conditioned water to a common loop header.

Pumps

Primary and Secondary pumps circulate water in all chillers @ 1.3GPM/ton.

Primary Pumps

Armstrong

Baldor Electric Motor, 10 horsepower (HP)

Circulate water in all chillers

Quantity: 3; with 2 in operation, one on standby.

Capacity: 535 gallons per minute (gpm). Pump

details are mentioned below.


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Secondary Water Pumps

Armstrong

Baldor Electric Motor, 75 to 100 HP

Supply conditioned water to all Embassy Office Buildings (EOBs).

Quantity: 3; with 2 in operation, one on standby.

Characteristics: Variable Frequency Drive (VFD)

Capacity: 720gpm.

Action: these pumps pass conditioned water from the chiller loop to the Air Handler Units

(AHUs)

Secondary pumps circulate chilled water to the mechanical room in the existing Embassy OfficeBuilding (EOB).

And to the mechanical rooms in four (4) other buildings.

Air Handler Units (AHUs)


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Trane, 2-coil, 4-pipe System, with Humidifier, VFD, quantity 12


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York, Model No. DXSH5LASA46/50, quantity 1

The EOB is equipped with a total of

twelve AHUs.

All AHUs consist of two coils in a four-

pipe system.

One coil each for cooling and heating.


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All are equipped with a steam humidifier system.

AHU blower motors are VFD.

Building Monitoring System (BMS)

Siemens Building Management System.

Integrates and controls building

environment condition sensors with the HVAC

systems.


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C. Equipment Observations

York Chiller No. 1:

o Chiller operating parameter out of specified range

o Compressor mechanically and electrically damaged


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York Chiller No. 2.o Compressor mechanically and electrically damaged

o Suspected Cause A. The system is forced to operate outside of its design parameters.

It is possible the maintenance staff is unable to read the condition and make necessary

adjustments. This may be a lack of training, certification with the York system.

o Suspected Cause B. The summer cooling season presents peak system demands.

Without a full understanding of air conditioning system operation in general and the

York and AirStack system operational requirements in particular, someone concluded

the mounting of a water spray system would aid in performance. It doesnt. All three

chillers are designed for the climate, elevation, loading of Kabul. If properly operated

and maintained (the key), the three units can be made to function right up to the

maximum design parameters, even exceed them periodically. Without this necessary

technical understanding of cooling concepts, a shade tree logic attempt at systemenhancement was attempted: directly spraying water on condenser coils of chiller units

specifically designed to be operated in air. Even when using the cleanest, contaminant-

free water, build-up of scale on the condenser coil is inevitable. This build-up interferes

coil design heat transfer, adversely affects the velocity of the refrigerant, causes

insufficient circulation of refrigerant-borne lubricating oil, and results in the under-

lubrication and eventual, repeated failure of the lube-starved compressors.

o A second phenomenon is also present in this condition. It was noted little to no effort

was made to de-scale the coils. When coils become scaled-over, the scaling acts as

waterproofing and insulation. Overly-scaled coils prevent the water from providing the

expected evaporative thermodynamics. And, when in this cocoon condition water iswithheld, a dangerously high head pressure may result. This high head pressure

increases heat in the compressor headcalled Hi-Super Heatwhich also may cause

severe mechanical/thermal damage the compressor, leading to failure.

o A third phenomenon may be present. Water spraying may at times over-cool or

super-cool the refrigerant stream. This causes the refrigerant to convert from its

normal gaseous state back into a liquid prematurely. This liquid refrigerant may then

flood back into the compressor and damage the compressor mechanically.

o The compressors are not equipped with pumps to circulate lubricating oil. The system

refrigerant gas pressure difference is used to particulate lube oil where needed. In

these York chillers the lower tubes in the condenser coil gallery are designed to act as

the oil cooler. However, when streams of water are applied to the condenser coil

galleries, the galleries cool down, the oil in them over-cools. In this more viscous

state, the over-cooled lube oil loses the ability to be carried by the gaseous refrigerant

stream. Hence the lube oil cant be carried with full volume necessary to provide

designed lubrication to the compressor units as required. Under-lubricated, the

compressors face imminent mechanical damage.


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D. Equipment Readings, Various Dates (note low Delta-T values)

Tuesday, 19 August 2014

York Chiller No. 1.Ambient Temperature 34 C

Set Point 4.5 C

RCWT 10.1 C

LCWT 9.4 C Delta-T = 0.7 C

System No. 1 Status Running System No. 2 Status Off

Oil Pressure 15.70 bar Compressor electrically and mechanically damaged

Discharge Pressure 17.0 bar

Suction Pressure 4.70 bar

Compressor 96 Amps

FLA 54% FLA

System No. 3 Status Running

Oil Pressure 16.20 bar



Compressor 94 Amps

FLA 53% FLA

York Chiller No. 2.Ambient Temperature 35.6 C

Set Point 4.5 CRCWT 10.3 C




Discharge Pressure 17.0 bar Cooler Freeze-up

Suction Pressure 3.50 bar Condenser Tube Busted

Compressor 139 Amps

FLA 77% FLA


Oil Pressure 17.60 barDischarge Pressure 19.00 bar


Compressor 144 Amps

FLA 78% FLA


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Wednesday, 20 August 2014


Set Point 4.5 C

RCWT 10.6 C






Compressor 100 Amps

FLA 56% FLA





Compressor 98 Amps

FLA 55% FLA


Set Point 4.5 C

RCWT 10.7 C

LCWT 8.9 C Delta-T = 1.8 CSystem No. 1 Status Running System No. 2 Status Off




Compressor 142 Amps

FLA 79% FLA





Compressor 155 Amps

FLA 85% FLA


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Thursday, 21 August 2014


Set Point 4.5 C

RCWT 8.8 C






Compressor 89 Amps

FLA 50% FLA

Suction Line Temp 9.9 C

Discharge Line Temp 51.7 CSST 4.6 C

Suction Super Heat 5.3 C

S. D. T. 43.3 C

Discharge Super Heat 8.4 C

SV Steps 75

EEV 28.2%


Cooler Inlet Refrig. Temp. 3.7 C



Discharge Pressure 15.30 barSuction Pressure 4.01 bar

Compressor 89 Amps

FLA 50% FLA


Discharge Line Temp 49.4 C

SST 2.7 C


S. D. T 42.1 C


S.V. Steps 75

EEV 100%Suction Super Heat 5.3 C



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Thursday, 21 August 2014


Set Point 4.5 C

RCWT 9.1 C






Compressor 146 Amps

FLA 91% FLA


Discharge Line Temp 58.7 COil Temperature 45.5 C

SST -1.3 C


S. D. T. 48.1 C


SV Steps 75

EEV 16.4%




Oil Pressure 16.40 barDischarge Pressure 18.30 bar


Compressor 139 Amps

FLA 75% FLA


Discharge Line Temp 70.5 C

Oil Temperature 53.3 C

SST -0.4 C


S. D. T 49.1 C

Discharge Super Heat 24.2 CS.V. Steps 40

EEV 33.1%


Cooler Inlet Refrig. Temp. -0.3 C


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E. Other Observations

Water Make-up

Date Time Reading (US Gal.) Remarks

20AUG14 1230hrs 0702940

21AUG14 1130hrs 0706470

3,530

Make-up

requirement,

23 hours

Within 23 hours of plant operation a total of 3,530 gallons of water was lost somewhere.

This water was conditioned, that is, the plant chilled or attempted to chill this water volume.

Since new water is constantly being introduced, the chiller plant is being placed under additional

loading to achieve set point temperatures. The new water constantly changes the input

temperatures.


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F. Corrective Suggestions

Water Make-up

o It is imperative that a full length investigation of the chilled water loop be conducted.

o Determine the point or points of leakage.

o Reduce the volume of make-up water to that recommended as acceptable in the York

and AirStack system manuals.

o Correction of the leakage issue, reduction of the additional loads placed on the system

in having to condition the infused volume, will enable the system to reach design stasis.

o Thusly balanced, a much better result and more comfortable air temperatures will be

delivered to the recipient office environments.

o How to trace?

Approach A. Introduce a non-toxic, non-corrosive, inert coloring agent into

the chilled water loop. Where that color puddles or stains, there may be found

one of the leaks. Repair or replace failed components.

Approach B. If A fails, a visual pipe trace will be necessary.

Exposed pipe runs should be straightforward.

As-built drawings should assist in the identification of those runs that

may be above false ceilings or behind walls.

For those runs in channels underground, an optical inspection system

can be used between hand holes.

For those runs that may have been buried directly, excavation and

inspection will be required.

York Chillers- General

o The three-day analysis and interviews with interested parties concluded that the

greatest concern was with past and present breakdowns observed in York chiller

systems.

o How to overcome these problems presently and prevent them in the future is the

essence of this report.

o Chiller systems designed and manufactured by York have an extremely good reputation

in the professional HVAC community. They are robust and designed to operateoptimally in a variety of different temperatures quite nicely.

o The key to the Yorks, as with all chiller systems, is to have them correctly installed and

commissioned. At start-up, baseline values need to be recorded religiously, then

compared to York design parameters.

o After installation, it is just as important to listen to what the system is trying to tell you:

record the readings, determine if they are within parameters, understand how the unit

communicates its various components, know what the chiller microprocessors display,

understand the relationships of the components, their readings, and what is suggested

as a symptom when variances from the norms are detected.


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o These are moderately large chiller plants. They were designed and built by

professionals. Similarly, professionals, trained and certified, must be employed to

operate, communicate, evaluate, and mediate these systems.

o Otherwise the customer is left with Band-Aid fixes put on by amateurs in hopes of any

result anywhere above zero. This unfortunately has been demonstrated in the appalling

present state of the chiller systems at the US Embassy, Kabul.

o Correct operation and proper preventive maintenance are the two keys to success.

The systems report or present readings the competent operating technician

can read and understand. Variances from the norm as given in the operating

manuals present clues as to what is happening, what courses of action might be

needed, well before any failure occurs. Failing to be able to read or failing to

understand these clues has led to the present state of the Kabul chiller plant.

The chillers are designed to operate within a specific design parameter. It is the

operators job to keep the plant running within those parameters.

o Chiller Design.

In general, these chillers designed optimally to operate in an environmental

temperature of 35C ambient.

They will operate in higher ambient temperatures, just not as efficiently.

o External Factors.

Can adversely affect operations.

It is possible the climatological data could record ambient temperatures up to

45C, for short periods.

Chiller physical location can have an impact. No surprise, adequate air flow is important to air-cooled chillers.

Separation from heat-generating plant equipment is a plus.

Partial shading from direct suns rays is an easy measure and can, if properly

done, increase system efficiency.

Finally, rather than suffer the deleterious effects of spraying water directly on

the condenser coils (as has damaged the system severely thus far), a more

effective approach would be to reduce the temperature of the airflow beforeit

reaches the condenser coils. This can be done easily and inexpensively by the

installation of a honeycomb boundary wall. This wall is sprayed with water.

Properly shrouded, the chiller fans will pull air through this evaporative cooling

device. When this air actually gets to the condenser coils, it will be several

degrees cooler. Hence the system should operate more efficiently, and, with

the benefit of no condenser coil or fin de-scaling sessions necessary.

This technique is simple, inexpensive, low tech, and a much safer method to

optimize chiller efficiency within its design parameters.

York Chiller No. 1, suggested improvements.

o Remove all spray systems.

o Professionals must be engaged to perform proper preventative maintenance

o Replace the damaged compressor

o Changeout all temperature sensors and transducers, and calibrate properly


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o Cooler tubes must be broken down for further investigation, normal procedure for an

open-loop system of this age.

o Of concern is the present state of imperfect fluidic balancing (only water added, no

glycol or corrosion inhibitors)

o If found to be corroded, replace; if calcified, de-scale.

o Flush the system.

o Institute proper fluidics balancing (water, glycol, inhibitors, etc.)

o Exterior surfaces of the condenser coils exhibit extreme (sprayed) water mineral build-

up. Remove and de-scale in accordance with York recommendations. Use the proper

de-scaling agents and procedures. Do not guess.

o All unit electrical contact points exhibit arc pitting (material fusing and transfer). Rather

than try to file, it is advised these points be replaced and re-gapped.

o Remove and replace all volumes of compressor oil, using only materials meeting

manufacturers specifications. Do not guess.

o Remove and replace all filter dryer elements with only specified components. Do not

substitute.

o Remove, thoroughly clean, and perform second- and third-level maintenance on all

condensers fan motors.

York Chiller No. 2o All issues identified in York Chiller No. 1have been repeated in this unit. Please read

and apply the above. Additional issues follow, below.

o System No. 2. The compressor has been damaged electrically and mechanically. Forcausality please see Section C. Equipment Observations, above. While this could have

been completely avoided with proper O&M, now, this unit, unfortunately, shall need to

be replaced.

o System No. 2. The condenser coils have been damaged with one tube completely burst

due possibly to overly high head pressure. Again, it could have been avoided, but now

shall need extensive repair or replacement.

o System No. 2. The cooler tubes appear to have been damaged as a direct result of the

expansion by freezing of apparently unconditioned fluidics. A repair might be possible.

Proper O&M of the fluidics in the future imperative. With attention to lab test results

and a proper balancing of the fluidic chemistry, all this damage could have been

avoided.

o Systems No. 1 and No. 3. It was reported both system compressors were recently

replaced on Aug 13, 2014. Neither has been calibrated.

o All Systems. Temperature sensors and pressure transducers need testing. If good,

calibration; if failed, replacement and calibration.

o System No. 2. Electronic Expansion Valve (EEV). Missing. Acquire one with proper

specifications and install.

o Chiller Sub-cooler System. This needs attention: the servicing and the replacement of

the thermostatic expansion valve (TXV) system.


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o Condenser Fan Motors (how many?). These units are damaged; repair or replace;

could have been avoided with proper maintenance.

o All Systems.

Replace filter-dryer cores.

Change (compressor?) oil with materials meeting specifications.

Electrical contacts points are pitted need to be replaced. Do not try to service

or attempt to calibrate unless trained and certified to do so.

o Refrigerant.

Charge the system only with Freon 407C exactly meeting the manufacturers

specifications.

Test the refrigerant for quality beforecharging.

Airstack Multi-Module Chiller

o This chiller consists of nine (9) modules .

o At the time of the field inspection, all were operating nicely, except one.

o The unit damaged is Module No. 4, rear side. See photograph. High Pressure (HP)

reading is zero.

o This modulescompressor has been damaged. Please refer to the operations log to

determine when this unit failed and the assessment why. The unit shall need to be

replaced.

o Failed compressor technical description:

Trane

3D Scroll-type Model No. CSHA150KOEOL / Part No. COM08014

3-phase, 400 Volt, 50Hz

LRA170 14.7 HP.

o Change the filter dryers after compressor replacement.

o Vacuum down for 36 hours.

o Use Freon 407C, verified to meet manufacturers specifications.

o Do not guess.


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G. Suggested Statement of Work

York Chiller No. 1o General.

Disconnect Chiller Power Supply (Electrical)

Establish safe working area; post safety caution signs on chiller and caution

table around the chiller work area

Disconnect water supply

Recover refrigerant and oil following EPA protocols using refrigerant type

unique servicing tool set.

Properly store recovered refrigerant and oil

o CONDENSER OIL

Dismantle condenser fan motors, cover and guards

Disconnect fan motor electrical connections

Disconnect all welding joints

Disconnect all condenser coils from chillers

Perform all maintenance operations on condenser coils, inside tubes, and

outside the coils

De-scale as necessary by flushing with approved chemicals in accordance with

manufacturers specifications. Dry with nitrogen.

Reassemble the condenser coil package back into the chiller

Re-weld joints; validate weldments

Perform detailed maintenance on all condenser fan motors.

Reinstall all condenser fan motors.

Test.

o CHILLER STRUCTURE

Remove scaled from chiller structure

Sand, prime and paint as necessary.

o SUB-COOLING HEAT EXCHANGER AND THERMOSTATIC EXPANSION VALVE, EEV

Dismantle sub-cooling heat exchanger

Disconnect all welded joints

Disconnect all valves (TXV and EEV) Service and maintain in accordance with manufacturers protocols and

specifications.

Test, repair, replace if defective

Reassemble components.


o COMPRESSOR

Disconnect water joints

Fabricate, connect recommended connections for de-scaling process

Execute descaling using recommended materials and methods.

Flush all cooler tubes with recommended materials and dry with nitrogen from

the refrigerant side


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Should extensive issues be found during these inspection and cleaning

operations, the compressor unit may need to be more fully serviced. This is

called Remanufacturing or Overhauling, common practices. Having the unit

completely replaced, is of course an option. But it is very expensive and may

not be necessary.

Note. These processes are not common maintenance procedures but are at the

next higher level of maintenance, both in terms of complexity and cost.

o ELECTRICAL AND CONTROL PANELS

Inspect all electrical components

Service all printed circuit boards

Inspect and service all chiller contactors and cables. If the contactors are found

to be faulty or pitted, it is recommended these be replaced rather than filed

and re-gapped. The adjustment is simply too difficult for the inexperienced.

Inspect all connections, clean with contact spray, tighten to specifications.

Check and validate all microprocessor programming for specified safety limits

and for being within stated system design parameters

At start-up and re-commissioning, check all:

meter and temperature sensor readings

pressure transducers readings

if out of range, re-calibrate

if calibration is not possible, replace

o LEAK TESTING, EVACUATION AND DEHYDRATION PROCESS

Completely reinstall all system components. Recheck condenser coils, cooler, heat exchanger, oil separator, all weldments

Validate all is go for pressure testing

Charge the system with nitrogen in accordance with manufacturer

recommended test pressure limits

Validate the system will hold the recommended pressure for twenty-four hours.

If pressure cannot be held, conduct component and system line checks. Re-

pressurize for an additional twenty-four hours.

If pressure testing is successful, bleed out nitrogen, drain and install new

compressor oil exactly meeting manufacturer specifications. DO NOT DEVIATE.

Evacuate the system to a vacuum of at least 500microns. Test, hold for thirty-

six to forty-eight hours.

o CHARGING PROCEDURE

Reassemble cooler inlet and outlet connections

Run the water pumps until perfect P is attained.

With the vacuum held, per manufacturer protocol, charge the high side with

liquid refrigerant exactly meeting specifications. DO NOT DEVIATE.

Try to achieve the maximum charge; adjust as necessary.

Operate the compressor; check all parameters; adjust super heat.

Adjust sub-cooling system via the refrigerant charging process. Check and record inlet and outlet water temperature, Delta-T ( T )


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York Chiller No. 2

o General.

Disconnect Chiller Power Supply (Electrical)

Establish safe working area; post safety caution signs on chiller and caution

table around the chiller work area

Disconnect water supply

Recover refrigerant and oil following EPA protocols using refrigerant type

unique servicing tool set.

Properly store recovered refrigerant and oil

o CONDENSER OIL

Dismantle condenser fan motors, cover and guards

Disconnect fan motor electrical connections

Disconnect all welding joints Disconnect all condenser coils from chillers

Perform all maintenance operations on condenser coils, inside tubes, and

outside the coils

De-scale as necessary by flushing with approved chemicals in accordance with

manufacturers specifications. Dry with nitrogen.

Reassemble the condenser coil package back into the chiller


Perform detailed maintenance on all condenser fan motors.

Reinstall all condenser fan motors.

Test.

o CHILLER STRUCTURE

Remove scaled from chiller structure

Sand, prime and paint as necessary.

o SUB-COOLING HEAT EXCHANGER AND THERMOSTATIC EXPANSION VALVE, EEV

Dismantle sub-cooling heat exchanger

Disconnect all welded joints

Disconnect all valves (TXV and EEV)

Service and maintain in accordance with manufacturers protocols and

specifications.

Test, repair, replace if defective

Reassemble components.


o COMPRESSOR

Disconnect water joints

Fabricate, connect recommended connections for de-scaling process

Execute descaling using recommended materials and methods.

Flush all cooler tubes with recommended materials and dry with nitrogen from

the refrigerant side

Should extensive issues be found during these inspection and cleaningoperations, the compressor unit may need to be more fully serviced. This is


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called Remanufacturing or Overhauling, common practices. Having the unit

completely replaced, is of course an option. But it is very expensive and may

not be necessary.

Note. These processes are not common maintenance procedures but are at the

next higher level of maintenance, both in terms of complexity and cost.

Note. The only difference between York Chiller No.1 and No.2 is that No.2 has

experienced a system freeze-up, possibly due to incorrect fluidics (water, glycol,

inhibitor mix, commonly and incorrectly called water). The No.2 system

compressor is damaged; the condenser coil tube burst and is beyond repair.

Note. The following items need to be replaced:

The compressor assembly entire.

The Electronic Expansion Valve, or EEV

All temperature sensors

All transducers

To determine how much damage has occurred in the cooler, both cooler side

end plates need to be removed. Carefully inspect how many tubes may be

damaged. If the damage is limited to under 3% of total tube numbers, a field

repair may be attempted at site.

If the damage to the cooler is over 3%, thats extensive. The cooler will need to

be removed for further inspection and field remanufacturing may be

attempted, given the availability of quality materials and technicians with

certification at the appropriate level of demonstrated expertise in fabrication

and welding. This is not amateur hour for a group of DIY wannabes. Theseextensive repairs are of course far above and beyond a simple maintenance

program and must be priced accordingly.

Note. This system has burst. The damage opened the interior to possible other

corrosion. Careful inspection and flushing protocols will need to be followed.

Note. All the above necessary repair and replacement actions could have been

completely avoided, the expenses spared, had a responsible and responsive

O&M procedure been in place. Now the customer has to pay twice: once for

poor or non-existent O&M, then again for the rework needed to fix these

avoidable errors, deficiencies, and omissions. A recovery of these financial

losses should be considered.

o ELECTRICAL AND CONTROL PANELS

Inspect all electrical components

Service all printed circuit boards

Inspect and service all chiller contactors and cables. If the contactors are found

to be faulty or pitted, it is recommended these be replaced rather than filed

and re-gapped. The adjustment is simply too difficult for the inexperienced.

Inspect all connections, clean with contact spray, tighten to specifications.

Check and validate all microprocessor programming for specified safety limits

and for being within stated system design parameters At start-up and re-commissioning, check all:


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meter and temperature sensor readings

pressure transducers readings

if out of range, re-calibrate

if calibration is not possible, replace

o LEAK TESTING, EVACUATION AND DEHYDRATION PROCESS

Completely reinstall all system components.

Recheck condenser coils, cooler, heat exchanger, oil separator, all weldments

Validate all is go for pressure testing

Charge the system with nitrogen in accordance with manufacturer

recommended test pressure limits

Validate the system will hold the recommended pressure for twenty-four hours.

If pressure cannot be held, conduct component and system line checks. Re-

pressurize for an additional twenty-four hours. If pressure testing is successful, bleed out nitrogen, drain and install new

compressor oil exactly meeting manufacturer specifications. DO NOT DEVIATE.

Evacuate the system to a vacuum of at least 500microns. Test, hold for thirty-

six to forty-eight hours.

o CHARGING PROCEDURE

Reassemble cooler inlet and outlet connections

Run the water pumps until perfect P is attained.

With the vacuum held, as per manufacturers recommendations, charge the

high side with liquid refrigerant exactly meeting manufacturer specifications.

DO NOT DEVIATE. Try to achieve the maximum charge; adjust as necessary.

Operate the compressor; check all parameters; adjust super heat.

Adjust sub-cooling system via the refrigerant charging process.

Check and record inlet and outlet water temperature, Delta-T ( T )

Airstack Multi-Module Chillero GENERAL

AirStack chiller needs full maintenance in accordance with the manufacturers

prototcols.o CONDENSER COILS

The ill-advised spraying of water directly on the condenser coils has resulted in

full scale buildup.

o COMPRESSORS

At the time of the site visit and inspection, issues were noted with one system:

the No. 4 rear compressor. Again, through a lack of proper maintenance, it

appears to have been damaged beyond repair. It will need to be replaced,

following strict manufacturer protocols.

o COOLER HEAT EXCHANGER (HEX)

Further inspection will be required. It appears at first glance that this system,too, is damaged.


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Unfortunately, this type of heat exchanger is not readily repairable. It must be

replaced.

o CONCLUSION

Improper or no maintenance caused all the damage noted. Items will need to be repaired and possibly replaced.

Once this has been accomplished, only proper, professional plant operation,

knowledgeable systems checks and diagnoses, and experienced maintenance

will keep these units running smoothly.


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H. Request for Proposal

I would be happy to provide the Facilities Office, US Embassy, Kabul, Afghanistan, with several proposal

packages in response to the possible HVAC system Operations and Maintenance requirements it may

have:

Package 1: Chiller Remediation.

o An immediate, more detailed, and much more extensive technical assessment of the

damage done as the result of past poor maintenance.

o The extended, detailed Bill of Quantities (Statement of Work Elements) required to

correct same.

o The requisite Bill of Materials.

o Putting together and providing direct on site supervision of the recovery team. Thisteam would be composed of credentialed, professionally competent HVAC technicians,

trained and having experience in both York and AirStack equipment.

o Guarantee of works for an agreed upon follow on period.

Package 2: Chiller and HVAC System Periodic Inspections, Tune-ups.

o The establishment of a preventive maintenance schedule for local onsite technicians.

o The establishment of a hard and soft copy reference library.

o The establishment of a Trouble Line for emergencies.

o The development of a monthly, quarterly, semi-annual, and annual schedule of sitevisits.

o The establishment of proper operational logs, maintenance logs, list of operational and

consumable spares, list of on-demand items.

o The establishment of warranty documentation, factory representative Points of

Contact.

o Identification of city and regional suppliers by parts and general materials types.

Package 3: Chiller and HVAC System Total Operations and Maintenance.

o Exactly what is says. We will do it all, keep it running, get it done professionally,

correctly, completely.


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I. Curriculum Vitae

Muhammad AminH.# 18, St. # 19, Main Bazar,Gunj Mughalpura, Lahore, Pakistan.Phone # +92 42 36880808Cell # +92 300 8133362

E-Mail:[email protected],

[email protected]

Personal Data:Name Muhammad Amin

Son of Atta Muhammad

Born September 03, 1964

Citizen of Pakistan

Marital status Married, three children.

Personality Normal height with strong physique and pleasing attitude.

Professional Data:

Profession HVACR Service Engineer

Status GM Services

Experience 30 years

Carrier, YORK, Marco, Saudi Oger Ltd., Al-Owaidah & Mitchells,

MIA Corporation, Qavi Engineering, Ltd. (QEL), Green Technology

References Available on request.

Education:

General: S.S.C (1982) with Science from Multan Board, Punjab, Pakistan.

Technical:

Diploma of Associate Engineering (DAE), HVACR Technology, 1985.Carrier International Training Programs:

CITC # 01. 9 weeks. Basic HVACR, packaged & split air conditioning

CITC # 02. 5 weeks. Advanced reciprocating air & water-cooled chillers

CITC # 03. 4 weeks. Fundamental service, centrifugal liquid chillers with

SM&MP32 controls

CITC # 04. Various. Composite advanced training, USA, UK & KSA.

Advanced Electrical Control Systems.

Advanced Electronics Control Systems.

Building Monitoring System (B.M.S).

Carrier Comfort Network (C.C.N) Level B&C.
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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CITC # 05: 2 weeks. Advanced training, troubleshooting, 30gb, 30gt, 30gtn,

30gtr, 30gun, 30gur, 130-420. Flowtronic and Flowtronic Plus liquid

chillers, microprocessors

Allen Bradley PLC-500. 1 week. Programming and trouble shooting.V.V.T Systems. Various. Variable volume temperature systems, programming

and troubleshooting

C.C.Z System. Various. Comfort Zone Systems, trouble shooting

Centrifugal Systems:

Carrier. 2 weeks. Advanced service techniques (19DG, 19FA, 19EA,

19ED)

Carrier 19XL, XR. Various. Chiller, microprocessor servicing, overhauling

Screw Systems:

Carrier 30GXN, 30GXA. Various. Service and troubleshooting, 30gxn &

30 gxa (130-240) screw chillersYORK International Training Programs:

ISN Micro Processor. Various. Maintenance and troubleshooting

YDAJ-YCAJ-YEAJ Chillers. Various. Advanced air cooled liquid chillers

JS,JG,JZ Compressors. Various. Advanced rebuilding techniques,

reciprocating compressors

YCAS Chillers. Various. Advanced maintenance and troubleshooting

Grasso Screw Compressors Training Program:

Grasso, Germany. Various. Screw compressors, thermo syphon open flush

low temperature systems

Seminars & Workshops:

Carlyle, Carrier (Joint). Seminar and workshop, Carrier core compressor types

O6D, O6E, 5H, 5L, O6T & 3CC (compound cooling)

York. Workshop, YT, YK centrifugal compressors, Cody Pack control systems

Trane. Seminar, E and R series reciprocating compressors

Copland. Workshop, DWM and Scroll compressors

Bitzer. Seminar, compressors and condensing units.

Bally. Workshop, low temperature cold storage and walk-in freezers

Supervisory Management Training:

Carrier XL9000, XL. Various.

Environmental:

Carrier. Various. Environmental Health & Safety. Refrigerant handling


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Achievements:

Global quality award (WCA). Member of Carrier Saudi service team; won the Wills

Carrier Global Quality Award (WCA); certificate; 1995

Recognition, WCA. Member of Carrier Saudi service team; WCA Recognition Award forextraordinary services over an extended period; letter of appreciation; 1994

Company Awards:

Best Technician of the Month

Best Technician of the Quarter (service techniques, safety practices

Carrier, Riyadh, KSA.

Special Team Recognition Award. Protecting the environment; Riyadh

Customer Appreciation:

Customer Satisfaction Certificate; multiple awards

Attaullah Villa and Resources

Oberoi Madinah HotelRiyadh Cable

Others

Field experience:

Carrier Saudi Service Company, Foreman, Riyadh, Jeddah and Damam.

King Abdul Aziz University Jeddah. Overhauled and commissioned four 10,000-ton

(40,000 ton) Carrier 17FA centrifugal chillers (worlds largest) with PLC controls

King Saud University, Riyadh, KSA. Overhauled and commissioned six 6,000-ton

(36,000 ton) Carrier 17EA centrifugal chillers

King Fahad International Air Port, Damam, KSA. Overhauled and commissioned allCarrier 17DA centrifugal chillers; installed Allen Bradley PLC controls

Youth Hostel, Damam, KSA. Overhauled two Carrier 19DG centrifugal chillers

Ministry of Foreign Affairs, Riyadh, KSA. Overhauled three Carrier 19FA centrifugal

chillers

Saudi Arabian Monitory Agency, Riyadh, KSA. Overhauled four Carrier19FA

centrifugal chillers

Yamama Hospital, Riyadh, KSA. Overhauled two Carrier19DG centrifugal chillers;

commissioned, executed startup of four Carrier 19XL chillers

King Faisal Foundation, Riyadh, KSA. Overhauled two Carrier 19EB centrifugal

chillers

Khazama Center, Riyadh, KSA. Overhauled two Carrier 19EB centrifugal chillers

At the following locations, overhauled and commissioned reciprocating chillers,

Flowtronic, Flowtronic plus, as well as screw chillers, various sites:

o King Abdul Aziz Science City, Riyadh, KSA

o AL-Akaria Shopping Mall, Riyadh, KSA

o Pakistan Embassy, Riyadh, KSA

o Turkish Embassy, Riyadh, KSA

o Australian Embassy, Riyadh, KSA

o Many others


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YORK Al-Salem Ltd., Mechanical Engineer, Chiller Specialist.

Haram Makkah Project. Engineer-in-charge, worlds largest project equipped with

YORK reciprocating chillers; total capacity 16,000 tons

Haram Madinah Manawarah Project. Service Engineer, worlds largest projectequipped with York Turbo Master centrifugal chillers; project capacity 48,000 tons

Commissioning, startup, and maintenance, reciprocating chillers, various projects:

o Oberoi Madinah hotel, Madinah Munawarah.

o Tayyaba Buildings, Madinah Munawarah.

o Intercontinental Hotel, Madinah Munawarah and many more.

Al-Owaidah Company, Mechanical Engineering Consultant.

Project: Modern Slaughterhouse at Mina, Makkah, KSA.

Part of Saud consultant engineering team

Worlds largest cold storage project (32 mega watts) Unit Storage Capacity: 600,000 Sheep Carcasses at -35C

Supervised:

o Construction erection phase

o Installation of HACR Grasso low temperature refrigeration systems

o Installation of PLC control systems

o Overall startup and commissioning

The Grasso low temperature project was designed to utilize the Open Flush

Thermosyphone Refrigeration System

Four (4) independent refrigeration units; each unit with a capacity of 8,000 tons

Each unit R-22 refrigerant capacity ~80,000 KGs or 80 metric tons The project utilized 50,000 meters of piping, 4,000 welding joints, various sizes

Marco Jafali, Ltd., Systems Service Supervisor.

Marco Jafali Ltd., is the oldest HVACR service company in KSA.

Daily assignment of technical staff to various job requirements: fault finding,

electrical control troubleshooting, customer meetings, site surveys, other varied

service tasks.

Interior Ministry Building, Riyadh, KSA. Overhauling of one York Turbo Master

centrifugal chiller, capacity 3,500 tons.

Al-Kharj Military factory, Riyadh, KSA. Overhauling of three Carrier 19DK centrifugal

chillers.

Ministry of Electricity Building, Riyadh, KSA. Overhauling two York YT centrifugal

Turbo Pack chillers plus annual maintenance services.

King Fahad Security College, Riyadh, KSA. Annual maintenance services contract,

four years, York Turbo Master centrifugal chillers, total capacity 30,000 tons.

Imam Saud Islamic University, Riyadh, KSA. Annual maintenance services contract,

two years, York Turbo Master centrifugal chillers, total 30,000 tons.

Military Directorate Office Building, Riyadh, KSA. Overhaul three Trane Centravac

chillers.

Other annual maintenance services contracts:


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o Saudi Hotel and Resort Company

o Riyadh Cables Industries

o Nova Water Purification Plant

o Saudi Royal Palaceso Other

Saudi Oger Ltd., KSA, Specialist HVAC Operating Engineer, Centrifugal Chillers.

Saudi Kingdom-wide area of responsibility.

o Palaces of the King

o Other Royal palaces

o Royal Diwans

o Royal offices

o ARAMCO Dehran utilities

o King Abdullah International University of Science and Technology Equipment attended:

o Carrier centrifugal chillers 19FA

o Carrier centrifugal chillers 19XR and 19XL

o Carrier reciprocating chillers 30GB, 30GT, 30GTN, 30XAA

o Trane Centravac chillers CVAC

o Trane reciprocating chillers ECGA, ECGAB

o York reciprocating chillers YCAJ, YDAJ, YEAJ

o SKM reciprocating chillers

o HVAC building monitoring and air control systems from Honeywell, Sttafa,

Siemens, etc. Examples of Work Executed:

o Fault finding, various systems

o Electrical troubleshooting

o Unit overhauling

o System commissioning

o Gulf Royal Complex, Damam, KSA. Overhauling and commissioning of seven

Carrier 19FA centrifugal chillers, adding dry coolers; capacity 1,600 tons

each.

o Alpha Royal Diwan, Yamama Palace, Riyadh, KSA. Overhaul three Carrier

19FA centrifugal chillers.o Royal Hajar Palace Haffou, KSA. Overhaul three Trane CVAC Centravac

chillers; capacity 320 tons each.

o New Guest Palace Riyadh, KSA. Overhaul three Carrier 19EB centrifugal

chillers; capacity 1,500 tons each.

Retrofitting jobs.

o Royal Palaces, KSA. Carrier 19FA and Trane CVAC Centravac chillers;

changeover from R-12 to DuPont R-TC-39 refrigerant.

o ARAMCO Dehran Utilities, North Park, KSA. Three Carrier 19XR centrifugal

chillers, capacity 1,200 tons each, to R-134-a.

o

Aramco Dehran Utilities,DOB Building, KSA. Four Carrier 19XR centrifugalchillers, capacity 1,000 tons each, to R-134-a.


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o Reciprocating compressors, various. York JS-84, JS-83; Trane Model E&R

compressors; Carrier reciprocating compressors, Models O6E, O6D and

others.

Mitchells Fruit Farms Ltd., Pakistan.

Various air conditioning systems, packaged systems, split systems, low temperature

units.

MIA Corporation, Services Manager.

Various locations, different projects in Pakistan.

Qaid-Azam International Hospital Islamabad.

NUST University Islamabad

COMSAT University Islamabad

FFC Head Office Rawalpindi. Pakistan Tobacco Company Jehlum

Independent HVAC Electromechanical Consultant.

With Qavi Engineers, Ltd. Creation of US Consulate, Herat, Afghanistan, 2010-12.

As above, bomb damage remediation and upgrade, 2013-14.

Green Technologies, General Manger, Services.

Area coverage: all of Pakistan, multinational organizations.

Various and wide-ranging responsibilities.

Site surveys, technical inspections, report generation, estimates of cost and labor,

daily job scheduling.

Service and maintenance, all types of air conditioning equipment; large centrifugal

compressors, chillers, reciprocating chillers, heavy equipment, water pumps,

unique heat recovery systems, large scale air handling units (AHUs), huge ducting

systems up to eight square meters, chilled beam systems, packaged and split air

conditioning units.

Electrical & electronic control systems, microprocessor controls, BMS, CCN, CCZ,

VVT, ISN, Honeywell, Staffa control systems.

Servicing and maintenance of refrigeration and low temperature systems used in

cold storage, blast freezers, walk-in freezers, walk-in coolers, and similar, with CFC,

HFC, HCFC.

Muhammad Amin Chaudhary.

kabul hvac survey report rev 03 30aug14

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