Process Chillers & Condensing Coil Maintenance

The risks of balancing of maintenance deferred with maintenance and budgetary DecisionsAs the majority of the equipment and engineers of maintenance know, suitable maintenance on the refrigerator and the condensation of the units is critical with the effective operation and without breakdown. However when you combine the fact that the majority of the refrigerators and units of condensation are located in low places of the traffic and out of the sight (C. - with-D., behind buildings, hidden behind walls, on tops of roof, etc,) with the fact that the part of cleaning of rolling up of the process of maintenance takes unpleasant and time to charge, refrigerator and maintenance of condensation of unit is not one of work that the majority of the engineers of maintenance wait with interest. In the situations where the department of maintenance is occupied or with court of manpower, the cleaning of rolling up is likely to be deferred beyond the moment when maintenance is really requ! ired by the equipment. One generally knows it in all the industry of the CAHT that even lightest clogging rolling up carries out to what can be described as first level of the failure which is distinguished by the following characteristics: First functioning principal pressure higher of compressor of failure of refrigerator of level (characteristics) (caused by high cooling pressure resulting from the flow of restricted air and poor heat exchange). Reduced capacity of cooling (caused by the poor flow of air by rollings up). The increased aspiration of kilowatt coupled to a reduction of unit of cooling of capacity of tonnage functions longer and works harder to carry out the regulated points of the temperature. The compressor continues to make a cycle with far and above under the high principal pressure. (The compressor is subjected to a constraint in dirty states of rolling up - the system overheats). The refrigerators suffering from the states of pressure of high-head pass! the impact length in the form of faintness of tenant, of comp! laints o f customer, reduction of the productivity of the employees and higher energy costs. While it Malayan of tenant and employees appears for periods of occupation, the penalty of energy occurs during every hour of operation (during the part-load and the operation full-load). Unless you supervise the aspiration of kilowatt of refrigerator with a system of management of energy or with a separate regulating device, you will most probably get information about the problem when the weather is hot and you cannot maintain the environmental water alarming and/or temperatures, when you see your consumption energy to go up out of arrow or when your compressor fails. In applications of cooling of process where a refrigerator supports the production, clogged rollings up have other ramifications such as the overheating of the equipment of production which can cause problems of quality of the product and even the failure of the equipment, (for example, equipment of process of computer control! , robot-like systems of welding, systems of moulding per injection, equipment of pressure, etc) bringing the production to a halt of grinding. To consider this real situation: A refrigerator of 20 tons employed to cool a room of computer control of a manufacturer of the important motor vehicles of parts becomes clogged and needs cleaning; but because the department of maintenance was given soon, they did not have the hour to carry out maintenance when it was necessary consequently; maintenance has put-with far for a not specified period. Thereafter, the remains load completely clogged rollings up of refrigerator having for result a second level of failure which had a catastrophic impact on the businesses: The second failure of refrigerator of level (of the characteristics and the implications of cost) the compressor failed the tested failure of computer of room computers due to overheating and the company was forced to replace failing computer equipement while the current p! roduction with the capacity reduced to the refrigerator was ba! ck on li ne. The supply of the new compressor took 2 days and had like consequence two days of downtime and lost the productivity on three lines of production ordered by computer having for result of the $500.000 per loss of production of day (note: the production cost lost will change to depend on the product and the process of production). Management sent the workmen of manufacture to the house with full the wages and advantages until the refrigerator was help and operation. The company paid workmen of manufacture productivité perdue. La compagnie a manqué des expéditions ayant pour résultat le mécontentement de client. Le coût de remplacement de compresseur - installation de $7.500 compresseurs coûter - mise en train d'équipement de production $4.000 a coûté $10.000 (inclut le coût de résulter de rebut de matière première première de la chaîne mise en train faire-prête et de production). Lover le nettoyage coûté : $1.500 car vous pouvez voir, si le nettoyage d'enroulement et l'en! tretien avaient été exécutés avant le premier niveau de l'échec, il aurait seulement coûté $1.500 ; cependant parce qu'il a été reporté et l'opération a été continuée jusqu'au deuxième niveau de l'échec, les coûts liés à la blessure de niveau du deuxième échec vous coûtant vers le haut au fabricant de pièces au-dessus de $1,000,000.Now pourraient se demander pourquoi il n'y avait pas une unité de secours en place pour cette application critique de mission. Bien, le fait est les refroidisseurs composés « de secours » de tache qui ont été déplacés autour de la salle des ordinateurs aux endroits essentiels, mais les refroidisseurs de tache ont été seulement employés pour augmenter le refroidissement si nécessaires - ils n'ont pas été conçus pour le chargement complet de la salle des ordinateurs. Ainsi la question se tient toujours - où était le support réfrigérateur ? La réponse est - ils n'ont pas eu un. Cette opération particulière avait converti le leur mécaniquement contro! lled production equipment to new computer control systems and ! as a res ult, the computer room supported by the chiller took on additional cooling loads and greater strategic significance to the business. Even though the computer room had both computer and electrical back-up systems, the cooling system had not been upgraded and was the Achilles Heel of the production facility. Preventative maintenance should have been of vital importance in this facility.Why Companies Defer Maintenance on Chillers and Condensing Units.There are many reasons cited by facilities and maintenance directors; however it's important to keep in mind that regardless of the reasons, when equipment is in need of maintenance, deferring it for any reason will not change that fact. Do any of these reasons sound familiar?Budgetary Constraints - "We'll put-off the maintenance until next month so we don't go over budget". When you consider all of the risks to a business associated with a system failure, deferring maintenance due to budgetary constraints is not usually a sound de! cision. When budgetary constraints are placed on the maintenance of "process and comfort critical" equipment, the results can be catastrophic to the business. Man Power & Time Constraints - "We'll get around to cleaning the chiller as soon as we can - we have too many other things to do right now". This reason for deferring maintenance is more common today than ever before. Why? Because companies have been forced to reduce staff and streamline operations to conform to the economic realities of the business, or cannot find qualified personnel. This places additional demand on maintenance engineers because they now have to do more with less. If chillers and condensing units support mission critical operations and facilities, then maintenance of those systems should be near the top of the TO DO LIST even when the maintenance department is busy or short handed. To help improve maintenance efficiency and reduce the time required for performing the maintenance task, the maintenan! ce should be outsourced to a reliable service company or techn! ologies such as air intake coil filters should be evaluated. In short, investment in technologies that can optimize operational efficiency and reduce the maintenance effort should be considered in lean maintenance staffing situations. Maintenance Complexity and Knowledge Constraints - "Maintaining this equipment is very difficult - we don't have the skills to maintain it correctly" - this reason is especially common in companies using advanced mechanical systems. Maintenance workers must be trained to properly maintain them or, the maintenance work should be outsourced to a service company that is knowledgeable with the maintenance process. Unfriendly Maintenance Process - "We hate cleaning chiller and condensing units because it's a dirty job - we get dirt and debris all over us when we power wash the coils - we'll clean the coils later". Although cleaning coils are in fact a dirty job, it is not a sound reason for deferring maintenance. When cleaning coils, proper safety equipment! including eye and respiratory protection, rubber gloves and protective outerwear should be worn to protect against coil cleaning chemicals and possible mold or bacteria problems that can pose a health hazard. As an alternative, air intake filtration systems that isolate the debris on the outside of the coils where it is visible and easy to clean using an ordinary broom, brush or shop vacuum can reduce the "hassle factor" associated with this important maintenance task. The list of reasons for deferring maintenance can go on and on but one thing is clear, deferring maintenance on HVAC equipment can be risky and can increase the odds that a system failure will occur; and when it does, it will usually cost more than the cost of the maintenance that could have prevented the failure in the first place.In the end, the decision for performing or deferring maintenance on HVAC systems fall squarely on the shoulders of the maintenance and facilities directors as they balance their m! aintenance and budgetary decisions, recognizing all the risks ! involved .Air Solution Company developed and patented the first Air Intake Filter specifically engineered to mount to the outside of cooling towers and other HVAC equipment for purposes of stopping the debris before it entered into the system. Since that time, Air Solution Company has been manufacturing and has introduced a variety of other innovative filter systems including its new Fine Mesh Filter which is engineered for use on small and medium size refrigeration coils and machine fan intake housing units.Air Solution Company Randy Simmons is with Air Solution Company, author of articles can be reached at http://www.airsolutioncompany.comArticle Source: http://EzineArticles.com/?expert=Randy_Simmons
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