Chiller repair, condenser & refrigerant loop test, pump alignment, videoscope

Task order - TO 675

Pictures that highlight the activities/ condition of the components-before & after the job done

Repair of Chillers 6 & 7 at Combined Utilities Building (CUB) , Bldg 753 NSA II

A. Condenser Loop

Scope of Work 1:

1) Contractor shall open condenser bell caps ( water boxes ) and examine the condition of the condenser tubes and piping with a camera probe. Copy of the finding and video footage are to be reported and submitted to the Government

Action Taken :

• Opened Condenser bell caps ( water boxes ) and examined the condition of the condenser tubes and piping with a camera probe( Video scope)

• The resultant pictures are shown in the following pages of this Presentation. The video scope recordings are separately given in the CD

• The condenser loop piping were found with loose and hard scale, the strainers were found clogged fully with contamination. The condenser water boxes / bell caps were found coated with slurry and other loose scales. The condenser tubes were examined with video scope and found deposits of loose particles and sediments

A. Condenser Loop1. Condenser Bell Cap / water boxes pictures ( Before cleaning )

Condenser Tube Sheet

Condenser Bell Cap

Condenser Tube sheet

Condenser Tube sheet & Water Boxes

Condenser water box

Condenser water box with outlet pipe view

Condenser tube sheet

A. Condenser Loop1. Tube examination with vedioscope

A. Condenser Loop1. Tube Internal View- video scope

Tube internal view – video scope ( shown in the link is of a single tubeThe balance video scope movies are saved in the CD)

Double-click on AVI

A. Condenser Loop

Scope of Work 2:

2. Contractor shall perform brush cleaning of the condenser tubes

Action Taken :

• Brush cleaned the condenser tubes of Chiller 6 & 7.

• Cleaned the bell caps / water boxes by mechanical means .

• Painted the bell caps / water boxes with epoxy paint

• The following Pictures shows the process

A. Condenser Loop 2. Brush Cleaning of the condenser tubes – Chiller 6

A. Condenser Loop 2. Brush Cleaning of the condenser tubes –Chiller 6

A. Condenser Loop 2. Brush Cleaning of the condenser tubes – Chiller 7

A. Condenser Loop 2. Brush Cleaning of the condenser tubes

A. Condenser Loop 2. Brush Cleaning of the condenser tubes- contamination passing out of the tubes

A. Condenser Loop 2. Brush Cleaning of the condenser tubes- contamination collected at the tray

A. Condenser Loop

Scope of Work 3:

1) Contractor shall perform chemical flushing and circulate the chemical thru’ condenser loop and Cooling Towers on units 6&7

Action Taken :

• Condenser loops of Chiller 6 & 7 were chemical flushed and chemical circulated until the pipes and accessories were fully cleaned of all contaminations. The cooling tower sump, nozzles , screen of Unit 6 & 7 were cleaned to remove the contaminations .

• The chemical used were NSF approved chemicals . MSDS of chemicals were submitted for approval

• Disposal of the waste chemical were done as per the Bahrain Environmental regulation.

• Cleaned and Painted the Water Boxes/ Bell Caps with Eoxy Paint

• The following Pictures shows the pipe internal coating / deposits prior to the cleaning and after the chemical cleaning .

A. Condenser Loop3. Pipe pictures ( Before chemical cleaning )

A. Condenser Loop3. Pipe pictures ( Before chemical cleaning)

A. Condenser Loop3. Pipe pictures ( Before cleaning)

A. Condenser Loop3. Strainer Chiller 7– fully clogged ( Before cleaning)

A. Condenser Loop3. Bucket Strainer Chiller 6 – fully clogged ( Before cleaning)

A. Condenser Loop3. Condenser Tube Sheet pictures ( Before cleaning)

A. Condenser LoopCooling Tower # 6 before cleaning

A. Condenser Loop3. Chemical flushing & Cleaning

Chemical Circulation

A. Condenser Loop3.Piping after chemical cleaning

A. Condenser Loop3.Pipe Interior after Chemical cleaning

A. Condenser Loop3.Pump Strainer after chemical cleaning

A. Condenser Loop3.Bucket Strainer Housing after chemical cleaning

A. Condenser Loop3. Bucket Strainer Housing after chemical cleaning- Chiller 6

A. Condenser Loop3.Bucket Strainer Housing after chemical cleaning - Chiller 7

A. Condenser Loop3.Bucket Strainer after chemical cleaning- Chiller 7

A. Condenser Loop3.Cooling Tower screen after chemical cleaning

A. Condenser Loop3.expansion joint after chemical cleaning

A. Condenser Loop3.cooling tower 6 after cleaning

A. Condenser Loop3.Cooling Tower 6 after cleaning

A. Condenser Loop3.Cooling Tower 7 after cleaning

A. Condenser Loop3.Cooling Tower after chemical cleaning

A. Condenser Loop3.Condenser water box after cleaning –Chiller 6

A. Condenser Loop3.Condenser Water Box /Bell caps after cleaning – Chiller 7

A. Condenser Loop3.Condenser end bell cap after cleaning – chiller 6

A. Condenser Loop3.Condenser Tube sheet after cleaning – chiller 6

A. Condenser Loop3.Condenser Bell Cap painted with epoxy paint – chiller 6

A. Condenser Loop3.Condenser Tube Sheet painted with epoxy paint – chiller 6

A. Condenser Loop3.Condenser Water Box painted with epoxy paint – chiller 6

A. Condenser Loop3.Condenser Bell Cap painted with epoxy paint – chiller 7

A. Condenser Loop3.Condenser Water Box painted with epoxy paint – chiller 7

A. Condenser Loop3.Condenser Tube Sheet painted with epoxy paint – chiller 7

A. Condenser Loop

Scope of Work 8:

2. Contractor shall properly connect Cooling Tower Fan Motor Gear Box Lubrication piping fittings to rectify Oil leakages on Cooling Tower 6 & 7

Action Taken :

• Drain the oil , disconnected and removed the lube oil piping fittings , connected back by piping thread sealant.

• Replaced the flexible hose with hydraulic flexible hose and with hydraulic fittings

• The above job done for both 6 & 7 cooling towers

• The following Pictures shows the new fittings that are leak free

A. Condenser Loop8. Renewed Lube Oil Piping fittings

. Condenser Loop8. Renewed Lube Oil Piping fittings

A. Condenser Loop8. Renewed Lube Oil Piping fittings

A. Condenser Loop

Scope of Work 9:

Contractor shall repair the Cooling Tower Pumps CTP-D-2 so that it will not make any abnormal noise

Action Taken :

• Test run the pump, identified bearing noise for the motor. Disconnected the motor from the drive coupling , dismantled and replaced both side bearing with new bearings

• Assembled the motor, connected the motor to the drive coupling , carried out alignment checks , test run and found no abnormal noise.

• The following Pictures shows the bearing replacement for the pump motor

A. Condenser Loop9. Cooling Tower Pump CTP-D-2 with abnormal noise

Replacement of Motor Bearing with new Bearing

Vibration check for motor

A. Condenser Loop

Scope of Work 10:

2. Contractor shall supply and Install Magnetic Sensors ( Vibration Sensors) on Cooling Tower Pumps CTP-D-2 and CTP-D-3

Action Taken :

• Procured i-Alert ( Brand ITT Bell & Gosset Pump) magnetic vibration sensors and installed on the Pumps

• Tested the function of the i-Alert sensors and found normal functioning

• The following Pictures shows the sensors installed

A. Condenser Loop10. Missing Magnetic Sensor/ Vibration sensor on CHW Pump CWP-D3

A. Condenser Loop10. Magnetic Sensor/ Vibration sensor installed on CHW Pump CWP-D3

A. Condenser Loop10. Missing Magnetic Sensor/ Vibration sensor on CHW Pump CWP-D2

A. Condenser Loop10. Magnetic Sensor/ Vibration sensor installed on CHW Pump CWP-D2

A. Condenser Loop

Scope of Work 11:

Contractor shall perform laser alignment on all pumps related to the Chiller unit 6 & 7 ( 4 pumps)

Action Taken :

• Conducted Alignment Checks on the pumps of Chiller 6 & 7 .

• Corrected the alignment of Cooling Tower Pump CTP- D-2

• The following Pictures shows the alignment check procedures

A. Condenser Loop11. Pump Alignment Test

A. Condenser Loop

Scope of Job 12.

• Contractor shall supply a Chemical Cleaning Skid which shall be used to chemically clean all chillers as necessary

Action Taken :

• Supplied Chemical Cleaning Skid

• Delivered to the CUB

B. Refrigerant Loop

Scope of Job 1.

• Contractor shall recover and recycle the Refrigerant on Chillers 6 & 7 to get rid of the contamination

Action Taken :

• Recovered the refrigerant from the Chiller 6 & 7

• Flushed the refrigerant loop with nitrogen, removed trapped debris / contaminations from the loop

• Vacuum the loop

• Recycled the refrigerant thru’ filter driers for further removal of contaminations

• The following pictures show the procedures

B. Refrigerant Loop1. Refrigerant Recovery

B. Refrigerant Loop1. Flushing the refrigerant loop with nitrogen to get rid of the contamination / debris

debris removed from chiller 7

B. Refrigerant Loop1. Flushing the refrigerant loop with nitrogen to get rid of the contamination / debris

debris removed from chiller 6

B. Refrigerant Loop1. Vacuum creation prior to Refrigerant recycle

Vacuum Pump operation in progress

B. Refrigerant Loop1. Vacuum creation prior to Refrigerant recycle

Vacuum gauge showing the vacuum condition in the refrigerant loop

B. Refrigerant Loop1. Refrigerant Recycle thru’ filter driers

B. Refrigerant Loop1. Refrigerant Recycle Process

B. Refrigerant Loop 1. Refrigerant recycle

Oil Filling

B. Refrigerant Loop1. Refrigerant Recovery

B. Refrigerant Loop1. Refrigerant Recycle

Refrigerant liquid level in the sight glass- clear refrigerant without contamination

B. Refrigerant Loop1. Refrigerant Recycle

Refrigerant liquid level in the sight glass- clear refrigerant without contamination

B. Refrigerant Loop

Scope of Work 2:

Contractor shall replace the Oil Filter, Oil and dehydrator of Chiller unit 6 & 7

Action Taken :

• Replaced the Oil Filter, Oil and Dehydrators of Chiller 6 & 7 .

• Leak tested the joints / fittings, Observed the Oil level . Found normal

• The following Pictures shows the process conducted

B. Refrigerant Loop2. Replacement of Oil Filter – Chiller 6

B. Refrigerant Loop2. Replacement of dehydrator – Chiller 6

B. Refrigerant Loop2. Replacement of dehydrator – Chiller 7

B. Refrigerant Loop2. Replacement of Oil Filter – Chiller 7

B. Refrigerant Loop

Scope of Work 3:

Contractor shall rectify the faulty differential pressure switches on Chiller unit 6 & 7

Action Taken :

• Rectified the faulty differential switches of Chiller 6 & 7 .

• The following Pictures shows the testing and setting up of DPS

B. Refrigerant Loop 3. Differential Pressure Switch Setting – Chiller 7

C. Distribution Pumps and Schneider Control System

Scope of Job 1:

Contractor shall perform laser alignment on Distribution Pumps DP-D-1 and DP-J-1

Action Taken :

• Tested the drive coupling alignment of Distribution Pumps DP-D-1 and DP-J-1

• Corrected the misalignment on DP-J-1

C. Distribution Pumps and Schneider Control System 1. Distribution Pump alignment test

C. Distribution Pumps and Schneider Control System

Scope of Job 2:

Contractor shall investigate and rectify the cause of system short cycling in the Schneider Programming.

Action Taken :

• The sequencing of the chillers and its ancillary units were tested and the control parameter of the return chilled water temperature set point was found below the design of 12.2 c .

• Reset the control to 12.2 C.

• Observed the system for proper sequencing without short cycle. Found normal

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