Engineering plant facilities 12 mechanics building preventive maintenance and energy conservation

L | C | LOGISTICS
PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT
Engineering-Book
ENGINEERING FUNDAMENTALS AND HOW IT WORKS
MECHANICS PREVENTIVE MAINTENANCE AND ENERGY CONSERVATION
September 2014
Supply Chain Manufacturing & DC Facilities Logistics Operations Planning Management
Expertise in Process Engineering Optimization Solutions & Industrial Engineering Projects Management

Facilities Management
Meaning of Facilities Management
Facilities management is an interdisciplinary field primarily devoted to
the maintenance, cleaning and care of large commercial, institutional
And manufacturing buildings, such as: hotels, resorts, schools, office
complexes, sports arenas or convention centers, and factory offices
Duties may include the care of HVAC systems, HVAC electric controllers,
Low Voltage Electric Power systems, electric motors, diesel engines,
pumps, valves, piping, water treatment and waste water plants, Vertical
Transportation, building plumbing, fixtures and lighting systems, landscape
decoration; and other FM safety, cleaning and office equipments
Facilities management (FM) is the total facilities management of all
services that support the core business of an administration organization

Benefits of Facilities Management
Facility Management Services provides to its clients
a dedicated technical team to solve the day to day
problems associated with: facility assets failure due to
usage and age deterioration, performs preventive and
corrective maintenance, as well as repair and cleaning
0utsourcing facility management provides the following:
healthy, comfortable, safe, clean and secure environment
with consistent and standardized management procedures
and overall support services quality improvements
extended asset life and reduced assets repairs costs

Roles
Highly Skilled Professional Engineers, technicians in refrigeration, electricity,
mechanics, water, environment, safety, sanitation, carpenters, plumbers, lifts,
electrical escalators, dock levellers, rolling shutter doors, office phone, LCD TV
Staff
FM Help Desk Operator and work orders administration
Management
Chief Engineer, Supervisors, technical advisor

Help Desk Operator
The main responsibilities of the Help Desk Operator are:
accept requests for assistance or problem reports from users,
obtain necessary information from users to adequately describe
the request or problem report,
enter information into the problem tracking system,
directly respond to the request or problem if within own areas of expertise,
complete information on problem reports that were solved personally and
close report in problem tracking system,
direct the request or problem to the most appropriate support area
(e.g., Electrical, HVAC, Mechanical, Carpentry, VT),
liaison with user to ensure that requests or problem reports have been
satisfactorily handled

DOCUMENTATION RECEIVED FROM CLIENT TABLE OF PRIORITY LEVELS
S/No System Sub-System
Sub-System
(Asset
Description)
Priority Level Response Time Completion Time
1 Vertical
Transportation
Roller shutter-manual,
highspeed & motorised;
Docklevellers;
Rolling doors;
Elevators;
P1 Critical Immediate <= 3 hours
P2 Urgent
Same Day
One hour for elevator only < 1 Days
P3 Routine 7 Days 15 Days
P4 Planned 30 Days 30 Days
P5 Project As Agreed As Agreed
2
Non Mechanical
Building
Maintenance
Plumbing & Sanitary;
Building;
Electrical;
IT & Electronics;
P1 Critical Immediate < 1 Day
P2 Urgent Same Day < 2 Days
P3 Routine 7 Days <3 days for minor & 10
days for major
P4 Planned 30 Days 30 days
3 HVAC
Air curtain;
Dehumidifier;
Split units AC;
VRV/VRF;
AHU, F&CU,
Chillers, Cooling Towers,
Pressurized Fans, Exhaust
Fans, Ventilation fans;
Mechanical; Electrical
P1 Critical Immediate < 1 Day
P2 Urgent Same Day < 3 Days
P3 Routine 7 Days <3 days for minor repair &
10 days for major
P4 Planned 30 Days 30 Days

ON-SITE SERVICES

Planned Preventive Maintenance
ON-SITE SERVICES

S/No
Request Details Assigned Details SLA
Status SLA Status
System
(HVAC
Electric
Buildin
g Toilet
Other)
Date & Time
dd/mm/yy
hh:mm
Requestor Recorded
By PO Ref No WRF Ref. No /
PM Ref.
Type
*(RM / CM /
PRO / Quote /
Move / CS /
FS / PM)
Priority Date commited
dd/mm/yy
Description of
Request Status
Description
Of Work
Done
Remarks

Assigned
Details
Sub-System /
Asset Usage
Description
Remark
Assigned
Details SLA Status Actual SLA Actual SLA
WRF Ref.
No / PM
Ref.
Used spare
part/consumable
(As per Inventory list)
Location Detail of
Location Assigned To
Targeted
Response
(Date &
Time)
Actual
Response
(Date & Time)
Actual
Completion
(Date &
Time)
Feedback
from End-
User
Spare part Qty

Spare Parts Assigned
Details
WRF Ref. No / PM
Ref. Spare Parts Used In
HVAC Electrical NMBM VT PM RM CM PRO Quote Move status

sodexo.com
WORK ORDER FORM
Date & Time: Reported By: WRF Ref. No:
(ie. DD/MM/YY HH:MM) - Contact No:
Received By: Email Address: -
Type Of WO:
Loại WO: *(RM / CM / PRO / Quote / Move /
CS / FS) WO Remarks:
Details of Request
Location: Equipment Details:
Description of Request:
Priority Level *(Critical / Urgent / Routine / Planned / Project)Assigned To:
System: *(VT / HVAC / NMBM / CS / FS)Dept:
Sub-system: Contact No:
Site Attendance Report
Inform Location Owner:
Name: Approval:
Permit To Work (PTW Required?) : *(YES / NO)
PTW Reference No. :
Observation on site:
Action Taken
Details of Spares Used
Item Code Item Description Issue Qty Return Qty Total Final Issued Qty Receipt Sign Store Personnel Sign
Follow Up Actions (If Required)
Actual Date & Time Responded Actual Completion Date & Time:
(ie. DD/MM/YY HH:MM) (ie. DD/MM/YY HH:MM)
Requestor Feedback: Details Of Feedback:
Acknowledgement of Completion: (Name/Date/Time/Signature)
Requestor
Acknowledgement of Completion(Name/Date/Time/Signature)
Sodexo Supervisor

PROACTIVE MAINTENANCE LOG REPORT INSTRUCTION
Introduction
1 Proactive Walkthrough shall be scheduled and assigned
2 Proactive Walkthrough Checklist' for Internal & External shall be use as a guide to conduct inspection.
Recording
3 Observation by respective personnel shall be entered into hard copy of the 'Proactive Maintenance Log Record' (PML).
4 Submit completed Proactive Maintenance Log Record to Helpdesk as soon as walkthrough completed.
Helpdesk
5 Helpdesk shall assign a PML reference no. to the log record and entered the observation details in PML Soft Copy
6 Helpdesk issue the PML record to Supervisor or Maintenance Manager who in turn issue them to Day Technician.
7 Supervisor or Maintenance Manager shall issue PML record (or selected observation) to Shift Technician where appropiate
8 Technicians to proceed and conduct Proactive Maintenance
9 Technician must envisage to complete the Proactive Maintenance within 1 week.
Works that are KIV, requires spares or are Chargeable or Requires Additional Spares (to Order)
10 For Works requiring Spares, technician draw spares from store and indicate PML reference no to the items drawn out.
11 For works that requires additional spares or are chargeable, Technician to enter remarks and refer them back to Helpdesk.
12 Helpdesk opens a Quote Work Order for such faults.
13 For KIV works, Technician must indicate reason for the works to be defered or kept in view.
Completion
13 Once completed, Technician return the PML to Helpdesk for record in the soft copy.
14 PML shall be signed and filed by Helpdesk.

PROACTIVE MAINTENANCE LOG RECORD
Date of
Inspection : Proactive Maintenance Log Reference No.
Location
Inspected : :
S
No.
Date &
Time
Description Of Proactive
Maintenance Works Sub Location Observed
By
Helpdesk -
WOF
Reference
No.
Date &
Time
Status (Completed/
KIV) Remarks
Inspection Conducted By: Received By Helpdesk/Supervisor:
Signature, Date & Time: Signature, Date & Time:

ROOT CAUSE ANALYSIS
S/No
Request Details
Description of
Request
Assigned Details
System
SLA
Status
Date & Time Requestor Recorded By
Sodexo Location Detail of
Location
WRF
Ref. No
Type Of Work
Order *
Assigned
To
Priority
Level
Problem Description
Root Cause Description
Solution Description
recommendation

DAILY TASK & MORNING BRIEFING
S No. Duties Responsibilities Time
1
Take Over of Shift Duties
·Keys & Card Access
·Mobile Phone
·Log Out Tag Out
·Central & Personal Tools
·PPE
·Store
Shift Leaders 0600hrs – 0615hrs
2 Sodexo Morning Briefing All 0700hrs – 0715hrs
3
Review & Submission of Reports:
·Summary of Work Order Report
·Summary of Preventive Maintenance
·Summary of Proactive Work Orders
·Summary of Spares & Consumables
Supervisor/ Manager 0715hrs – 0745hrs
4 P&G Safety Tool Box Meeting All 0800hrs – 0820hrs
5 Daily meeting with Client Supervisor/ Manager 0900hrs
6 Daily Walkthrough Management 0830hrs – 0930hrs
7 Take Over of Shift Duties Shift Leaders Future
8 Daily Walkthrough Shift Team 1900hrs – 2000hrs
9 Take Over of Shift Duties Shift Leaders 1800hrs – 1815hrs

DAILY OPERATIONAL MEETING WITH TECHNICAL TEAM
MINUTES OF MEETING – Day /Month / Year/ (time)
Date Venue Attendees
Summary WO
No. PO Ref. WO Ref. Type Priority Date
commited Description Status Remarks
1
Inventory
No. WO Ref. Spare part Qty Asset Usage Description Location Detail
Location
1
Total
Daily PM
No. PM Ref. Spare part Qty Asset Usage Description Location Detail
location
1
Total
Minutes of Meeting Yesterday
No. WO
type Plan Qty Actual
qty Remarks
1
Minutes of Meeting Today
No. WO
type Plan Qty Actual
qty Remarks
1
Safety Information
No. Description Action Remarks
1.
2.
Instruction from Representative
1
Help needed by tecnicians
1

TOOLBOX TALK – TOPIC 1 (HEARING CONSERVATION)
LIMITS OF EXPOSURE :
OSHA Regulations state that when noise levels
exceeds 82 dB for an eight-hour TWA, a hearing
conservation program must be in place.
PERMISSIBLE NOISE EXPOSURE :
Duration per day, in
hour
Sound level dBA slow
response
8 90
6 92
4 95
3 97
2 100
1 ½ 102
1 105
½ 110
¼ or less 115

TOOLBOX TALK – TOPIC 2 (HOT WORKS)
HOT WORK :
Any spark-producing work such as welding, ox-acetylene cutting,
grinding, or open flame
HOT WORK PERMIT :
A permit that, when signed by authorized personnel, allows hot work to be done
in specific designated areas within the limitations listed on the permit. Only those
named on the permit are allowed to perform the hot work.
A permit is valid only for one (1) operations shift (8 hrs)
SPECIAL HAZARD AREA :
Areas that have the following characteristics:
Explosive atmospheres
Special circumstances which prevent the removal of highly flammable and
combustible materials
Ignition sources that cannot be shut down
Hot work being performed on any pipe, tank, vessel, drum, and so on that
contains flammable liquid, vapors, or gases
Work that penetrates the roof and/or electrical classified areas
Hot work in special hazard areas requires approval by two
Authorizers.

TOOLBOX TALK – TOPIC 3 (BARRICADES &
SIGNBOARDS)
BARRICADES:
Barricades will be used to isolate areas where there is unusual
hazard to approaching personnel or to protect personnel inside a
barricade from external hazards
Examples:
Open grating and holes or openings in floor or roof area
Excavations
Elevated works/Overhead works where a falling object hazard exists
Chemical spills, leaks, or line breaks
Maintenance Works
SIGNBOARDS:
Signs should be posted and should be visible when work is being
performed that constitutes a hazard or potential hazard. Signs also
should be posted wherever a reminder of accident prevention
requirements would be beneficial or where the hazard

TOOLBOX TALK – TOPIC 4 (SITE TIDYING & CLEANING)

MANAGEMENT OF LOCKOUT TAGOUT SYSTEM
1. Purpose
•For the protection of workers, equipment being worked on will be at its lowest practical
energy state to prevent the accidental release of energy or the inadvertent operation of
equipment.
•This instruction establishes requirements that will be followed when locking and tagging
equipment during operations. Particular circumstances or conditions may warrant more
restrictive measures.
Energy sources (e.g. steam, air, oil, hot water) will be disconnected or isolated, and
precautions taken to prevent loose or movable parts from rotating or otherwise moving
and becoming a hazard.

2. Scope
The instruction applies to all Sodexo site personnel whom will be required to execute
technical works and need to lockout/tagout energy sources during the course of work.
3. Procedure
•Duty Supervisor and Lead Technician will draw out the lockout lock, MCB hasp, a multi-lock
device and his personal tag. One of his personal tag will be in place of the lock in
the lockout/tagout cabinet.
•All technicians whom require to lockout/tagout energy sources will draw out a lock and
personal tag. One of their personal tag will be in place of the lock in the lockout/tagout
cabinet.

•The duty supervisor and Lead Technician will be responsible for administration of the
lockout/tagout system on site.
•The Sodexo Maintenance Manager or Supervisor will review and approve the Permit-
To-Work for all internal lockout/tagout requirements only
•Where a lockout/tagout is required for the following types of work, the Permit To
Work(P & G) form will need to be submitted to P & G Safety team and technical team
Head for review and approval:
•Routine works requiring PTW without JSA;
•Confined Space Entry;
•Working On Height;
•Hot Works;
•Minor project Works;

Review safety procedures.
Set priorities for all maintenance work.
Assign cost accounts.
Complete the work order.
Review the backlog and develop plans for controlling it.
Predict the maintenance load using effective forecasting technique.
A job priority ranking reflects:
The criticality of the job
The availability of all materials needed for the work order in the plant
The production master schedule
Realistic estimates and what is likely to happen
Flexibility in the schedule

Effective planning and scheduling
contribute significantly to the following:
Reduced maintenance cost.
Improved utilization of the maintenance workforce by reducing delays and
interruptions.
Improved quality of maintenance work by adopting the best methods and
procedures and assigning the most qualified workers for the job
Minimizing the idle time of maintenance workers
Maximizing the efficient use of work time, material, and equipment
Maintaining the operating equipment at a responsive level to the need of
production in terms of delivery schedule and quality

Classification of Maintenance Work
According to Planning and Scheduling Purposes
Routine maintenance: are maintenance operations of a periodic nature. They are
planned and scheduled and in advance. They are covered by blanket orders
Emergency or breakdown maintenance: interrupt maintenance schedules in order
to be performed. They are planned and scheduled as they happened
Design modifications: are planned and scheduled and they depend on eliminating
the cause of repeated breakdowns
Scheduled overhaul and shutdowns of the plant: planned and scheduled in
advanced
Overhaul, general repairs, and replacement: planned and scheduled in advanced
Preventive maintenance: planned and scheduled in advanced
The maintenance management system should aim to have over 90% of the
maintenance work planned and scheduled

Determine the Maintenance works procedure
Prepare for each Facilities Asset/Equipment the maintenance procedure in detail
Develop Maintenance Schedule, showing sequence and timing of the activities
Establish the Job Risk Assessment for the maintenance works
Determine if they requires a Work permit prior to the execution of Maintenance works
Plan and order parts and materials required for the Maintenance works as per schedule
Check if special tools and equipment are needed and obtain them
Assign technicians with appropriate skills
Establish the crew size for the maintenance works
Maintenance works focus on cleaning equipment components, checking their condition,
functionality; secure proper connectivity and tightness of all component, and replace
those that are not working properly or are about to fail

AC Split Units Maintenance Procedure
SAFETY CHECKLIST
PPE (safety gloves, shoes, helmet, goggles etc.)
Barricade work area
Working at height safety
Other safety measures or permits as required
TASK DESCRIPTION-MONTHLY
Check and clean air filter and unit casing.
Check and clean drip tray. Flush drain pipe
Check and clean condenser coil if necessary
Check and clean blower fan.
Lubricate all fan and motor bearings
Check all mounting bolts and fan guard of condenser
unit.
Check all mounting bolts for indoor unit.
Record air flow reading (cfm)
Clean indoor unit
Test proper functioning of thermostat
Check low pressure of freon gas
Check electrical contactor and isolator
Record running current for the compressor motor
(ampere) and compare against name plate
Clean area after servicing

S/NO JOB
HAZARD
EXPOSU
RE/
DETAILE
D
HAZARD
PLANT,
EQUIP
MENT
AND
TOOLS
USED
HEALTH
AND
SAFETY
RISKS
EXISTING
OPERATION
CONTROLS &
PPE
RISK
RATING
RECOMMEND
ADDITIONAL
OPERATION
CONTROLS
Residu
al risk
rating
COMPLET ON
DATE &
ASSIGN TO
S L R S L R
1
Check and
clean air
filter and
unit
casing.
Ladder/
wash
tap
Eye
injury &
fall
Googles/hand
gloves/safety
harness &
proper usage
of ladder
2 2 4
If motorized lifter
is used-require
to be trained &
certified
2 2 4 EMPLOYEE
NAME (PRINT
NAME)
EMPLOYEE
SIGNATURE
DATE
2
Check and
clean drip
tray. Flush
drain pipe
Wet/dry
vacuum
cleaner
Eye
injury
Googles/hand
gloves 2 2 4 No further
controls required
3
Check and
clean
condenser
coil if
necessary
Water
jet hose
Eye
injury
Googles/hand
gloves-caution
when jet
spraying
2 5 10 No further
controls required
EMPLOYEE
NAME (PRINT
NAME)
EMPLOYEE
SIGNATURE
DATE
4
Check and
clean
blower
fan.
rags
Eye
injury/mo
ving parts
Googles/hand
gloves/Logout
& Tagout
2 2 4 No further
controls required

5
Lubricate all
fan and
motor
bearings
Grease
gun
Moving
parts
Googles
/hand
gloves/L
ogout &
Tagout
2 2 4
No
further
controls
required
RISK
ASSESSMENT
NAME
AUTHOR’S
SIGNATURE
ASSESSMENT
DATE
6
Check all
mounting
bolts and
fan guard of
condenser
unit.
Hand
tools
Hand
injury
Self
care
when
using
hand
tools
2 2 4
No
further
controls
required
7
Check all
mounting
bolts for
indoor unit.
Hand
tools
Hand
injury
Self
care
when
using
hand
tools
2 2 4
No
further
controls
required
MANAGERS
NAME
MANAGER’S
SIGNATURE
ASSESSMENT
DATE
8
Clean
indoor unit rags Eye
irritation
Googles
/hand
gloves
2 2 4
No
further
controls
required
9
Test proper
functioning
of
thermostat
No tools Non Non
required - - -
No
further
controls
required
10
Check low
pressure of
freon gas
Gas
manifold Non Non
required - - -
No
further
controls
required
SAFETY
DEPARTMENT
NAME
SAFETY
OFFICER’S
SIGNATURE
APPROVED
DATE
11
Check
electrical
contactor
and isolator
Visual
inspectio
n
Electroc
ution
Goggles
&
electrica
l gloves
2 2 4
No
further
controls
required

13 Record
running
current for
the
compressor
motor
(ampere)
and
compare
against
name plate
Ampere
meter Electrocution
Goggles
&
electrical
gloves
2 2 4
No
further
controls
required

Monthly Preventive Maintenance day by day monthly cycle
It includes all the activities related to the preparation of:
The work job order
Bill of materials
Purchase requisition
Necessary drawings
Labor planning sheet
including standard
works times
All data needed prior
to scheduling and
releasing of the job
work order

KPI 2014
Client Score guide:
Location 95% - 100%:
Excellent
Review by 85% - 94% : Good
Date review <85% :
Unsatisfactory
No Performance Total
points
Minus
points
Actual
points
Comments
I Productivity
1 100% Training record is documented to prove
that technicians have been trained to provide
good service.
10 0 10
2 Re-work on work orders < 2% 10 0 10
3 Maintenance site cleanliness maintained and
10 0 10
captured as per standard = 100%.
4 Master plan and month plan completion rate >
95%
10 0 10
5 Control faclitily by planning CM&PM and
providing spare part in <3 days> 95% work
orders
20 0 20
6 Use 3rd party vendor for repairing <2% work
orders.
10 0 10
7 Minor repairs completed < 3 days > 95% of
work orders (after issue of PO# or approval for
parts if applicable)
20 0 20
8 Major repairs completed < 10 days > 95% of
work orders (after issue of PO# or approval for
parts if applicable)
10 0 10
9 Emergency work orders completed < 24 hours
on > 90% of work orders
20 0 20
10 Replacement parts supplied in < 3 days > 95%
of work orders (after issue of PO# or approval
for parts)
10 0 10
11 Late completion of scheduled work orders <2% 10 0 10

II Quality of work
1 Clearly and timely communication between
maintenance team and user to keep work
process on track.
20 0 20
2 Root cause defined on corrective
maintenance > 95%
20 0 20
3 No unresolved defects found during
walkthrough in facilities inspection.
10 0 10
4 Root cause and work order proper
documentation followed 100%
10 0 10
5 Customer satisfaction feedback capture on
work order >95%
10 0 10
6 Working based on facilities standard for
providing a professional service.
10 0 10
III Cost controlling
1 Do more work by technician team to reduce
the 3rd party to involve<1% of work orders.
20 0 20
2 Actual cost at or below estimate for work
orders > 95%
10 0 10
3 Adhere to repair Plan as per budget
accordingly.
10 0 10
4 Performance of % of unplanned repair
budget vs. time elapsed is within +2%.
10 0 10
IV Delivery
1 Work orders for in scope maintenance
services completed on time > 95%
10 0 10
2 Proper prioritization of work orders > 95% 10 0 10
3 Adequate resources avaialble for in scope
10 0 10
maintenance services > 95%
4 Dropped requests for maintenance service =
0%
10 0 10

V Safety
1 Zero record of injury. 30 0 30
2 Behavior Observation System compliance and
participant > 95%.
10 0 10
3 Job Safety Assessment and safety procedure
are in place and compliance 100%.
10 0 10
4 100% staff follow defined plant's regulation. 10 0 10
5 Zero incident while providing maintenance
20 0 20
service in the plant.
VI Moral
1 Proactively Suggest simple improvement. 10 0 10
2 100% job done based on quality, safety to
prove a moral service in etablishing
satisfaction.
10 0 10
3 Actively propose new areas where technicians
expertise can be applied to the benefit of the
facilities.
10 0 10
420 0 420

Integrated Building Management
Operating and maintaining the Utilities and Power distribution of the plant
by using BMS(Building Management system) with optimal man power
HVAC
Fire protection
Lighting
Access control
Security
and others…
Energy efficiency
- Cost savings
- Improved working conditions
- Environmental benefits

Monitoring & controls of chiller management system.
Monitoring & controls of primary pumps & secondary pumps
Monitoring the variable frequency drive in secondary pumps, AHU
Monitoring the Fire fighting pumps
Controlling the AHU temp through set point adjustment for maintaining room
temp 24+°C
Integrated parameters like
* Chiller
* UPS
* Diesel generators
* Precision Air conditioner
* Package units

Supply air temp sensor
Return air temp sensor
RH sensor
Actuator
CO2 sensor
CO sensor
DPS
DPT
Parameters
-Pressure
-Flow
-Air Velocity
-Valves
-Damper Actuators
-Humidity
-Water Detection
-Occupancy Detection
-Test Equipment
-CO2 content

Client
Communication Network
CClliieenntt IInntteerrffaaccee
Object Model
Request
Driven
Service
Application
Active
Service
Application
Data Model
DDaattaa IInntteerrffaaccee
Dynamic
DB
Component
BMS Service
DDaattaabbaassee
BACnet Interface Echelon Interface Remote Interface
TToo BBAACCnneett NNeettwwoorrkk TToo EEcchheelloonn NNeettwwoorrkk TToo RReemmoottee CCoonnnneeccttiioonn

Energy Conservation and Energy Saving
Energy conservation refers to reducing energy through using less of an energy service.
Energy conservation differs from efficient energy use, which refers to using less energy
for a constant service
For example, driving less is an example of energy conservation
Driving the same amount with a higher mileage vehicle is an example of energy efficiency
Energy conservation and efficiency are both energy reduction techniques
Energy benchmarking - process of collecting, analyzing and relating energy
performance data of comparable activities with the purpose of evaluating and comparing
performance between or within equipment

Cooling Tower; a properly sized cooling tower is designed to cool water to within 5
degrees of wet bulb temperature.
lbs of water per hour cooled x temperature change in degrees F = BTU's/ hr cooling
capacity.
12,000 BTU's hr = 1 TonR tons of refrigeration
12,000 BTU/hr / 3412 = 3.517 Kw hr
Chiller Sizing Information; Before you begin, you must know three factors:
The incoming water temperature
The chill water temperature you require
The flow rate
General sizing formula:
Calculate Temperature Differential (ΔT°F) ΔT°F = Incoming Water Temperature (°F) -
Required Chill Water Temperature
Calculate BTU/hr. BTU/hr. = Gallons per hr x 8.33 x ΔT°F
Calculate tons of cooling capacity Tons = BTU/hr. ÷ 12,000
Oversize the chiller by 20% Ideal Size in Tons = Tons x 1.2
You have the ideal size for your needs in tons of refrigeration

How to Calculate the Capacity for an Industrial Chiller
Industrial chillers work by letting a fluid flow through the device. The fluid has a high
specific heat capacity, which means that it absorbs and releases a lot of energy when its
temperature rises and falls. The greater the fluid's temperature change as it goes through
the chiller, the greater the chiller's capacity for moving energy. The other relevant factor is
the fluid's rate of transfer through the chiller. The chiller's capacity is proportional to this
flow rate
1. Find the refrigerant's temperature change as it passes through the chiller. For
instance, if refrigeration fluid enters the chiller at 60 degrees Fahrenheit and leaves it
at 79 degrees Fahrenheit: 79 - 60 = 19 degrees.
2. Multiply the temperature rise by 500, a conversion constant: 19 x 500 = 9,500.
3. Multiply this answer by the fluid's flow rate, measured in gallons per minute. For
instance, if 320 gallons go through the chiller each minute: 9,500 x 320 = 3,040,000.
This is the capacity of the chiller, measured in British Thermal Units (BTUs) per hour.
4. Divide your answer by 3,412 to convert your answer to kilowatts: 3,040,000 / 3,412
= 890.97 kW/hr

Chiller efficiency in terms of the energy efficiency ratio, or EER, and the coefficient of
performance, or COP, for chillers
total heat removed in Btu/hr = h
h = 500 X q X dt = 40 tons of refrigeration hr
q = chilled water flow rate in gpm, (example 40 gmp)
dt = chilled water's total temperature differential, (example 24 F)
h = 500 X 40 gpm X 24 deg-F = 480,000 Btu/hr.
Kw hr = 480,000 / 3412 = 140.68
1 Ton of refrigeration = 12,000 Btu/hr,
System running at 24.8 Kw hr,
EER = 480,000 / 24,800 = 19.35 > 13-14 standard for AC split unit
COP = 19.35 x 0.293 = 5.67 => 140.68 / 24.8

Air handling unit capacity calculation 136 gpm to tone Small units (up to 1,000 cfm, 500
L/s) may be placed inside ceiling space
Air handling unit is a device to treat air. It has the ability to perform air circulation,
ventilation, heating, cooling, humidification/dehumidification and filtering. On average you
will need one ton of capacity per 500 square feet ( x 0.092903 = 46.45 m2)
Cooling load is defined as the rate at which heat has to be removed from a space to
maintain a constant temperature; the cooling load is calculated in units of BTU/hr, which
represents the speed heat is removed
Estimate the cooling load factor, or CLF, for your type of space using the following as a
guide: residential/apartment, CLF is 1.0; office, CLF is 1.2; classroom, CLF is 1.5; and
assembly, CLF is 2.5. CLF is in units of CFM/SF which is cubic feet per minute per square
feet; example if: 500 SF x 2.5 CLF = 1,250 CFM
Air cooling requirements in cubic feet per minute = floor area x cooling load factor
Total cooling load, TCL = 1.08 x CFM x T
If the interior design temperature is 75 degrees F, cooling coil temperature is 55 degrees F
CFM is 1,250 CFM, then TCL = 1.08 x CFM x "T = 1.08 (1,250) (75-55) = 27,000 BTU/hr
27,000 / 3412 = 7.91 Kw/hr; 27,000 / 12000 = 2.25 ton refrigeration hr.

The lux is one lumen per square meter (lm/m2), and the corresponding radiometric unit,
which measures irradiance, is the watt per square meter (W/m2)
A flux of 1000 lumens, concentrated into an area of one square meter, lights up that
square meter with an luminance of 1000 lux. However, the same 1000 lumens, spread out
over ten square meters, produces a dimmer luminance of only 100 lux
There is no single conversion factor between lx and W/m2; there is a different conversion
factor for every wavelength, and it is not possible to make a conversion unless one knows
the spectral composition of the light
Lifetime: LEDs can have a relatively long useful life. One report estimates 35,000 to
50,000 hours of useful life, though time to complete failure may be longer
Fluorescent tubes typically are rated at about 10,000 to 15,000 hours, depending partly on
the conditions of use, and incandescent light bulbs at 1,000 to 2,000 hours.
Several demonstrations have shown that reduced maintenance costs from this extended
lifetime, rather than energy savings, is the primary factor in determining the payback
period for an LED product

In practice, most buildings that use a lot of lighting use fluorescent lighting, which has
22% luminous efficiency compared with 5% for filaments, so changing to LED lighting
would give only 34% reduction in electrical power and carbon emissions
A typical 100 watt tungsten filament incandescent lamp may convert only 5% of its power
input to visible white light (400–700 nm wavelength), whereas typical fluorescent lamps
convert about 22% of the power input to visible white light
The efficacy of fluorescent tubes ranges from about 16 lumens per watt for a 4 watt tube
with an ordinary ballast to over 100 lumens per watt with a modern electronic ballast,
commonly averaging 50 to 67 lm/W overall

AC is the form in which electric power is delivered to businesses and residence
AC voltage may be increased or decreased with a transformer
Use of a higher voltage leads to significantly more efficient transmission of power
The power losses in a conductor are a product of the square of the current and the
resistance of the conductor, described by the formula
This means that when transmitting a fixed power on a given wire, if the current is doubled,
the power loss will be four times greater
The power transmitted is equal to the product of the current and the voltage (assuming no
phase difference)
where represents a load resistance
Since the current tends to flow in the periphery of conductors, the effective cross-section
of the conductor is reduced. This increases the effective AC resistance of the conductor,
since resistance is inversely proportional to the cross-sectional area
The AC resistance often is many times higher than the DC resistance, causing a much
higher energy loss due to ohm heating (also called I2R loss)

Thus, the same amount of power can be transmitted with a lower current by increasing
the voltage. It is therefore advantageous when transmitting large amounts of power to
distribute the power with high voltages (often hundreds of kilovolts)
High voltage transmission lines deliver power from electric generation plants over long
distances using alternating current
However, high voltages also have disadvantages, the main one being the increased
insulation required, and generally increased difficulty in their safe handling
In a power plant, power is generated at a convenient voltage for the design of a
generator, and then stepped up to a high voltage for transmission
Near the loads, the transmission voltage is stepped down to the voltages used by
equipment

Direct current (DC) is the unidirectional flow of electric charge
Direct current is produced by sources such as batteries, thermocouples, solar cells, and
commutator-type electric machines of the dynamo type
Direct current may flow in a conductor such as a wire, but can also flow through
semiconductors, insulators, or even through a vacuum as in electron or ion beams
The electric current flows in a constant direction, distinguishing it from alternating current
Electric motor found in applications as diverse as industrial fans, blowers and pumps,
machine tools, household appliances, power tools, and disk drives, electric motors can
be powered by direct current (DC) sources, such as from batteries, motor vehicles or
rectifiers, or by alternating current (AC) sources, such as from the power grid, inverters or
generators

Efficiency
To calculate a motor's efficiency, the mechanical output power is divided by the electrical
input power:
,
where is energy conversion efficiency, is electrical input power, and is mechanical
output power:
where is input voltage, is input current, is output torque, and is output angular
velocity
Electric power is the rate at which electric energy is transferred by an electric circuit.
The SI unit of power is the watt, one joule per second; It is equal to the energy expended
(or work done) in applying a force of one Newton through a distance of one meter (1
Newton meter or N·m), or in passing an electric current of one ampere through a
resistance of one ohm for one second

Cavitation is the formation of vapor cavities in a liquid – i.e. small liquid-free zones
("bubbles" or "voids") – that are the consequence of forces acting upon the liquid
It usually occurs when a liquid is subjected to rapid changes of pressure that cause the
formation of cavities where the pressure is relatively low
When subjected to higher pressure, the voids implode and can generate an intense
shockwave
The most common examples of this kind of wear are to pump impellers, and bends where
a sudden change in the direction of liquid occurs
In pipe systems, cavitation typically occurs either as the result of an increase in the kinetic
energy (through an area constriction) or an increase in the pipe elevation.
When uncontrolled, cavitation is damaging; by controlling the flow of the cavitation,
however, the power can be harnessed and non-destructive

Hard water is water that has high mineral content (in contrast with "soft water")
Hard water is formed when water percolates through deposits of calcium and magnesium-containing
minerals such as limestone, chalk and dolomite
Temporary hardness
Temporary hardness is a type of water hardness caused by the presence of dissolved
bicarbonate minerals (calcium bicarbonate and magnesium bicarbonate)
When dissolved these minerals yield calcium and magnesium cat ions (Ca2+, Mg2+) and
carbonate and bicarbonate anions (CO2-, HCO-)
3
3
The presence of the metal cat ions makes the water hard. However, unlike the permanent
hardness caused by sulfate and chloride compounds, this "temporary" hardness can be
reduced either by boiling the water, or by the addition of lime (calcium hydroxide) through
the softening process of lime softening
Boiling promotes the formation of carbonate from the bicarbonate and precipitates calcium
carbonate out of solution, leaving water that is softer upon cooling
Total Permanent Hardness = Calcium Hardness + Magnesium Hardness

Water softening is the removal of calcium, magnesium, and certain other metal cat ions
in hard water. The resulting soft water is more compatible with soap and extends the
lifetime of plumbing. Water softening is usually achieved using lime softening or ion-exchange
resins
Ion-exchange resin devices
Conventional water-softening appliances intended for household use depend on an ion-exchange
resin in which "hardness ions" - mainly Ca2+ and Mg2+ - are exchanged for
sodium ions; ion exchange devices reduce the hardness by replacing magnesium and
calcium (Mg2+ and Ca2+) with sodium or potassium ions (Na+ and K+)“
Regeneration of ion exchange resins
When all the available Na+ ions have been replaced with calcium or magnesium ions, the
resin must be re-charged by eluting the Ca2+ and Mg2+ ions using a solution of sodium
chloride or sodium hydroxide depending on the type of resin used
For anionic resins, regeneration typically uses a solution of sodium hydroxide (lye) or
potassium hydroxide
The waste waters eluted from the ion exchange column containing the unwanted calcium
and magnesium salts are typically discharged to the sewage system.

Energy
In a thermodynamically closed system, any power dissipated into the system that is being
maintained at a set temperature
(which is a standard mode of operation for modern air conditioners)
requires that the rate of energy removal by the air conditioner increase
This increase has the effect that, for each unit of energy input into the system
(say to power a light bulb in the closed system),
the air conditioner removes that energy
In order to do so, the air conditioner must increase its power consumption by the inverse
of its "efficiency" (coefficient of performance)
times the amount of power dissipated into the system

As an example, assume that inside the closed system a 100 W heating element is
activated, and the air conditioner has an coefficient of performance of 200%.
The air conditioner's power consumption will increase by 50 W to compensate for this,
thus making the 100 W heating element cost a total of 150 W of power
It is typical for air conditioners to operate at "efficiencies" of significantly greater than
100%
However, it may be noted that the input electrical energy is of higher thermodynamic
quality (lower entropy) than the output thermal energy (heat energy)

Air conditioner equipment power in the U.S. is often described in terms of "tons of
refrigeration"
A ton of refrigeration is approximately equal to the cooling power of one short ton (2000
pounds or 907 kilograms) of ice melting in a 24-hour period
The value is defined as 12,000 BTU per hour, or 3517 watts
Residential central air systems are usually from 1 to 5 tons (3 to 20 kilowatts (kW)) in
capacity
In an automobile, the A/C system will use around 4 horsepower (3 kW) of the engine's
power

Thermal insulation is the reduction of heat transfer (the transfer of thermal energy
between objects of differing temperature) between objects in thermal contact or in range of
radiation influence
Thermal insulation can be achieved with specially engineered methods or processes, as
well as with suitable object shapes and materials
Heat flow is an inevitable consequence of contact between objects of differing temperature
Thermal insulation provides a region of insulation in which thermal conduction is reduced
or thermal radiation is reflected rather than absorbed by the lower-temperature body
The insulating capability of a material is measured with thermal conductivity (k)
Low thermal conductivity is equivalent to high insulating capability (R-value)
In thermal engineering, other important properties of insulating materials are product
density (ρ) and specific heat capacity (c)

Factors influencing performance
Insulation performance is influenced by many factors the most prominent of which
include: Thermal conductivity ("k" or "λ" value); Surface emissivity ("ε" value
insulation thickness; Density; Specific heat capacity; Thermal bridging
It is important to note that the factors influencing performance may vary over time as
material ages or environmental conditions change
Calculating requirements
Industry standards are often rules of thumb. Both heat transfer and layer analysis may be
performed in large industrial applications, but in household situations (appliances and
building insulation), air tightness is the key in reducing heat transfer due to air leakage
(forced or natural convection)
Once air tightness is achieved, it has often been sufficient to choose the thickness of the
insulating layer based on rules of thumb. Diminishing returns are achieved with each
successive doubling of the insulating layer
It can be shown that for some systems, there is a minimum insulation thickness required
for an improvement to be realized

Thermodynamic heat pump cycles or refrigeration cycles are the conceptual and
mathematical models for heat pumps and refrigerators
A heat pump is a machine or device that moves heat from one location (the 'source') at a
lower temperature to another location (the 'sink' or 'heat sink') at a higher temperature
using mechanical work or a high-temperature heat source
Thus a heat pump may be thought of as a "heater" if the objective is to warm the heat
sink (as when warming the inside of a home on a cold day), or a "refrigerator" if the
objective is to cool the heat source (as in the normal operation of a freezer)
In either case, the operating principles are identical
Heat is moved from a cold place to a warm place
Heat pump and refrigeration cycles can be classified as vapor compression, vapor
absorption, gas cycle, or Stirling cycle types

In this cycle, a circulating refrigerant such as Freon enters the compressor as a vapor.
The vapor is compressed at constant entropy and exits the compressor superheated. The
superheated vapor travels through the condenser which first cools and removes the
superheat and then condenses the vapor into a liquid by removing additional heat at
constant pressure and temperature. The liquid refrigerant goes through the expansion
valve (also called a throttle valve) where its pressure abruptly decreases, causing flash
evaporation and auto-refrigeration of, typically, less than half of the liquid.

L | C | LOGISTICS
PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT
Engineering-Book
ENGINEERING FUNDAMENTALS AND HOW IT WORKS
MECHANICS PREVENTIVE MAINTENANCE AND ENERGY CONSERVATION
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