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How to Start a Chiller Plant Revised

By following this sequence you can start any chiller plant

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engr.mujtaba01
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124 views2 pages

How to Start a Chiller Plant Revised

By following this sequence you can start any chiller plant

Uploaded by

engr.mujtaba01
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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How to Start a Chiller Plant

Pre-Requisite: System Readiness


Before starting the chiller plant, ensure the following readiness steps are completed:
1. Chiller Valves:
o Verify that all chiller valves (inlet butterfly valve, outlet butterfly valve, motorized butterfly
valve, and balancing valve) are fully open.
o Ensure valves of chillers not in operation are closed.
2. Power Supply:
o Confirm power supply is available for the chiller.
o Ensure the oil temperature is within the specified range and no alarms are displayed on the
control panel.
3. Water Pressure:
o Check that chilled water and condenser water pressures are at normal working levels or design
specifications.
4. Pump Readiness:
o Confirm all valves of primary and secondary pumps are fully open.
o Ensure power is available at the pump electrical panels.
5. Air Purging:
o Manually purge air at the top of the chilled water riser to remove trapped air.
6. Cooling Tower Readiness:
o Ensure cooling tower valves are fully open, the basin is full of water, and power is available at
the cooling tower fan panel.

Step-by-Step Chiller Starting Procedure


Start the equipment in the following sequence:
1. Primary Pump:
 Power on the primary pump. This will circulate chilled water within the chiller via the decoupled line.
No water flows to the Air Handling Units (AHUs) at this stage. Verify this on the display panel.
2. Secondary Pump:
 Power on the secondary pump. Water will now flow to the AHUs, and the flow through the decoupled
line will cease.
3. Condenser Pump:
 Start the condenser pump. This pump draws water from the cooling tower and circulates it through the
condenser and back to the cooling tower.
4. Chiller:
 Once the system displays readiness, power on the chiller. The sequence is as follows:
o The oil pump starts first and runs for two minutes.
o The chiller starts softly and gradually ramps up to full load in approximately 15 minutes.
Note: The oil heater remains powered on even when the chiller is off. If the heater is off, turn it on for two
hours before starting the chiller to warm the oil to the required temperature.
5. Cooling Tower:
 Start the cooling tower fan when the chiller’s oil pump is running.

Step-by-Step Chiller Powering Off Procedure


1. Chiller:
 Power off the chiller. It will take approximately two minutes to stop completely.
2. Cooling Tower:
 Power off the cooling tower fan.
3. Condenser Pump:
 Turn off the condenser pump two minutes after stopping the cooling tower fan.
4. Primary and Secondary Pumps:
 Turn off the primary and secondary pumps after two hours to utilize the residual cooling from 7°C
chilled water for energy efficiency.

DO’s (During Chiller Operation)


1. Check the rotation and inlet/outlet pressure of all pumps. Ensure the pressure difference aligns with
the design specifications (e.g., for a 30-meter head, the difference should be approximately 3 kg/cm²).
2. Monitor the current and voltage of all pumps.
3. Observe pumps for any abnormal sounds or vibrations.
4. Check the current and voltage of cooling tower fans.
5. Monitor inlet and outlet pressure across the evaporator and condenser. The difference should be
within 0.5–1 kg/cm²; higher values indicate partial blockages.
6. Verify water flow from the cooling tower fills and check fan rotation. Ensure water is showering
properly, not forming dense streams.
7. Inspect the cooling tower body for unusual vibrations or noises from the fans.
8. Check chiller parameters to confirm they are within the standard range.
9. Inspect the chiller for any abnormal vibrations, sounds, or oil leakage.

DON’Ts (During Chiller Operation)


1. Do not run the primary or condenser pump until the oil temperature reaches the design value.
2. Never bypass flow switches.
3. Avoid running the chilled water pumps until the system is completely filled.
4. Do not run condenser pumps if the cooling tower basin is empty.
5. Avoid disturbing the balancing valve.
6. Do not throttle the butterfly valve.
7. Do not alter the chiller parameter settings.
8. Do not open valves of chillers that are off.
9. Avoid running extra pumps unnecessarily during chiller operation.

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