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7.

0 Operation Philosophy Chilled Water System

The equipment is dimensioned according to chilled water flow rate requirement of the air
handling unit for accommodation, the air handling unit for galley, the air handling unit for engine
control room & workshop, the air handling unit for electrical compartments and the air handling unit
for new battery room.
The system consists of 2 ( 2 x 100 % ) sets of fresh water cooled chiller unit.
2 ( 2 x 100 % ) sets of chilled water circulation pump, one unit acts as duty and the other acts as
100 % standby. The chilled water piping and accessories are arranged in such a way that each chilled
water pump can be operated together with any chiller unit.
These equipment will be installed at machinery space at platform decks which is certified as
non hazardous safe area. The fresh water cooled chilled units and chilled water circulation pumps are
suitable for operation at safe area.
The system shall be started while the air handling unit for accommodation, the air handling unit for
galley, the air handling unit for engine control room & workshop, the air handling unit for electrical
compartments, the air handling unit for new battery room are in operation.

Temperature Regulation
1. The temperature transmitters ( 49-TT-001 and 49-TT-002 for System A ) are installed at
chilled water supply and return piping respectively and suitable for safe area application.
These transmitters will monitor and control / regulate the capacity control solenoid valves of
refrigeration compressor by skid mounted panel 97-EC-001A according to cooling demands.
2. The temperature transmitters ( 49-TT-003 and 49-TT-004 for System B ) are installed at
chilled water supply and return piping and suitable for safe area application.
These transmitters will monitor and control / regulate the capacity control solenoid valves of
refrigeration compressor by skid mounted panel 97-EC-001B according to cooling demands.

System Monitoring and Safety Devices


1. The pressure gauge are installed according to chilled water piping schematic diagram
C110-M433.01.
The flow switch ( 49-FS-80003 ) is installed at common chilled water return line to monitor
conditions of pumps.
When the measured value is lower than set point, no water flow alarm ( audio and visual )
shall be generated at the VCS / ICSS. Operator shall check the pumps.
Since this particular safety device will monitor the both pumps operation and the alarm shall
be lock in for failure equipment till operator reset it manually.
In auto mode, the system shall change over to standby pump accordingly.

C110-M406.01 Rev. 4 Operation Philosophy - HVAC System 61


During pump change over, the compressor will be stop for operation according to
manufacturers safety protection and chiller unit will not give low chilled water flow alarm to
VCS / ICSS within 60 sec.,

2. Cooling water flow to chiller unit A ( 97-GB-001A ) is monitored by water flow switch
53-FS-80001 and cooling water flow to chiller unit B ( 97-GB-001B ) is monitored by water
flow switch 53-FS-80002. When the measured value is lower than set point and an alarm
shall be generated at the respective skid mounted control panel ( 97-EC-001A / 001B ).
3. Chilled water flow from chiller unit A ( 97-GB-001A ) is monitored by water flow switch
49-FS-80001 and chilled water flow from chiller unit B ( 97-GB-001B ) is monitored by
water flow switch 49-FS-80002. When the measured value is lower than set point and an
alarm shall be generated at the respective skid mounted control panel ( 97-EC-001A / 001B ).
4. If there is fault / malfunction on the chiller unit and respective skid mounted panel will
provide alarm to PLC ( VCS / ICSS ) through Chiller Unit A - Common Alarm Status
Feedback ( 97-XA-80001-A ) and / or Chiller Unit B - Common Alarm Status Feedback
( 97-XA-80001-B ), the operator shall check the alarm status accordingly at respective skid
mounted chiller unit control panel.

System Change Over


Chilled Water Pump Change Over
In auto mode only, the chilled water pump will be able to change over from duty to standby pump
when conditions are met ( by fault, by HMI, etc,. )
Change over will occurs when any one of the event is activated :-
Operator select the standby HVAC pump as the duty at HMI,
The duty HVAC pump had trip alarm ( breaker fault, over current protector trip, no water
flow sense by flow switch 49-FS-80003, etc,. )

Fresh Water Cooled Chiller Unit Change Over


2 ( 2 x 100 % ) sets of fresh water cooled chiller unit is provided for the project and it will be acts as
100 % backup arrangement to each other. The fresh water cooled chiller unit shall be change over
from duty to standby backup equipment when any one of the following is occurred :-
1. Operator select the backup HVAC equipment as the duty at HMI due to operational
requirement ( Step e to g mentioned below ),
2. The duty HVAC equipment had trip alarm ( breaker fault, over current protector trip, chiller
units safety devices activated / trip, no chilled water flow, etc,. ),
( Step a to g mentioned below ),

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Below mentioned sequence shall follow for change-over of Chiller Unit A to Chiller Unit B :-
a. When PLC ( VCS / ICSS ) received Chiller Unit A - Common Alarm Status Feedback
( 97-XA-80001-A ) from skid mounted chiller unit control panel ( 97-EC-001A ) and
Manual change over fresh water cooling system if required ALARM shall be activated
at VCS / ICSS,
b. Operator shall check detail alarm ( list ) at respective skid mounted panel ( 97-EC-001A ),
c. Operator shall check the fault, rectify it and reset it after rectification. The chiller unit A will
restart it automatically,
d. Or else, operator shall plan to change over to backup chiller unit B if it is available,
e. Operator shall stop the failure chiller unit A from VCS / ICSS
( by giving signal 97-XS-80002-AC to skid mounted panel 97-EC-001A ),
f. Operator shall manually open / close the respective cooling water line valves according to
marking position(s) that made during testing and commissioning ( in order to avoid water
flow variation in other consumers on same fresh water network ),
The butterfly valve ( 40-200BU-608 and 40-200BU-607 ) for chiller unit 97-GB-001A and
the butterfly valve ( 40-200BU-606 and 40-200BU-607 ) for chiller unit 97-GB-001B.
g. Start backup Fresh Water Cooled Chiller Unit B from VCS / ICSS,
( by giving signal 97-XS-80001-BB to skid mounted panel 97-EC-001B ).

Below mentioned sequence shall follow for change-over of Chiller Unit B to Chiller Unit A :-
a. When PLC ( VCS / ICSS ) received Chiller Unit B - Common Alarm Status Feedback
( 97-XA-80001-B ) from skid mounted chiller unit control panel ( 97-EC-001B ) and
Manual change over fresh water cooling system if required ALARM shall be activated
at VCS / ICSS,
b. Operator shall check detail alarm ( list ) at respective skid mounted panel ( 97-EC-001B ),
c. Operator shall check the fault, rectify it and reset it after rectification. The chiller unit B will
restart it automatically,
d. Or else, operator shall plan to change over to backup chiller unit A if it is available,
e. Operator shall stop the failure chiller unit B from VCS / ICSS
( by giving signal 97-XS-80002-BC to skid mounted panel 97-EC-001B ),
f. Operator shall manually open / close the respective cooling water line valves according to
marking position(s) that made during testing and commissioning ( in order to avoid water
flow variation in other consumers on same fresh water network ),
The butterfly valve ( 40-200BU-608 and 40-200BU-607 ) for chiller unit 97-GB-001A and
the butterfly valve ( 40-200BU-606 and 40-200BU-607 ) for chiller unit 97-GB-001B.
g. Start backup Fresh Water Cooled Chiller Unit A from VCS / ICSS,
( by giving signal 97-XS-80001-AB to skid mounted panel 97-EC-001A ).

C110-M406.01 Rev. 4 Operation Philosophy - HVAC System 63


Note for Fresh Water Cooled Chiller Unit :
Fresh water net work to fresh water cooled chiller unit ( 97-GB-001A and 97-GB-001B ) shall
be referred to C110-M43.01 P&ID Modification of Existing Fresh Water Cooling System.
The manual operated butterfly valve ( 40-200BU-608 and 40-200BU-607 ) are installed at
cooling water line inlet and outlet piping of fresh water cooled chiller unit 97-GB-001A.
The manual operated butterfly valve ( 40-200BU-606 and 40-200BU-607 ) are installed at
cooling water line inlet and outlet piping of fresh water cooled chiller unit 97-GB-001B.
The respective valves must be opened manually prior to start or prior to change over. The
butterfly valves for standby chiller unit shall be closed.
The operator will be able to close 2 way motorized valve manually during maintenance mode
or as required.

Modes of Operation
This HVAC system will operate in the following modes :-
Normal Operation ( Automatic / Manual ),
Emergency Operation ( Shutdown / Black Out / Overrides )

Functional Operation
Automatic / Manual Operation
The following equipment, component will be active during this operation :-
97-GB-001 A Fresh Water Cooled Chiller Unit A
97-GB-001 B Fresh Water Cooled Chiller Unit B
97-PA-001 A Chilled Water Pump A
97-PA-001 B Chilled Water Pump B
49-200MO-001 2 Way Motorized Valve Chiller Unit A ( N.O )
49-200MO-002 2 Way Motorized Valve Chiller Unit B ( N.O )
49-125WT-001 3 Way Modulating Valve Air Handling Unit A Accommodation ( N.C )
49-125WT-002 3 Way Modulating Valve Air Handling Unit B Accommodation ( N.C )
49-080WT-001 3 Way Modulating Valve Air Handling Unit A Galley ( N.C )
49-080WT-002 3 Way Modulating Valve Air Handling Unit B Galley ( N.C )
49-065WT-001 3 Way Modulating Valve Air Handling Unit A ECR & Workshop ( N.C )
49-065WT-002 3 Way Modulating Valve Air Handling Unit B ECR & Workshop ( N.C )
49-080WT-003 3 Way Modulating Valve AHU A Electrical Compartments ( N.C )
49-080WT-004 3 Way Modulating Valve AHU B Electrical Compartments ( N.C )
49-065WT-003 3 Way Modulating Valve Air Handling Unit A New Battery Room ( N.C )
49-065WT-004 3 Way Modulating Valve Air Handling Unit B New Battery Room (N.C )

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The 2 way motorized valves ( 49-200MO-001 & 002 ) are designed for Normally Open ( N.O )
position to protect the chilled water circulation pump during start up and manual operation.
These valves can be closed manually during maintenance mode or as required.

Emergency Operation
This system will operate according to vessels F&G philosophy.

PRE START CONDITION


The power supply to the HVAC equipment is available,
All MCCB / MCB are in ON position,
All the E Stop push buttons are released,
All the space heater for electric motor, oil heater shall be energized,
All the manual operated valves ( N.O ) inside the chilled water piping network is opened,

Chilled Water System Principle


To start up the chilled water system and the following sequence shall be followed :-
1. The chiller unit shall not be started when no air handling unit (s) are in operation,
2. PLC ( VCS / ICSS ) checks for alarm status of chilled water system equipment / components,
3. PLC ( VCS / ICSS ) checks for isolator switch ( MCC ) status,
4. Start up sequence of System A or System B depending on duty selection,
4.a Start up sequence can be chosen on HMI at VCS / ICSS,
4.b On any active alarm, the HVAC equipment shall be manually change over to
standby backup unit,
5. PLC ( VCS / ICSS ) shall give Start Chiller Unit A Command ( 97-XS-80001-AB ) to skid
mounted control panel ( 97-EC-001A ) and ( 97-EC-001 A & B ) will give signals to 2 Way
Motorized Valves, close 49-200MO-002 signal from 97-EC-001B and confirm opened
49-200MO-001 signal from 97-EC-001A for operation of System A. If the valve is not
confirmed according to require status and will provide alarm to PLC ( VCS / ICSS ) through
Chiller Unit A - Common Alarm Status Feedback ( 97-XA-80001-A ) and / or Chiller Unit B
- Common Alarm Status Feedback ( 97-XA-80001-B ), the operator shall check the alarm
status accordingly at respective skid mounted chiller unit control panel and local indication at
valve.

6. If the duty equipment had trip / malfunction alarm and the operator shall check the sequence
mentioned on above page 63 - Fresh Water Cooled Chiller Unit Change Over,

C110-M406.01 Rev. 4 Operation Philosophy - HVAC System 65


7. If there is no common alarm inside the respective skid mounted control panel ( 97-EC-001 A
or B ) and the skid mounted panel 97-EC-001A will send chiller unit A to pump A or B
interlock signal 97-XS-80001-AA ( or skid mounted panel 97-EC-001B will send chiller unit
B to pump A or B interlock signal 97-XS-80002-BA ) to PLC ( VCS / ICSS ) in order to start
the chilled water circulation pump ( 97-PA-001A or 97-PA-001B ) according to duty /
standby selection at PLC.
8. Then PLC ( VCS / ICSS ) shall give On / Off ( activate ) starter signal 97-XS-001A to
HVAC MCC ( 83-EN-009 ) to start the Chilled Water Circulation Pump A ( 97-PA-001A ) or
PLC ( VCS / ICSS ) shall give On / Off ( activate ) starter signal 97-XS-001B to HVAC
MCC ( 83-EN-009 ) to start the Chilled Water Circulation Pump B ( 97-PA-001B ). The duty
pump will start and check the status of pump 5 sec. ( adjustable timing ) after the pump start
up,
8.a A water flow switch 49-FS-80003 will monitor the pump operation / running status,
8.b The power circuit of the pump is electrically controlled by PLC and it shall check
status of MCB ( On / Off / Trip ),
9. While the pump is in operation, the PLC ( VCS / ICSS ) shall give respective Chilled Water
Pump A ( or B ) running status to chiller unit A interlock signal 97-XI-80001-AA to skid
mounted control panel 97-EC-001A to start up the chiller unit A compressor(s) OR PLC
( VCS / ICSS ) shall give respective Chilled Water Pump A ( or B ) running status to chiller
unit B interlock signal 97-XI-80002-BA to skid mounted control panel 97-EC-001B to start
up the chiller unit B compressor(s).
The fresh water cooled chiller unit A ( or ) B will start and operation status of chiller unit is
controlled, regulate and monitored by dedicated ( skid mounted ) electrical control panel
( 97-EC-001A for chiller unit A and 97-EC-001B for chiller unit B ).
The chiller unit operation status will send to ICSS / VCS accordingly.
10. Malfunction shall express on the PLC ( VCS / ICSS ) and is visualized on the HMI in the
following conditions :-
8.a Circuit breaker failure ( MCC ),
8.b No water flow on chilled water line,
8.c Chiller unit fault common alarm,

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Note :-
Chiller unit A skid mounted control panel 97-EC-001A and chiller unit B skid mounted control panel
97-EC-001B will send Unit A Common Alarm Status Feedback ( 97-XA-80001-A ) and
Unit B Common Alarm Status Feedback ( 97-XA-80001-B ) to VCS / ICSS respectively.
The common alarm will include the following as minimum :-
High refrigerant pressure protection device activated,
Low lubricant level protection device activated,
Compressors motor protection device activated,
Motor current protection device activated,
Emergency stopping of chiller unit,
Refrigerant gas detection,
Low cooling water flow,
Low chilled water flow,
Low chilled water temperature at chiller unit outlet, etc,.

However, detail of alarm and list can be checked at HMI on respective skid mounted panel and chiller
unit operation manual.

Emergency Shutdown / Local Operation


Emergency stop push button is provided on the panel ( 97-EC-001A and 97-EC-001B ) as
emergency stop device for Fresh Water Cooled Chiller Unit A ( 97-GB-001A ) and Fresh
Water Cooled Chiller Unit B ( 97-GB-001B )
Emergency stop push button ( 97-PA-001A-A02 ) is provided as emergency stop device for
Chilled Water Circulation Pump A ( 97-PA-001A ) and emergency stop push button
( 97-PA-001B-A02 ) is provided as emergency stop device for Chilled Water Circulation
Pump B ( 97-PA-001B ).
These safety devices will be installed near the respective equipment.

Refer to Cause and Action table Chilled Water System for interlocking method.

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