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FANS: OPERATION
AND MAINTENANCE
This month’s Skills Workshop provides an overview of the maintenance
requirements for fans and associated systems. Last month, in part one,
PART TWO
we looked at the operation of fans.
MAINTENANCE Preventative routine maintenance extends the life of the fan and the
performance of the system. Maintenance routines comprise checking
and periodically replacing the wearing components.
The maintenance imperative
Most fan maintenance involves checking drives and belts for wear, performing Predictive maintenance
preventative or predictive maintenance activities on bearings, and ensuring
correct alignment and proper motor condition and function. Predictive maintenance goes one step further and is generally applied to
critical systems where failure is costly or unacceptable. Predictive maintenance
However, maintenance regimes also need to extend beyond the fan itself
includes continuously or periodically monitoring the fan key performance
and for many HVAC&R applications, “system maintenance” is crucial for
PULLOUT
Mandatory maintenance
In some applications, maintenance of fans is a mandatory requirement;
including fans covered by NCC Volume One (BCA Class 2 to 9 Buildings)
Section J, and fans covered by AS/NZS 3666.2. Fans that operate as part
of the building’s essential fire safety measures under the requirements
of AS/NZS 1668.1, Section E2.2b of the BCA or Section G3.8 of the BCA
are required by state legislation and AS 1851 to be maintained and routinely
tested for satisfactory performance.
Preventative maintenance
Maintenance requirements vary with the type of fan, the type of installation
and the system application. Maintenance recommendations specified
by the manufacturer should take precedence.
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HVAC&R SKILLS WORKSHOP ▲ Module 69
Where possible, inspect the internal surfaces of the fan casing and the
11. If accessible, check cleanliness of fan blades runner for any build-up of dirt, grime, grease, etc. Steam cleaning or
and scroll or casing and record/report if 12 high-pressure water jets can be used to restore the surfaces to an as-new
cleaning is required. condition. The surfaces should then be examined for corrosion and, if
necessary, they should be repainted.
Replace with new matched sets. This could refer to belts, in-belt drives,
buffers, indirect drives, or any other item that is provided for flexibility in
13. Replace flexible drive components. 36 the drive. If replacement becomes necessary in less than 36 months due to
normal wear, then the maximum replacement period restarts from the time
of replacement.
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Module 69 ▲ HVAC&R SKILLS WORKSHOP
Recommissioning begins with a review of the system operating
Maintenance procurement requirements to determine what, if any, changes in requirements have
occurred. The system operating requirements need to be updated
The selection of a good maintenance service provider is the key to or confirmed prior to any recommissioning activities commencing.
satisfactory maintenance, which will result in reliable plant performance, If changes have occurred, systems are reviewed to establish if corresponding
good plant life and reasonable expenditure. Lowest tender price is the least changes to equipment, controls or operation procedures are required. Systems
appropriate way to select a service provider. Value for money should be the are then fully surveyed and a list of findings or issues compiled. System trend
determining factor. The ideal situation is where the customer and service logs or functional performance tests may be used to determine if the system
provider establish a partnering relationship, recognising that the service meets the performance defined in the reviewed operating requirements.
provider needs to make a profit and the customer needs to contain the costs.
Thus a potential maintenance service provider should have the following Extensive changes to operating requirements or installed plant may mean
attributes: that system retrocommissioning is required. Refer to AIRAH DA27 for full details
on recommissioning and retrocommissioning protocols.
• Competent, committed and well-trained technicians
• Appropriate licenses, insurances and accreditation
• Appropriate level of resources
Upgrades
• Efficient and accurate maintenance management system Fan or plant replacement is carried out for a number of reasons, including
failure, degraded performance, and changed system goals or parameters.
• Informative reporting system
Fan replacement could even be considered at initial commissioning if, due to
• Accurate and timely invoicing excessive margins, the selected fans are so oversized the system needs to be
excessively throttled.
• Economical and reliable after-hours service When upgrading or replacing a fan, the system requirements should
• Quality, environmental and safety management systems. be revisited and a fan selection process carried out. Do not simply replace
like for like.
The assessment of maintenance contractors should include an evaluation
of their sustainability practices. It is important to incentivise maintenance A facility upgrade strategy might schedule the replacement of inefficient fans
contractors to consider the energy-efficiency of the system during and associated equipment with modern high-efficiency alternatives. However,
maintenance inspections. the load/system requirements should always be reviewed for changes. ▲
PULLOUT
System tuning
In a typical HVAC&R system, chillers, pumps, valves, fans, and the like are all
required to operate together in coordination to achieve a space temperature
that is within specification. System tuning and the maintenance of controls
are crucial to achieving this. Prior to any tuning taking place, key performance
More information
indicators for equipment and systems and condition responses need to be
established.
System management THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
DA13
made to the system without being properly documented and approved.
• Documenting changes – Any changes made to the system should be
documented; the as-installed drawings and the operating and maintenance
manuals should be updated to reflect the changes made.
FANS
• Verifying improvements – any changes made to the system should be
verified against the stated goals or objectives of the change. Simply
assuming that the changes made have achieved the required objectives
is insufficient and confirmation should be encouraged to verify the
performance of any implemented improvements.
APPLICATION MANUAL
Recommissioning
Systems change over time – components wear, set points are altered, control
calibrations drift – often resulting in deterioration of system performance. This month’s Skills Workshop was taken from AIRAH’s
Recommissioning is intended to bring a system back to its original
performance and operating efficiency, and is carried out periodically (every application manual DA13: Fans, which was revised and
three to five years) or in response to operating problems. Recommissioning republished in 2013, and is available in AIRAH’s
activities include tuning, calibrating, testing and verification and generally online store at www.airah.org.au
follows the tests and methodology developed for the original commissioning
program.