During the design and installation of a BAF refrigeration plant, an objective is to maximise performance under the following criteria:
It is of course better if these criteria are considered and designed in before the plant is put into operation. In many cases however we are asked to service existing refrigeration plants which fail to meet the required standards in all or some of the above, leaving the end-user exposed to capacity shortfalls, accidents, plant unavailability, increased power costs and excessive maintenance costs.
We have therefore devised a Service Plan which proposes a structured menu of tests, checks and remedial work with the objective of raising the operating standard of the plant and through training programmes, the standard of the operating personnel. Collaboration with the end-user is required to tailor the package and to select from the ‘menu’ those items that best serve the requirements of the end-user.
Comprehensive Plant Surveys
The first step is to determine the status of the plant with respect to each of the above criteria.
Is the plant capable of generating the required cooling capacity at the required temperature? Capacity measurement of liquid chilling plant is relatively straightforward. The BAF flow and temperature logging system requires no invasion of piping systems and provides valuable data regarding actual cooling capacity and load profiles. Refrigerated storage provides a more difficult evaluation. Development of a system using a combination of primary refrigerant temperature, pressure and flowrate to determine refrigerant plant capacity is in progress but until this system has been approved, a calculated rather than measured capacity may be used.
What are the COP and the COSP of the refrigerating plant? How does it compare to other plant operating at similar temperatures? Using the capacity data obtained above and with the addition of power measurements the COP (Coefficient of Performance) and COSP (Coefficient of System Performance) may be derived. Comparison between these data and data emanating from other similar plant is compared to identify the relative performance. An analysis of the efficiency and the factors contributing to shortfall is conducted.
Is the plant always available when required? How much unscheduled downtime occurs? Is standby capacity available? Are ‘critical’ spare parts held? An analysis of existing service records and logbooks, together with interviews of operating personnel is done to establish the reliability history of the plant. Using data derived earlier regarding capacity and load profiles the level of standby is assessed, and critical components are identified. Consideration is given to the installation of standby components but only after the process of determining if better use of available capacity can be made. Current spare parts stock level is reviewed with special emphasis placed on parts for critical components.
Is the plant as safe as is ‘reasonably practicable?’ Does the plant comply with relevant Directives? A safety audit is carried out to identify if the plant complies with EN 378. Theoperation and maintenance procedures currently being carried out by client staff are reviewed and recommendations made where relevant. Assistance with drafting of SOPs is given.
What does the plant cost to own and operate on an annual basis? Deficits in the criteria above result in costs associated with production losses, power, emergency call-outs, inefficient maintenance and trouble-shooting, insurance, lost time, administration etc.
A report is generated for each survey with details of current status, shortfalls, and recommendations to improve, costs to execute recommendations and estimated benefits accruing from improvements. The end user is then in a position to make an informed decision whether to carry out any or all of the recommended work.
Information regarding the operating characteristics of the plant is vital in managing the maintenance of a refrigeration plant. A relevant operating log and maintenance checklist is a necessary tool to analyse developing trends and to record and prompt maintenance inspections. A generic list is available from which the items relevant to the particular plant are identified, the frequency of record or inspection is decided and the party responsible for carrying out the function is noted. A plant specific log is then produced.
The BAF Preventative Maintenance is based on regular scheduled visits, of which the frequency and detail would be site specified. During a visit, the BAF representative will review the operating logs, inspect the plant using the agreed log, issue Maintenance Reports containing a description of work carried out, and work required together with cost estimates.
It may be that scheduled component inspections and overhauls are included in the contract. In this instance the compressor or other component will be stripped down, inspected and overhauled as required by our certified engineers. The scheduling of such work is managed via the BAF central Equipment Register, which is used to record and prompt component overhauls. It is also used to schedule BAF parts procurement to ensure that the necessary parts are available when required. BAF engineers are certified to overhaul screw, centrifugal and piston compressors.
Temperature Mapping :
This is a service BAF offer which can record temperatures from up to 16 points in a particular area over any specified time. Recording can be down loaded, analyzed and specific graphic print off can be obtained to produce an in-depth report of all recordings. This documentation can be used to ensure specific areas comply with regulations for their design criteria.
Air Velocity / Temperature Measurement
Correct air velocity and distribution of air across large industrial evaporator and condenser coils is extremely important as this has a major impact on the efficiency of a plant. BAF can easily measure air velocity/temperature and offer on-site solutions to inefficiencies caused by incorrect air velocity or air distribution.
Liquid Flow and Pipe Thickness Measurement:
Accurate measurement of chilled liquid is essential from time to time to determine exact heat loads entering specific equipment. BAF can measure liquid flow without breaking into lines by means of Ultrasonic flow measurement equipment. This ensures on the spot accurate information to determine correct plant operation. Insulation breakdown creates an ideal environment for accelerated corrosion on low temperature pipework and vessels. Rapid determination of the extent of corrosion is extremely important for the safe operation of the system. BAF can accurately measure the extent of metal corrosion with the aid of ultrasonic metal equipment. This information can be instantly processed and prompt precise solutions, which is then validated by our engineering department.
Refrigerant Pump-Out and Storage:
Carrying out major work on an industrial refrigeration plant may require removing the complete refrigerant charge from the system to safe storage. BAF can offer both Ammonia and Freon pump-out units capable of pumping up to 1 tonne of refrigerant per/hr into fully certified vessels which comply with PED/EN378 regulations. This offers an efficient and safe solution to removing and storage of refrigerants. All BAF service engineers are certified in Ammonia and “Freon” handling.
Ammonia recovery unit & recovery vessel
Freon recovery unit & evacuation vessel
Shaft Laser Alignment:
Shaft misalignment is responsible for up to 50% of break-downs in rotating machinery, leading to increased machine down time, which translates directly into higher costs. In addition incorrect alignment places a greater load on machine components, resulting in increased wear and tear, as well as higher energy consumption.
This also is especially important for industrial refrigeration equipment as wear and tear on shaft seals leads to refrigerant leaks, resulting in unnecessary gas emissions to the atmosphere.
Industries spend vast amounts each year to remedy the effects of misaligned shafts.
BAF can easily eliminate shaft misalignment through our continued Laser Alignment checks as part of preventive maintenance. Our engineers are fully trained on highly innovative shaft laser alignment tools. BAF offer print outs of current alignment and post Laser Alignment procedure.
Advantages of proper alignment:
Longer bearing life
Less stress on couplings
Less wear on shaft seals lowering risk of lubricant and refrigerant leakage
Lower energy consumption
Compressor overhaul in accordance with manufacture recommendations are essential for extending the life and efficient operation of all compressors.
Planned compressor overhauls will:
Reduce the risk of unplanned compressor down time.
Reduce the risk of bearing breakdown leading to compressor damage beyond repair.
Reduce running costs due to increased efficiency.
Increased running hours life expectancy.
The BAF overhaul service is based on:
Manufacturer training and certification of all engineers overhauling compressors.
Scheduling and prompting of planned overhaul by our Computerized Central
Equipment Register (CER).
Meeting costumer demands, delivering an efficient and professional service to minimize disruption.
BAF certified engineers overhaul all major industrial screw and reciprocating compressors either on site or in our work shop as necessary.
Compressor specific overhaul kits
Brian A Flynn Ltd. is committed to providing appropriate health and safety training for all employees applicable to their function within the organization. This training will begin with induction training on commencement of employment. The purpose of induction training is to ensure that new employees fully understand the potential hazards of their respective work activity and the safety precautions and emergency preparedness required.
The profile of training in occupational health and safety is necessary, not only because of increased legislative requirements, but for other reasons also. Training is now recognized as resulting in increased productivity, safety awareness and reduced accident rates.
Failure to provide adequate health and safety training is a breach of the law. Employers have a general requirement to provide suitable and sufficient health and safety training under the relevant safety legislation and codes of practice. Specific training requirements associated with a specific hazard may also be detailed in individual pieces of legislation.
In addition to Health and Safety training Brian A. Flynn Ltd. is committed to ensuring that all staff in the organization receive the highest degree of skills training so as to perform their duties effectively. Brian A. Flynn Ltd service engineers are exposed to a training program which ensures that amongst other skills they are certified by OEMs to carry out compressor overhauls, configure and troubleshoot control systems and plant, act as site supervisors and provide first aid expertise on site.
Brian A. Flynn Ltd also recognize that training and technical information for the end user is absolutely necessary so as to maximize their knowledge and understanding of the refrigeration plant.
This knowledge and understanding will enable the clients maintenance team to carry out basic maintenance routines safely and efficiently and to conduct basic fault analysis.
Documentation seldom keeps pace as plant grows and evolves. BAF offer a service whereby drawings and documents are produced to reflect the current as-built status of the plant. This can be important in assessing spare part needs, in facilitating the analysis of future modifications, and assisting troubleshooting.