CONDITION REPORT Chiller Plant Bayvue Centre, … Annexure C... · The chiller plant and necessary equipment is located behind Bayvue Centre and forms part of the heating, cooling

TNPA, Port of Saldanha: Chiller Plant

Technical Report TNPA SLD213/07/2017

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TRANSNET SOC LIMITED

(REGISTRATION NO 1990/000900/30)

(trading as TRANSNET NATIONAL PORTS AUTHORITY)

(hereinafter referred to as TRANSNET NATIONAL PORTS AUTHORITY)

PORT OF SALDANHA

CONDITION REPORT

Chiller Plant Bayvue Centre, Saldanha

1. SECTION 1: Overview

1.1 Technical Information and Description

The chiller plant and necessary equipment is located behind Bayvue Centre and forms part of the

heating, cooling and ventilation system. It supplies the building with air-conditioner services on all

floors, of which there are three. The chiller is an air-cooled chiller plant.

Air-cooled chillers are refrigeration systems used in both commercial and industrial facilities to cool

fluids and/or dehumidify air. They are used in a wide variety of settings.

Air-cooled chillers actively absorb heat from process water; they then transfer this heat into the air

around the chiller unit. This type of unit is typically used in areas where additional heat discharge is

not an issue, but instead works as a benefit. For instance, the additional heat can be used to warm a

space during the winter for less money than traditional heating systems.

The cycle starts with the evaporator, which has a liquid refrigerant that flows over the evaporator

tube bundle where it evaporates. In the process, heat is absorbed from the chilled water circulating

through the bundle. The compressor then pulls the refrigerant vapor from the evaporator. The

compressor is then tasked with pumping the refrigerant vapor to the condenser, which increases

temperature and pressure. The refrigerant condenses when it’s in the condenser tubes, releasing its

internal heat to the air or cooling water. The high-pressure liquid then moves through the expansion

device and into the evaporator; in the process the refrigerant pressure is reduced along with the

temperature. To complete the continuous cycle, the refrigerant flows back over the chilled water coils

and absorbs more heat.



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The Original Equipment Manufacturer (OEM) /Agent of the Chiller Plant at Bayvue is Carrier. It has

been in commission for 10 years.

The plant itself is in working order and has been fairly reliable over the years. Monthly maintenance

inspections are conducted as prescribed.

However, the salt laden sea air is accelerating the corrosion process on various parts. This has

impacted the reliability of the unit and several motor trips, water leaks and inefficient heating has

taken place.

As shown below, Figure 1 shows a new Chiller plant supplied by the OEM, Carrier.

An inspection was performed by AHI, an accredited Carrier supplier and refurbishment

recommendations were made.

Further inspection shows the deterioration of the plant to a point where it needs urgent

refurbishment.

2. Condition assessment

2.1 Chiller Plant

The plant itself has a lot of surface corrosion. The corrosion is at its worst in places where water can

be trapped and where there’s no direct sunlight or wind. All bolts and rivets are rusted. All the

enclosure panels at the end of the coils intended to improve aesthetics and for protection of coils and

piping against impact are rusted. The locking mechanisms of doors and covers are still working

properly in the majority of cases. Figure’s 1-7 show the overall condition of the chiller plant.

Figure 1: Chiller Plant



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2.2 Pipework

2.3 Pipes

The pipework is laden with rust and the surfaces covered with iron ore dust. There are numerous

water leaks at various different locations. There are traces of white rust which is a white powdery

deposit formed from a natural corrosion process that can occur on any zinc coated steel product. It is

damaging to the appearance of the steel, not to mention to the anti-corrosion layer of zinc that

protects the body of the steel. The entire piping system will need refurbishment or replacement with

a stainless steel type system. Figure’s 8 – 13 show the condition of the piping system.

Figure 2 Figure 3

Figure 5 Figure 4

Figure 6 Figure 7



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Figure 8 Figure 9

Figure 10 Figure 11

Figure 12 Figure 13



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2.4 Pumps

There are two pumps shown in figures 14- 16. The pump in figure 15 have ceased and are

not currently working which places the entire workload on the other pump. The cable gland

at the electrical connection point of this pump will also need to be replaced. In general, both

are in a poor state with the couplings connecting the pumps to the piping system severely

corroded. Many of the water leaks occur via the flanges/couplings. The hostile

environmental conditions caused most of the damage to this equipment and it requires a

major overhaul.

Figure 14 Figure 15

Figure 16



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2.5 Valves

All valves on the chiller plant are in terrible condition. All of them are corroded beyond repair

or are operationally ceased. The damage is so severe that opening or closing them is

impossible. The handles have corroded so much that they are brittle and touching them

leads to disintegration of the metal with parts of the metal flaking off.

They cannot perform their basic function that is to regulate, direct and controls the flow of a

fluid. All the valves on this Chiller plant needs to be replaced.

Note: No water testing can be done due to the poor condition of the valves, which is

required in accordance with SANS standards for legionella testing.

Figure 17 Figure 18

Figure 19 Figure 20

Figure 21 Figure 22



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2.6 Flanges

The flanges are severely rusted on the chiller plant and are in terrible condition. All of them

are rusted. All bolts used for tightening them are also rusted. There are several water leaks

on these flanges. All of the flanges will need replacement.

2.7 Condensors

The condensers plays one of the most critical roles in the Chiller plant system. The condition

can be seen in Figures 26- 29. They are damaged and extremely dirty. Figure 29 shows the

damage on one of the condensers. All the condensers will need replacement.

Figure 23 Figure 24

Figure 25



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2.8 Pressure Guages

Both pressure gauges are still at the unit with only one operational. The other pressure

gauge fell off due to a corroded pipe and valve connection failure. The pressure gauges

could be re-used but replacement is recommended.

Figure 26 Figure 27

Figure 28 Figure 29

Figure 30 Figure 31



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2.9 Stainless steel piping

The stainless steel cover over piping in Fig 31 shows how stainless steel behaves within this

harsh coastal environment. It hardly has any damage. It has no rust or corrosion on the

surfaces, bends or connection points.

It would be an ideal solution to have the rest of the piping done from the same material.

3. Recommendations

The following lists the recommended actions to be taken regarding the chiller plant:

1. All bolts and rivets that are rusted to be replaced;

2. All the enclosure panels/covers should be cleaned, treated with corrosion protection

and re-sprayed (if the damage is too severe, all panels should be replaced);

3. The entire piping system needs refurbishment or replacement with a stainless steel

piping system;

4. The pumps require a major overhaul;

5. All valves on this chiller plant need to be replaced;

6. All flanges need replacement;

7. All condensers will need replacement; and

8. The pressure gauges can be re-used but is it preferred and recommended that they

are replaced.

Figure 32

Documents

CONDITION REPORT Chiller Plant Bayvue Centre, … Annexure C... · The chiller plant and necessary equipment is located behind Bayvue Centre and forms part of the heating, cooling