Escolar Documentos
Profissional Documentos
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SGE500-10-C-0012
PROJECT NO. XJ-MC-0001
30 August 2014
MECHANICAL ENGINEERING
EXISTING CONDITIONS SURVEY
HVAC SYSTEM REPORT
FINDINGS
AND
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Table of Contents
Building Mechanical Systems
A. Summary
B. Existing Conditions
C. Equipment Observations
11
18
E. Other Observations
22
F. Corrective Suggestions
23
27
33
I.
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34
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A. Summary
This HVAC report has been developed by the Qavi Engineering, Ltd (QEL) staff mechanical
engineer Mr. Muhammad Amin after a site visit 19 through 21 August, 2014, to the U.S.
Embassy, Kabul, Afghanistan.
The visit was requested by the Facilities Engineer Office, U.S. Embassy, Kabul. Mr. Amin was
escorted and assisted on site by a Facilities Staff representative, Mr. Scott Biffle.
Request for Assistance Mission Statement:
1. Conduct an existing conditions survey, HVAC systems
2. Focusing on the three HVAC air chiller units.
3. Determine causes for the failure of four (4) compressor units in a short period of time.
Mr. Amins Curriculum Vitae is at Section H. He has more than 25 years experience in the
design, installation, testing, operations, maintenance, overhaul, and repair of Carrier, York,
Trane, Honeywell and similar large scale HVAC and refrigeration plants and their integrated
digital control systems. Proof of certification, training and experience is available on request.
This is an initial report. It is limited to the three days time allocated on site and the directed
Mission Statement. A cursory technical analysis is offered as are various remedies.
Due to the advanced state of disrepair and system imbalance as a result of the questionable
installation of the water sprayer contraption on air-cooled chillers, a greater degree of
remediation efforts will be required. These will include the removal, descaling, and reinstallation of the condenser coils. Lubrication oils and their correct amounts will need to be
checked and re-established per spec. Then the drawing down, vacuuming, and recharging of
the system.
With knowledgeable, timely maintenance, the deterioration of the system in general and the
specific replacement of four (4) York compressor units could all have been avoidable.
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B. Existing Conditions
The following system equipment was identified: Air-cooled chillers, Pumps, Air Handler Units, Building
Monitoring System
Chillers
Three air-cooled chillers have been installed on the roof top of the Utility Service Building.
o York , Model YCAS0953EB
o York , Model YCAS0953EB
o AirStack, Multi-module Chiller, Model ASP-30A (9 Modules)
All chillers feed conditioned water to a common loop header.
Pumps
Primary and Secondary pumps circulate water in all chillers @ 1.3GPM/ton.
Primary Pumps
Armstrong
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C. Equipment Observations
York Chiller No. 1:
o
o
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34 C
4.5 C
10.1 C
9.4 C
Running
15.70 bar
17.0 bar
4.70 bar
96 Amps
54% FLA
Running
16.20 bar
16.50 bar
4.16 bar
94 Amps
53% FLA
Delta-T = 0.7 C
System No. 2 Status
Off
Compressor electrically and mechanically damaged
35.6 C
4.5 C
10.3 C
8.6 C
Running
16.0 bar
17.0 bar
3.50 bar
139 Amps
77% FLA
Running
17.60 bar
19.00 bar
3.94 bar
144 Amps
78% FLA
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Delta-T = 1.7 C
System No. 2 Status
Off
Compressor electrically and mechanically damaged
Cooler Freeze-up
Condenser Tube Busted
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35.7 C
4.5 C
10.6 C
10.1 C
Running
16.4 bar
17.9 bar
4.83 bar
100 Amps
56% FLA
Running
16.20 bar
16.70 bar
4.32 bar
98 Amps
55% FLA
Delta-T = 0.5 C
System No. 2 Status
Off
Compressor electrically and mechanically damaged
36.4 C
4.5 C
10.7 C
8.9 C
Running
16.4 bar
17.6 bar
3.61 bar
142 Amps
79% FLA
Running
18.30 bar
19.20 bar
3.90 bar
155 Amps
85% FLA
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Delta-T = 1.8 C
System No. 2 Status
Off
Compressor electrically and mechanically damaged
Cooler Freeze-up
Condenser Tube Busted
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30.6 C
4.5 C
8.8 C
8.2 C
Running
14.3 bar
15.4 bar
4.36 bar
89 Amps
50% FLA
9.9 C
51.7 C
4.6 C
5.3 C
43.3 C
8.4 C
75
28.2%
4.7 C
3.7 C
Running
14.90 bar
15.30 bar
4.01 bar
89 Amps
50% FLA
7.8 C
49.4 C
2.7 C
5.1 C
42.1 C
7.3 C
75
100%
5.3 C
7.3 C
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Delta-T = 0.6 C
System No. 2 Status
Off
Compressor electrically and mechanically damaged
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31.7 C
4.5 C
9.1 C
7.2 C
Running
16.6 bar
17.6 bar
3.38 bar
146 Amps
91% FLA
5.4 C
58.7 C
45.5 C
-1.3 C
6.7 C
48.1 C
10.9 C
75
16.4%
6.7 C
5.8 C
Running
16.40 bar
18.30 bar
3.34 bar
139 Amps
75% FLA
7.1 C
70.5 C
53.3 C
-0.4 C
6.2 C
49.1 C
24.2 C
40
33.1%
6.5 C
-0.3 C
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Delta-T = 1.9 C
System No. 2 Status
Off
Compressor electrically and mechanically damaged
Cooler Freeze-up
Condenser Tube Busted
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E. Other Observations
Water Make-up
Date
Time
20AUG14
21AUG14
1230hrs
1130hrs
0702940
0706470
3,530
Remarks
Make-up
requirement,
23 hours
Within 23 hours of plant operation a total of 3,530 gallons of water was lost somewhere.
This water was conditioned, that is, the plant chilled or attempted to chill this water volume.
Since new water is constantly being introduced, the chiller plant is being placed under additional
loading to achieve set point temperatures. The new water constantly changes the input
temperatures.
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F. Corrective Suggestions
Water Make-up
o It is imperative that a full length investigation of the chilled water loop be conducted.
o Determine the point or points of leakage.
o Reduce the volume of make-up water to that recommended as acceptable in the York
and AirStack system manuals.
o Correction of the leakage issue, reduction of the additional loads placed on the system
in having to condition the infused volume, will enable the system to reach design stasis.
o Thusly balanced, a much better result and more comfortable air temperatures will be
delivered to the recipient office environments.
o How to trace?
Approach A. Introduce a non-toxic, non-corrosive, inert coloring agent into
the chilled water loop. Where that color puddles or stains, there may be found
one of the leaks. Repair or replace failed components.
Approach B. If A fails, a visual pipe trace will be necessary.
Exposed pipe runs should be straightforward.
As-built drawings should assist in the identification of those runs that
may be above false ceilings or behind walls.
For those runs in channels underground, an optical inspection system
can be used between hand holes.
For those runs that may have been buried directly, excavation and
inspection will be required.
o
o
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The three-day analysis and interviews with interested parties concluded that the
greatest concern was with past and present breakdowns observed in York chiller
systems.
How to overcome these problems presently and prevent them in the future is the
essence of this report.
Chiller systems designed and manufactured by York have an extremely good reputation
in the professional HVAC community. They are robust and designed to operate
optimally in a variety of different temperatures quite nicely.
The key to the Yorks, as with all chiller systems, is to have them correctly installed and
commissioned. At start-up, baseline values need to be recorded religiously, then
compared to York design parameters.
After installation, it is just as important to listen to what the system is trying to tell you:
record the readings, determine if they are within parameters, understand how the unit
communicates its various components, know what the chiller microprocessors display,
understand the relationships of the components, their readings, and what is suggested
as a symptom when variances from the norms are detected.
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These are moderately large chiller plants. They were designed and built by
professionals. Similarly, professionals, trained and certified, must be employed to
operate, communicate, evaluate, and mediate these systems.
Otherwise the customer is left with Band-Aid fixes put on by amateurs in hopes of any
result anywhere above zero. This unfortunately has been demonstrated in the appalling
present state of the chiller systems at the US Embassy, Kabul.
Correct operation and proper preventive maintenance are the two keys to success.
The systems report or present readings the competent operating technician
can read and understand. Variances from the norm as given in the operating
manuals present clues as to what is happening, what courses of action might be
needed, well before any failure occurs. Failing to be able to read or failing to
understand these clues has led to the present state of the Kabul chiller plant.
The chillers are designed to operate within a specific design parameter. It is the
operators job to keep the plant running within those parameters.
Chiller Design.
In general, these chillers designed optimally to operate in an environmental
temperature of 35C ambient.
They will operate in higher ambient temperatures, just not as efficiently.
External Factors.
Can adversely affect operations.
It is possible the climatological data could record ambient temperatures up to
45C, for short periods.
Chiller physical location can have an impact.
No surprise, adequate air flow is important to air-cooled chillers.
Separation from heat-generating plant equipment is a plus.
Partial shading from direct suns rays is an easy measure and can, if properly
done, increase system efficiency.
Finally, rather than suffer the deleterious effects of spraying water directly on
the condenser coils (as has damaged the system severely thus far), a more
effective approach would be to reduce the temperature of the airflow before it
reaches the condenser coils. This can be done easily and inexpensively by the
installation of a honeycomb boundary wall. This wall is sprayed with water.
Properly shrouded, the chiller fans will pull air through this evaporative cooling
device. When this air actually gets to the condenser coils, it will be several
degrees cooler. Hence the system should operate more efficiently, and, with
the benefit of no condenser coil or fin de-scaling sessions necessary.
This technique is simple, inexpensive, low tech, and a much safer method to
optimize chiller efficiency within its design parameters.
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o
o
o
o
o
o
o
o
o
o
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Cooler tubes must be broken down for further investigation, normal procedure for an
open-loop system of this age.
Of concern is the present state of imperfect fluidic balancing (only water added, no
glycol or corrosion inhibitors)
If found to be corroded, replace; if calcified, de-scale.
Flush the system.
Institute proper fluidics balancing (water, glycol, inhibitors, etc.)
Exterior surfaces of the condenser coils exhibit extreme (sprayed) water mineral buildup. Remove and de-scale in accordance with York recommendations. Use the proper
de-scaling agents and procedures. Do not guess.
All unit electrical contact points exhibit arc pitting (material fusing and transfer). Rather
than try to file, it is advised these points be replaced and re-gapped.
Remove and replace all volumes of compressor oil, using only materials meeting
manufacturers specifications. Do not guess.
Remove and replace all filter dryer elements with only specified components. Do not
substitute.
Remove, thoroughly clean, and perform second- and third-level maintenance on all
condensers fan motors.
o
o
o
o
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All issues identified in York Chiller No. 1 have been repeated in this unit. Please read
and apply the above. Additional issues follow, below.
System No. 2. The compressor has been damaged electrically and mechanically. For
causality please see Section C. Equipment Observations, above. While this could have
been completely avoided with proper O&M, now, this unit, unfortunately, shall need to
be replaced.
System No. 2. The condenser coils have been damaged with one tube completely burst
due possibly to overly high head pressure. Again, it could have been avoided, but now
shall need extensive repair or replacement.
System No. 2. The cooler tubes appear to have been damaged as a direct result of the
expansion by freezing of apparently unconditioned fluidics. A repair might be possible.
Proper O&M of the fluidics in the future imperative. With attention to lab test results
and a proper balancing of the fluidic chemistry, all this damage could have been
avoided.
Systems No. 1 and No. 3. It was reported both system compressors were recently
replaced on Aug 13, 2014. Neither has been calibrated.
All Systems. Temperature sensors and pressure transducers need testing. If good,
calibration; if failed, replacement and calibration.
System No. 2. Electronic Expansion Valve (EEV). Missing. Acquire one with proper
specifications and install.
Chiller Sub-cooler System. This needs attention: the servicing and the replacement of
the thermostatic expansion valve (TXV) system.
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o
o
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Condenser Fan Motors (how many?). These units are damaged; repair or replace;
could have been avoided with proper maintenance.
All Systems.
Replace filter-dryer cores.
Change (compressor?) oil with materials meeting specifications.
Electrical contacts points are pitted need to be replaced. Do not try to service
or attempt to calibrate unless trained and certified to do so.
Refrigerant.
Charge the system only with Freon 407C exactly meeting the manufacturers
specifications.
Test the refrigerant for quality before charging.
o
o
o
o
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General.
Disconnect Chiller Power Supply (Electrical)
Establish safe working area; post safety caution signs on chiller and caution
table around the chiller work area
Disconnect water supply
Recover refrigerant and oil following EPA protocols using refrigerant type
unique servicing tool set.
Properly store recovered refrigerant and oil
CONDENSER OIL
Dismantle condenser fan motors, cover and guards
Disconnect fan motor electrical connections
Disconnect all welding joints
Disconnect all condenser coils from chillers
Perform all maintenance operations on condenser coils, inside tubes, and
outside the coils
De-scale as necessary by flushing with approved chemicals in accordance with
manufacturers specifications. Dry with nitrogen.
Reassemble the condenser coil package back into the chiller
Re-weld joints; validate weldments
Perform detailed maintenance on all condenser fan motors.
Reinstall all condenser fan motors.
Test.
CHILLER STRUCTURE
Remove scaled from chiller structure
Sand, prime and paint as necessary.
SUB-COOLING HEAT EXCHANGER AND THERMOSTATIC EXPANSION VALVE, EEV
Dismantle sub-cooling heat exchanger
Disconnect all welded joints
Disconnect all valves (TXV and EEV)
Service and maintain in accordance with manufacturers protocols and
specifications.
Test, repair, replace if defective
Reassemble components.
Re-weld joints; validate weldments
COMPRESSOR
Disconnect water joints
Fabricate, connect recommended connections for de-scaling process
Execute descaling using recommended materials and methods.
Flush all cooler tubes with recommended materials and dry with nitrogen from
the refrigerant side
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General.
Disconnect Chiller Power Supply (Electrical)
Establish safe working area; post safety caution signs on chiller and caution
table around the chiller work area
Disconnect water supply
Recover refrigerant and oil following EPA protocols using refrigerant type
unique servicing tool set.
Properly store recovered refrigerant and oil
CONDENSER OIL
Dismantle condenser fan motors, cover and guards
Disconnect fan motor electrical connections
Disconnect all welding joints
Disconnect all condenser coils from chillers
Perform all maintenance operations on condenser coils, inside tubes, and
outside the coils
De-scale as necessary by flushing with approved chemicals in accordance with
manufacturers specifications. Dry with nitrogen.
Reassemble the condenser coil package back into the chiller
Re-weld joints; validate weldments
Perform detailed maintenance on all condenser fan motors.
Reinstall all condenser fan motors.
Test.
CHILLER STRUCTURE
Remove scaled from chiller structure
Sand, prime and paint as necessary.
SUB-COOLING HEAT EXCHANGER AND THERMOSTATIC EXPANSION VALVE, EEV
Dismantle sub-cooling heat exchanger
Disconnect all welded joints
Disconnect all valves (TXV and EEV)
Service and maintain in accordance with manufacturers protocols and
specifications.
Test, repair, replace if defective
Reassemble components.
Re-weld joints; validate weldments
COMPRESSOR
Disconnect water joints
Fabricate, connect recommended connections for de-scaling process
Execute descaling using recommended materials and methods.
Flush all cooler tubes with recommended materials and dry with nitrogen from
the refrigerant side
Should extensive issues be found during these inspection and cleaning
operations, the compressor unit may need to be more fully serviced. This is
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GENERAL
AirStack chiller needs full maintenance in accordance with the manufacturers
prototcols.
CONDENSER COILS
The ill-advised spraying of water directly on the condenser coils has resulted in
full scale buildup.
COMPRESSORS
At the time of the site visit and inspection, issues were noted with one system:
the No. 4 rear compressor. Again, through a lack of proper maintenance, it
appears to have been damaged beyond repair. It will need to be replaced,
following strict manufacturer protocols.
COOLER HEAT EXCHANGER (HEX)
Further inspection will be required. It appears at first glance that this system,
too, is damaged.
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An immediate, more detailed, and much more extensive technical assessment of the
damage done as the result of past poor maintenance.
The extended, detailed Bill of Quantities (Statement of Work Elements) required to
correct same.
The requisite Bill of Materials.
Putting together and providing direct on site supervision of the recovery team. This
team would be composed of credentialed, professionally competent HVAC technicians,
trained and having experience in both York and AirStack equipment.
Guarantee of works for an agreed upon follow on period.
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Exactly what is says. We will do it all, keep it running, get it done professionally,
correctly, completely.
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I. Curriculum Vitae
Muhammad Amin
H.# 18, St. # 19, Main Bazar,
Gunj Mughalpura, Lahore, Pakistan.
Phone # +92 42 36880808
Cell # +92 300 8133362
E-Mail:ch.amin@yahoo.com,
ch.amin63@gmail.com
Personal Data:
Name
Son of
Born
Citizen of
Marital status
Personality
Muhammad Amin
Atta Muhammad
September 03, 1964
Pakistan
Married, three children.
Normal height with strong physique and pleasing attitude.
Professional Data:
Profession
Status
Experience
References
Education:
General: S.S.C (1982) with Science from Multan Board, Punjab, Pakistan.
Technical:
Diploma of Associate Engineering (DAE), HVACR Technology, 1985.
Carrier International Training Programs:
CITC # 01. 9 weeks. Basic HVACR, packaged & split air conditioning
CITC # 02. 5 weeks. Advanced reciprocating air & water-cooled chillers
CITC # 03. 4 weeks. Fundamental service, centrifugal liquid chillers with
SM&MP32 controls
CITC # 04. Various. Composite advanced training, USA, UK & KSA.
Advanced Electrical Control Systems.
Advanced Electronics Control Systems.
Building Monitoring System (B.M.S).
Carrier Comfort Network (C.C.N) Level B&C.
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Achievements:
Global quality award (WCA). Member of Carrier Saudi service team; won the Wills
Carrier Global Quality Award (WCA); certificate; 1995
Recognition, WCA. Member of Carrier Saudi service team; WCA Recognition Award for
extraordinary services over an extended period; letter of appreciation; 1994
Company Awards:
Best Technician of the Month
Best Technician of the Quarter (service techniques, safety practices
Carrier, Riyadh, KSA.
Special Team Recognition Award. Protecting the environment; Riyadh
Customer Appreciation:
Customer Satisfaction Certificate; multiple awards
Attaullah Villa and Resources
Oberoi Madinah Hotel
Riyadh Cable
Others
Field experience:
Carrier Saudi Service Company, Foreman, Riyadh, Jeddah and Damam.
King Abdul Aziz University Jeddah. Overhauled and commissioned four 10,000-ton
(40,000 ton) Carrier 17FA centrifugal chillers (worlds largest) with PLC controls
King Saud University, Riyadh, KSA. Overhauled and commissioned six 6,000-ton
(36,000 ton) Carrier 17EA centrifugal chillers
King Fahad International Air Port, Damam, KSA. Overhauled and commissioned all
Carrier 17DA centrifugal chillers; installed Allen Bradley PLC controls
Youth Hostel, Damam, KSA. Overhauled two Carrier 19DG centrifugal chillers
Ministry of Foreign Affairs, Riyadh, KSA. Overhauled three Carrier 19FA centrifugal
chillers
Saudi Arabian Monitory Agency, Riyadh, KSA. Overhauled four Carrier19FA
centrifugal chillers
Yamama Hospital, Riyadh, KSA. Overhauled two Carrier19DG centrifugal chillers;
commissioned, executed startup of four Carrier 19XL chillers
King Faisal Foundation, Riyadh, KSA. Overhauled two Carrier 19EB centrifugal
chillers
Khazama Center, Riyadh, KSA. Overhauled two Carrier 19EB centrifugal chillers
At the following locations, overhauled and commissioned reciprocating chillers,
Flowtronic, Flowtronic plus, as well as screw chillers, various sites:
o King Abdul Aziz Science City, Riyadh, KSA
o AL-Akaria Shopping Mall, Riyadh, KSA
o Pakistan Embassy, Riyadh, KSA
o Turkish Embassy, Riyadh, KSA
o Australian Embassy, Riyadh, KSA
o Many others
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o
o
o
o
o
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Saudi Oger Ltd., KSA, Specialist HVAC Operating Engineer, Centrifugal Chillers.
Saudi Kingdom-wide area of responsibility.
o Palaces of the King
o Other Royal palaces
o Royal Diwans
o Royal offices
o ARAMCO Dehran utilities
o King Abdullah International University of Science and Technology
Equipment attended:
o Carrier centrifugal chillers 19FA
o Carrier centrifugal chillers 19XR and 19XL
o Carrier reciprocating chillers 30GB, 30GT, 30GTN, 30XAA
o Trane Centravac chillers CVAC
o Trane reciprocating chillers ECGA, ECGAB
o York reciprocating chillers YCAJ, YDAJ, YEAJ
o SKM reciprocating chillers
o HVAC building monitoring and air control systems from Honeywell, Sttafa,
Siemens, etc.
Examples of Work Executed:
o Fault finding, various systems
o Electrical troubleshooting
o Unit overhauling
o System commissioning
o Gulf Royal Complex, Damam, KSA. Overhauling and commissioning of seven
Carrier 19FA centrifugal chillers, adding dry coolers; capacity 1,600 tons
each.
o Alpha Royal Diwan, Yamama Palace, Riyadh, KSA. Overhaul three Carrier
19FA centrifugal chillers.
o Royal Hajar Palace Haffou, KSA. Overhaul three Trane CVAC Centravac
chillers; capacity 320 tons each.
o New Guest Palace Riyadh, KSA. Overhaul three Carrier 19EB centrifugal
chillers; capacity 1,500 tons each.
Retrofitting jobs.
o Royal Palaces, KSA. Carrier 19FA and Trane CVAC Centravac chillers;
changeover from R-12 to DuPont R-TC-39 refrigerant.
o ARAMCO Dehran Utilities, North Park, KSA. Three Carrier 19XR centrifugal
chillers, capacity 1,200 tons each, to R-134-a.
o Aramco Dehran Utilities,DOB Building, KSA. Four Carrier 19XR centrifugal
chillers, capacity 1,000 tons each, to R-134-a.
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