How to Properly Maintain an Air-Cooled Chiller to Ensure Maximum Efficiency
Machinery maintenance is one of the myriads of chores that causes panic among managers, and that is the source of headaches for millions of company owners worldwide. With the ever-changing world economic context, making businesses stay afloat gets increasingly harder.
But, taking one item off that dreaded list seems to be the zenith of overhead reduction. When disregarded, chillers can be those machines that require technician visits. Yet, there is some solace. Under the assumption that you can take care of them consistently, they can last considerably with minimal to no additional costs.
If you have an air-cooled chiller, grab a chair and take a seat to read these maintenance tips to ensure maximum chiller efficiency.
Air-Cooled Chillers and Their Inner Workings
Before diving headfirst into how to maintain a chiller, you must know how one works first. No proper maintenance can be done if you really do not know what you are dealing with beforehand.
Essentially, the main purpose of chillers is to take water, collect its heat, and dissipate it. This is done to keep the temperature of the environment at a desired constant while getting rid of this heat elsewhere.
The way in which this heat is disposed of is what creates the “Air-cooled chiller vs water-cooled chiller” debate. The main difference relies on the fact that water-cooled chillers employ a cooling tower, whereas air-cooled chillers do not.
While water-cooled chillers may seem convenient at a glance, they call for increased installation and maintenance costs because of the additional components. Plus, they are less environmentally friendly than their air-cooled relatives.
Regarding how the air-cooled chiller works, it first welcomes refrigerant liquid into the evaporator to absorb water heat. This contrast transforms refrigerant into a high-temperature substance.
Secondly, the compressor takes this substance to physically change it into a high-pressure, high-temperature gas.
It is then pumped into the condenser, which liquefies—or condenses—the matter with the aid of condenser tubes. It is then transported to the expansion valve and evaporator once again, where the whole process once more begins.
How to Maintain an Air-Cooled Chiller
When you want to preserve the product lifespan of your machinery, it is vitally required that proper maintenance is done to avoid inconveniences. When it comes to chillers, they are no exception.
Besides, they are the ones that keep your other equipment chilled and the air temperate. So, with little to no work, you will not only be taking care of the chiller but of your whole infrastructure instead.
Here is the air-cooled chiller maintenance checklist:
Revise Water Inlets and Outlets
Inlets and outlets are particularly susceptible to leaks. Always make sure that you are inspecting them periodically. This will prevent water leaks from happening, or at the very least, reduce them.
Keep an Eye on Coils
Coils tend to have problems sporadically. The fins can get bent, and the coils themselves can suffer corrosion or leaks. Make sure that you revise them so as to prevent issues with coils.
Analyze Actuators
Zone control actuators can sometimes require adjustments, clean-ups, or just plain revision. When actuators work right, the amount of water let into the evaporator coil is just right.
Closely Inspect Your Compressor
The compressor is one of the most important parts of the chiller. It is the one in charge of moving the liquid to the condenser. Due to its importance, it should be revised accordingly.
Always ensure to check the refrigerant charge, the amount of vibration—or lack thereof in the best of cases—crankcase heater, oil and/or refrigerant leaks, and operational temperatures. And most importantly, look for oil level changes.
Keep Condenser Fans Clean
Condenser fans are usually subdued to more wear and tear than other components. Keep them clean, inspect bearings frequently—especially when they are lubricated, and supervise the tightness of couplings and belts. Adjust when necessary.
Beware of the Condenser Coil
Condensers also have coils that could be harmed by dust, corrosion and leaks. If there are any bends on the combs, consider changing the condenser coils.
Examine Electrical Disconnects
Contacts can sometimes be dirty or go unsupervised. This part might go overlooked, but it can certainly cause electrical failures in your system. Try to examine electrical disconnects for better operation.
Evaluate the Exhaust Air Daamper
Are bearings lubricated? Are they also properly calibrated? Have you checked if they are in need of a quick adjustment? Check exhaust air dampers!
Revise Return Air Dampers As Well!
These dampers demand care too! Make sure to keep bearings lubricated and calibrated.
Find for Anomalies in the Fresh Air Damper
Once again, ensure that bearings are properly lubricated and calibrated for optimal functioning.
Examine the Filter Dryer
Given that they are exposed to liquids, you must check that they are not either old, damaged, dirty, or broken. When you are under the suspicion that the filter needs a change, do it. It is better to be safe than sorry.
What Is the Best Way to Maintain a Chiller?
Keep a Log of Chiller Activities on a Daily Basis
Knowing what is going on with the chiller at all times can make you save a couple of dollars’ worth of electricity bills and specialist check-ups. From pressures to flow rates, temperatures, and fluid levels, keep track of any form of maintenance done to the machines.
In the past, it was desirable to inspect equipment twice a month.
However, with the advancement of technologies, it is much easier to keep an even more frequent log of all that is happening to your chiller—or chillers. The more you check it, the lesser chance you have of having bigger issues down the line.
Have an Eye on Water
Some of the inconveniences that affect chillers the most are scaling, corrosion, and the appearance of contaminants such as bacteria.
These drawbacks can cause a lack of heat transfer in units, mostly because of bacterial build-up in piping.
Always try to check loops remotely, and if possible, inspect them personally on an annual basis.
Also, treat your water to increase the chances of diminishing any bacteria spreads in your units.
Maintain Heat Transfer Tubes
When transfer tubes are not in a good shape, most of the heat transfer will become inefficient within the piece of equipment.
Undesired sightings of algae, mud, minerals, scaling, bacteria and others are bound to coat the inner part of the tubes. This creates an insulation effect that should be avoided since it absolutely hinders the machine’s performance.
Failing to check inner tubes can positively lead to augmented operational costs due to inefficiency, with a latent possibility of increased downtime and maintenance costs. If you keep the tubes clean, the chiller shall work in an equal fashion.
Do Not Run Short on Refrigerant!
As simple as it sounds, if you do not keep your refrigerant levels to acceptable degrees, the chiller will suffer. It is of utmost importance for the sake of top performance and longevity to have sufficient refrigerant at all times.
The combination of biotic—and abiotic—acumen, coupled with a lack of refrigerant directly translates into more expensive electricity bills. This will happen because you will need more electrical power to provide the same output level.
Do Not Run Short on Cooler Water Either!
A condenser with enough water in it works better than if it does not. The reason is that it will not have to force itself to work harder to perform condensation. If you have any problem with the chiller’s coils, this is even more relevant, though it is deemed a temporary fix.
Get Rid of Non-Condensables
A chiller relies on the physical phenomenon of condensation in order to serve its purpose. Moisture of any kind can bring in non-condensable matter. This robs it of its much-needed efficiency.
It is believed that up to 7% of its performance can be hampered by non-condensables. Less than 7% can cause an impact on your overheads both in the short and in the long term.
Keep an Adequate Flow Rate
Simply explained, the flow rate is the rate at which the water within the chiller flows along. Given that it solely relies on these liquids to function properly, having a slow flow rate can contribute to diminished chiller efficiency.
However, on the opposite side, it can also cause more wear and tear on your product to have a very rapid flow rate.
You should aim between 1 m and 3.5 m per second of flow rate for the best results. Furthermore, the load is also molded by your chiller’s location, and your flow rate is determined by the product’s design.
Variable Speed Drive Upgrades Are to be Considered
It is no surprise that chiller motors demand quite a bit of electricity. When only single-speed drives are employed, the system fails to adjust load differences. They work like “On/Off” switches.
With variable speed drives, you can save up a lot of energy, and it eliminates any sort of abrupt energy differences in diverse circumstances, like, for example, emergencies.
Never Run Empty of Compressor Oil
Provided your unit utilizes oil, send your oil for a yearly inspection to the nearest laboratory. You should only change the oil if they deem it necessary. The reason is that because of its nature, any close refrigerant system shouldn’t change its oil unless specified otherwise.
Get Your Best Air-Cooled Chiller in Malaysia!
Get yourself and your company some of the highest-end chillers in the market. You should never have to worry about having to fret about breakdowns or inefficient machinery. AMCON is your best chiller choice. Go to https://amcon.com.my/ to purchase the best air-cooled chiller in Malaysia.
