An industrial water chiller is a costly investment and one of the leading cost centers in an industrial facility. It’s vital to ensure that the chiller is well maintained in order to guarantee its efficiency and reliability. While most industrial units have installed systems which help them detect faults in advance, putting in place comprehensive maintenance measures helps in ensuring that chiller performance and efficiency is achieved. Here are important steps which should be taken to improve the efficiency of an industrial water chiller.
Ensure that an operating log is maintained
Those operating the chiller should maintain daily log with regard to current performance and compare it with the design and start-up data. This will help in detecting inefficient control set points. The daily data forms a history that can be analyzed so as to provide important trends and offer crucial warnings whenever there are potential problems. Today’s chillers have microprocessor controls that assist managers tune the systems towards high efficiency levels.
Keep the tubes clean all the time
One of the factors that may bring down the level of performance of this industrial water chiller is its heat transfer efficiency. The condenser tubes and evaporators can transfer heat well when they are clean. Large industrial chillers have many miles of tubes in their heat exchange systems hence its necessary to keep it in a clean condition all the time. To achieve this goal, facility managers can adopt both mechanical and chemical cleaning which helps to remove algae, mud, loose materials and sludge from the tubes.
Fix all leaks in the unit
Compressors may leak and it’s imperative that they be checked quarterly. Any leakage makes it possible for moisture and air to enter the tubes therefore impacting negatively on the performance as well as efficiency of the unit. However, low pressure chilling units are able to remove non condensable dirt automatically and because of this, its able to maintain an efficient operation.
Ensure that water is properly treated
Most chilling units use water for transferring heat and it’s of great essence that the water is treated so as to prevent corrosion, biological growth and scaling from occurring. If you are using a closed water system, it’s critical to consider using chemical treatment occasionally. For open systems, you will need to use the condenser that’s connected to the system. Technicians should do a thorough inspection of the systems once a year to find out if there is erosion and corrosion in the chilling system.
Check the system’s refrigerant and oil
Technicians should consider doing an annual tests on the oil as well as the refrigerant of the cooler. This will assist in identifying contaminants before they cause serious performance and efficiency problems on the system. An oil sample can be taken when the chiller is operating and should only be changed if the results of the tests indicate so. Facility managers should comprehend that oil analysis helps in detecting if there are other problems on the chiller. For example, high moisture level is a sign of problems with the purge of the industrial water chiller while change in the characteristics of the oil could be a sign that the compressor needs to be replaced.