Category Archives: chiller maintenance

Water Chiller Maintenance

Water Chiller Maintenance

Maximus chillers provide maintenance to a wide range of water chillers. Some of which have kilowatt hour meters fitted. This means we can monitor the reduction in energy consumption, directly as a result of our maintenance being carried out

Efficient Water Chiller Maintenance

Maintenance is carried out to ensure every aspect of your water chiller is running efficiently. We believe our Tick Sheet is the best in the industry. It looks in detail at the running conditions of the plant, component adjustments and the parameters in the controls. The Tick Sheet is used to assess if there are problems that are starting to occur before a safety shutdown happens. Below are some of the issues that we keep on top of to increase the efficiency of your plant

Shell and Tube Insulation

The build up of dirt acts as an insulator in shell and tube heat exchangers. These are used for the evaporation and the condensing of the refrigerant

The evaporator

In the evaporator, should the tubes be fouled, there will be a reduction in heat absorbed into the system. This will cause the plant to stay on longer and use considerably more energy. Should the tubes become considerably fouled, the water chiller will malfunction and eventually system shutdown will occur

The Condenser

In a shell and tube condenser, the reverse of the above will occur. Tube fouling, acting as an insulator, will prohibit the rejection of heat from the system. The head pressure control will open the condenser controls to try and assist in heat rejection. Heavy fouling will cause an increase in the consumption of energy. Eventually a safety shutdown will occur causing loss of production

0161 370 7193

service@maximuschillers.com

Contact Form

Compressor Loading

Should the loading of the compressors be found to be faulty. The plant will not be able to effectively match the load

Over Loading

Too much loading may occur, causing the water chillers to achieve set point too quickly. The plant will then go through the off cycle. This means that the plant will have to load back up, using more energy than matching the load continuously

Under Loading

Should the plant be unable to load up to the required level to match the load, this will cause the water temperature to creep up and the lag chillers being called for to match the load. More water chillers running than necessary dramatically increases energy consumption

Follow this link to read more about water chiller maintenance | Click Here

Visit the Refcom site to read about leak checking during water chiller maintenance | Click Here


Chilled Water System Flow Switch Maintenance

Chilled Water System Maintenance

Maintenance of the Chilled Water System Flow Switch

The chilled water system flow switch requires regular maintenance due to a to build up of contaminants on the sensor. Over time, slime accumulates giving false readings. The problem is relatively easy to sort out: a wipe with a cloth

Retrieving the sensor

The more difficult part is deciding how the retrieve the sensor. It is fixed with a bolt into the chilled water system being maintained. Therefore there is pressure inside. The textbook way to do the job is to valve off the section of pipework, then drain the glycol into a vessel. There are other ways known to an engineer

Snatching the Flow Switch!

Although not text book: snatching the flow switch is a considerably easier way of maintaining the chilled water system! One of our seasoned engineers unscrewed the bolt whilst holding the flow switch in. He whipped it out- gave it a quick wipe and stuck it back in! Only a small amount of the secondary coolant was lost (which shot out- loosing no height) He re-tightened the bolt and the job was done

0161 370 7193

service@maximuschillers.com

Contact Form

Checking the Fault Out Level

As you can see from the picture: there is a green light on 0. This indicates that the pump is off. Not to be confused with pressure, as there will be a couple of bar on a roof an 6 bar or so in a basement. The higher pressure in a basement is due to the head of water pushing down. With the pump on: the green lights go all the way up to 9 with the fault out level showing red on 7

Maintaining the Chilled Water System Fault Out Level

Maintaining the chilled water system flow switch can be achieved with a terminal driver. Using the manual that comes with the flow switch: the buttons can pressed a number of times to 'self test' Also, the fault out level can be set

Testing the Flow Switch

As part of the maintenance, the flow switch is manually tested using one of two methods. This ensures that the switch will function correctly when it needs to

Read more about flow measurement on Wikipedia


Air Cooled Glycol Chiller Maintenance

Air Cooled Chiller Maintenance

Air Cooled Chiller Maintenance Bodger Watch

A chiller maintenance is usually very good, but this is bodger watch!

We maintain the air cooled chillers in an office building. The customer told me there had been this guy who used to come who spent most of his time in the canteen- reading manuals on his lap top! Not even the manuals for that site either! You couldn't make it up could you? What kind of a chiller maintenance schedule is that? They said he used to fix everyone's bathrooms in the evening to make up his pay! This is bodger watch!

Air Cooled Chiller Maintenance of Glycol

Our junior engineer rang me from a job the other week. Struggling to carry out air cooled chiller maintenance- the glycol dosing. Get your refractometer out I said before you ring. We are teaching how to think for himself instead of just ringing everybody up. He came back with the result- too much glycol. The customer uses propylene even though the site is heavy industrial. This is because the price is narrowing between propylene and ethylene and propylene is not toxic

0161 370 7193

service@maximuschillers.com

Contact Form

Customer Adding Glycol

The customer adding glycol is the usual course. It means their onsite chiller maintenance engineer can keep on top of things on site. This onsite engineer was a little too keen though: he had been putting too much in

Glycol Removal

The job was performed by telling my engineer to get half of it out into the empty drums that were still on site. The glycol can be used again in the future maintenance of the chiller. He then topped up the water system with water

For the efficient running of your chilling plant- choose Maximus Chillers to maintain Click Here for more info

Clear Site

Last but not least all off our engineers give the machine a wipe down and the chiller location a sweep. Good house husbandry is a part of expert chiller maintenance

Visit Refcom for industry guidance and advice


Translate