Process Chiller Vacuum Service

2 Torr showing on a gauge during process chiller vacuum service

Process Chiller Vacuum Service

During a recent process chiller vacuum service, our engineer achieved a deep vacuum of 2 Torr. This is the same pressure as if the Torr gauge had been fitted directly to the vacuum pump.

Torr Gauge

The Torr gauge was fitted to a refrigerant hose. The refrigerant system uses a different kind of fitting used for breaking in. Therefore, an adaptor fitting was used to go between the two kinds of fitting. A specialist sealant was used between the adaptor fitting and the refrigerant system and another sealant was used between the adaptor fitting and the refrigerant hose. This completed, the Torr gauge was located in a convenient location for inspection on achieving a deep vacuum.

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Process Chiller Vacuum Service Pump

Each of our engineers is issued with a high capacity 10cfm pump which is used for process chiller vacuum service. Only the best equipment will do at Maximus Chillers. The oil was changed as per standard industry procedures and the correct level of oil was checked. The vacuum pump was ran up to operating temperature for half an hour with the inlet valve closed. This was to ensure the correct operating temperature of the oil was achieved before load was given to the vacuum pump. A steel braided refrigerant hose with bolted ends fits with the service ports on the refrigerant system. Therefore, adaptor fittings were again used to get between this hose and the vacuum pump.

Dehydration Process

The purpose for evacuation is the removal of moisture from the refrigerant system. Air contains usually around 50% relative humidity of moisture carried within it. Air had ingressed into the system during the works that had been carried out. The pressure temperature relationship of moisture is 100°C at 760 Torr (1 bar absolute- Earth’s air pressure at sea level) This boiling point drops, corresponding to pressure until at 15°C the boiling point of water is 10 Torr. The boiling point of water at 0°C is 5 Torr. Therefore, with our vacuum pump achieving 2 Torr, a dry system is capable of being achieved regardless of the UK ambient temperature. Also, various heaters were used to speed up the process. Eventually the pressure in the refrigerant system was recorded at 2 Torr.

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Read more about the unit of pressure Torr on Wikipedia | Click Here


Chilled water system repair of condenser to a silver chiller with blue compressors

Chilled Water System Repair of Condenser

Chilled Water System Condenser Beyond Repair

Chilled water system repair of condenser was required because the previous company had been chasing leaks round in a circle. Therefore, the customer had decided to buy a new condenser. This was our first job with a new Maintenance Contract, so we wanted to make a good impression.

Condenser Removal on the Chilled Water System

There was no refrigerant in the chilled water system so our engineer cut the discharge and liquid line to the condenser. He then removed the rivets so the frame could be taken apart. Lifting equipment was fitted to the old condenser to aid the removal. Then, slings were fitted and a forklift truck removed the old condenser.

Condenser Replacement on the Chilled Water System

Our engineer supervised the condenser replacement on the chilled water system. He found that the new condenser did not fit correctly. The new condenser was 5mm thicker than the old one. It was decided to lift it back out and angle grind the frame to make more room. Once this was completed, the new condenser fitted correctly and was bolted in place.

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Chilled Water System Pipework Repair

The pipework had to be repaired and brazed in on the chilled water system. Then, the standard practice of a pressure test to ensure the integrity of the system.

The Evacuation Process

Having passed the pressure test, our engineer set up the vac pump and started the evacuation process. This is to dehydrate the system by pulling a vacuum of less than 2 Torr. Any moisture in the system will boil away and leave the system dry.

Recharge and Test Operation

The refrigerant is R410a. Our engineer put around half the charge in, then trimmed the remaining charge according to the superheat and subcooling values. He monitored the chilled water system for the rest of the day. He was looking for leaks as the plant was at operating pressures of 30 Bar. All was well, so the customer signed off the paperwork as he was pleased with the capability of our engineer.

Read more about air cooled condenser installation at the Institute of Refrigeration Click Here


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