Packaged chiller service due to a refrigerant leak, resulting in a trip out. This visit was to identify the leak and get the plant back online.
Leak Testing during Packaged Chiller Service
Nitrogen was added to the system to aid in the identification of the leak. All parts of the system were checked, including the removal of lagging around the couplings onto the evaporator. The leak was found on a poor quality ‘eliminator’ which had rubbed through on the evaporator.
Vibration Eliminators
We decided to fit high quality vibration eliminators- see picture. These are fitted one in the horizontal position and the other in the vertical. They absorb both directions of vibration, then they are clamped to the chiller frame.
Brazing during Packaged Chiller Service
The pipework brazing was carried out with all combustible materials being removed from the work location. A permit to work was opened with our engineer as the responsible person. A half hour fire watch was carried out on completion of works.
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Pressure Test during Packaged Chiller Service
The pressure testing was carried out using nitrogen. As nitrogen is an inert gas, it will not cause other potential risks to the chiller and other personnel. The pressure test was a pass, so the next phase of the job could be carried out…
Vacuum Pump
Each engineer carries a 10 cfm vacuum pump. This high capacity ensures a fast vacuum. The Torr gauge was fitted to the system and 2 Torr was pulled.
Refrigerant Saturation
In the cylinder, the saturation of R407c is 7 bar at 11°C The refrigerant in the cylinder is in its liquid phase with vapour on top.
Subcooling
On run testing the chiller, the subcooling value was found to be nominal at the industry standard level.
Superheat
The superheat was adjusted, little by little, with the charging of the refrigerant until a good value was achieved. This was tested across all loading conditions for the rest of the visit.
Related Articles:
Chilling Plant Service
Chilled Water System EEV Service
Water System Service of Evaporator
Process Chiller Vacuum Service
Chiller Fault Finding & Diagnosis
Read more about reducing refrigerant leaks at the Institute of Refrigeration