Chiller service, maintenance and repair
Industrial Chiller Service
- December 31, 2020
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- June 8, 2020
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Chilling Plant Maintenance Visit
Category : Chilling Plant
On this chilling plant maintenance visit, particular attention was made to compressor loading. This was to ensure that the compressors are capable of operating at 100%. With summer now here- we want the plant capable of running at full capacity.
Controller Loading Timer
On start up, the controller goes through a timer, this is to prevent the compressor from loading up too quickly, achieving set point and going off. With available load, the compressor would start back up and a short cycling condition occur. With 5 minute intervals, the controller brings System 1 screw compressor on at 25%. Then System 2 screw compressor on at 25%. In stages, the controller loads up the compressors until it matches the load.
Compressor Loading Solenoid Coils
These are 24vac. The controller sends out a run signal through the solenoid coil which magnetises the lift valve inside.
0161 370 7193
service@maximuschillers.com
Compressor Loading Solenoid Valves
As the valve lifts, discharge pressure oil passes through a channel and pushes the slide valve open a 25% stage. There are 4 valves for the 4 stages.
Chilling Plant Maintenance Visit at 100%
The chilling plant being maintained on this visit was now running at 100% on both systems. The system readings can easily be read by following the menu in the Carrel controller. Superheat and subcooling readings were found to be within operating limits and a good read back on the water system.
Compressor Unloading
At the end of the day, the three way valves on the air handlers closed down according to the BMS schedule. This meant that the water was diverted away from the heat exchangers in the air handlers. This return water had not picked up any heat, so the controller started unloading the compressors. It did this through 75% to 50% then 25% until the chilling plant water system had achieved setpoint.
Off Cycle at Chilling Plant Maintenance Visit
The BMS stops the chiller with the remote start/ stop signal. Should the BMS malfunction, the chiller would stay off most of the night anyway. The water system pump adds heat into the water system. Therefore, every so often enough load would be available to bring one system on at 25% for a short while.
To read more about chilling plant maintenance click the Tag at the top of the page.
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Read all about solenoid valves on Wikipedia | Click Here
- November 10, 2019
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Water Chiller Maintenance
Category : Water Chillers
Maximus chillers provides water chiller maintenance to all kinds of machines. 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 chiller is running efficiently. We believe our maintenance checklist 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 checklist 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 latent 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 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
Compressor Loading
If the loading of the reciprocating compressors is 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.
Related Articles:
R134a Chilling Plant Maintenance
Air Cooled Chiller Planned Maintenance
Process Chiller Maintenance Visit
Chilled Water System Maintenance
Centrifugal Chiller Maintenance
Industrial Chiller Maintenance
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Preventative Chiller Maintenance
Visit the Refcom site to read about leak checking during water chiller maintenance | Click Here