Industrial Chiller Service

Oil return solenoid removed during industrial chiller service

Blue recovery unit with a grey recovery cylinder during a chiller breakdown

Chiller Breakdown

A rainy day for a chiller breakdown for our engineer in the North West.

News Article No.8

Electrical Faults during Chiller Breakdown

Our customer called us out because he was having electrical faults with the chiller. The power supply to part of the panel had gone down and he required our assistance. Our engineer found a blown fuse which he replaced and tested operation- it blew again. Using his multimeter, he followed the diagnosis though to an earth fault on the flow switch…

Water System Flow Switches

The flow switch vapour seal had failed allowing rain water to ingress. This caused an earth failure on the 240v control circuit, and so blowing the fuse. The customer raised an order forthwith and so our engineer replaced the flow switch with the stock from his car. Each of our engineers keeps a range of flow switches for a variety of applications…

Stainless Steel

Where water system chemicals are corrosive, we carry corrosion resistant flow switches. This type has a longer working life due to the use of stainless steel. They are more expensive due to the higher manufacturing costs, but they are worth the money as they are less likely to fail, causing a potential loss of production.

Outside Use

This was the type fitted by our engineer on site in this news article. It has been developed and tested across a range of adverse weather conditions including freezing conditions and heavy rain. The electrical and switching compartment is protected by a sealing gland to keep the weather out. A rubber ‘o’ ring provides the seal into this compartment.

Inside Use

Some applications have the flow switch located inside the building in the plant room with the control cable extending out to the chiller controls. Another configuration allows for the flow switch to trip out the building controls and so dropping out the run signal to the chiller. In either case there is no need for weather proofing. This kind of flow switch is cheaper due to the lower construction costs.

High Pressure

Some water systems operate at considerable pressure. Therefore, high pressure flow switches have been developed for this application. They are capable of preventing water ingressing from the water system and into the electrical and switching compartment.

Test and Adjustment

Our engineer carried out testing and adjustments to the flow switch to ensure that it ran reliably. He achieved this by monitoring the water system readings and measurements against the design specifications of the switch. When he got it to settle down, he replaced the fuse and ran tested the chiller...

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Condenser Fans

The condenser fans were not coming on at all at first and later only slowly. They are controlled by a fan speed controller which is sensitive to pressure. A minimum value of volts is supplied to the fans, so as to prevent stalling and over heating of the internal motor windings. The fans were found to be in good working order, so he decided to turn his attention to…

Refrigerant Pressure Temperature Relationship

There was found to be a lower pressure and so a lower temperature in the condenser. After careful fault finding and diagnosis involving putting the pressures and temperatures into a calculator, our engineer decided that the chiller was running short of refrigerant. This is consistent with Charles’s Law of Constant Volume: one of the fundamental scientific principals of how a chiller works- the higher the pressure- the higher the temperature/ the lower the temperature- the lower the pressure.

Refrigerant Recovery Units

After receiving a further order from our customer, we gave the go ahead to our engineer to use his refrigerant recovery unit to decant the gas. The refrigerant is sucked into the unit using a small one cylinder reciprocating compressor. The compressor discharges into the on board condenser which is cooled by a fan. The subcooled refrigerant travels down a refrigerant hose which is connected to the recovery cylinder in the picture. After this process was complete, he started looking for a leak...

Leak Testing and Pressure Testing

The leak was identified on the flange for the expansion valve. This component was removed, cleaned with our in house refrigerant grade solvent, then the joint re made with a compound suitable for the temperature range of the component. After a satisfactory nitrogen pressure test, the evacuation process can begin…

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Refrigerant System Vacuum Pumps

Each of our engineers carry a high capacity vacuum pump of the highest quality. We believe in investing in state of the art equipment as this is part of how we provide the MAXIMUS ADVANTAGE™ Any Chiller- Any Problem- Any Part- Any Refrigerant- Anywhere. Good equipment makes the job go easy.

Vane Pump

The pump works by sucking vapour into the inlet port. A rotary vane system extracts the vapour and discharges it through the top of the pump module. Oil is used to lubricate the vanes that slide around the pump cylinder. The vanes are kept a tight fit against the cylinder with the use of springs. As our pumps are high capacity, an oil filter is fitted to the outlet with a gauze inside to catch any oil droplets.

Electric Motor

This motor fits onto the back of the vane pump module. It comes from the factory set to 240v, but we change the pins for the electrical connections to convert it for use with 110v. This is because customers and engineers demand the use of 110v as if is safer for use in the UK climate. The 110v plugs and extension cable are shrouded and weather resistant. Weather resistant does not mean weatherproof, so we take measures to limit the exposure to adverse weather conditions. The pump motor, however, is not weather resistant at all, so care is taken to locate it somewhere dry. After a long time running, the motor runs hot, so our engineers take readings and carry out adjustments to ensure that it stays within its nominal operating temperature range.

Oil Changes during Chiller Breakdown

The vac pump oil is changed before each use with our specialist grade, high quality oil. Contact our office for prices and delivery times. The manufacturer of the pump recommends these oil changes as moisture and impurities absorb into the oil and so reduce its performance, also the working like of the pump.

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Refrigerant System Evacuation Process

Having set up the vacuum pump, our engineer started the evacuation process.

Torr Gauges used During Chiller Breakdown

We use analogue Torr gauges as they are more reliable than digital ones. Also, they do not need batteries and it does not matter if they get wet. He attached the Torr gauge to a suitable part of the system with a refrigerant hose, ensuring that a good seal was made between the components with a sealing compound.

Fittings used during Chiller Breakdown

Fittings were used to get between the different thread types from the vac pump to the fridge system. Having warmed up the pump for half an hour he was ready to start the process.

Non Condensables Removed during Chiller Breakdown

One purpose of evacuation is to remove the gasses that will not condense such as nitrogen remaining in the system from pressure testing. Another non condensable is air that has entered the system from when the expansion valve was removed. These non condensables affect how a fridge system works according to Dalton’s Law of Partial Pressures: that all gasses in a vessel act as if they are on their own. The non condensables cause a higher head pressure and false readings: when this pressure is added into our calculation- it throws out the sum and so gives a false reading of subcooling.

Dehydration during Chiller Breakdown

The other purpose of evacuation is to dehydrate the system. Water, as we know, has a boiling point of 100°c at sea level, which is 1bar absolute or 760 Torr. As you start to drop the pressure, so correspondingly, the boiling point also drops. For example, water boils at the top of Mount Everest at around 68°c. If we continue vacuuming a refrigerant system, eventually we can remove all moisture by dropping the pressure below the saturation point of water. This works even in the winter in UK ambient conditions. Moisture in the system causes system failures and malfunctions leading to expensive breakdowns.

To read more about flow switches hit the Tag at the top of the page.

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Read more about rotary vane pumps at Wikipedia | Click Here


400 kw white chillers with panels open during air cooled chiller maintenance

Air Cooled Chiller Maintenance

A nice day to carry out air cooled chiller maintenance at a new site we have taken over in the South East.

News Article No.6

Our engineer attended site at around 9am with the risk assessment method statement having been sent in advance. A site survey was carried out to see if there were any additional risks. Should there have been any changes- the RAMS have a section for the additional risks and control measures. After gaining a permit to work, our engineer was issued with a security pass to access the chiller compound. Three chillers are located in the compound which feed air handlers for a critical application. Two of the chillers are multiple system, scroll compressor, air cooled chillers. The other is a single system screw chiller.

Program Settings During Air Cooled Chiller Maintenance

A complete download of the program settings is available in our engineer’s phone. This is to cross reference the settings, should one of them be accidentally changed by the maintenance engineers. Onsite engineers are the first port of call for chiller trip outs, with the responsibility to get the plant up and running. We offer real time assistance, over the phone from our Technical Support Desk and can send user manuals in PDF form, direct to their computer. The settings were found to be nominal, so a detailed analysis of the alarm history was carried out:

Alarm History During Air Cooled Chiller Maintenance

In reverse date order, the alarm history of all the systems was interrogated. There had been several system shut downs to carry out the periodic maintenance by the onsite personnel. The electricity having been shut down, there was a subsequent oil pre heating timer in the history too. On Chiller 2, System 1 however, there had been several low pressure trip outs. Our engineer decided to start the maintenance with this system by carrying out a full diagnosis of the low side of the refrigerant system:

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Superheat During Air Cooled Chiller Maintenance

The system runs on R410a refrigerant. This refrigerant has higher operating pressures in comparison with other HFC refrigerants. It has an efficient temperature range which can be seen on a pressure enthalpy chart. Below or above this range- the refrigerant loses efficiency and so has a lower coefficient of performance. The most common saturation point for this refrigerant is 0° which corresponds to a 7 bar suction pressure in the evaporator. Above this is the superheat of the refrigerant returning to the compressor. On this occasion there was found to be 26° of superheat and a suction pressure of 4 bar- close to the low pressure trip out. After careful diagnosis, our engineer decided to focus his attention on the expansion valve:

Thermostatic Expansion Valve

There are 4 forces acting on a TEV:

Liquid line pressure coming from the condenser.
Versus
Suction pressure down the equalising line from the far side of the evaporator. This compensates for the pressure drop across the evaporator and shows the true compressor side pressure.

Spring pressure acting upwards and closing the valve.
Versus
Bulb pressure forcing the valve open.

To reduce the superheat, the bulb should have forced the valve open. The refrigerant charge in the bulb acts upon the bellows to achieve this. The reason for the malfunction, on this occasion, was found to be the failure of the expansion valve orifice. It had become jammed- causing a shortage of refrigerant in the evaporator/ high superheat.

Latent Heat

Our engineer was carrying out the above fault finding with one compressor running and the other two being held off. This was to prevent a low pressure trip. Where chillers are left running with a high superheat condition, the reduced amount of latent heat causes a higher cost in electricity relative to refrigeration effect (COP) The refrigerant carries on superheating without absorbing latent heat- pointless and inefficient for a chiller.

Chiller Pump Down

For convenience, this chiller can be pumped down and valved off using the service valves. The evaporator can be worked on after breaking in procedures are carried out. Therefore, we have arranged for this to be carried out before fitting the new expansion valve parts. These chillers also have the ability to pump down the refrigerant on receiving a fault feedback from the electronic leak detector. This is an added measure to lower the environmental impact of refrigerant leaks.

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Subcooling During Air Cooled Chiller Maintenance

Cooling the refrigerant vapour down, through the latent heat phase and then subcooling the liquid down further. On System 2 of the same chiller, a subcooling issue was identified. 21 bar/ 36° saturation was normal for that system as defined by the fan speed controller. Now, the system pressure was higher at 28 bar/ 47° saturation, so our engineer decided to work out the subcooling. A very high reading of subcooling was recorded at 28° this was diagnosed to be due to non condensables in the refrigerant:

System Non Condensables

Non condensables are gases that will not condense, such as, air and nitrogen. If nitrogen is not vented properly and a deep vacuum then achieved, the gasses will remain in the refrigerant system. When calculating the subcooling, the readings work out incorrectly due the presence of the gasses. This can lead to false diagnosis. The remedy for the issue was to arrange a full refrigerant decant, pressure testing and dehydration, before charging with new refrigerant.

Efficiency

Having good subcooling values on a refrigerant system is critical to efficiency. Where there is no subcooling- the refrigerant has not fully rejected all the latent heat from the condenser. This can be seen when looking at a PH chart and plotting the pressures and temperatures. This heat remains in the refrigerant and adds to the system along with heat added from the compressor and heat from the process. This is another reason the coefficient of performance is reduced and so incurring increasing electricity costs for the plant.

Economizer

These chillers are also fitted with refrigerant economizers- one for each system. They work by diverting some of the refrigerant from the condenser, through a small expansion valve, then through a plate heat exchanger. The rest of the liquid refrigerant passes on the other side of the plate heat exchanger and so is further subcooled.

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To read more about air cooled chiller maintenance hit the Tag at the top of the page.

For further reading on chilled water visit Wikipedia | Click Here


A pile of completed chiller maintenance checklists on a table

Chiller Maintenance Checklist

Introducing  a series of in depth news articles, this time featuring the chiller maintenance checklist:

News Article No.1

This article has been written with you- the customer in mind. Read below for practical advice on how to keep your chillers in the best condition.

Each day when you walk round, you can check to see if your plant is starting to malfunction. Become accustomed with the usual readings to help you diagnose the faults.

Here are the things to check for and how to remedy them:

Water System Pressure

Keep an eye on the pressure in the water system.

Small Chiller Maintenance Checklist

On a small chiller, there will be a water outlet pressure gauge. Make a mark on the gauge where the pressure is when the chiller is in good working order. You can use this mark to notice if the pressure is starting to drop off.

Strainer

The most common cause for low water system pressure is a blocked strainer. It is usually a ‘Y’ type with a bolted fitting. With the chiller off and the water system valves closed, unscrew it and check for debris. If it is blocked, make a note of how long it took to block, then add the cleaning of the strainer into the periodic maintenance schedule.

Pump

Ensure the pump rotation is correct by checking that the cooling fan is sucking into the pump. If it is going backwards: isolate electrically, then swap any 2 of the 3 phase wires. Brush down the inlet to the cooling fan to ensure good air flow and a cool pump motor.

Large Chiller Maintenance Checklist

On a large chiller, the water system pressures may be available in the controller- have a look through the menus. The pressure will be measured in bar. Another popular method on a large chiller is a flow meter. This may be a stand alone device on the chiller panel, or on a control panel nearby. It will read in m3/hr. Check to see if the pressure or flow is lower than usual. If so, ring one of our trained professionals.

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Water System Temperature

The chiller should be:

  • Matching the load and running continuously.
  • Loading and unloading in sequence with other chillers.
  • Going through a cycle and achieving set point.

In any case, you will become accustomed with the usual chilled water temperature according to varying load conditions. If the plant is struggling to achieve set point, or is running higher than usual- this is a sign of system faults.

Walk along the chillers that feed the same water system and make a log of the faults showing on the controllers.

Here are the things to check for high water system temperature:

Small Chiller Maintenance Checklist

Low Refrigerant Pressure

If it has a low pressure gauge, look to see if the pressure is lower than usual. If so, this is a sign of refrigerant shortage in the plate evaporator. A scheduled visit from one of our trained engineers to carry out a pressure test can be arranged.

Breakers

Look for any breakers that have tripped in the panel. One reset can be carried out by a qualified onsite electrician. If the fault reoccurs- ring our support team. If the scroll compressor has tripped, check to see if the compressor is hot. If so, isolate and do not attempt a restart.

Condenser

A blocked condenser will inhibit the rejection of heat. Brush it down and give it a rinse with water. A common occurrence onsite with some condenser designs is a panel being left off with the chiller running! This happens when the onsite engineers are fault finding another issue with the chiller. The fans will suck through the opening as this is the easiest path. The gauge will be higher than usual as the condenser builds in pressure. A high pressure switch trip out will occur.

High Pressure Switch

To locate the switch- first identify the discharge pipe. It is the smaller of the 2 pipes on the compressor. The high pressure switch will either be bolted onto the pipe, or a thin pipe will lead from the discharge to the frame of the chiller. In any case, you are looking for a small box with a button and a wire leading to the panel. Press the button and you should hear it click. If this fault reoccurs- ring our technical support desk.

Large Chiller Maintenance Checklist

Suction

Should there be a refrigerant shortage, the controller will display a pre alarm: suction limiting. This is the controller preventing the compressor from loading up to prevent a low pressure trip out in the shell and tube evaporator. As above, one of our team of engineers can be sent to site to resolve the issue.

Discharge

If the controller is showing: discharge limiting- this is a sign of a condenser issue. A full strip down and cleaning of the tubes may be required. Ring our technical support desk for further advice.

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Chiller Remote Monitoring

We at maximus chiller can install remote monitoring systems to your chillers so we can fault find and diagnose from a laptop. This means we can give you real time advice over the phone. Now you are accustomed with our chiller maintenance checklist- you can give feedback regarding the plant to assist our engineer.

Parts

For our contract maintenance customers: a range of commonly used parts are kept onsite to reduce downtime. We can give practical, step by step advice on the fitting of parts. We often carry out video calls with our customers, as chiller data plates, parts and components can be easier to show than describe.

Any Chiller- Any Problem- Any Part- Any Refrigerant- Anywhere- The MAXIMUS ADVANTAGE™

To read more about air cooled chiller maintenance click the Tag at the top of the page.

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Process Chiller Maintenance Visit

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Read more about chillers on Wikipedia | Click Here


Controls panel open during chilling plant maintenance

Chilling Plant Controls Maintenance

Prior to this chilling plant controls maintenance visit, another contractor had changed some of the settings and adjustments in the controllers. They did this while they were diagnosing a fault with the water system and the pumps. Therefore, this visit was to recommission the plant and to resolve the issues resulting from the adjustments.

Chilling Plant Flow Controls Maintenance

The flow controls were found to be set wrong. Therefore, our engineer adjusted the pumps, then various valves on the water system, a little at a time, while monitoring the controller. Full load and part load readings were taken until they came to within standard industry limits.

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Compressor Run On Time

A timer had been adjusted which made the compressor wait to stop after reaching 0% on achieving set point. In the meantime, some more heat would build up in the water system and the compressor slide valve would open up a little. The result was that the compressor would run for an hour with the slide valve shut most of the time. The oil pump carried on pumping during this time resulting in a head of oil building up in the discharge pipe- all the way back up to the oil separator. Then, a low oil level fault had occurred. This being confirmed by the sight glass on the oil separator. The compressor had enough oil charged into it to allow a start up. During the start up, a low oil level timer counts down. As soon as the compressor loaded and started pumping, the oil level returned to the correct level on the sight glasses. The timer was adjusted along with the dead band to ensure the chiller off cycled after achieving set point.

Slide Valve Potentiometer

The slide valve potentiometer has a configuration mode button. It can be pressed to set the 4mA or 0% position. This is the usual position of the slide valve as a spring and 2 drain valves return it to the start position. The slide valve can then be manually opened in the program. Then, the potentiometer button can be pressed to set the 20mA or 100% position. “Chattering” can occur on the fully closed position so a setting is available to only close the slide valve to 2%.

To read more about chilling plant maintenance click the Tag at the top of the page.

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Follow this link to read more about potentiometers on Wikipedia Click Here


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