Chiller Condensers

Boxed, shell and tube chiller condenser being lifted into a building with a crane

Chiller Condensers

Shell & Tube

The chiller condenser on a 2 MW centrif we look after had deteriorated over a long period of time. We had carried out tube cleaning and noticed that it had been extensively repaired in the past. There were a lot of damaged tubes that had been blanked off. This had reduced the useful surface area for heat exchange to occur. The chiller was experiencing a ‘discharge limiting’ condition which was causing it to back off to 54% capacity.

Air Cooled

Because of the difficulty to remove and replace the condenser from the plant room, the customer had explored the possibility of air cooled condensers. His idea was to fit the discharge and liquid piping up the side of the building and into the plant room. After considering this possibility, we decided to advise him against using air cooled condensers because it would take two, 16 fan ‘V’ types. This would have a footprint too big for the available space. We decided to use a crane to lift out the old condenser, then lift in the new one.

Pump Out

The old condenser was valved off from the rest of the system and the refrigerant was pumped into an 800 kg recovery vessel. This was one of 2 vessels in the plant room that had been there since the chiller was new.

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Lift Out for Chiller Condensers

The pipework was unbolted and the ancillaries removed. When it came to unbolting the condenser, some of the bolts were seized due to a long period of rusting. Some of them came loose by heating them with oxy-acetylene, the others were ground off with an angle grinder. We used a specialist lifting company to shift the condenser from the plant room and out to the lifting bay. They then attached slings to one end, manoeuvred that end of the condenser to the outside of the building, then attached slings to the other end. Rather them than me! Quite a dangerous operation, but it had been assessed when composing their Risk Assessment Method Statement. The condenser was lifted onto the back of an articulated truck and taken to a scrap yard for recycling. There was quite a lot of copper inside- so our customer got quite a good weigh in!

Lift In for Chiller Condensers

The new condenser, in the photo, was kept in its packaging during the lift up, so as to protect it from damage. Once it was in the building and near to the plant room, it was removed from the box and shifted the rest of the way with dollies. There was some difficulty getting it into its final location. This was because the old steelwork had to be cut back with a blow torch to make the new condenser fit. Also, with limited room and no gantry crane, the lifting company had their work cut out to manoeuvre it. Eventually, it was in location and we decided to call it a day.

Adapting the Pipework

This particular condenser was selected because it was similar in dimensions to the old one. The positioning of the refrigerant and water system pipework was similar too. That said, it was not an exact match. We called an industrial plumbing and welding company in to make the changes we needed. They measured up and built adaptors to bolt in between the condenser and the water system pipework. They cut back the new condenser discharge connection and welded a new flange on. This was so it could be bolted onto the existing discharge elbow from the chiller. The liquid pipe connection on the new condenser was in the same location, but came with a different thread. Therefore, this too was cut back and an adaptor fitting was welded into place.

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Ancillaries

The fittings on the new condenser were BSP and the fittings on the chiller were Flare. We carry an extensive range of fittings that go between BSP and Flare. We can go from male to female, female to male, male to male and female to female. We can step up and step down in size too. Using these fittings, we attached the high pressure switch and high pressure transducer. The wires for the liquid and discharge temperature sensors were extended. This was so they could reach the location of the pockets that were built into the new condenser. Then, we used a special heat transfer paste to get a good transmission of heat in between the sensors and the pockets.

F-gas Pressure Test

We then carried out a strength test and a pressure test in accordance with F-gas guidelines. This was witnessed at the beginning and at the end by the customer. A satisfactory outcome was achieved, so on to the next phase of the job…

Dehydration of Chiller Condensers

We needed to dehydrate the system and remove the nitrogen that was used in the pressure test. This is because nitrogen is a non condensable which will affect system performance. Our powerful vacuum pump was set up, then we left it running overnight. A 1.5 Torr vacuum was achieved, which was the same pressure as when the Torr gauge was fitted directly on to the vacuum pump.

Open the Valves and Test

After removing the vacuum pump, the recovered refrigerant was pumped back in, then the discharge and liquid valves were opened back up. Then, our engineer had a good look round for leaks. I know it had just been pressure tested, but we think it’s always a good idea to check again. This done, the water system pumps were started and the water temperature showed at 23°C on the controller. The set point for the chilled water was 6°C so this warm water was helpful as it gave us plenty of load to carry out the testing. The chiller went through a timer and then started up. It loaded steadily up to 100% with no dramatics- splendid!

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Large chiller, refrigerant cylinder, brazing equipment and tools during chiller service company visit

Chiller Service Company Visit

A typical rainy day in the North West, perfect for a chiller service company visit.

News Article No.11

Electrical Faults during Chiller Service Company Visit

This was a return visit to do a refrigerant leak, but the customer alerted our engineer’s attention to an electrical fault. System 2 was found to be locked out in fault on the recent maintenance visit, but now System 1 was being held off too. The fault message on the controller was High Pressure. The controller sends a 240v fault feedback signal, through the high pressure switch which returns to the controller. Our engineer had a look at the wiring diagram to find the number on the terminal strip and checked it out with his multimeter. As he suspected, there were volts going out, but not coming back. He removed the side panel for system 1 and found the switch on the discharge pipe. It was the type that has a red button on the top. When he pressed it, there was a click and volts returned to the controller.

Alarm Reset during Chiller Company Service Visit

He interrogated the Carel controller and followed the reset procedure. The controls went through a timer and then the start sequence was initiated.

Run Testing during Chiller Company Service Visit

After the first scroll compressor started, the head pressure started to build up, but the condenser fans did not start. The on board high pressure gauge carried on rising until the high pressure switch was tripped again.

Head Pressure Control

A transducer on the discharge is used by the controller to sense the pressure in the condenser. When our engineer looked for this in the controller, it was found to be reading wrong by a considerable amount. There is a facility to enter a password and recalibrate the transducer, but this only allows for a small adjustment.

Test Instrument

Our engineers carry various kinds of test instruments which can be used to give a temporary false reading to the controller. This gets the customer up and running and back in production whilst a new transducer is ordered and sent to site.

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Chiller Company Service Low Pressure Visit

Now on with the job to resolve the low pressure issue with the chiller.

Refrigerant Pump Out

Our engineer lifted the liquid line solenoid valve and decanted the remaining refrigerant into a vessel using his recovery unit. He only got out 7kg of a charge of 36kg.

Leak Testing during Chiller Company Service Visit

We use nitrogen for the leak testing as it is an inert gas that will not cause problems with the refrigerant system. There was a sign of the leak in between the steel frame at the middle of the condenser and the condenser tubes. We always strip the chiller down and leak test the entire system though. This is so that the job does not end up going round in circles. At first the leak could not be found, so the pressure was built up in stages, taking into account industry recommended guidelines for a chiller. Sure enough the leak was where it was suspected to be. The occurrence of this kind of leak can be reduced with the use of vibration eliminators.

Brazing during Chiller Company Service Visit

The location of the leak was reported to the maintenance engineer onsite and a hot work permit obtained. The equipment we use is tested at regular intervals to be safe and in good working order. A half hour fire watch was stipulated in the permit, along with the removal of combustible materials from the work location. Correct PPE being donned, he brazed the leak to the required industry standards.

F-gas Pressure Test

A chiller has a different pressure test procedure to other systems, so our engineer built the pressure up according to industry standards, then recorded it on his pressure test certificate. After the required time had elapsed, he rechecked the readings which were found to be satisfactory.

Vac Pump

Each of our engineers carries a state of the art 10 cfm vacuum pump to speed up the dehydration process. We use high quality Torr gauges too, so as to get an accurate pressure reading. A good read back was achieved at the end of the process.

Recharge and Run Test

After the refrigerant recharge was carried out, a satisfactory run test was achieved.

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Refrigerant Economizers

This particular chiller uses an economizer to further subcool the refrigerant. Chiller designers have worked out that the end user can save a considerable amount of money over 10 years if these components are used. After the subcooled liquid refrigerant leaves the condenser, it goes through a plate heat exchanger. Some of this refrigerant, however, is diverted through a thermostatic expansion valve, to the other side of this plate heat exchanger. Further subcooling occurring through the plates.

Expansion Valve

The refrigerant drops in pressure as it goes through the expansion valve. A bulb is fitted to the suction pipe on the outlet of the heat exchanger. The bulb has to be at the correct 'o clock position as oil insulation will affect the operation of the valve. A capillary tube connects the bulb to the valve. Inside the bulb, the same kind of refrigerant that is running in the system is present in its liquid state. As the temperature rises in the suction pipe, this refrigerant boils off, adding pressure into the capillary tube. This added pressure forces the power element down on the valve body and a needle forces the valve open.

Flash Gas

Imagine if the refrigerant was not subcooled at all. It would be around its saturation point with a lot of it flashing off into its vapour phase. Not good when you have warm water coming back from the process. The refrigerant would not absorb very much latent heat into the refrigerant system.

Efficiency

Imagine, on the other hand, the economizer which is fitted to this chiller. Now we have a good proportion of refrigerant in its liquid phase, on the low side of the system, with a minimum amount of flash gas. The warm process water has more chance to cool and the refrigerant absorbs a lot more latent heat. The chiller achieves set point easier and therefore saves a considerable amount of electricity. With this further subcooling monitored for a while, time for a signature from the customer and another job well done!

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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…

Pressure Temperature Relationship of Refrigerant

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. It is one of the fundamental scientific principals of how a chiller works: the higher the pressure- the higher the temperature/ the lower the pressure- the lower the temperature.

Recovery Units for Refrigerant

After receiving a further order from our customer, we gave the go ahead to our engineer to use his 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 Vac 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

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. Our engineer 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 in the condenser. 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.

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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 when you have high water system temperature:

Small Chiller Maintenance Checklist

Low Pressure

If the chiller 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 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 like 'suction limiting' This is the controller preventing the compressor from loading up, so as to prevent a low pressure trip out. 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™

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Brazing equipment box and vibration eliminators during packaged chiller service

Packaged Chiller Service

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.

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Engineer carrying out process chiller service with yellow and black cylinder

Process Chiller Service

Maximus Chillers has just carried out process chiller service to a flooded evaporator. The refrigerant seal on a four bolt, flanged coupling had been found to be leaking liquid refrigerant. There was no possibility to valve off that section of the machine, as the flooded evaporator is the storage vessel for all of the charge of the system in its liquid phase.

Refrigerant Recovery during Process Chiller Service

Our high capacity refrigerant recovery unit was set up next to the machine to carry out the task. 55 kg of refrigerant was recovered in a short time into our recovery cylinder. This refrigerant was collected for recycling after the job was completed.

Stainless Steel

Our unit is made from stainless steel because this metal works well with ammonia.

Condenser for Process Chiller Service

The condenser is made from tubing which is connected to ‘u’ bends on either end. These ‘u’ bends send the condensing refrigerant back along the next tube in the opposite direction. This process, back and forth allows time for the refrigerant to condense into a liquid. Fins are pressed around the tubing to increase the surface area and help to dissipate more heat from the refrigerant. A condenser fan is fitted to suck the air through the fins and so reject the heat.

Reciprocating Compressor

A four cylinder reciprocating compressor is fitted to the unit to provide the pressure difference to pump the refrigerant into the above mentioned condenser. It has an air cooled electric motor fitted which is open drive. This is because ammonia would corrode the windings of the motor if a semi hermetic compressor were to be used. Semi hermetic meaning that the windings, stator and rotor of the motor would be internal to the system. The motor is fitted in the vertical position with the four cylinders opposing each other on the central crank shaft.

Controls for Process Chiller Service

For safety reasons controls are fitted to the unit. These include:

HP Switch

If the recovery cylinder were to become over filled, the pressure would build up to a dangerous level. The TARE and the ullage need to be calculated prior to the job to prevent this from happening. The below mentioned liquid pipes have been designed with pressure issues in mind, but somewhere on the system would be the weakest point. This would burst causing a catastrophic refrigerant leak. The whole charge of the machine and all the refrigerant in the recovery cylinder would leak to atmosphere. The HP switch is set by the engineer on site to the correct level given the ambient conditions. This takes into account the temperature of the refrigerant and the safe operating pressure of the vessel.

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Refrigerant Liquid Pipe

Steel Braided

The refrigerant in its liquid phase is pumped into the above mentioned unit down a steel braided liquid pipe. The steel braiding is to provide additional protection from the pipe being damaged on the outside. Damage like being driven over by a forklift truck, or having sharp objects coming into contact with it. Also, the braiding helps to prevent bursts when pressure builds up on the inside. This can be due to a restriction, malfunction of system components or vessel overfilling.

PTFE

The inner part of the pipe is PTFE. Other types of plastics and compounds corrode due to the toxicity of ammonia. Polytetrafluoroethylene is the chemical name for this compound, it is a fluorocarbon solid and is considered to be non reactive.

Fittings

There are various metric and imperial thread types that can be used. This depends on the fitting size on the machine and the fitting size and type going onto the recovery unit. We carry a wide range of fitting types to step down and step up in size. We can go between male to female types and use male to male and female to female where necessary. We carry adaptors to go from metric to imperial thread types.

Remote Access during Process Chiller Service

We carry an extensive stock of liquid pipes that can be connected end to end to provide remote access. We will always try to get the recovery equipment as near as possible to the plant, but when this cannot be achieved, we can arrange access up cat ladders or the side of a building. We can use our lift and shift team to arrange the hauling of all the required equipment and ancillaries to any location. Just part of what we call the MAXIMUS ADVANTAGEAny Chiller- Any Problem- Any Part- Any Refrigerant- Anywhere. Contact our office for prices for the above mentioned pipes.

Process Chiller Leak Service

The flanged coupling was unbolted and the failed refrigerant seal was removed. The new seal was fitted from our full range of sizes that we keep on the shelf in our stores. Our engineer bolted the flanged coupling back up to the correct torque setting.

Pressure Leak Test

A nitrogen pressure leak test was carried out to ensure the integrity of the system with the result being a pass.

Dehydration Process

As the system was open to atmosphere, air had got into the system which carries moisture content. The moisture and non condensables were removed down to a near perfect vacuum using one of our high capacity vacuum pumps.

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Charging of Refrigerant

The photo shows the charging of a cylinder of refrigerant into the system in its liquid phase. The cylinder has a dip tube fitted for ease of handling. Once the pressure in the system and the cylinder equalized, remaining refrigerant was drawn into the system during the operation of the plant.

Run Testing

The sight glasses and level glasses were found to be at the optimum level under the normal running conditions of the plant. As it is a flooded system, there was found to be a low superheat value. A high subcooling value was achieved with the use of a subcooler. Our engineer monitored a full cycle of an hour and a half: compressor temperatures and oil level were found to be within normal operating limits.

Remote Service Monitoring of Process Chiller

The process chiller can be remotely monitored via a data uplink through the internet. Our office continued to monitor the plant for some days as it went into seamless operation.

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

Chilled Water System Condenser Repair

Chilled Water System Condenser Beyond Repair

The repair of the condenser was required on this chilled water system 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 contract, so we wanted to make a good impression.

Condenser Removal

There was no refrigerant in the 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

Our engineer supervised the condenser replacement. 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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Pipework Repair

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

The Evacuation Process during Chilled Water System Condenser Repair

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 system for the rest of the day- 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.

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