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. 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 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 vac 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 boiling point 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


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 Decant for Process Chiller Service

Our high capacity pump out 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.

Process Chiller Refrigerant 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.

0161 370 7193

service@maximuschillers.com

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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 process chiller. 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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Follow this link to purchase BESA pressure testing technical bulletin Click Here


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