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Top 10 Techniques to Maintain High Efficiency Chiller

You’re probably looking for high-efficiency chillers!You must to know that chiller efficiencies have improved significantly during the past 10 years, mostly as a result of new refrigerants and microprocessor controls, as well as improved compressor and motor design. However, high-tech chillers have narrower tolerances, so that service and upkeep are more crucial than ever for keeping them operating at peak performance.

Chiller performance varies significantly with operating conditions. Full-load performance is not a good indicator of overall performance, because chiller plants rarely operate at full load. Instead, part load performance is critical to good overall chiller plant performance. Consult ASHRAE Standard 90.1-2001, which lists minimum chiller efficiency requirements. Several variables affect chiller efficiency. 

Achieving performance is a matter of common sense. Here are the top 10 techniques to Maintain High Efficiency Chiller systems.

1. Keep a daily log

The daily log is still the first step toward maintaining an efficiently-run chiller plant and it allows you to easily generate trend reports that help to identify maintenance needs before they become an issue.

2. Keep tubes clean for efficient heat transfer

Heat transfer efficiency has the greatest single effect on chiller performance, so clean heat transfer is fundamental to maintaining high efficiency.Condenser tubes should be brush cleaned at least annually, or per your demand maintenance schedule to keep them free of contaminants.

3. Treat condenser water to prevent scale, corrosion

All condenser water loops using open cooling sources (such as atmospheric cooling towers) require water treatment of some sort to eliminate scale, corrosion and biological growth.Inspect chilled water loops once a year or regularly with remote monitoring for general water quality and evidence of corrosion.

4. Lower entering water temperature

Lowering the temperature of the entering condenser water will improve the chiller’s efficiency.

5. Keep chilled water flow rate between 3 to 12-ft per second

Changing the chilled water flow rate affects a chiller’s performance. Too low a flow rate lowers the chiller efficiency and ultimately leads to laminar flow.The maximum recommended flow rate is typically around 12 FPS.

6. Maintain adequate refrigerant charge

The actual amount of cooling a chiller provides depends on how much refrigerant it moves through the compressor. Refrigerant leaks, as well as air and moisture introduced into the system, will decrease efficiency and the reliability of the system. A low refrigerant charge will cause the compressor to work harder for less cooling effect.

7. Prevent inefficiencies caused by non-condensates

Non-condensates can lower the real efficiency of the chiller from the rated performance by as much as 4% at 60% load and 7% at 100% load. Purge units minimize the effect of non-condensates.

8. Analyze compressor oil

Send a sample of the lubrication oil to a laboratory for a “spectrometric” chemical analysis once a year.Check oil filters for pressure drop and replace them if the oil charge is replaced.Inspect chilled water loops once a year or regularly with remote monitoring for general water quality and evidence of corrosion.

9. Check operation of starters and motors

For efficient operation of starters and motors, check the safety and sensor calibrations on microprocessor controls.To prevent insulation faults, test electrical motor windings for insulation resistance to ground and winding-to-winding.

10. Install variable speed drives

The chiller motor is typically the largest single electrical load in a building. With the right operating conditions, variable speed drives (VSD) can offer significant energy savings.

Contact Us-Kingfit Chiler & Heat pump

At Kingfit, we manufacture dependable water-cooled chillers, air-cooled chillers, and different types of chillers suitable for various industries. We aim to help you achieve maximum productivity by offering excellent industrial cooling solutions.

To learn more about our products and services, please contact us today!



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