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Chillers are essential for meeting the temperature requirements of several industrial processes, thus, consuming significant amounts of energy in these facilities. As a result, operators must prioritize the correct operation and maintenance approach to maximize system performance, ensure prolonged lifespan, and minimize energy costs. This article identifies common chiller problems and solutions and highlights relevant troubleshooting guidelines.
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Incorrect operating practices, negligence to maintenance, and incorrect chiller sizing are three common causes of chiller problems. Therefore, operators must actively consider these factors to mitigate potential threats to the cooling equipment.
Industrial chillers come with manuals containing manufacturer's guidelines for correctly operating them. Operators must follow these guidelines as poor operating practices adversely affects equipment efficiency and lifespan. While these cooling systems may continue working regardless of improper practices, it is noteworthy that the systems become more susceptible to more severe and expensive problems. Mitigating this threat involves implementing training programs on correct chiller operation and maintenance and efficient chiller maintenance programs.
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Operators may disregard proper maintenance practices, which are detrimental to the overall performance of chillers and lead to excessive energy consumption. Operators must ensure effective maintenance comprising adequate equipment diagnostics using operating logs. Moreover, chiller units require regular inspections to ascertain their conditions and schedule preventive and corrective maintenance.
Chiller sizing is a top consideration for installing cooling systems in industrial facilities. Undersized equipment may lead to insufficient airflow and cooling capacity inefficiencies. Conversely, oversizing restricts low-load operations significantly and results in higher operating costs. Operators must assess the cooling capacity of existing chillers to ascertain their suitability for the prevalent cooling loads.
Chillers remain vulnerable to damage regardless of proper operation and regular maintenance due to degradation or deterioration over time. Understanding common initial troubleshooting steps can allow operators to identify the potential issue before chiller repairs.
Two common factors that can prevent chillers from starting include loose wiring and a blown fuse/circuit breaker. Moreover, a power switch in the off state may prevent the chiller from running. Operators must check the equipment for these common problems to ensure the system runs effectively.
Operators can troubleshoot this problem by checking the temperature of the coolant at the chiller outlet. A temperature different from the standard process requirement indicates an iced-up evaporator or deteriorating coolant fluid.
Insufficient pumping may result from inadequate coolant volume, a partially closed valve, pump failure, or process line restrictions. These factors can significantly prevent adequate coolant flow within the refrigeration cycle.
Manufacturers equip modern-day chiller systems with fault or error code display capabilities. These features can rapidly notify operators about prevalent conditions affecting system performance. Moreover, operators can rapidly diagnose and identify problems due to the specificity of the error codes and fault displays. Some common conditions or faults chiller systems notify operators about include:
The process temperature may increase above the user-set temperature value of the chiller system. This condition can trigger an alarm from the system and may result from a higher heat load than the chiller capacity. Moreover, a lower setting than standard requirements in the chiller system may also trigger the high-temperature alarm.
A process temperature below the user-set temperature value can also trigger an alarm. This condition is common with insufficient heat load or improper low-temperature alarm settings in the chiller system.
This condition involves the coolant falling below the acceptable level in the chiller reservoir. A low coolant level alarm may go off as a result of evaporation or leakages in the evaporation system within the chiller.
An over-temperature safety alarm can go off in a chiller system when the process temperature exceeds the user- or factory-set safety cutoff. Refrigeration system issues or improper safety settings are common causes of this over-temperature problem.
At Cold Shot Chillers, we offer our clients high expertise and deliver advanced solutions for various industrial applications. Our best-in-class air-cooled and water-cooled chillers can efficiently reduce and maintain the ideal temperature for all your cooling needs. At the same time, our experts can help you adequately troubleshoot and identify prevalent chiller issues.
Contact our experts today for further information about our industrial chilling products and services.
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Difference temperature in supply and discharge water in a chiller
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(Mechanical)
(OP)
9 Aug 18 07:41Hi
I am a new engineer in a consultant company. A chiller manufacturer company suggest us to Manufacture a chiller which is work with 6 degree celsius as a supply and 15 degree as a return to evaporator and it said that it is goning to be better as efficiency.
That's my question if it is better or not?! And how does it affect on air handling units?!
Thanks
Replies continue below
(Mechanical)
9 Aug 18 21:13It's not clear what your question or point of comparison is but generally speaking:
The higher the operating temperatures of your chilled water system, especially your return water temperature - the more efficient your chiller will be as far as heat exchanged compared to electrical consumption
But having a higher chilled water temperature and/or a larger delta T (difference in supply and return) will means you will need bigger coils in your air handlers to exchange the same amount of heat and also you may not be able to reach discharge air temperatures from your air handler as cold as you may want
(Mechanical)
(OP)
11 Aug 18 05:23Thanks for reply
As you know according to AHRI the inlet and outlet chilled water temperature to evaporator are 44°F (6°C) and 54°F (12°C) respectively. The question is if the outlet temperature of chilled water will change to 15°C how does it affect on efficiency of chiller, heat exchanger (evaporator), electrical consumption (compressor), pumps, pipes and finnaly air handling units
Thanks
(Mechanical)
11 Aug 18 18:10This is a complicated question and depends on the chiller you have. Hopefully the manufacturer has performance and efficiency curves showing what your chiller output is when you increase your chiller delta T. You really just have to look through that to find your answer as to whether or not your chiller performance improves by operating at 44-60 EWT/LWT temps, and reducing your flow accordingly.
AHRI conditions you mention are just to provide like for like comparisons between chillers, but not to be used to determine your actual operating efficiency.
You will definitely saving pump energy, since higher delta T means less flow to cover the same load. As far as the chiller goes, I'd defer to the chiller catalogue which hopefully will demonstrate the difference by looking through all their performance tables. Chiller efficiency generally speaking is typically maintained by keeping your chiller or chillers running in the 65-85% capacity range, and is definitely improved by raising your entering water temperature. But as far as delta T goes, I don't have that boiler plate answer for you - since each chiller is unique as far as compressor quantities, compressor modulation capabilities, etc.
(Mechanical)
14 Aug 18 07:33Chiller Outlet temperature should be 44°F (6.7°C)as per AHRI.
Capacity calculation of chiller is based on dT (differential of Supply and return temperature) and manufacturer usually provide part load characteristic of chiller and efficiency at that load. If outlet temperature of your chiller is 15°C (59 F), what will be the return (Inlet) temperature? will this 15°C (59 F) sufficient to meet cooling of building?
AHRI req. 44°F chilled water supply temperature at 2.4 gpm per Ton. I believe, AHRI did required inlet temperature to be 54°F (12°C), which you have mentioned in your statement.
(Mechanical)
14 Aug 18 12:48A chiller is a carnot cycle and the closer the chiller inlet and outlet temperatures, the greater the efficiency.
(Mechanical)
14 Aug 18 13:21Closer the chiller inlet and outlet temperature means, there is no cooling load (inside the building). So, it is running on 5% or maybe 10% of load (min set-point). How it could be efficient? Please explain.
(Petroleum)
14 Aug 18 14:24jrrocks - Not really - it just means there is more water flowing around the system for the same load surely?Back to the OP - the vendor says it is going to be "better"... Better than what?
Remember - More details = better answers
Also: If you get a response it's polite to respond to it.
(Mechanical)
(OP)
19 Aug 18 08:23Sorry I made mistake in my question I should have swapped the inlet and outlet temperature
Outlet temperature, (supply temperature) 44°F (6.7°C)
Inlet temperature, (return water) 59°F (15°C)
(Mechanical)
23 Aug 18 17:20With hospitals that are always expanding we would lower the chilled water supply temperature to 42F and add more chiller capacity (at 42F supply). This is to not have to increase existing pipe sizes. With 42F supply existing coils (sized for 44F supply) would require about 20% less gpm to handle the same cooling load.
(Aerospace)
23 Aug 18 19:43What was the alternative?For air conditioners, it's often claimed that undersizing relative to general rules of thumb about tons/square foot is "better" because the A/C can run longer and take advantage of the fact that the plumbing is cooled and stays cool longer, resulting in fewer stop/start cycles. For something that is mostly continuously running, it depends on the relative efficiency curve of the chiller vs. cooling capacity. The result ought to be a cost-surface, but it's likely to the relatively flat near the peak efficiency.
TTFN (ta ta for now)
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