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An Overview of Chiller Systems

Nema Line

An unsung hero of many medical, manufacturing, and industrial processes, the humble chiller is a simple piece mechanical equipment that handles the important task of dissipating heat in high temperature processes. That purpose spans many different types of machines across many different industries. That means that chillers must also be diverse to meet the demands placed upon them by usage across a wide spectrum of fields.

Industrial chillers systems are a critical component in any process that generates excess heat that can cause damage to sensitive equipment or endanger the health and safety of personnel. Industrial chillers use air, water, evaporation, or refrigerant to remove heat from high temperature machinery and processes before releasing it into the environment. Keep reading to learn more about what chillers are, how they work, and the applications in which they are used.

What Is a Chiller?

In brief, a chiller is a device that removes heat from a liquid or gas via vapor-compression or an absorption-refrigeration cycle. The liquid or air is forced through a heat exchange unit or water or vapor are used to dissipate heat from the equipment. The heat that is collected is then discharged into the ambient atmosphere away from sensitive machinery or processes. In some cases, the heat is recaptured and used for processes that require high heat.

Types of Chillers

Despite a diversity of styles of chillers used in different industries, there are three primary types of chillers that are distinguished by their cooling media. There are air-cooled chillers which allow heat to be transferred to cool air which is used to remove the heat from the process. Water-cooled chillers have a similar methodology for removing heat, only the exchange medium is water instead of air. Finally, some chillers work on evaporative principals, which use mist and evaporation to rid processes of heat.

How Chillers Are Used

Chillers can be found in a wide assortment of applications. For example, they are used in commercial and institutional HVAC systems to cool and dehumidify the air in much the same way that an air conditioner cools and dehumidifies a residence. They are also commonly used in the medical field to cool pieces of sensitive diagnostic equipment that generate high heat during usage. For example, chillers are often required for use with MRI machines, CT scans, and PET scans to prevent damage to the costly equipment and vent ambient heat generated by use from the diagnostic area. Chillers are often used alongside lasers, as laser technology generate heat that can cause damage to equipment or nearby facilities. In the industrial and manufacturing sectors, chillers are commonly used in processes such as plastics manufacturing, food and beverage preparation, welding, casting, pharmaceutical manufacturing, power generation, chemical processing, and semiconductor manufacturing.

Vario Line

Chiller Components

While there are distinct types of chillers that function in slightly different ways, most of them share a common set of components. Most chillers consist of a vapor compression mechanical refrigeration system connected to the process water system, an evaporator where heat exchange takes place, a compressor, a condenser, and an expansion device.

How Chillers Work

The way that chillers work depends largely on the type of chiller in question. Water-cooled chillers use chilled water or other liquid such as glycol, for example, to remove heat from equipment and processes. The liquid is circulated in proximity to the heat, which is transferred to the liquid. The liquid is then pumped or otherwise circulated through a looped system that travels away from the heat-producing equipment. Many water-cooled chillers use a cooling tower to further enhance cooling efficiency. The liquid then discharges the gathered heat into the ambient atmosphere before beginning the cycle anew. Water-cooled systems are installed indoors with an outdoor cooling tower fed by a condenser water loop. Air-cooled systems function in a similar way but can be installed outdoors. They rely on the ambient air for cooling purposes. The air is drawn into the machine and circulated through the condenser coil to remove heat, which is then expelled into the atmosphere. Evaporator chillers are basically air-cooled chillers with one important addition. Evaporator chillers use a cooling mist sprayed over the condenser coil to remove heat, which increases the chilling efficiency of evaporator chillers when compared to basic air-cooled chillers. Water-cooled chillers are more efficient than any other type.

Industrial chillers are a critical part of many medical, manufacturing, and industrial processes as they protect costly equipment from the damaging effects of their own heat generation. To learn more about industrial chillers, contact KKT Chillers at (847) 734-1600.

Evaluating Medical Chiller Providers

Doctor Does Research

If you’re in the market for a new medical chiller, there are several factors you should consider. Product selection, company reputation, credentials, and support are just a few things you need to consider when evaluating MRI chiller manufacturers. Keep reading to learn more.

Product Selection

When you begin your search for a medical chiller company, you usually start by looking for a specific chiller make or model. You typically know what your business needs; now it’s just a matter of finding the chiller that meets your criteria. A chiller manufacturer with an extensive product selection is a great find, especially if they offer customized integration solutions that allow you to tailor your order to your business needs. An important question to ask yourself as you consider the product selection of a specific company is: are they just a product dealer, or do they also manufacture their products on-site? Distinguishing between dealers and manufacturers can impact the type of product support you receive -- but more on that later. As you narrow down your list of chillers, there are several other factors to consider.

Customer Reviews

A well-designed website and large product selection are great, but to get a feel for a company, take some time to check out past customer reviews. There are several places you can use to research chiller manufacturers and dealers, but The Better Business Bureau is by far your best resource. The BBB analyzes and confirms business credentials to determine the legitimacy of a company, which protects the consumer from falling for a scam. They also act as a third-party mediator between companies and their clients using an open-forum method of dialogue. Clients can post a complaint, and the company has the chance to remedy their concerns through open dialogue.

Doctor on Phone

Business Credentials

After you’ve checked customer reviews online, now it’s time to verify the company’s business credentials. Business credentials include an operating license, business insurance, professional affiliations, and training standards. A business license is issued by the state or regional business bureau; it verifies that the company is legitimate and permits them to operate. Business insurance protects the client from liability in the event of an accident caused by the company’s product or personnel. Professional affiliations with trade organizations ensure that a company is up to date on the latest industry standards. It also signifies a company’s adherence to sustainable practices and employee training. Training standards will vary from one position to another. However, most employees in the industry are required to have some medical and workplace safety training in addition to advanced degrees or certificates in mechanical engineering.

Support and Maintenance

Finally, before you make your final chiller selection, consider the future of your equipment after installation. Whom do you call if you have a problem? Does your chiller provider offer comprehensive troubleshooting and emergency support? Do they offer service and maintenance plans that will help keep your chiller running at its best? Regular maintenance and inspections of your equipment will help reduce the occurrence of common problems and improve the longevity of your machine.

To learn more about MRI chillers, chiller manufacturers, and provider standards, contact the professionals at KKT Chillers, Inc. today!

How Industrial Chillers Differ from HVAC Chillers

Industrial chiller

Chillers are a versatile component critical to the safe and effective operation of a range of equipment. While the desired goal of any chiller is to reduce temperatures, the applications of chillers can vary widely. While both HVAC andindustrial chillers systems may work in similar ways, they are quite different. The standards and performance metrics for industrial chillers are more rigorous because of the core function they fulfill. HVAC chillers are responsible for cooling air, and if they fail, the worst outcome is likely discomfort. However, the best industrial chillers keep high-heat equipment at safe operating temperatures, preventing damage that could cost tens of thousands of dollars and protecting the safety of those in close proximity to high-heat equipment.

Though it’s obvious the stakes are higher for industrial chillers when it comes to performing their core purpose, there are other differences between the two chiller types that may not be as readily noticeable. Keep reading to learn about a few of the many differences that separate industrial chillers from HVAC chillers.

Different Standard Features

In many cases, industrial chillers come stocked with features that are considered standard, though the same features on many HVAC chillers may be considered optional. As a result, the cost for an HVAC chiller with the same features as a standard industrial chiller may be significantly higher. For example, there are many small industrial chillers that feature integrated water pumping systems. However, a similarly sized HVAC chiller system may not have that feature and adding it can come at a much higher cost while creating a chiller unit with a much larger footprint. Additional features that are often standard on industrial chillers but considered optional on HVAC chillers include reservoirs and controls for the pumping system, condenser water regulating valves, and water manifolds with service valves for the condenser and evaporator.

Independent Water and Refrigeration Circuits

Another key difference between the two types of chillers is that industrial chillers usually have independent water and refrigeration circuits that are used to provide cooling, while HVAC chillers may only have an independent refrigeration circuit. This provides a redundancy for industrial chillers that acts as an extra layer of protection if one circuit fails. That means the chiller can still work at 50% in the event that one of the circuits fails. HVAC chiller usually share a multi-circuit evaporator, meaning that if one circuit fails the whole chiller unit goes down.

Labor Warranty and Training is Standard

Start-up and maintenance of your chiller are two important concerns, and in both cases most industrial chillers feature programs that come standard with the chiller. For example, most industrial chiller manufacturers include set-up and training in the cost of the chiller, though HVAC chiller manufacturers will only provide those services at an additional cost as an option. Likewise, industrial chillers typically come with a standard labor warranty. However, while labor warranties are also available for HVAC chillers, they are considered an option and therefore come at a higher price point.

HVAC chiller

Service and Support

Servicing your chiller unit is a straightforward affair since there are a wide range of technicians who can assist you. A technician doesn’t necessarily need to be trained by a specific manufacturer in order to service chiller units of a variety of makes and models. That means finding a qualified technician is easier. However, HVAC chiller technicians are usually trained to work on only one brand, which restricts the number of techs who may be available to service your chiller. Support is another point of difference. Most industrial chiller manufacturers maintain phone support with technicians that is available even after the warranty has expired. HVAC chiller manufacturers may offer phone support while the unit is under warranty, but once the warranty expires, that service will come at a premium price.

Before you begin shopping for chiller units, make sure you understand between chillers meant for industrial applications and chillers intended to be used in HVAC system. While they provide the same general result, they differ greatly in features, available options, and support and maintenance. If you’re in need of an industrial chiller, contact KKT Chillers Inc. to learn about available options.

Chillers for Lasers: An Introduction

Chiller

Chillers for lasers are the most important device for industrial manufacturing, welding, and various laser processes. They are used to control temperature, ensuring quality performance and a long life span for industrial, medical, military, and other laser systems. Laser chillers are fully self-contained systems that remove heat from components of lasers. Here are some more facts about industrial laser chillers.

Thermoelectric Chillers

Thermoelectric Chillers, or TECs, use a heat flux generated at the junction of two, unlike materials. Across the materials, DC electric current is passed. TECs are made of semiconductors arranged side by side in a thermal path and succession along an electrical path. When you apply voltage to the semiconductor, electrons transport heat to one side, leaving the other side cold. As the one side gets hotter, the more current is needed to maintain the temperature.

Heat is removed through dissipation of the main heat sink, where hot air turns into ambient air and is removed by a fan. Laser chillers manufacturers can make TECs in several shapes and sizes and with no moving parts and minimal maintenance. You can mount thermoelectric chillers onto the laser cold plate, or use separately to cool flowing liquid.

Vapor-Compression Chillers

Vapor-compression refrigeration chillers involve a process of moving heat from a cold source to a heat sink. There are four main components of a vapor-compression chiller: compressor, condenser, expansion valve, and evaporator. The process starts with exploiting the physical properties of the refrigerant to create an isothermal, two-phase heat transfer.

The compressor inhales gas discharged from the evaporator and increases the pressure and temperature. A condenser condenses the extremely hot gas into a liquid while heat dissipates into the surrounding environment. An expansion valve carries the hot liquid refrigerant and lowers the pressure and temperature. This type of industrial laser chiller is works extremely efficiently for cooling air, liquid, or laser cooling plates.

Direct Refrigerant Chillers

Direct refrigerant coolers are some of the best industrial lasers chillers on the market right now. With this type of laser chiller, the refrigerant flows right through the cold plate, and the circulation gets powered by a compressor. This removes the need for a recirculation pump, fluid reservoir, and related tubing, which can be sources for leaks and other failures.

Using direct refrigerant enhances the effectiveness of industrial laser chillers. Cooling capacity is increased by at least twenty-five percent more than liquid chillers. The system also lowers the risk of losses related to cooling the liquid and saves energy used in driving pumps. Additionally, you can use a refrigerant line quick disconnect, which will help you remove the cooling system from the laser quickly and easily.

If you would like to know more about industrial chillers for lasers, contact KKT Chillers, Inc.

Everything You Need to Know about OEM Chillers

Mechanical machines

If you work in a medical, industrial, or manufacturing environment, there’s a good chance that you’ve encountered an OEM chiller. Chillers are common in a variety of environments and are applicable in situations that feature high heat that can be damaging to sensitive equipment if not properly and safely dispersed during operation. A chiller not only mitigates heating associated with high-powered devices, equipment, and processes, but it also protects expensive equipment from the damaging effects of intense heat.

OEM chillers use a variety of systems that utilize air- or water-cooling capabilities to disperse heat away from critical areas. Despite their importance in many industries, many people don’t understand chiller function or other simple facts about these critical devices. If you work in an industry in which high heat is a concern, it pays to learn more about the best OEM chillers offered by OEM chiller manufacturers in today’s marketplace. Keep reading to learn a few important facts about chillers and what they can do to improve your processes and protect your equipment.

Types of Chillers

OEM chillers come in three primary types, though there can be variance among those depending on their application and the industry in which they are used. Chillers are broken down by their cooling medium, such as water-cooled, air-cooled, or evaporative condensed chillers. Within those categories are four primary mechanisms that drive cooling. Those four types are screw-driven, centrifugal, reciprocating, and absorption chillers. The first three feature mechanical drives, while the absorption chiller is powered by a heat source. Among water-chilled systems, there are four main types that include drop-in chillers, open-loop chillers, closed-loop chillers, and in-line chillers.

Industries That Use Chillers

Chillers are used in a wide variety of industries in which the dispersal of heat is critical. For example, chillers are often used in conjunction with medical diagnostic imaging equipment such as MRIs, CT scanners, and PET scanners. They can also be used alongside high-intensity lasers used in many fields, as they can keep precision equipment cool despite the heat surrounding them. Other equipment that warrants the use of OEM chillers includes semiconductors, precision optics, medical research equipment, laboratory equipment, supercomputer components and servers, and automated manufacturing processes.

MRI Scan Device

Key Chiller Components

While chiller components can vary widely based on the type, style, and system used for a model, there are some common components that can be found in most chillers. Most water chillers have a holding tank for the coolant, though that coolant tank may be situated alongside the other chiller components or in a remote location that is connected by plumbing. Most types of chiller must have an evaporator or cooling surface that allows for the dissipation of heat from the equipment that is generating it to the cooling medium used by the chiller. Most chillers also have pipes of plumbing to transport the coolant throughout the system. Finally, whether the coolant is air or water, there is usually a pump or fan in place to circulate the coolant through the system, which allows for heat dissipation and cooling.

Benefits of Chillers

Chillers offer many benefits in the industries in which they are employed. Chief among them is the protection of powerful precision equipment that may be used constantly, such as in a research laboratory or medical setting. Devices such as large centrifuges or MRI machines can be expensive and protecting them from the effects of high heat can extend their lifespans. Also, some styles of chillers can remove heat from an environment in which the ambient temperature must be kept stable. Though off-the-shelf chillers are available for some applications, they are also highly customizable and can be crafted to meet your specifications. They also provide an energy-efficient method for cooling heavily used equipment.

If you work in an industry that features high heat equipment and processes, there’s a good chance that you’ve come into contact with an OEM chiller before. OEM chillers are a critical protective element in many modern fields of endeavor, as they protect sensitive equipment and disperse dangerous heat from the work environment. To learn more about OEM chillers, visit KKT Chillers, Inc. at https://www.kkt-chillersusa.com/products/oem-solutions.html.

The Functions of an Industrial Chiller

Vario Line

Industrial equipment and machinery are often prone to overheating. Fortunately, today's industrial chiller systems have been well-designed to accommodate the needs and demands of modern industry. Whatever your specific requirements, there should be plenty of options when it comes to cooling systems. Of course, while cooling is always the ultimate goal, there are many functions performed by industrial chillers.

Chillers

Industrial chillers are used both in commercial and industrial settings. As you would expect, they serve basically the same functions in both cases. Chillers can be broken down into two main types. They're either air-cooled or water-cooled systems. These systems can be broken down even further into four processes. You're probably already somewhat familiar with refrigeration, compression, evaporation, and condensation. Chillers used for refrigeration are quite common for foods and beverages. With compression, the compressor is used to increase the pressure and temperature of a vapor. Evaporation allows heat to be transferred to and removed in either air or water. After that, it escapes in the form of vapor. Most people have seen this vapor released via pipes or releases through vent stacks. For condensation, the vapor is cooled and eventually transformed into a liquid.

Several of these might be needed at a single commercial or industrial site, depending upon the work being performed. There are many industries that rely on chillers for their daily needs. Pharmaceutical companies, food and beverage producers, chemical manufacturers, and even injection moulding and dye casting facilities all require the use of industrial chillers. Depending upon your demands, either a water-cooled or air-cooled industrial chiller could be ideal.

Water

A water-cooled chiller has water as its primary component throughout the cooling process. A water-cooled chiller tends to be significantly quieter than air-cooled systems, so they're typically preferred if noise is a major concern. Additionally, water-cooled chillers are remarkably efficient, so you may be able to lower your energy costs with a water-cooled system. With water-cooled chillers, you have a very durable, efficient, and accurate cooling system that won't need to be replaced for quite some time.

Compact Line

While there are distinct advantages to using a water-cooled industrial chiller, there are some drawbacks. A water-cooled system does need regular maintenance and upkeep. Although they can work reliably for many years, their performance and endurance are both dependent on frequent attention and care. Additionally, water-cooling requires extra equipment. This equipment is usually store in an adjoining room, so space can be an issue.

Air

Air-cooled chillers are rapidly improving in terms of efficiency, although they're still not equal to water-cooled systems. However, there are some advantages to air cooling. Air-cooled chillers usually cost less, and they're not as expensive to install. They also tend to be more compact, so they don't need as much space. When compared to water-cooled chillers, the air-cooled systems don't need as much regular maintenance and care.

Of course, the heat transfer isn't as efficient as it is with water cooling. If you require greater heat transference, water-cooling is the better option. For many commercial and industrial companies, an air-cooled chiller is more than adequate, but this isn't always the case. Be sure to consult experts to determine your specific cooling needs.

There are many pros and cons to different industrial chillers systems. While there are advantages and disadvantages to both air-cooled and water-cooled systems, ultimately your best choice will depend upon a number of variables. Be sure to speak with the professionals at KKT Chillers to learn more.

The Different MRI Chiller Types and Their Uses

MRI machine

Medical diagnostic imaging equipment provides caregivers with advanced tools for diagnosing and treating a full range of medical conditions, from torn ligaments to head trauma. This miraculous equipment provides insight that is invaluable to physicians and surgeon. That performance comes with a caveat, however, as the expensive equipment also generates a tremendous amount of heat that must be dissipated to protect the sensitive equipment from damage.

The primary method for dealing with the heat generated by diagnostic imaging equipment is the use of a chiller. A chiller is a cooling device that can take many configurations and relies on air or water to remove heat from the environment and safely dissipate it. A medical MRI chiller is much like an air conditioner, only instead of cooling the air it is cooling a piece of equipment. Chillers are used in conjunction with several imaging systems, including MRIs, CT scans, PET scans, and linear accelerator machines. Because of the diversity of applications necessary to perform in a demanding medical environment, MRI chillers may take several forms, with each type boasting its own strengths. Read on to learn more about the different types of medical chillers and MRI chillers in use today.

Open Loop

An open-loop system is one of the most commonly used types of chillers in a medical environment because of its simplicity and high level of efficiency. In an open-loop system, water is stored in an external tank that is removed from the heat source. When the imaging equipment is being used, water is circulated from the water tank to the chiller. There, a condenser allows for the chiller to cool the desired equipment. As the water moves through the chiller and back to the tank in a constant loop, it carries the heat away from the equipment and dissipates it into the environment. Most open-loop chillers use water as the coolant rather than air because it’s more efficient and can handle heavier heat loads. Water also allows for a more compact chiller that doesn’t require fans to move coolant. Open-loop systems are ideally suited to the high heat dissipation requirements associated with MRI machines, and are, therefore, common in that application.

Closed Loop

Closed-loop chillers operate on the same basic principal as their open-loop counterparts, only instead of utilizing a remote tank to store water, they feature an internal tank. The closed-loop system is more complex than an open=loop system. Whereas an open-loop system depends on heat dissipation of water as it travels back to a remote tank, closed-loop systems incorporate an evaporator that helps to cool the water before it returns to the tank. The evaporator is used to maintain the temperature of the coolant, which maintains the proper operating temperature of the chilled equipment. Coolant temperature is constantly monitored and adjusted within the sealed system. While closed-loop chillers are sometimes used with MRI machines, they are more commonly seen used with PET machines and linear accelerators used in oncology.

In-Line

Doctor

In-line chillers combine several key features of closed-loop and open-loop chillers to achieve the same temperature reduction and maintenance standards. They are similar to open-loop chillers in that the coolant is stored in a remote tank that is isolated from the heat source. Like closed-loop chillers, they use an evaporator plate that helps to control the temperature of the coolant. The key difference that distinguishes in-line chillers from their counterparts is that the coolant is put under pressure using a pump. They are sometimes used in conjunction with MRI equipment but are more often used with CT scanners.

Drop-In

Drop-in chillers are unique in the way they perform the task of dissipating heat in a medical environment. They feature an evaporator coil that is embedded in a coolant tank. The chiller itself sits on top of the tank in most cases. Pumps agitate the coolant that surrounds the evaporator, which keeps cool liquid in constant contact with the evaporator. That allows for constant heat dissipation as the coolant circulates within the tank. A sensitive temperature control unit monitors the coolant temperature and can adjust cycling rates in the tank to maintain the desired temperature. Drop-in chillers are ideal in applications where floor space may be limited, or when it may not be feasible to install infrastructure for an open-loop or in-line system. They are used with MRI, CT, and PET scan equipment.

Because the needs of medical imaging equipment are diverse, MRI chillers come in several types that each have their own strengths. If you’re searching for the right way to keep your medical diagnostic equipment cool, visit KKT Chillers, Inc.

Best Ways to Check Condenser Temperature of Water Chillers

Water chiller

For your water chiller to continue working properly, it’s essential that the condenser remains at the optimal temperature. The only way to guarantee this is to measure the temperature. But what is the best way to do this? Keep reading to learn about the relationship between condenser pressure and temperature, and how to measure the temperature of the condenser of a water chiller.

Condenser Pressure and Condenser Temperature of Water Chillers

To learn how to figure out the temperature, you must first understand what the condenser pressure and condenser temperature are. The condenser temperature is the saturation temperature of the refrigerant steam when it is at a specific pressure in the condenser. It isn’t the same as the temperature of the cooling medium. There is, in fact, a distinction in the transfer of heat between the two.

The condensing pressure is the pressure required to condense refrigerant into a liquid while in the condenser. The pressure inside the condenser can’t be measured. Any drop in pressure in the exhaust pipe or the condenser is minuscule. Regardless of the water chiller design or maintenance you complete, it’s thought that the condensation pressure is nearly equal to the exhaust pressure, which is easier to measure.

The Relationship Between Condenser Pressure and Condenser Temperature

The condenser temperature and condenser pressure are directly related, and they change at a proportional rate. The higher the condenser pressure, the higher the condenser temperature is. The lower the pressure, the lower the temperature. This information is vital to measuring the condenser temperature of an OEM chiller.

Estimating the Condenser Temperature

Condenser temperature

To ensure a water chiller is working correctly, you will often need to measure the condenser temperature so you can calculate the condenser pressure. This will give you the information you need to figure out whether or not the water chiller is functioning properly. This method is most often used to determine whether or not more refrigerant is needed in the water chiller. You can use this estimate to perform your measurement: Condensing temperature ambient temperature / water temperature + (10 ~ 20 °C).

Here is an example: During the summer, an air-conditioned environment is around 35 degrees Celsius. You can then estimate the condensation temperature as 35 + (10 ~ 20 °C)50 °C. Using the temperature and pressure table, you can see that the evaporation pressure at this temperature is around 3.05 MPA.

When to Call a Professional

If you suspect there is something wrong with your water chiller, it is best to reach out to a professional. These are complicated devices that require expert knowledge to repair and maintain. At the first sign of a problem, contact your water chiller supplier or another local company that provides services for water chillers. They will be able to easily measure the condenser temperature and the condenser pressure, and determine what, if anything, is wrong with your device. They will also be able to repair it and help you to prevent these issues in the future. Contact us at KKT Chillers, Inc., to learn more about the water chillers and parts we sell, along with the services we offer.

The Benefits of Routine Chiller Maintenance

MRI

An MRI chiller system is integral to the continued operation and proper performance of an MRI machine. Many medical practices rely on their MRI for a number of tests, and a well-maintained MRI is essential for many diagnoses. Your patients and your staff rely on it to function as expected. In order to continue operating optimally, your MRI needs a chiller that does its job.

Energy

Energy efficiency is key. A chiller is incredibly demanding when it comes to energy consumption. Unfortunately, poor maintenance will only make it even less efficient. In fact, improperly maintained chillers can lose as much as 25% of their energy efficiency annually. Cooling systems can be responsible for as much as half of a company's energy usage. If you aren't keeping your chiller running at peak performance, you should expect to see higher utility bills. Routine maintenance is a big part of keeping your chiller performing well.

Lifespan

Chillers can last for many years, especially if they're maintained on schedule and repaired as needed. But there are ways that the lifespan of a chiller can be unintentionally shortened. The four most common contributing factors to chiller failure are a lack of regular maintenance, improper operation, corrosion, and using a chiller that isn't of the appropriate size. While these may seem like obvious errors, they're also encountered quite frequently.

The good news is that many issues can simply be avoided. Your chiller should have an owner's manual that shows and explains diagnostic codes. Those codes can help you identify most problems. Additionally, you ought to have guidelines for regularly scheduled maintenance and directions for operating the chiller. As long as you follow all of these instructions, your chiller should remain in good working condition for several years. Although the loss of energy efficiency is basically inevitable as machinery ages, it'll be at a minimum if your chiller is well maintained.

Size

MRI

Bigger isn't always better. It may intuitively seem obvious that a larger chiller will chill better and possibly use less energy, but the opposite is often true. A chiller that's too large will use more energy, and it won't operate as efficiently. When cooling a decreased load than what the chiller is designed to handle, it'll also have fewer operational hours. This results in the chiller not cycling as it was built to do. Over time, its already poor efficiency will continue to decline. The result is that you paid more than needed for a chiller that performs poorly. Energy costs will climb, and you may have to replace the chiller. Those added expenses were unnecessary and avoidable.

Benefits

By now, the benefits of routine chiller maintenance should be fairly obvious. You can save money by buying a chiller that's the proper size, which prevents you from overpaying for unnecessary equipment upfront. Over time, proper care and upkeep will aid in preserving the chiller's efficiency, preventing it from declining more than expected over its operational lifetime. With care and attention, any corrosion can be identified and remedied. Parts may be replaced and repairs performed as needed. If you keep a good maintenance schedule, it shouldn't be difficult to notice any telltale signs of worn parts. This enables you to preempt any serious problems and correct them before they become more problematic or too costly.

All cooling systems require attention and care. If you'd like to learn more about MRI chillers, contact the expert team at KKT Chillers.

Top Tips for Maintaining Chiller Efficiency

Checking Log on Tablet

Your business’ industrial chiller system is a substantial investment. As such, you want to make sure it works efficiently. Did you know that chillers are the largest single-energy fixture in your building? For this reason alone, it’s important to stay on top of maintenance to ensure efficient operation and continual reliability. Check out these top tips for maintaining chiller efficiency on your commercial property.

Keep a Daily Operating Log

All chiller operators must keep a daily operating log that details performance. This information lets operators stay updated on potential problems or signs of lacking efficiency. The process of detailing the operating conditions daily allows operators of industrial cooling system chillers to pick up on trends that are often the early warning signs of impending problems.

Keep the Tubes Clean

A problem that happens often to chiller systems is an issue with heat-transfer efficiency. When performance is affected because of this problem, it’s usually an issue with the condenser tubes and the evaporator. Both of these parts must be cleaned regularly to ensure maximum efficiency. Large industrial chillers have many miles of tubing in the heat exchangers. For this reason alone, it’s so important to keep the tubes clean for the best performance. Over time, these tubes become clogged from mud, algae, and other debris. Annual cleaning is recommended. However, with closed systems, you might only need this cleaning once every 3 years. Refer to manufacturer recommendations for cleaning schedule suggestions.

Keep the Unit Leak-free

Even the best industrial chiller systems can develop condenser leaks. That’s why it’s recommended that commercial properties have their chillers tested for leaks once every quarter. Taking this preventive action saves you money and keeps the unit running leak-free.

Leak Drip

Keep Contaminants Out of the Water

In order for the heat transfer to occur, the majority of chillers on the market use water. If your building has hard water or is contaminated with corrosion or biological growth, this needs to be treated. You can’t operate a chiller system when there is the possibility for scale buildup because it will affect the heat transfer. For closed-water systems, it’s possible to use a one-time chemical treatment. Open systems require more maintenance. Therefore, it’s recommended that operators of open systems work with a chemical-treatment vendor who is familiar with the water system problems and develop a full-time maintenance routine to keep contamination from affecting the chiller. When the right chemical treatment is used for open and closed systems, there shouldn’t be a problem with scale or other contaminants in the chiller.

Get a Chemical Analysis of Oil and Refrigerant

Chiller-contamination resulting from oil and refrigerant problems can cause serious issues for chillers. Have the unit tested regularly for oil and refrigerant contamination. These tests determine the presence of metals, acids, and moisture, all of which can hamper efficiency. Only professionals with experience in chemical laboratory equipment are qualified to perform this analysis.

Maintaining your industrial chiller system is critical for continual efficiency. Protecting your business’ chiller system saves you money and prevents unnecessary repair or replacements. To learn more about chiller products or services such as replacement parts and professional services, contact KKT Chillers, Inc., today.