Industrial chillers are highly efficient in maintaining desired temperature in industrial settings. They make the entire process hassle-free.
It is important that these machines run smoothly so that there are no fluctuations in temperature. Their flawless performance depends on how well they are maintained. Just like any other machines, industrial chillers need maintenance, too.
So, how will you know if your chiller needs maintenance besides the scheduled ones? Here’s how.
How to tell if the chiller needs care?
If you see one of the following signs in your chiller, then there’s a likely possibility that it needs maintenance.
- Reduced cooling capacity: The chiller is not operating with the same cooling efficiency as it used to. Or it is taking too long to attain the desired temperature.
- Increased energy consumption: The chiller is consuming more electricity than it used to carry out the same amount of work.
- Unusual noises: When the chiller is running, you hear unusual noises like rattling or growling.
- Leaks: You find that the chiller is leaking fluids like water from one or more locations.
- High or fluctuating pressures: The pressure dial of the chiller is looking off the chart for a few days.
- Increased operating temperatures: The chiller is heating up too much on the outside and, in turn, increasing the temperature of its surroundings.
- Unusual odors: You smell unusual odors from the chiller, especially when it’s running.
If one or more of these problems persist for a while, it could cause unwanted damage to the chiller. What can you do in such cases?
Chiller Servicing Tasks
You can begin by doing a general check-up about the source of the problem. If that is identified, you can resolve the problem from the root. But, besides that, you can follow these best practices to ensure no such issues arise.
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Regular cleaning
To maintain chiller longevity, you must clean it regularly. The condenser and evaporator coils should be cleared of all residues and rust particles. Dirty coils could lead to a reduction in heat transfer, thus decreasing the overall chiller efficiency.
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Timely lubrication
Any joints and moving gears should be properly lubricated from time to time to prevent jamming. If they catch rust and jam, the entire machine’s operation will be hindered.
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Maintaining refrigerant level
We all know that refrigerant plays the main role in a chiller. If its levels go down, the complete cooling process will either slow down or the chiller won’t achieve the desired temperature. So, it’s important that you maintain refrigerant levels.
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Tightening all connections
A clinking and clattering noise could mean some connection, screw, or joint has fallen loose. If left unattended for long, the machine can break down. So you need to tighten all connections whenever you find a loose one.
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Replacing filters
Air filters trap all the fine dust particles that enter the airflow of the chiller, and the liquid filter stops any solid contaminants that might have entered the refrigerant stream. But these filters need to be cleaned and replaced from time to time. Otherwise, they can block the flow and create unwanted pressure in the system.
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Water treatment
The water that enters a chiller should be of high quality. It should be free of hard metals and other contaminants as these could corrode the pipes from the inside. That’s why proper water treatment is necessary for water entering the chiller system.
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Checking electrical connections
Sometimes, the fault is in electrical connections. A loose wire or damaged component can lead to an interruption in chiller performance. So check all the connections from time to time.
These practices need to be followed from time to time. Doing them once in a while won’t work. For instance, you need to check the refrigerant levels daily to ensure smooth performance. Let’s look at a rough schedule for chiller upkeep.
Chiller care schedule
If you are wondering what is the ideal schedule to check on the different components listed above, then here’s a rough schedule.
| Daily | Weekly | Monthly | Quarterly |
| Check refrigerant levels | Clean condenser tubes | Change oil filters | Analyze oil samples |
| Check oil levels | Clean evaporator tubes | Change air filters | Perform vibration analysis |
| Inspect for leaks | Inspect electrical connections | Lubricate moving parts | Inspect belts and pulleys |
| Monitor operating temperatures | Test safety devices | Test alarms and controls | Clean cooling towers |
This is just a sample, and you can customize your maintenance schedule according to your cooling system’s needs. To know how to best look after your chiller, refer to the instruction manual provided by your manufacturer. Let’s look at more such practices for chiller upkeep.
Best Practices for Chiller Maintenance
If you follow the below-mentioned best practices while maintaining your chiller, you can successfully avoid major issues.
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Keep a maintenance log
Keeping a maintenance log will help you track on all the maintenance tasks that have been carried out on your chiller. The date, time, action, and technician name should be noted in the log. So, if any problem arises in the future, you can exactly pinpoint exactly what was the last status of the machine.
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Use qualified technicians
Don’t let just anyone perform the maintenance tasks. Trained and qualified technicians know exactly how to perform technical tasks. It’s ideal to leave these critical tasks in the hands of professionals.
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Use high-quality replacement parts
Don’t use low-quality or cheaper replacement parts just to save a few bucks. Use high-quality replacement parts if you ever need to replace any. They will give optimum performance and ensure chiller longevity.
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Schedule maintenance during off-peak hours
Try to carry out the maintenance tasks during off hours or when there are minimum people around. This not only reduces downtime in your industry but also reduces risks to people present around.
Conclusion
Maintaining the chiller is a necessary evil you have to do. It might seem like an unnecessary waste of resources, but truly it isn’t. You would rather discover a small hole in the pipe than know when it has turned into a long crack and is leaking fluids all over.
If you follow the suggested practices, you can ensure your chiller’s longevity as well. Save costs by performing proper chiller maintenance at appropriate intervals.
