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FEATURE HVAC maintenance musts to protect a system CHILLER CHECKLIST:


the evaporator, the condenser and the expansion devise) and log the circuit(s) during operation.


CHILLER COMPRESSOR In the main, compressors are positive displacement pumps. Refrigerant is pumped around the circuit, rejecting heat from within the condenser to the atmosphere or fluid, and absorbing heat from the air or fluid in the evaporator.


CHILLER EVAPORATOR The evaporator transfers heat from the process or HVAC system into the refrigerant. This effect reduces the chilled water temperature. The flow rate through the evaporator and the system kW capacity determines the outlet temperature compared to the inlet.


Alistair Michie, service manager UK at ICS Cool Energy advises on best practice for chiller and system maintenance to help mitigate the risk of downtime, extend the lifetime of equipment, and provide peace of mind that everything possible is being done to keep a process running


M


uch like with a car, performing some simple and regular daily


checks can go a long way in improving operation and preventing a breakdown. Checking for irregular or unusual


sounds and vibrations should form part of a daily routine as well as monitoring temperatures of process fluids. Visual checks should also be undertaken, taking note of and removing debris in the area surrounding the chiller, as well as keeping an eye out for any fluid leaks, excessive condensation, and loose components on the chiller such as thermal insulation. Any issues spotted can quickly turn into


serious faults if left unaddressed so checks should be made daily by more than one person and noted in a daily log. However, if the chiller performance deteriorates or begins to display fault codes, it is time to call in an expert. Settling for a stop-gap measure to keep production running could at best void the chiller’s warranty and at worst, result in irreparable damage to the unit.


A DEEPER LOOK Maintenance certainly doesn’t stop with these daily routine checks – a more


16 SEPTEMBER 2018 | FACTORY EQUIPMENT


thorough examination of equipment will be required, preferably on a weekly basis, and at the very least once a month. Planned downtime is always better than preventable downtime, and as such these checks can be scheduled around the production processes’ quieter periods. Before starting these checks, the side


panels of the unit will need to be removed and the unit will need to be isolated from the electrical supply. Once safe, the fixings and fastenings on the unit can be inspected, ensuring they are tightly secured and adjusted as necessary. All pipework should then be examined


to be certain there is no fluid leaking from the equipment. If any is found, an expert should be contacted immediately.


REFRIGERATION CIRCUIT CHECKS When it comes to any work being undertaken on the refrigeration circuit, this should be conducted only by an F Gas certified engineer. The engineer should look through any existing logs detailing the date of the last check or commissioning including system design data, and after taking note of the general surroundings they should inspect the four main components (the compressor,


Checking for irregular or unusual sounds and vibrations should form part of a daily routine


CHILLER CONDENSER The condenser rejects any heat absorbed from the process (evaporator) and from the compression cycle. Checks will alter slightly depending on whether the chiller is air cooled or water cooled.


The equipment’s glycol concentration also needs to be checked regularly. The addition of glycol prevents water from freezing allowing low temperature operation. If the concentration is too low though, damage to the evaporator can occur causing irreparable damage and contamination to the refrigerant circuit and its components. It is important that automotive glycol isn’t used as this is not formulated for chilled water system components. Ideally the glycol should be inhibited, and a biocide added to protect the system from corrosion and bacteria. Chilled water is frequently overlooked


in a planned preventative maintenance plan. Oversight and poor control can lead to system failures. The refrigerant leak test is the most important aspect and a legal requirement for many refrigeration circuits. It is a legal requirement to repair any leak found without undue delay, as loss of refrigerant not only damages the environment but also reduces the efficiency and capacity of equipment. Using the above information, a detailed


action plan can be created which encompasses daily checks and routine planned preventive maintenance.


ICS Cool Energy www.icscoolenergy.com T: 0800 774 7426


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