Industrial chillers are reliable pieces of equipment used in various industries. They protect valuable facilities and help raise the safety standards in industrial workplaces. As such, it is not surprising that industrial chillers must always be in good condition to make the most of their benefits.
Commercial chiller maintenance is essential for ensuring peak performance, longevity and energy efficiency of your cooling systems. In this guide, we’ll explore the different ways to keep your chiller in optimal condition through diligent care and proactive upkeep.
The Importance and Benefits of Industrial Chiller Maintenance
Chiller maintenance is crucial for a company’s success and cost savings. A chiller is typically one of a company’s highest-cost machines and can consume the most power within a facility. Maintaining your chiller prevents machine downtime and helps you conserve energy.
Regular chiller maintenance benefits your company in the following ways:
- Time and money savings: While scheduling or performing regular maintenance may seem like a significant expense or time-consuming task, it can save you time and money. Regular chiller maintenance helps prevent damage, helping your company save on future repairs. While routine maintenance can’t eliminate all risks, it can significantly reduce potential damage.
- Machine longevity: As proper maintenance reduces damage, it also increases your machine’s longevity. A chiller’s life span is typically longer when a company maintains it and makes repairs when necessary. Regular inspections enable you to identify chiller problems and solutions early. You’ll be able to make repairs before the damage worsens or affects other machine components, helping the system last longer.
- Greater efficiency: Proper maintenance can increase a chiller’s operational efficiency. Regular cleaning, tuneups and repairs allow machines to operate properly, helping them function effectively while conserving energy. A machine that works efficiently will conserve power and help you save money on energy costs.
- Regulatory compliance: Regular chiller maintenance ensures your systems comply with industry standards related to refrigerant handling, safety and environmental regulations. Maintaining compliance is crucial for avoiding potential penalties or legal issues and upholding your company’s reputation.
- Increased safety: Conducting frequent maintenance checks enables you to detect and address potential safety issues promptly. By conducting timely commercial chiller repair, you can create a safe working environment for employees and mitigate risks associated with exposure to hazardous substances, refrigerant leaks or electrical faults.
Developing a Chiller Maintenance Checklist
Determining when and how to conduct chiller maintenance requires careful consideration that involves several factors, ranging from manufacturer recommendations and environmental conditions to usage and age. A proactive approach is always best and developing a chiller maintenance checklist can make the process more manageable.
Maintain your chiller with the following daily, weekly, annual and professional maintenance checklists:
Daily Maintenance Checklist
Create a daily checklist so employees can ensure maintenance checks and tasks are complete. At least one person should perform the following tasks each day and communicate their completion:
- Clear debris: Inspect your chiller closely at the end of each day to ensure it’s free of debris. Loose materials such as leaves or insulation can fall around chillers. Removing debris before it becomes lodged in the machines’ components is crucial.
- Listen for vibrations or sounds: Listen for anything that doesn’t match your chiller’s typical sounds. Abnormal sounds can indicate loose components or a part that requires repair.
- Check for leaks: Ensure your chiller is free of leaks each day. Excessive condensation and fluid leaks indicate you may need to repair a hole or crack in the chiller. Schedule professional maintenance if you notice any leaking components.
- Check for fault codes: Contact a professional immediately if your chiller alerts you with any fault codes. Avoid making temporary repairs yourself — you could accidentally damage your machine and void your warranty. A professional can repair your chiller properly and allow you to remain within your warranty’s guidelines.
Weekly Maintenance Checklist
Completing a weekly inspection lets you investigate your chiller more deeply. Most of these checks can be completed without scheduling downtime.
You should perform the following checks weekly. Be sure to follow your company’s safety protocols prior to performing any inspections or repairs:
- Clear debris: Similar to checking the outside of a chiller for debris, you should check inside the unit and clear any debris that has entered the chiller.
- Tighten fastenings: Check the chiller’s fastenings and tighten any loose ones you find.
- Check for leaks: Check the chiller’s pipes to ensure they are free of condensation and leaks. Contact a professional immediately if you spot any leaks or any oil puddles that could signify a refrigerant leak.
Quarterly Professional Maintenance Checklist
Hire a professional technician with a detailed service log that covers all necessary chiller maintenance checks. You can contact a professional to perform the following maintenance checks and repairs during a quarterly maintenance appointment:
- Compressor tuneup: A professional can check your chiller’s compressor to ensure the suction and discharge have the proper pressure and temperature. Additionally, they’ll check the current voltage and the oil pressure and levels.
- Evaporator tuneup: A professional technician inspects a chiller evaporator to check the pressure and temperature of the air or fluid inlet and outlet. They’ll also check the refrigeration outlet and inlet temperatures and the insulation condition.
- Secure enclosures and boxes: You should also check enclosures and boxes to ensure the screws, locks and hinges are secure. Tighten these components if necessary.
- Glycol level check: Allow a professional to help you manage your chiller’s glycol concentration. Maintaining the proper glycol concentration prevents freezing and protects your pipework from damage. (Note: It is not recommended to ever exceed 50% glycol to water concentration.)
- Condenser tuneup: In addition to the condenser coil’s condition, the inspector should check the temperatures of the air intake, air exhaust, refrigeration outlet and refrigeration inlet. They should also check the fan motor currents and repair any issues causing vibrations or noise.
- Leak tests: Service engineers have the proper certification to perform leak tests safely and ensure refrigerant is not leaking from the chillers.
- Water quality tests: Hiring the right technician for water quality checks is essential. Some professionals inspect water quality but do not offer water treatment services. It’s vital to look for a professional who can both identify and help you solve water issues.
Annual Maintenance Checklist
Complete the following maintenance checks annually:
- Clean the chiller’s evaporator: Impurities and contaminants can contribute to thermal resistance, so cleaning your chiller barrel for optimal functioning is essential. Removing dust and particles from the evaporator shell will help your chiller transfer heat more efficiently. (This cleaning can only be performed by a licensed refrigeration service technician.)
- Change the compressor oil and filter: You should change a new chiller’s compressor oil and filter after its first year of operation. Afterward, you can analyze the oil and determine how often to perform future oil changes. (This service can only be performed by a licensed refrigeration service technician.)
Additional Maintenance Planning:
Handling industrial chillers takes careful and detailed planning. You do not want to compromise the performance of your equipment just because of substandard chiller maintenance practices. To give you an idea of how to maintain your chiller and make it work optimally, take a look at the following:
- Water treatment: As water is a huge component for industrial chillers to function, you need to ensure the water is properly treated. This is to prevent extensive damage such as rust, corrosion, and biological growth. It is better if you can have the water system facilities treated through full-service maintenance.
- Chemical analysis: Apart from the water facilities, you also have to consider chemical analyses. Prevent contamination or chemical imbalance by testing the substances you use(like oil and refrigerants) regularly. Furthermore, you can prevent chiller issues if you understand the level of contaminants, moisture or acid in your chiller.
- Heat-transfer efficiency: Heat transfer efficiency plays a large role in industrial chiller performance. Once it starts producing substandard results, it might compromise the whole operation and cause costly delays. Make sure the evaporators and condenser tubes are cleaned either mechanically or chemically. This ensures that the heat-transfer capacity of your chiller does not dip below standards.
- Monitor logs: Lastly, it is important to monitor and keep a daily log of your chiller’s performance. This helps track any changes and can project possible issues in the future. Keeping a log also guides you with the creation of strategies for streamlining production and improving safety measures.
Common Chiller Issues to Watch Out For
While commercial chiller maintenance is crucial for ensuring reliable performance and longevity, some issues can still occur despite your efforts. It’s essential to identify and understand these issues to prevent them from escalating over time. Here are some common signs you can commercial chiller repair and maintenance:
- Reduced cooling capacity: A noticeable decline in cooling performance signifies that the chiller is struggling to meet its designated output, which can stem from refrigerant leaks, blocked air filters, heat transfer inefficiencies or other issues.
- Unusual noises and vibrations: Unusual sounds or vibrations emanating from a chiller can signify mechanical distress, ranging from loose components to bearing failures.
- High energy consumption: When a chiller begins consuming more energy than usual, it often indicates underlying problems or potential failures that require immediate attention.
- Frequent breakdowns: A pattern of frequent breakdowns is a clear signal that the chiller has an electrical problem or the cumulative effect of unresolved minor issues. This disruption in service can lead to significant downtime and calls for immediate attention to chiller operation and maintenance.
- Leaks and corrosion: Leakages in the system, whether of refrigerant or water, along with visible signs of corrosion, are critical signs that the integrity of the chiller is compromised. These issues not only reduce the unit’s efficiency but can also lead to environmental hazards.
- Outdated components: Outdated components in a chiller system can negatively impact performance and lead to compatibility issues with newer, more efficient parts. Regularly updating components is essential to ensure optimal functionality and to stay ahead of technological advancements that can enhance operation and energy efficiency.
Stock up on Spare Parts
Keeping spare chiller parts in your facility enables you to make rapid repairs and reduce machine downtime. Spare parts may be in low supply when you need them, so it’s crucial to stock up on parts when you can. Create a list of spare parts to keep on hand in case you need to replace parts on your chiller.
Learn About Chiller Operation and Maintenance With Our Smart Academy Videos
Chiller maintenance is essential for efficient operation, damage prevention and cost savings. Creating and following daily, weekly, quarterly and annual maintenance checklists will help you keep your chiller functioning efficiently.
Smart Family of Cooling Products offers a wide selection of chillers and cooling products. We also provide online resources to help you maintain these products. View our Smart Academy service videos to learn more about chiller maintenance, process chillers and everything about industrial chiller systems. Contact us to learn more about our high-quality chillers.
