Industrial chillers are key elements of many manufacturers’ operations, removing heat from fluids for air conditioning, dehumidification and controlled cooling for various applications. Given their importance for controlling temperatures and environmental conditions within manufacturing plants, it’s critical that owners and operators pay close attention to chiller maintenance and keep up with their obligations. Without proper care and attention, a chiller system can experience breakdowns, loss of energy efficiency and an overall shorter lifespan.
Proper maintenance is all the more important when you consider how complex a modern industrial chiller system is. A typical chiller consists of compressors, evaporators, condensers and cooling towers, each component having its own unique set of requirements and vulnerabilities. This means taking care of your chiller requires a systematic approach based on organization and leveraging advanced technology to create efficiencies wherever possible. Having a chiller maintenance checklist is one important step all manufacturers should take, but there’s more to it than simply getting organized. What follows is a brief overview of the risks involved in letting your chiller maintenance fall by the wayside, as well as the steps you can take to ensure improved equipment efficiency.
Common issues that industrial chillers face
The complexity and workload of industrial chiller systems mean they are prone to some potentially serious issues if they are not maintained properly. These include:
- Refrigerant leaks — Cracks and holes in supply lines can lead to the refrigerant leaking out of the system. Whether they are sudden or slow, leaks can reduce the efficiency of a chiller system and cause mechanical failures elsewhere in the equipment unless they are dealt with as soon as possible.
- Compressor failures — A broken compressor means your chiller system may not function at all. These can be caused by faulty parts as well as normal wear and tear, meaning regular maintenance is needed to prevent them.
- Scaling and fouling — Over time, minerals left behind by water flow or biofilm buildup caused by bacteria infestation can accumulate inside your chiller system. These can impact the performance of your equipment, which is why cleaning out your lines on a regular basis can make a big difference.
Benefits of routine chiller maintenance
Keeping up to date with your chiller system’s maintenance needs prevents problems such as those mentioned above and provides your operations with a wide range of benefits. Among the many reasons why you should stay on top of your maintenance requirements are:
- Cost savings — If your chiller system breaks down for any reason, it can cost a lot to get it back up and running again. Many of these costly industrial chiller repairs could have been prevented with the right maintenance plan to swap out parts that need replacing or provide fine tuning.
- Increased energy efficiency — Chillers that aren’t properly maintained consume more energy than those that are kept in good working order. This means you can save a lot on your utility bills over the long run just by performing a few regular maintenance tasks.
- Prolonged equipment lifespan — Industrial chiller systems are some serious hardware and represent a substantial investment. If you want to make sure you get the most out of yours, a maintenance plan is crucial. Keeping all components in good shape means your system can last longer.
Machine health monitoring for industrial chillers
Fortunately for manufacturers, modern technology provides them with a solution for watching the condition of their chiller systems. Machine health monitoring tools including hardware and software can help you track your chiller’s performance and schedule preventive maintenance services before major problems arise.
For example, sensor technology including industrial pressure sensors, vibration monitoring sensors and temperature probes can tell you when conditions may be putting too much strain on your system’s components. Through Industrial Internet of Things connections, these sensors can deliver critical data to help you make informed choices and even predict when certain elements of the system may be about to fail.
Common tools used for chiller maintenance
- Thermal imaging cameras: Thermographic testing can detect temperature inconsistencies that could indicate problems with certain components.
- Vibration analysis sensors: By measuring the vibrations around them, these can be used to predict issues with compressors and fans.
- Pressure gauges and sensors: Industrial pressure sensors and gauges can measure refrigerant levels to spot leaks and ensure optimal system performance.
Preventive maintenance checklist for industrial chillers
Daily checks:
- Check refrigerant levels
- Monitor system temperatures
- Inspect for unusual vibrations or noises
Weekly/monthly checks
- Clean condenser coils
- Inspect electrical components
- Check water flow rates
Annual maintenance tasks
- Calibrate sensors
- Replace worn components
- Perform full system inspections
A chiller system is essential for many manufacturing operations. This is why it’s important to have the right predictive maintenance solutions at hand and pay close attention to the health of your system. To learn more, contact the experts at ATS to discuss your industrial chiller maintenance needs and how we might be able to help.
