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Chiller Maintenance Checklists
Chiller Maintenance Checklists
Routine maintenance of industrial chillers is required to maintain high uptime and extend
the useful life of the asset. A nice bonus is that well-maintained chillers have a reduced
power consumption.
Below, we outline daily, weekly, monthly, and annual maintenance steps you should
consider to keep industrial chillers in good operating condition at all times.
Cleanliness: Keep the chiller and its surrounding environment clean. This
helps to reduce inefficiency and improve overall performance.
SOPs and checklists: Create standard operating procedures (SOP) for all
chiller maintenance activities. Create preventive maintenance checklists out
of the SOPs. Use them to ensure that maintenance tasks are performed up
to the required standard.
Maintenance records: Keep record of all maintenance activities and
measurements (such as temperature and pressure readings). You can
use cloud platforms like CMMS to store that data in an easily accessible
place.
Preventive schedules: Create preventive schedules for chiller
maintenance. The schedule created has to be in alignment with OEM
recommendations and inputs from experienced technicians. You can use
a CMMS like Limble to automate and organize maintenance work and stay
on top of your spare parts inventory.
Treated water: Regular water causes corrosion. Use treated water to
reduce the chances and impacts of corrosion, as well as to reduce scale
formation inside conduits.
Oil testing: Regularly test the quality of oil and lubricants used in chillers
via spectrometric analysis. Replace the oil as soon as degradation in oil
quality is detected.
Keep in mind that these are just rough recommendations. You will have to adjust
maintenance frequency based on the age/condition of your asset, operating conditions,
and the type of chillers you run.
Contents
Circuit breaker is a costly electrical device which is used for power supply
making and breaking as switched On or switched Off. Preventive maintenance
is a important activity for keeping good health of motor starter. Many type
maintenance activity is carried out as monthly, quarterly, half yearly and yearly.
These all activities is carried out according maintenance checklist which is
written step by step maintenance process.
2-Format or template of circuit breaker PPM checklist:
Monthly
Quarterly
Half Yearly
Annually or Yearly
During PPM activity we should follow safety guideline for stopping any
misshaping. Safety related some points below mentioned.
Check and clean contact holding mechanism like as spring charging etc.
Check and adjust breaker protection relay setting as short circuit, earth
Check all release in functional mode like as shunt coil, UV and spring
charge.
Incoming Voltage
Contents
1. Equipment Logbooks
2. Schematic diagram.
o HT panel logbook.
o Transformer logbooks.
o LT panel logbook.
o UPS logbooks.
1- Equipment Logbooks:
Log book is a record book which is used for manual storing parameters data
of equipment, events and machines. The parameters of equipments are
mentioned in it. Parameters data is taken in a frequency according
requirement as a hourly, 2 hourly, 4 hourly or per day.
Different types log books are used in a different formate are used according
equipments. Here we are going to discus electrical log books like as UPS log
book, transformer logbook, HT panel log book etc. Electrical equipments
parameters are logged as voltage, current, frequency, temp etc.
3- Types of logbooks :
Different types logbooks are used in technical system like as transformer log
book, chiller plant logbook which below mentioned.
1- HT panel logbook.
Parameters detail:
Maximum demand
Power factor
Auxiliary voltage
Parameters:
Transformer current
Parameters:
frequency.
Power factor.
Parameters:
Incoming voltage.
Outgoing voltage.
Current in Amp
Battery voltage.
Chiller plant is an Airconditioning machine which is used for high rise offices,
premises, malls. It is costly machines so parameters are very important for its
health.
Parameters:
Running hours.
Voltage
Current
Energy in KW.
Diesel generator is a mechanical and electrical device which is used for back
up power generation. It converts mechanical energy into electrical energy so
record parameters are important for its better health.
Parameters:
Running hours.
Voltage
Current
Energy in KW.
Oil pressure.
Water temp
Coolant temp.
Battery voltage.
WTP is a water control center where the water is received, storage, filtered and
distributed for utilization. So parameters are very important for knowing the
status of water plant.
HT Panel Logbooks
Description and Types of parameters.
Home
Documentation
Log Book
HT panel Logbooks
Contents
1. HT panel logbook.
3. Types of parameters.
1- HT panel logbooks:
HT panel log book is a parameters note book where the required parameters
are noted down in manually. The all parameters data is noted down in a
frequency base according requirement as a hourly, 2 hourly, 4 hourly or per
day.
We can observe the HT panel status on daily basis, monthly basis, quarterly
basis and annually basis. If any parameters is not functioning according
default value then we can check and find out the problem. If any fault is
occurred suddenly then we can check log book data related fault.
2- Logbook formate :
Different types logbooks are used in technical system like as transformer log
book, chiller plant logbook which below mentioned.
HT energy consumption.
Maximum demand.
Incoming HT voltage.
Date and time is the most important in log book. If we want to know about
exact parameters from last week then we can easily find out.
2- HT energy consumption:
Ones time recorded highest load limit is called a maximum demand. It should
be low in against of section load. Section load is the highest load of premises
which has to be approved from electricity board authority.
4- Incoming HT voltage.
Control supply is used for all protection relay auxiliary supply, ON and OFF
TNC switch, Circuit breaker shunt and closing coil. The UPS or battery is used
for control supply. If the battery voltage then 12 volt is used. If the UPS supply
then 230 V AC is used.
7- Temp and humidity.
Temp and humidity meter are used in HT room because high temp and high
humidity is very dangerous for technical system. So temp and humidity
parameters are required.
Transformer logbook
Description and Types of parameters.
Home
Documentaion
Logbook
TR Logbooks
Contents
1. Transformer logbook.
2. Logbook format.
3. Types of parameters.
1- Transformer logbooks:
Transformer logbook is a parameters note book where the required
parameters are noted down in manually. The all parameters data is noted
down in a frequency base according requirement as a hourly, 2 hourly, 4
hourly or per day.
Transformer current
Date and time is the most important in logbook. If we want to know about
exact parameters from last week then we can easily find out.
2-Transformer input voltage:
Ones time recorded highest load limit is called a maximum demand. It should
be low in against of section load. Section load is the highest load of premises
which has to be approved from electricity board authority.
4- Transformer current.
Line power factor should be .98 of .99 . If the power factor value is low as .85
then energy consumptions will be 100 present but actual energy will be used
only.85 % . It means 15 % energy losses so power factor value is important for
system.
6- Transformer oil level.
Control supply is used for all protection relay auxiliary supply, ON and OFF
TNC switch, Circuit breaker shunt and closing coil. The UPS or battery is used
for control supply. If the battery voltage then 12 volt is used. If the UPS supply
then 230 V AC is used.
7- Dry type transformer temp.
Temp and humidity meter are used in HT room because high temp and high
humidity is very dangerous for technical system. So temp and humidity
parameters are required.
LT Panel Logbook
Template and Types of parameters.
Home
Documentaion
Log book
LT panel logbooks
Contents
1. LT panel logbook.
2. Logbook format.
3. Types of parameters.
1- LT panel logbooks:
LT panel logbook is a parameters note book where the required parameters
are noted down in manually. The all parameters data is noted down in a
frequency base according requirement as a hourly, 2 hourly, 4 hourly or per
day.
Frequency.
Power factor.
Ones time recorded highest load limit is called a maximum demand. It should
be low in against of section load. Section load is the highest load of premises
which has to be approved from electricity board authority.
4- Frequency.
Line power factor should be .98 of .99 . If the power factor value is low as .85
then energy consumptions will be 100 present but actual energy will be used
only.85 % . It means 15 % energy losses so power factor value is important for
system.
UPS Logbooks
Description and Types of parameters.
Home
Documentation
Logbook
UPS Logbook
Contents
1. UPS logbook.
2. Logbook formate.
3. Types of parameters.
1- Transformer logbooks:
UPS logbook is a parameters note book where the required parameters are
noted down in manually. The all parameters data is noted down in a frequency
base according requirement as a hourly, 2 hourly, 4 hourly or per day.
Incoming voltage.
Outgoing voltage.
Current in Amp
Battery voltage.
Date and time is the most important in log book. If we want to know about
exact parameters from last week then we can easily find out.
2-Incoming voltage.
Ones time recorded highest load limit is called a maximum demand. It should
be low in against of section load. Section load is the highest load of premises
which has to be approved from electricity board authority.
4- Current in Amp.
Line power factor should be .98 of .99 . If the power factor value is low as .85
then energy consumptions will be 100 present but actual energy will be used
only.85 % . It means 15 % energy losses so power factor value is important for
system.
6- Battery voltage.
Control supply is used for all protection relay auxiliary supply, ON and OFF
TNC switch, Circuit breaker shunt and closing coil. The UPS or battery is used
for control supply. If the battery voltage then 12 volt is used. If the UPS supply
then 230 V AC is used.
7- Battery charging current.
Temp and humidity meter are used in HT room because high temp and high
humidity is very dangerous for technical system. So temp and humidity
parameters are required.
8- Temp and humidity.
Equipment Health Checklist
Template, Types of Checklist and Checkpoints.
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Documents
Equipment checklist
Contents
3. Types of checklist.
5. Why it is used?
3- Types of checklist:
Different type checklist are used according equipment characteristic. Different
types checklist are available in electrical, mechanical, HVAC, WTP, BMS system.
Types of checklist below mentioned.
Maintenance checklist.
Parameters checklist.
Testing checklist.
1- Health status checklist.
Check vibration.
Some electrical equipment parameters are very important for knowing its
status.
Input supply.
Output supply.
gauge.
Connect the electrical testing Instrument with earth.
HT panel checklist.
Transformer checklist.
LT panel checklist.
AHU checklist.
5- Why it is used?:
Check list is a important part for health of any equipment. Checklist activity is
performed on daily basis, weekly or monthly basis. If checklist activity is
carried out per day then we can know about equipment actual status. If any
type problem is present in equipment then we can resolve or repair of
problem. So in this way we can say checklist activity is carried out equipment
health and performance.
Contents
1. HT panel checklist
3. Types of checkpoints
1- HT panel checklist:
3- Types of checkpoints :
Different types checkpoints are executed on the HT panel during daily check.
which below mentioned.
Contents
1. Transformer checklist.
3. Points of checkpoints.
Contents
3. Points of checkpoints.
1- LT Panel checklist:
Input voltage.
First of all we should check abnormal sound, power factor value. Check critical
feeders load according capacity like as UPS, Server etc. LT panel circuit breaker
should be working condition. All supported equipment like as
meter,indicators, selector switch, protection relay should be check visibly if any
err found then find out.
Contents
3. Details of checkpoints.
WTP health checklist is a inspection type checklist where the all equipment of
water treatment plant is inspected visibly and on load condition so that the
health condition of equipment could be check properly. If found any problem
then we can note down for rectification. Status of all parts and efficiency are
noted down in checklist.
Here some points are focused as health status of water MGF filter, pumps and
motors, RO and softener plant etc.
Different types checkpoints are executed in the WTP plant during daily check
which below mentioned.
1- Checkpoints
Water flow meters.
All water pump health status as abnormal sound, leakage problem etc.
All water pump motor health status as abnormal sound, load capacity,
heating etc.
according health checklist we should make a fault or err list according its
severity. We can categorized the fault list as normal and major. The normal
fault is rectified by inhouse team and major fault is rectified in weekend by
inhouse team or OEM vendor.
Contents
2. Format or templates.
3. Types of SOP .
5. Why it is used?
Different types SOP are used but we can categorized in two types as technical
and management. Technical SOPs are used for technical process and technical
equipment operating and management SOPs are used for management work
flow process according organization policies.
Technical SOP.
Management SOP.
1- Technical SOP:
Technical SOP is a two type as one is digital technical process and second is
operating of technical equipment.
Technical process
Technical equipment.
A- Technical Process:
B- Technical equipment:
2- Management SOP:
Core SOP.
Training SOP.
Production SOP.
A- Core SOP:
Creation.
Revision.
Approval.
Publishing.
Distribution.
B- Training SOP.
Training SOP is the important role of improving employee skill. Working role,
responsibilities and work process is executed through training SOP. Working
efficiency of skilled person is more in comparison of unskilled employee.
C- Production SOP.
Production SOP is the important role for increasing production with good
quality. A process is followed step by step by employee for getting required
production according production SOP.
4- Benefits of SOP:
Employee safety.
Time saving.
Maintained compliance standard
Improved accountability.
Increased consistency.
5- Why it is used?:
Contents
HT panel is a high voltage power center where the high voltage power supply
is received and distributed for power utilization. If we want to start and stop
this panel then we will have to follow standard operating procedure which was
written as step by step process with safety instruction so that any operation
mistakes could not activate.
First of all we will have to take safety precautions then we can start and stop
HT panel. details of SOP given below mentioned.
1- Object:
Check the power factor value if the low then start the capacitor.
Contents
Transformer is a high voltage static device where the high voltage is increased
and decreased and distributed for power utilization. If the voltage is low as per
requirement then we will have to increased voltage through manually
operated voltage regulation mechanism in OLTC of transformer. These voltage
regulation process will be followed Under standard operating procedure which
was written as step by step process with safety instruction so that any
operation mistakes could be remove.
First of all we will have to take safety precautions then we can regulate the
voltage as increased or decreased. Details of SOP given below mentioned.
1- Object:
If the voltage is as required then stop the pressing push button function.
If the voltage is not as required then again start the pressing push
button function.
Contents
LT panel is a low voltage power control center where the power is received
and distributed. It has two power incoming sources one is EB source and
second is DG source. One time one source can be used when power supply
switched off then DG backup supply is used. If the EB power supply available
then the supply source is replaced as DG to EB source through changeover
process.
1- Object:
Contents
UPS is a uninterrupted power supply which is used for backup supply sources.
When electricity power source is not available then it is used for backup which
is available in single phase and three phase. Low capacity UPS is used for
domestic used but high capacity UPS is used for industrial and IT sectors as 50
KVA to 500 KVA.
If we want to start and stop high capacity UPS then we will have to follow
standard operating procedure which was written as step by step process with
safety instruction so that any operation mistakes could be remove.
First of all we will have to take safety precautions then we can start ON and
OFF procedure. The details of SOP given below mentioned.
1- Object:
UPS start and stop standard operating procedure.
2- Responsibility:
Contents
Weekly
Monthly
Fortnightly
Quarterly
Half Yearly
Annually or Yearly
Incoming Voltage
Contents
1. TR maintenance checklist.
Monthly
Quarterly
Half Yearly
Annually or Yearly
During PPM activity we should follow safety guideline for stopping any
misshaping. Safety related some points below mentioned.
source.
discharging.
Incoming Voltage
Contents
Electrical panel is a costly electrical device which is used for power receiving
and distribution. Preventive maintenance is a important activity for keeping
good health of electrical panel. Many type maintenance activity is carried out
as monthly, quarterly, half yearly and yearly.
These all activities is carried out according maintenance checklist which is
written step by step maintenance process.
Monthly
Quarterly
Half Yearly
Annually or Yearly
During PPM activity we should follow safety guideline for stopping any
misshaping. Safety related some points below mentioned.
Use lock out and tag out on the electrical incoming source panel.
earth fault.
Parameters status :
Incoming Voltage
Contents
Electrical motor is a costly electrical device which is used for electrical power
into mechanical power. Preventive maintenance is a important activity for
keeping good health of electrical motor. Many type maintenance activity is
carried out as monthly, quarterly, half yearly and yearly.
These all activities is carried out according maintenance checklist which is
written step by step maintenance process.
Monthly
Quarterly
Half Yearly
Annually or Yearly
During PPM activity we should follow safety guideline for stopping any
misshaping. Safety related some points below mentioned.
Use lock out and tag out on the electrical starter panel.
Check all winding insulation value if value is low then use insulation
varnish.
Check and fill greasing in air ventilation fan and both bearings.
Incoming Voltage
Contents
Circuit breaker is a costly electrical device which is used for power supply
making and breaking as switched On or switched Off. Preventive maintenance
is a important activity for keeping good health of motor starter. Many type
maintenance activity is carried out as monthly, quarterly, half yearly and yearly.
These all activities is carried out according maintenance checklist which is
written step by step maintenance process.
Monthly
Quarterly
Half Yearly
Annually or Yearly
During PPM activity we should follow safety guideline for stopping any
misshaping. Safety related some points below mentioned.
Check and clean contact holding mechanism like as spring charging etc.
Check and adjust breaker protection relay setting as short circuit, earth
Check all release in functional mode like as shunt coil, UV and spring
charge.
Incoming Voltage
Home
Documentation
Reports
MMR
Contents
1. Equipment Logbooks
2. Schematic diagram.
o HT panel logbook.
o Transformer logbooks.
o LT panel logbook.
o UPS logbooks.
1- Equipment Logbooks:
Log book is a record book which is used for manual storing parameters data
of equipment, events and machines. The parameters of equipments are
mentioned in it. Parameters data is taken in a frequency according
requirement as a hourly, 2 hourly, 4 hourly or per day.
Different types log books are used in a different formate are used according
equipments. Here we are going to discus electrical log books like as UPS log
book, transformer logbook, HT panel log book etc. Electrical equipments
parameters are logged as voltage, current, frequency, temp etc.
2- Tech Logbook format :
3- Types of logbooks :
Different types logbooks are used in technical system like as transformer log
book, chiller plant logbook which below mentioned.
1- HT panel logbook.
Parameters detail:
Maximum demand
Power factor
Auxiliary voltage
Parameters:
Transformer current
Parameters:
frequency.
Power factor.
UPS is an electrical device which is used for receiving backup supply without
any interruption. So parameters are very important for knowing the status of
UPS.
Parameters:
Incoming voltage.
Outgoing voltage.
Current in Amp
Battery voltage.
Chiller plant is an Airconditioning machine which is used for high rise offices,
premises, malls. It is costly machines so parameters are very important for its
health.
Parameters:
Date and time:
Running hours.
Voltage
Current
Energy in KW.
Diesel generator is a mechanical and electrical device which is used for back
up power generation. It converts mechanical energy into electrical energy so
record parameters are important for its better health.
Parameters:
Running hours.
Voltage
Current
Energy in KW.
Oil pressure.
Water temp
Coolant temp.
Battery voltage.
Fuel level.
7- Water treatment plant logbook.
WTP is a water control center where the water is received, storage, filtered and
distributed for utilization. So parameters are very important for knowing the
status of water plant.
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Electrical Safety
Description, Types and functions.
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Electrical Safety
Electrical safety
Contents
1. Electrical safety.
o Electrical earthing.
1 - Electrical safety:
Electrical system is very useful to human. The life of human is very comfortable
with use of electricity. Many equipments are using according requirement as
fan, motor, blower, AC etc. During operate and maintenance of these
equipments, we will have to keep in mind for electrical safety. Different types
electrical safeties are used as PPE, insulated tools, LOTO procedure, earthing
and many more.
Electrical earthing.
Electrical earthing is the important safety system and it prevents from leakage
current in equipment body. Earth wire is connected to equipment body and
leakage current is circular into ground through earthing. So in this way when
any human touch the equipment body then the leakage current will not be
affected.
Plate earthing.
Pipe earthing.
Chemical earthing.
Rod earthing.
Conductor earthing.
READ MORE
2 - Electrical LOTO procedure.:
Electrical system is a boon for human but due to wrong use it can be
danger.For electrical safety, the display poster are very important for
increasing safety awareness. Safety instructions are mentioned on it step by
step. It is installed on electrical room, transformer, HT room, substations etc.
5 - Electrical safety sign board.:
Electrical safety sign board is a important part for safety. It is called another
name as danger sign board and danger word is mentioned on it. It is installed
on electrical panels, substations, high voltage transformers etc.
6 - Electrical safety tools and tackles.:
During maintenance activity the tools should be insulated properly like as all
type pliers, screw driver set etc.
7 - Electrical PPE- Personal protective equipment.:
Contents
2. Connection diagram
3. Working principle
Three phase energy meter is a measuring instrument device which is used for
measuring the utilizing power of three phase. many types of meter are used as
details below mentioned.
Electromechanical induction type.
Here we are going to discuss about electronic or digital three phase energy
meter.
2 - Connection Diagram:
3 - Working Principle:
Microchip additionally works out stage point among voltage and current, so it
likewise gauges and shows responsive power. It is modified so that it
computes energy as per the duty and different boundaries like power factor,
greatest interest, and so on and stores this multitude of values in a non
unpredictable memory EEPROM.
It contains ongoing clock (RTC) for working out time for power reconciliation,
most extreme interest computations andfu rthermore date and time stamps
for specific boundaries. Moreover it collaborates with fluid precious stone
showcase (LCD), specialized gadgets and other meter yields. Battery is
accommodated RTC and other huge peripherals for reinforcement power.
Current:- R, Y, B, R, Y, N
CT polarity check.
Three phase energy meter is used as widely in industrial, Commercial high rise
buildings, Residential societies etc.
lectrical Earthing
Parts, Types and Why it is used.
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LT Power
Earthing
Electrical Earthing
Contents
1. Electrical earthing
2. Schematic diagram.
3. Parts of earthing.
4. Types of earthing.
1- Electrical Earthing:
3- Parts of Earthing
1- Earth Pit:
Earth pit is the main part of ground where earth electrode is connected to the
distribution earth wire or strip.
2- Earth pipe or Strip:
Earth pipe or strip is connected to the earth plate for current discharging.
3- Earthing Plate:
Earthing plate is used for discharging the current quickly into ground.
4- Earthing wire:
Earthing wire is used for current discharging from equipment to earth pit.
4- Types of Earthing:
A- Construction type:
1- Pipe Earthing
2- Rod Earthing
3- Plate earthing
4- Chemical Earthing
5- Conductor Earthing
B- Connection type
1- Neutral earthing
2- Equipment Earthing.
equipment body.
insulation failure.
protect to the high rise building and electrical system from sky lightning.
We have published a more recent article about water treatment tips, read on here.
————
Brent Hall, Technical Manager offers his top six tips for prolonging a chiller’s life to help
keep it working as efficiently as possible.
Chillers are the backbone of commercial and industrial cooling systems across the
country. However, they are not a ‘fit and forget’ solution, and there are some easy ways
to look after your chiller to ensure it lasts 10 years and more.
Glycol is an essential element of any heat transfer fluid used as part of a chilled water
system, as it allows the fluid to be sufficiently chilled without freezing. However, an
uninhibited glycol system can pose even more of a risk than plain water due to the
highly corrosive nature of most glycols, so inhibitors must be used at all times.
For those operating in areas where there is a risk of incidental human contact, such as
the food processing industry, the wrong inhibitors in an MPG solution creates a serious
contamination risk, but an NSF-accredited glycol overcomes that.
2. Take regular water samples from various parts of the system.
Corrosion and degradation can happen anywhere within a system and it’s not enough to
take water samples from just one location. Samples need to be taken from available
access points around the system and especially from high risk areas such as heat
exchangers, cooling jackets and any other sensitive product-fluid interfaces.
Not taking pH level readings as part of routine water sampling can have a major
negative impact on a system’s performance. While chiller pH tolerances will vary slightly
depending on the materials used, I would recommend limits of 8.0 – 8.5. Incorrect pH
levels may indicate that either not enough inhibitors have been used, or the glycol levels
are too concentrated. Both scenarios can very quickly cause high levels of corrosion
throughout a system if left unchecked, leading to costly maintenance bills and
unplanned downtime.
Not all tests are as in-depth as pH level, and one of the most obvious signs that a chiller
system is degrading or corroding internally is when there’s visible debris in the water
sample. A water sample from a chiller operating correctly should be clear and if it’s not,
then there’s already some internal system damage. This needs to be addressed
immediately as the debris can soon lead to blockages in key areas of operation such as
the heat exchanger, which will rapidly decrease the chiller’s efficiency.
As soon as a new chiller is installed, the whole system should be flushed immediately to
ensure the fluid is completely free from contaminants and at the highest quality
possible, with no legacy debris or surface contamination present to cause damage to
the fluid, the pipework and the new equipment. This golden rule should be followed
whether it’s a permanent or temporary installation for planned or reactive maintenance.
Given the intricacies of taking a thorough and correct chilled water system sample,
sometimes it pays to call in an expert. Regular water sampling and off-site laboratory
analysis is available as part of some chiller manufacturer’s aftersales and servicing
packages – including Planned Preventative Maintenance Packages (PPM) from ICS
Cool Energy.
Learn about the specific water treatment procedures and requirements that are needed for
situations where the facilities water system (FWS) water or the technology cooling system (TCS)
water can be used to directly cool the datacom equipment.
Overview
The datacom equipment cooling system (DECS) is a water loop in which the water comes in
contact with the components to be cooled. There are cases where the DECS water is supplied by
an in-rack CDU or can be supplied by an external CDU that service multiple racks. For details of
potential liquid cooling systems and loops within a data center and the terminology that is used,
see Figure 1.
The water quality standards that are specified pertain only to the DECS water loop that comes
into contact with compute components. The ongoing monitoring and maintenance procedures are
also described.
The cooling loop hardware consists mainly of corrosion resistant alloys, such as copper alloys
and stainless steels. EPDM rubber must form the inner lining of all the hoses in the system. The
chemistry of the cooling water must be properly maintained to avoid system disruption or
shutdown due to any of the four common water-related problems of corrosion, microbiological
growth, scale formation, and fouling.
The details of the water treatment depend on whether the local municipality allows the disposal
of water that contains some cleaning chemicals down a sanitary drain. If the local municipality
does not allow the disposal of contaminated water down a sanitary drain, a deionizing bypass can
be included in the water cooling loop to allow the cleaning of the water to purity levels
corresponding to resistivity > 0.1 MΩ.cm (conductivity < 10 μS/cm) before pouring the water
down the drain. You are responsible for verifying the local regulations before you dispose any
water.
Figure 1. Example of liquid cooling systems and loops within a data center
Water-related problems
Proper treatment of the water is necessary to avoid the following common water-related
problems: corrosion, microbiological growth, scale formation, and fouling. Any of these
problems can significantly reduce the cooling efficiencies and increase the risk of system
downtime.
Corrosion - corrosion can take on many forms. The common forms of corrosion that are
relevant to the cooling loop include the following forms:
o Uniform corrosion, also referred to as general corrosion, is the spatially uniform
removal of metal from the surface. It is the typical expected mode of corrosion.
o Pitting corrosion is a localized attack of a metal surface that in the case of copper
tubes can lead to water leaks with a typical mean time to failure of around 2 years.
o Galvanic corrosion arises when two metals that are wide apart in the galvanic
series are in electrical contact and immersed in the same water environment. The
potential difference that arises between the two metals in contact, forces electrons
to flow from the less noble to the more noble metal. On the less noble metal
surface, corrosion occurs, giving off electrons that are consumed on the more
noble metal surface by a reduction reaction that can take many chemical forms.
Examples are the reduction of metal ions or the consumption of oxygen and water
to form hydroxyl ions. Even when not in electrical contact, aluminum can be
galvanically attacked by copper because of dissolved copper ions in low
concentrations that deposit on the aluminum surface forming the galvanic
corrosion couple.
Microbiological growth - microbiological growth in water cooling systems can lead to
deposition, fouling, and corrosion within the cooling loop. Prevention of microbiological
growth involves making sure that the cooling loop hardware is assembled from
components that are free of biological organisms and treatment with biocides to control
the bacteria population. To avoid biological growth, the water cooling loops must be
shipped and stored dry. Every effort must be made to blow out the water and dry the
water cooling loop as much as possible before shipping and storage.
Scale formation - scaling is the deposition of dense, adherent material on the cooling loop
surfaces. Scaling occurs when the solubilities of salts in water are exceeded because of
high concentrations or because of increased temperature.
Fouling - fouling of cooling loops is the deposition of non-scale-forming substances such
as corrosion products and organics. Fungi, such as Fusarium sp, are known to grow, foul,
and plug filters and fine finned heat sinks. They generally grow at the water line in
cooling tower basins or sumps.
Design clean - Restrict the water-wetted metallurgies to copper alloys and stainless steels.
Avoid the use of plain-carbon steel hardware that can rust and foul the water cooling
loop.
Build clean - Ensure that the cooling loop components are clean and free of bacteria and
fungi. The cooling loop assembly must be free of soldering, brazing fluxes, or both.
Clean water must be used in the assembly operations. Any residual water must be blown
out of the assembly. The finished assembly must be clean and dry.
Ship clean - Any residual water from the assembly, testing operations, or both must be
blown out from the cooling loop before any shipping to avoid corrosion and
microbiological growth. As a final step, use nitrogen gas to dry the system. Plug ends and
ship the system with the cooling loop pressurized with nitrogen gas.
Install clean - The cooling loop must be kept clean during the installation step. Brazing is
preferred over soldering. Problem with soldering is porous joints that keep leaching out
flux residue. All flux residues must be cleaned off. Fill the system with clean water and,
if possible, include a secondary step to deionize the water in the cooling loop before the
addition of biocide and corrosion inhibitors.
Maintain clean - Monitor and maintain the pH, water conductivity, bacteria count, and the
corrosion inhibitor concentration.
The water that is required to initially fill the system side cooling loop must be reasonably
clean, bacteria-free water (less than 100 CFU/ml), such as demineralized water, reverse
osmosis water, deionized water, or distilled water.
The water must be filtered with an in-line 50 μm filter.
If reasonably clean water is not available, the following guidelines are recommended. It
is especially useful for large cooling loops: In this method, the water is deionized before
any of the racks are connected to the water loop.
o It is important to ensure that the system water is cleaned before any chemicals are
added to the water. This can be accomplished by deionizing the water by using
deionizing cartridges that are installed in the cooling loop. Even if deionized
water is used to fill the system, a deionizing step is prudent for two reasons: the
first is to ensure that the starting water is deionized and the second is to remove
any ions that might leach off the walls of the cooling loop.
o When the water needs to be deionized, the valves V2 and V3 can be opened and
valve V1 partially closed to bypass some of the water through the deionizing
canister.
o During this deionizing step, the cooling loop and the computers can keep
operating normally.
o When the deionization is complete, the V2 and V3 valves must be closed and V1
fully opened.
o The deionization step raises the resistivity of the water greater than 1 MΩ.cm.
o Under normal operation, the V2 and V3 valves are closed and V1 valve is fully
open.
Figure 2. Deionizing the water using deionizing cartridges installed in the cooling loop
Material selection and installation is a complex issue that is governed by building codes and
other local requirements. You are encouraged to consult with appropriate authorities that have
jurisdiction (such as building inspectors, fire departments, insurance providers, and code
compliance officers) before you plan and install cooling distribution systems. The following
information is provided for chemical compatibility purposes.
Solder joints that come in contact with water must be avoided. Solder joints are porous
and they leach flux residue into the cooling loop. Solder joints might pass inspection and
pressure tests as manufactured, but still might be unreliable.
Brazed joints are preferred for joining copper plumbing pieces.
Braze joints must not be used to join stainless steels. Tungsten inert gas (TIG) and metal
inert gas (MIG) welding are preferred for joining stainless steels. Sensitization must be
avoided. Welded assembly must be cleaned and, if possible, passivated if there is a low
possibility of acid entrapment in crevices.
Deionizing equipment
Deionizing equipment is optional. It is recommended for use in large cooling loops. When the
water needs to be deionized, some of the water can be bypassed to flow through the deionizing
cartridge.
Dosing Equipment
The following equipment is used to dose the cooling loop:
Initial treatment for systems smaller than 75.7 liters (20 gallons)
Use the following procedure to clean your system:
Note: This procedure must be performed on the cooling loop before any computer racks are
connected to the system.
1. System must be empty. If it is not empty, you must drain the system completely.
2. Remove all the filters from the filter housings.
3. Ensure that bypass hoses are connected between the supply and return portions of the
cooling loop to ensure the cleaning of all sections of the system.
4. One of the following two cleansing procedures can be used:
a. Chemical cleaning - This method is the most effective way for cleaning the
plumbing loop.
i. Fill the system with cleaning solution. The suggested cleaning solutions
are Nalco 460-CCL2567 or Nalco CCL2567.
ii. Circulate the cleaning solution for a minimum of 30 minutes (longer if
time permits) to ensure that it reaches all sections of the system.
iii. Drain the system completely, disposing of the cleaning solution according
to local regulations
iv. Refill with demineralized water, reverse osmosis water, deionized water,
or distilled water.
v. Circulate the water for 15 minutes.
vi. Drain the system completely, disposing of the cleaner according to local
regulations.
vii. Immediately proceed to fill the system with water that contains premixed
inhibitor and preservative.
b. Cleaning with deionized water. This procedure can be used if the cleaning
chemical cannot be obtained or if local laws prevent the disposal of the chemicals.
i. Completely fill the system with demineralized water, reverse osmosis
water, deionized water, or distilled water.
ii. Deionize the water by bypassing some of the water flow through the
deionizing cartridge or cartridges and circulate the water normally through
the complete system until the resistivity of the water increases above 1
MΩ cm.
iii. Proceed to the inhibitor dosing procedure.
If the system was cleaned by using deionized water only and the system is full of
deionized water, complete the following steps:
Initial treatment for systems larger than 75.7 liters (20 gallons)
Use the following procedure to clean your system:
Note: This procedure must be performed on the cooling loop before any computer racks are
connected to the system.
1. System must be empty. If it is not empty, you must drain the system completely.
2. Remove all the filters from the filter housings.
3. Ensure that bypass hoses are connected between the supply and return manifolds of the
cooling loop to ensure the cleaning of all surfaces of the cooling loop.
4. One of the following two cleansing procedures can be used:
a. Chemical cleaning - This method is the most effective way for cleaning the
plumbing loop.
i. Fill the system with demineralized water, reverse osmosis water,
deionized water, or distilled water.
ii. Add the required volume of cleaning solution Nalco 2567 according to the
manufacturer recommendation.
iii. Circulate the cleaning solution for a minimum of 4 hours.
iv. Drain the system completely utilizing all drain ports available, disposing
of the cleaning solution according to local regulations
v. Refill with demineralized water, reverse osmosis water, deionized water,
or distilled water.
vi. Circulate the water for 1 hour.
vii. Drain the system completely utilizing all drain ports available, disposing
of the cleaning solution according to local regulations
viii. Refill with demineralized water, reverse osmosis water, deionized water,
or distilled water.
ix. Circulate for 15 minutes.
x. Immediately proceed to the inhibitor dosing procedure.
b. Cleaning with deionized water. This procedure can be used if the cleaning
chemical cannot be obtained or if local laws prevent the disposal of the chemicals.
i. Completely fill the system with demineralized water, reverse osmosis
water, deionized water, or distilled water.
ii. Deionize the water by bypassing some of the water flow through the
deionizing cartridge or cartridges and circulate the water normally through
the complete system until the resistivity of the water increases above 1MΩ
cm.
iii. Proceed to the inhibitor dosing procedure.
If the system was cleaned by using deionized water only and the system is full of
deionized water, complete the following steps:
It is important to conduct a bacteria test on a quarterly basis and add 100 ppm of Nalco
H-550 or 200 ppm of Nalco 73500 biocide if the bacteria count is greater than 1000
CFU/ml. Nalco 77352 fungicide can be added if fungi have been a concern in the past.
o Fungi might not be detected in the water, even though it can grow and cause
blockage of cooling channels in cold plates that are used to cool the computer
processors. Reduced coolant flow rate through the cold plates might be an
indication of blocked channels due to fungi growth.
On large systems that have more than 250 gallons of water, Nalco 3D TRASAR®
controller must be installed on the system cooling loop to enable precise and continuous
monitoring of system water chemistries, conductivity, pH, corrosion rate, and turbidity.
It is important to conduct an azole test on an annual basis and add Nalco 3DT-199 to
bring the azole concentration to the wanted 40 ppm level or any other desirable ppm
level.
Multiple racks
Use the following guidelines when adding additional racks:
The choice of biocide depends on the expected microbiological material in the cooling
loop. Glutaraldehyde biocide is more effective against anaerobic bacteria. Isothiazolone
is more effective against aerobic bacteria, fungi, and algae. When in doubt, use the
isothiazolone biocide.
Add 120 ppm of Nalco 3DT-199 to achieve 40 ppm of azole concentration. The amount
of inhibitor dosage is calculated based on the volume of the makeup water.
Confirm azole residual using Nalco azole test kit.
If you prefer that no water goes down the sanitary sewer, use the following procedure:
The choice of biocide depends on the expected microbiological material in the cooling
loop. Glutaraldehyde biocide is more effective against anaerobic bacteria. Isothiazolone
is more effective against aerobic bacteria, fungi, and algae. When in doubt, use the
isothiazolone biocide.
If the water can be poured down the sanitary sewer, use the following procedure:
1. Pour the water down the drain with the permission of the local municipality.
2. Fill the system by using one of the following procedures:
o Systems less than 75.7 liters (20 gallons): Initial treatment for systems smaller
than 75.7 liters (20 gallons).
o Systems larger than 75.7 liters (20 gallons): Initial treatment for systems larger
than 75.7 liters (20 gallons).
The water can be deionized to a purity corresponding to resistivity greater than 0.1
MΩ.cm and then can be poured down any municipal drain.
The water can be poured down a sanitary drain with the permission of the local
municipality.
IBM is not responsible for the disposal of water. You are responsible for determining the local
regulations that govern the disposal of water.
Troubleshooting
If you encounter any problems with your water-cooled system, use the following table to
troubleshoot your problem.
Problem Solution
Poor cooling performance Contact IBM Service
Reduced water flow Contact IBM Service.
Chemical pump issues (where Follow procedures that are provided by installer, contact your
installed and used) site water treatment contractor or local Nalco office, or both.
3D TRASAR® alarms or
Contact the local Nalco office.
operational issues
Might be an indication of corrosion and or microbiological
Discolored water
issues. Refresh the water supply.
Might be an indication of corrosion and or microbiological
Slime in flow meter areas
issues. Refresh the water supply.
For systems of smaller than 75.7 liters (20 gallons),
refresh the water supply.
For systems of larger than 75.7 liters (20 gallons), add
100 parts per million (ppm) of Nalco H-550 or Nalco
Elevated microbial counts 73500 biocide. Retest the bacteria content between 24
– 48 hours after biocide dosing. If the bacteria level is
not less than 100 CFU/ml contact Nalco or your water
treatment company.
Contact IBM
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Parameters
How to Calculate the Injection Molding Chiller for PE, PS, NYLON,PC, PP, ABS.
Model Injection Injection Injection Injection Injection Injection Injection Injection Inj
Molding Molding Molding Molding Molding Molding Molding Molding Mo
Chiller Chille Chille Chille Chille Chille Chille Chille Ch
3.1ADT 5.1ADT 8.1ADT 10.1ADT 12.1ADT 15.1ADT 20.1ADT 20.2ADT 25
10′ Kc a
Cooling Capacity 1. 2 1. 5 1. 10 1. 11 1. 13 17.9 24 25.2 28
1/h
TR 12. 31 1. 1 3.7 1. 3 1. 3 1. 4 1. 6 1. 7 1. 8
Compresso
Quantity Set 1 1 1 1 1 1 1 2 2
r
Evaporator
Pipe
DN 20 20 25 25 25 32 32 32 32
Diameter
Water Power kW 0.37 0.37 0.37 0.55 0.55 0.75 0.75 0.75 12
Pump Head M 15 20 21 18 16 23 22 22 21
Diament Width mm 700 700 850 850 850 1000 1250 1250 12
Geson water cooled chiller for injection molding machine can meet all your varied of
requirements.
Here, you will have the ultimate economical injection mold chiller solution.
From the professionally experienced R&D team, you will satisfy the industrial water
cooled chiller system.
Screw Chillers
Centrifugal Chillers
Rotary Screw Chillers
Scroll Chillers.
Contact our engineer, to get the right solution for your plastics industry injection molding
applications.
Plastic extrusion manufacturing is that the melted thermoplastic material is fed through
a hole.
Film blowing extrusion, compressed air passes through holes to create air bubbles with
plastic and form plastic film.
The process of plastic extrusion requires the use of chillers, because the temperature of
plastic needs to be controlled at all times during production.
Chillers are used to cool down the temperature of hot molten plastic in order for it to
become solid and flowable.
If the temperature is too high, then there will be problems with adhesion and other
defects in the final product.
Chiller for Injection Molding Machine
Thermoplastics are generally used, and thermosetting plastics are used individually
The cooling process of plastic injection molding machine is a key factor in the success
of products. Without proper cooling, the product can be deformed and has reduced
mechanical strength. The cooling process is also important because it helps maintain
the dimensional accuracy of the product.
An effective way to cool down the heated plastic is by using a chiller for injection
molding machine. It has many advantages such as:
Injection Blow Molding – Blow-molded parisons are cast into a mold and then blown into
shape.
The use of chillers in the blow molding process is essential for the quality of the finished
product. The blow molding process requires a plastic that can be heated to its melting
point and then cooled quickly. This cooling has to happen fast enough so that the plastic
does not have time to cool too much before it is injected into a mold.
Blow molding is an industrial process by which hollow, semi-solid objects are formed in
a shape, typically by extrusion or injection, and then cooled. Blow molded products are
very common in everyday life, such as food containers, bottles, toys and cups.
Chillers for Compression Molding Application
– Air-cooled chillers
– Water-cooled chillers
– Oil-cooled chillers
– Gas coolers
Chillers for Transfer Molding Application
The plunger turns the plastic into a liquid that flows into the mold cavity.
The major use of chillers is for cooling liquids in the plastic transfer molding process.
The chiller removes heat from the liquid and transfers it to a cooling surface. The cooled
liquid then cools the plastic parts being transferred into the mold cavity.
Chillers for Rotational Molding Application
A rotational molding machine has a barrel in which molten plastic is injected and rotated
to cool it evenly. The cooled, solidified part is then ejected from the machine.
In order to produce high quality parts, the temperature of the liquid plastic inside the
barrel has to be maintained at a certain level throughout the entire injection process. If it
gets too hot or too cold, it will affect how well the finished product turns out. This can be
done by using a chiller system that cools or heats as needed.
Chillers for Thermoforming Application
Plastic thermoforming is a process which involves the heating of plastic sheets and
shaping them over a mold. The shape of the mold determines the final product.
The main objective of a chiller is to maintain the temperature of the plastic at an optimal
level by cooling or heating it, depending on requirements. A chiller may be used as an
alternative to water baths in some cases.
– Injection Molding
– Blow Molding
– Vacuum Forming
Hence, it includes version, kind, advantages, price, and maintenance, among other
important points.
So before you buy a Chiller Plant For Injection Molding machine, go through this guide.
After the plastic pellets are injected into the mold after heating and melting in the
injection molding machine to condense, the mold is opened to eject the molded plastic
workpiece.
In the continuous production process, the chilled water system of the chiller is required
to cool the mold to shorten the plastic condensing time and improve the dimensional
accuracy of the workpiece.
Molding quality and surface quality, this is the working principle of injection molding
water chillers, injection molding water cooled chillers generally use water-cooled box
chillers.
If the chiller is applied to the cooling cycle of molding molds of plastic processing
machinery, it can greatly improve the surface finish of plastic industry products, reduce
the surface marks and internal stress of plastic industry products, make the products do
not shrink or deform, facilitate the demolding of plastic products, and accelerate product
shaping.
Thereby greatly improving the production efficiency of the plastic molding machine;
Portablechiller for injection molding
What is a Chiller?
A chiller is an appliance that eliminates heat from a fluid through different methods.
Moreover, this fluid can then be transferred through a heat exchanger to cool
processing equipment or another process stream. i.e., air or process water
Thus, the heat transfer takes place, the refrigerant evaporates, changing from a low-
pressure fluid into a vapor.
While the Blow Molding and Molding Water proper cooling temperature of the process
coolant decreases.
The injection mold chiller is cooling cycle device for the injection mold machines.
The blow molding and injection molding machine cooling requirements chilled water
flow rate with precise proper cooling temperature.
Injection mold coolers inject the cooling water into the mold body.
The low temperature chilled water flow rate is generated by the small process chillers.
Low-temperature water is pressurized and poured into the mold body through the
booster pump to improve the cooling efficiency.
The pressure regulating valve can adjust the pressure of the water flow into the injection
mold, So that the cooling effect can be control;
They are:
Compression Chillers
Absorption Chillers
When nozzles are pushed away from the mold after injection, blow molding has been
processed out.
When the efficiency of the chiller cooing is low, it is possible because of the scale
formation.
You need to do the water treatment for the plastic injection molding chiller.
However, due to these thermoplastic features, ABS is easily plastic injection molded.
Chiller Plant
The switchover position is the ram position where the injection position switches to the
packing part.
However, the cushion length is the distance from the switchover position to the farthest
place that the end of the screw can reach.
For injection-molding processing of PTT melt, and blow molding Water Temperature
Control, recommend being between 232–260°C and 88–121°C, respectively.
The “tonnage” is the calculation of energy needed to keep the tool closed during the
injection.
Thus, this energy is the main component in determining the molding appliance size
needed for producing the processing equipment.
The foremost step in calculating accurate clamp tonnage is to measure the surface area
of the part.
However, this means achieving the space’s square inch area by multiplying the length
by the width.
Then as you gently heat the area of the component where the bubble is formed.
Moreover, it raises the surface and often will pop as the part surface gets smooths.
How to convert the hp and btu of the chiller? The conversion relationship of the cooling
capacity unit is as follows:
Description:
Up-front expenses are high due to the style, assessing, and tooling needed.
Then the design of a prototype mold tool to produce copies of the component in
proportion.
Lastly, and only after massive testing during both steps, you can finally get injection
mold a component.
Components must be created with injection molding consideration and must follow the
fundamentals of injection molding.
For instance:
Prevent undercuts and sharp borders as much as possible
Use regular wall thicknesses to avoid inconsistencies in the cooling process resulting in
issues like sink marks.
Draft angles are recommended for better de-molding.
Small runs of components can be expensive:
Due to the intricacy of processing equipment, and the need to rid the appliance of all
previous material before the next product can be produced, the setup time can be too
long.
Therefore small runs of parts have typically always been thought of as too costly to
injection mold.
Thus, that must give reliable execution through many years of constant, around-the-
clock production cycling.
Thus, to keep the nozzle against the sprue of the mold and to keep the mold closed.
The use of a chiller for injection molding machines is one of the technological
breakthroughs in the plastic industry. It is crucial to be able to mass-produce the
components of plastic furniture.
In order to succeed with this manufacturing process, it requires precision and accuracy.
Speed is also important.
The cooling process with the help of a small water cooled chiller chiller is crucial. In fact,
experts believe that the use of water cooling system for injection molding makes up
80% of the molding process.
The use of an efficient water cooled chiller can significantly reduce the amount of time
spent for each batch. It is important to evaluate your cooling needs so you can invest in
the right system.
The main objective for choosing water cooled chiller industrial use is to find the right fit
for the job. Different sized jobs have different cooling requirements.
There are 1 ton chiller, 2 ton chiller, 3 ton chiller, 10 ton chiller, 20 ton chiller, 50 ton
chiller, 60 ton chiller, 100 ton chiller, 200 ton chiller, 500 ton chiller.
You can maximize your time by choosing the right chillers for injection molding.
The most important factors to consider when choosing which portable air chiller to
invest in are: melting point, heat distortion temperature (HDT), desired mold
temperature controller, cooling power, and the availability of space.
Why Is Melting Point Important When Selecting Chiller For Injection Molding
Machine?
The melting point of the plastic is an important factor to consider when choosing water
mold cooling system for injection molding.
You need to understand that there are different melting points for every type of plastic.
The first step is, therefore, to know what type of plastic you are working with.
It is something that you need to evaluate prior to starting the cooling process. To give
you an idea, it is important to look at the types of plastic and their corresponding melting
points.
Polypropylene is one of the most common types of plastic in the market. It has a melting
point of 160 degrees Celsius.
Low-density polyethylene is another common type of plastic for injection molding. It has
a very high melting point that can go up to 240 degrees Celsius.
Next is the high density polyethylene plastic with a melting point of up to 270 degrees
Celsius.
Polycarbonate is the type of plastic with the highest melting point at 287 degrees
Celsius.
It is also important to note that the melting point of plastic might vary from one
manufacturer to another. Before you handle with these plastic materials, it is important
to consult the manufacturer first.
Aside from knowing the heating needs of the plastic, you need to know about your goal
temperature so you can decide the right portable chillers for injection molding.
The heat distortion temperature is another factor that must be taken into account when
choosing air cooled portable chiller.
You need to research on the HDT range for your plastic to help you choose the right
small portable chiller for the job.
Ideally, you need to chill plastic components before they reach the HDT range. If not,
then the plastic components could easily deform once you take it out of the injection
mold.
There are many factors within the plastic components themselves that would determine
the HDT such as the composition of the plastic itself, pressure in the mold, and the
molten density.
You need to talk with the plastic manufacturer so you can get the exact gauge on this
and choose the right portable chillers for injection molding.
There is more to plastic chilling than just blasting your plastic components with cooling
as soon as possible. You need to be able to optimize your temperature targets in the
most efficient manner possible.
Again, you must refer to the plastic manufacturer, to learn the ideal heating and cooling
temperature for the components.
This information is vital in putting together a chiller plant for injection molding machine
or buying injection molding chillers.
Knowing your temperature target will enable you to select the right mold temperature so
you can select your portable air chiller accordingly.
By knowing and achieving the ideal mold temperature controller, you can match that
with the injecting molding chillers that can deliver such cooling capacity.
As a result, the plastic can cool and crystallize efficiently once it is molded. This will
prevent cracking, seeping plastic, deformities, cavity formation, and other defects with
the injection molding process chiller.
What Is The Cooling Power For In Injection Molding Chillers in the Injection
Molding Process?
There are several different sizes and injection mold cooling process capacities available
with portable chillers for molding cycle. They are often measured out in “tons”.
You need to look at the “tons” when comparing chiller sizes for molding cycle with
plastic. It does not refer to the actual weight of the industrial chiller units.
Instead, tons indicate the horsepower of the portable chillers industrial molding. It refers
to the refrigeration cooling capacity of the unit.
For example, 1 ton of injection mold cooling process power can deliver safe ejection
temperature for 35 lbs per hour for polypropylene plastic or 65 lbs per hour for
polycarbonate plastic.
As a general rule, 1 ton of cooling power should be enough to cool and complete the
molding cycle for most types of plastic. It is something to consider when shopping
around for portable chillers for injection molding process.
The injection molding process equipment is bulky. It can take up a lot of floor space in
the factory. This is something to think about when choosing portable air chiller systems.
You need to know how much space is available for injection molding process so that
you can size the chiller accordingly.
Water cooling system for molding cycle take up more space than air cooled portable
chiller. This is because the former will require the use of cooling towers.
It is also the reason why a portable air chiller makes most sense in this injection molding
applications. Since it is not fixed into position, you can free up the space once you are
done with injection molding.
Relying on portable chillers for injection molding has its own benefits that will facilitate
ease of plastic manufacturing.
There are also certain limitations to the cooling capacity of a portable air chiller. It might
not be enough to provide the cooling you need.
You need to keep in mind that during the plastic processing, the injection molding
equipment is not the only one that will require chilled water injection mold cooling
process. There will be other processing equipment that will be in use that will generate
heat in the water loop.
During plastic molding, refer to the temperature to the process, the following equipment
must be cooled as well: hydraulic heat exchanger motor, feed throat, thermometer,
dryer aftercooler, and hot runners.
It is important to determine how much the equipment would heat up during plastic
molding. This will enable you to choose the best chiller plant for plastic molding machine
and other equipment.
Chiller Plant
What Features Do You Look For In Portable Chillers For Injection Molding
Process Cooling?
The best way to choose the best portable chillers for plastic molding is to look at the
features you need.
Make sure that the small portable chiller you buy has the following features: quiet
compressor, Screw compressor, scroll compressor, recirculation, efficient cooling fluids,
precise temperature controls, customization, and flexible temperature ranges.
Screw Compressor
A quiet compressor is a must when choosing the best portable chillers for plastic
molding. This is important so you can reduce the noise within the plastic molding facility.
If you are looking for injection molding chillers with a quiet compressor, make sure to
avoid reciprocating compressors. They are the loudest to operate when compared to
other types of compressors.
The ability to precisely control temperature is another important factor to consider when
buying injection molding chillers.
It goes without saying that getting your temperature right is vital to the success of
injection molding in plastic. You will be able to be efficient with plastic molding if you
control the temperature correctly.
The efficiency of the cooling fluids for water or air-cooled chiller is also important. The
best cooling fluids for this purpose, are those with water and glycerol since they
facilitate in effectively removing waste heat.
The ability to control the temperature during the plastic cooling process is important.
This will enable you to achieve the optimum cooling requirement based on the plastic
selection.
Finally, you want a water chiller for injection molding machine that can be easily
customized. Each injection molding job is unique. Make sure you can tweak the controls
and the function of the chiller to suit your needs.
This innovation has brought about many benefits in terms of how plastic products are
manufactured.
First off, it has helped reduce cooling times so that it can speed up the manufacturing
process cooling. With less cooling time, it means you can mold more plastic in the same
amount of time.
Water Cooling Towers
It can also deliver better quality for your molded components. By efficiently cooling the
plastic, you can reduce the possibility of having defects on the plastic material once you
take it out of the mold.
The final advantage of using water cooled chiller for injection molding is the reduced
costs and higher efficiency. There will be less waste and the processes can be
accomplished using a shorter amount of time.
There are two systems to choose from when it comes to choosing a water cooled chiller
for injection molding machine: water- or air-cooled chiller, also can use cooling towers.
The decision on which of the two systems to buy will depend on your own needs as
there will be certain benefits and drawbacks for each system.
Air Cooled Chiller Diagram
– The water used to cool our injection molding machines must be chemically treated to
prevent bacterial growth, scaling or contamination of the entire system.
Two water treatment methods: The first is a tower system that maintains the water
temperature around 70 o – 90 o F. This system is used to keep the machine at a safe
operating temperature. The machine must be cooled to maintain maximum oil
temperature and reduce feed inlet temperature. The feed port is where the plastic is fed
into the heated barrel, and the temperature needs to be controlled to prevent premature
melting of the plastic as it transitions from solid to molten plastic.
The second is the cooling water system, which is maintained at a more stable 50 o F
temperature. The system is used to cool tools. Chilled water is directed through molds
and tooling to remove heat from the injected plastic as quickly as possible. Cooling is
often the longest part of a production cycle, so reducing wait times is beneficial. In most
cases, we try to bring the plastic down from about 500 o F to 100 o F to 140 o F as
quickly as possible.
GESON 120 ton chiller system to improve cold water distribution throughout the plant.
This system helps maintain a consistent 50 o F water temperature distribution
throughout the facility and provides our tools when needed.
To achieve the optimum mold temperature, possibly higher than the chilled water supply
temperature, we use a mold thermostat, which increases the water temperature in a
small closed loop system that pumps water through the mold. Using these, we can run
different temperatures at each machine location. Each thermostat has a separate valve
that lets in a small amount of cold water and releases some hot water to maintain a
stable temperature.
The process water temperature is different for each mold and is determined by a
number of variables. The wall thickness of the part, dimensional requirements, the type
of resin used, and dimensional factors in the mold design can all affect the process
water temperature.
Extreme conditions sometimes call for temperatures too high to use tap water safely. In
these cases, we would use a hot oil thermostat and then use chilled water to maintain
the temperature of these oil units through a heat exchanger.
The water cooled chiller is the more cost-efficient of the two. While the air-cooled
chiller costs less to initial setup, the water cooled chiller will offer more savings in the
long run.
It is also important to note that water cooled chillers will require the installation of a
cooling towers. Take this additional cost to mind when choosing what water cooled
chiller system to use for plastic molding.
8. Water-cooled chillers are typically more efficient than air-cooled chillers. Using
water evaporation to dissipate heat uses significantly less energy than blowing
air across a hot surface. This is thanks to water's high heat capacity. Additionally,
water chillers tend to last longer than air-cooled chillers.
hat to Know When Selecting an Injection Molding Chiller
Cooling molten plastic is a complex science with many variables. However, there are
certain questions that will guide you when selecting an injection molding chiller.
These melting points and ranges may vary depending upon the plastic manufacturer.
Be sure to thoroughly research your plastic’s heating needs so you know what your
goal temperatures are.
As a general rule of thumb, 1 ton of cooling power is sufficient to cool the following
flow rates of molten plastics to a safe ejection temperature:
30 lbs/hour of HDPE
35 lbs/hour of LDPE
35 lbs/hour of PP
50 lbs/hour of HIPS and GPPS
50 lbs/hour of ABS
65 lbs/hour of Polycarbonate
In most cases, the injection mold will not be the only piece of equipment in need of
cooling. There are other pieces of auxiliary equipment that require process cooling in
order to extend your machine’s duty cycle.
Quiet Compressors
Anytime you install additional equipment on an injection mold factory floor, you
increase the operational noise in your facility. Your chilling unit should be powered
by compressors that operate efficiently but quietly. In general, chillers with
reciprocating compressors are much louder than centrifugal, scroll, or screw
compressors.
Recirculation
Save money and protect our precious resources by installing a recirculating chiller.
Recirculation greatly reduces water consumption and will help you save on utility
bills in the future.
Customization
Some injection molding operations require specific components and specifications to
meet their cooling needs.
For example, plastic products made for the food and beverage, bio and
pharmaceutical, industries must meet FDA standards for food-grade materials.
Facilities that manufacture these plastics must maintain clean-room conditions and all
equipment must be easy to wipe down and sanitize. Injection mold chillers for these
facilities should contain corrosion resistant components. They should also be
contained inside easy-to-clean enclosures to help maintain factory cleanliness.
At North Slope Chillers, we are proud to offer portable and powerful injection mold
chilling solutions. Easy to install and use, our chillers come with a wide range of
cooling temperatures. In addition, our customization process is the fastest on the
market and can provide you with the exact specifications you require.
No matter what your application, there is a single formula for determining the size of chiller you
need. Before you begin, you must know three variables:
For our example, we will calculate what size chiller is required to cool 40 GPM (gallons per minute)
from 70 °F to 58 °F? Use the following five steps and general sizing formula:
1. Calculate Temperature Differential (ΔT°F)
ΔT°F = Incoming Water Temperature (°F) - Required Chilled Water Temperature.
2. Calculate BTU/hr.
BTU/hr. = Gallons per hr x 8.33 x ΔT°F
2. Determine how many pounds per hour are required for each ton of cooling capacity using Chart 1.
Example: Polypropylene requires 1 ton of cooling capacity for every 35 lbs./hr processed
75 lbs. ÷ 35 lbs. = 2.14 tons of cooling
3. Determine if the extruder or any auxiliary equipment will require chilled water using Chart 2. If not,
go to step #5.
Extrusion
50#/hr 1 ton
Polyethylene/Polypropylene
Auxiliary Equipment
Cooling
Air compressor (no 0.16
aftercooler) ton/hp
When the potable water flowing through your plumbing system has a pH value that is
less than 6.5, it can harm your copper water pipes. As the water moves through your
copper pipes, it causes internal pitting of the pipe. Once those pits penetrate entirely
through the copper, a pinhole leak develops.
What causes copper pipes to crack?
If the water flowing into the building through the copper pipes is acidic or contains a lot
of dissolved solids, the acidic nature of the water can corrode the copper pipes, creating
pits, cracks, and holes.
Pinhole leaks are unique to copper pipes and are caused when corrosion inside the pipe eats
through to the outside, creating a leak. And they’re the last thing any homeowner wants for
their copper pipes.
So, how can you prevent your copper pipes from getting pinhole leaks?
If your pipes are 20+ years old and you’ve already noticed pinhole leaks, you really can’t
prevent them from happening elsewhere in your piping. The most cost-effective option is
to have a professional re-plumb your home.
If your pipes are LESS than 20 years old and you haven’t had any pinhole leaks (or have had
very few), you can have a professional:
1. Reduce turbulence in your pipes
2. Install a whole-home water softener
Hopefully if you’re reading this you don’t already have pinhole leaks. But if you do, just give us a
call, and we can help walk you through your options to fix them.
Situation #1: Your pipes are
20+ years old
Copper pipes typically last 20–50 years, so if your plumbing system is older than 20 years, it’s
generally not worth trying to save your pipes—especially if you already have pinhole leaks.
You see, as copper ages, the inner linings of the pipe become weaker, which makes them
more prone to pinhole leaks.
So if you find yourself in this situation, we recommend repiping your home with PEX pipes.
PEX piping is a lot less susceptible to pinhole leaks, plus they’re less expensive to install.
For more information about PEX pipes and re-piping your home, read our article, “What’s the
Average Cost of Re-plumbing a House in Florida.”
You see, as minerals in the water supply are pushed at high speeds inside your pipes, they can
wear out the inner lining of the pipe, especially in areas where water is forced to change flow
direction quickly (like fittings and elbows). Once this lining is worn out, small pinhole leaks
can form.
1. Lower the water velocity. According to standard plumbing practices, water velocity
should be kept at a fixed speed of 8 fps (for cold water) and 5 fps (for hot water) in copper
pipes. If water is traveling faster than that, your pipes will experience greater turbulence.
Contact a plumber to check your water velocity and make sure it’s not too fast.
2. Make sure you have the right size pipe. Smaller pipes increase the friction of the water
moving against the lining of the pipe. If you hear banging noises, or get frequent clogs, those
could be signs your pipes are too small.
Since it requires specialized calculations, you’ll need a professional to inspect your pipes to
make sure they’re the right size. In the worst case scenario, the pipes are too small which
means they’ll need to be replaced.
3. Check your pipe fittings to make sure they’re not too close together. Copper pipe
fittings change the direction or flow of water in your system and join pipes together. If they’re
placed too close together it increases turbulence, which means water grates harder against
the inner lining of the pipe. However, adequate space between fittings on a line of pipe
reduces turbulence, which could prevent pinhole leaks from forming.
You should contact a plumber to check your fittings and make sure they’re spaced apart
properly.
So what is “hard water” and why does it corrode your copper pipes?
Hard water is water with a high concentration of dissolved minerals like calcium, magnesium
and other metals. Over time, these metals can wear out the inner lining of copper pipes,
eventually creating pinhole leaks.
Luckily, a whole-home water softener removes dissolved minerals from your home’s water so
that these metals don’t buildup or react negatively with your pipes. To reduce your risk for
pitted corrosion, you’ll need to hire a water specialist to provide a soft water treatment
system for your home.
Contributing Writer
Updated September 12, 2023
Is My Leak Serious?
Signs of a Pipe Leak
Short-Term Solutions
Long-Term Solutions
Leak Prevention
When to Hire a Pro
FAQs
No soldering iron, no problem
Find pros
Clogs
Damaged joints
High water pressure
Turbulent water flow
Uneven or shoddy plumbing work
Loose connections
Age
Before you attempt to fix a leaky pipe, make sure you turn off
the water using your home’s main water shut-off valve. If not,
both you and your home will end up pretty wet. Water damage
remediation is never fun.
INTRODUCTION –
Water leaks can be a very frustrating experience, whether it’s from a toilet or a copper
pipe that needs repair. In this how-to article you will find out how to stop leaks in your
copper pipes, how to get the job done fast and efficiently with minimal tools and cost
involved.
If a copper pipe is leaking it’s important to find the source of the leak and take steps to
repair it as soon as possible.
The longer you allow the leak to persist, the more likely it will damage your home, or
worse yet cause injury by flooding an area of your house that could potentially cause
harm.
If unsure how to do these repairs, contact your local plumber for assistance.
A ruptured copper water pipe is a common problem for many homeowners. You can
easily repair copper pipes by using a few different techniques, but if you’re not
comfortable getting your hands dirty it may be best to call a plumber from Plumbing
Express.
Some homes have copper pipes in the walls, which can cause a bit of a hassle to get
too.
So, the DIY repairs we suggest are primarily for easily accessible copper pipes with
large holes
If you’re experiencing water leaks from pinholes in copper pipes, then one of these
solutions might provide some short term relief. However, pinhole leaks are often a sign
of complete failure to your plumbing system. You can read more about that on our
article: Pinhole Leaks in Failing Copper: An Atlanta Problem
Once you have turned off the water supply, begin removing sections of piping around
where you suspect there may be a problem. Take extra care not to remove too much
piping so that you can easily replace each section once they are exposed.
This type of repair will be easier if there is a large tear or hole in the piping. If you’re
experiencing pinhole leaks in the copper piping, then you’re likely experiencing
a complete failure of the entire piping system.
8) Freeze Fix epoxy compound (harsh chemicals will come in contact with drinking
water / not code approved / temporary)
Pros:
Cons:
Requires soldering
Not for beginners
Requires sufficient access to the pipe
Pros:
Cons:
1. Use the fitting itself to determine the area of the pipe to cut.
2. Mark areas to cut
3. Use a pipe cutter to remove damaged section of pipe
4. Deburr the inside and outside of the pipe
1. You can use a sharp utility knife for the inside
2. You can use a file for the outside
5. Identified the slip end of the fitting
6. Then use an adjustable wrench to push the fitting back over the other end of the
exposed pipe, until you can see your marks
This method is code approved if done correctly. It’s best for repairing a single hole in a
pipe.
Pros:
No soldering
Good for beginners
Cons”
Not good for pipes exposed to sunlight
Not as robust as soldering
Might leak if improperly installed
This is a temporary fix. It’s a great option if you have a single hole in your copper pipe,
and a plumber can’t come to make the repair right away.
However, this repair is not to code. So, it is only for temporary repairs.
Pros:
Very easy
Great for any skill level
Best temporary option
No soldering
Cons:
Not to code
Temporary
Pros:
Allows you to continue using water while waiting for plumber to arrive
Cons:
Involves soldering
No one should really do this
Will probably not stop leak
Not a solution for pinholes
1. Clean the damaged area of the pipe with an abrasive material like Scotch-Brite
pad
2. Tightly wrap copper wire around the hole in the copper pipe and secure it in
place
3. Then solder the wire to the pipe
Pros:
Allows you to continue using water while waiting for plumber to arrive
Cons:
Involves soldering
No one should really do this
Will probably not stop leak
Not a solution for pinholes
Pros:
No soldering
Easy for beginners
Cons:
You can either use an epoxy putty to plug the hole, or you can use epoxy to create a
bandage that’s similar to a cast put on a broken arm.
This is probably the most popular repair method for copper pipes with pinholes.
However, it’s important to remember that this is temporary & toxic.
Step 1: The epoxy will be separated into two different compounds. You will need to
combine the compounds thoroughly. This will create a chemical reaction, which will
create a new compound. Be sure to wear protective gloves.
Step 2: Apply this compound to the visible holes in the pipe. Allow this to fully dry.
Pros:
No soldering
Easy for beginners
Temporary solution
Cons:
Toxic
Not good for pinhole leaks
Step 1: The epoxy will be separated into two different compounds. You will need to
combine the compounds thoroughly. This will create a chemical reaction, which will
create a new compound. Be sure to wear protective gloves.
Step 2: Apply this compound to the large hole in the pipe. Allow this to fully dry.
This is not an ideal method, because the harsh chemicals will enter into the drinking water.
This method is not code. It should only be used temporarily, until the pipe can be properly
fixed.
Pros:
No soldering
Easy for beginners
Cons:
Toxic
Not good for pinhole leaks
Temporary
CONCLUSION:
You’ve probably heard of a few different options for repairing leaks in copper pipes.
But, what is the best solution?
The answer to this question depends on where and how big your leak is. If you have a
single hole or if it’s localized to one area, then there are many solutions that could work
well for you.
However, if the problem has spread throughout most of your plumbing system, then
you’ll need more than just a quick fix-and we’re here to help with that!
We offer comprehensive services from diagnostics to repairs so that our customers can
get their systems up and running as quickly as possible without having any major
issues down the road. Give us call today at 770-691-5837
But there is very little wearing on the tubes. These most often happen on the bottom row of a coil. This
bottom row carries the greatest weight (the refrigerant is now liquid). This bottom row is also where the
flexing of the corrugated fins allows the tubes to make greatest contact with the tube sheet during
bouncing. These failures happen at the intermediate tube sheets since these carry twice the weight of end
sheets.
2.A second cause of leaks is due to flexing of the coil bundle when vibration is present. The possibility of
this happening is magnified by having fewer rows of tubes and/or a wide span between supports.
Engineering figures show that a 25 percent reduction in rows (four rows to three rows) results in about a
60 percent increase in flexing. Similarly, a 15 percent increase in span (from 48 to 55 inches, for example)
results in about a 50 percent increase in flexing. This type of leak shows up as a fatigue crack across the
top of the tube at the support point and can eventually result in the tube totally breaking off at the tube
sheet.
Multiple circuits in typical condenser coil.
2.The discharge header itself expands/contracts, bending the tubes and creating fatigue.
Leaks can occur if the tube sheet makes contact with the tubes that are attached to the discharge header.
Thermal expansion/contraction of the tubes causes wear. Most manufacturers have solved this problem by
having clearance holes in the tube sheet at these locations (essentially the top row).
Leaks can be caused by the thermal expansion/contraction of the discharge header itself. Because the
expansion coefficient is linear, a long header expands more than a short header. The outermost tubes
connected to the header will therefore bend the most. Headers over 4 feet long can cause fatiguing of the
outermost tubes. In an actual application field manifolding should be configured so that some of the
expansion/contraction can be absorbed at the manifolds.
Leaks also result from improper support of field piping connected to either the discharge or liquid
headers. Piping with multiple bends very quickly amplifies compressor pulsations or any other vibrations.
The resulting stress is concentrated at the core tubes that tie into the header, right at the point where these
tubes pass into the core bundle. Small circuits with only one, two, or three tubes into the header are
particularly susceptible to leaks from this cause.
CAUSES OF VIBRATION
As you can see, most leaks result from vibration. There are many sources of vibration, most out of the
control of the condenser manufacturer. Examples include:
• Dirty condenser;
• Loose bolts;
Paul Evans
3
How to estimate the energy savings from replacing a chiller. In this article we’ll
be looking at how to estimate the potential energy savings from replacing a
chiller. We’ll look at why to replace an existing chiller, when to replace an
existing chiller, how to calculate the savings as well considerations for advanced
calculations.
Scroll to the bottom to watch the free video tutorial
They’re committed to helping you build better chillers — from the inside out.
Learn more at http://bit.ly/SolutionsForChillers
As you probably know, chillers are typically the single largest energy consuming
piece of equipment within a commercial building. There’s growing pressure on
building owners, the building and facilities managers as well as engineers and
contracted service companies to reduce energy consumption, carbon emissions
and operating costs. As the chiller is typically the largest single energy
consumer within the building, it is often looked at for energy efficiency
improvements, and rightly so.
In our previous chiller article, we discussed different ways to improve the
efficiency of an existing chiller, you can learn about this by clicking here, but in
this article we’ll look at replacing a chiller for a newer, more efficient, option.
For example, replacing an existing chiller for a Turbocor chiller in many cases is
able to cut the annual energy consumption by around 30%, sometimes even
higher. The maintenance costs are around 50% less because the Turbocor
compressor is oil free so the only maintenance requirements are to change out
the capacitors once every five years, tighten the electrical connections once
quarterly, and annually dust off and clean the electronic cards. That’s it, no oil
replacements, no periodic teardowns, no major overhauls.
There are many ways to compare the chillers performance, one of the most
common ways is to compare the (IPLV Integrated Part Load Value) or NPLV
(non-standard partload value) rating. This is supplied by the chiller
manufacturer on request or can usually be found in their sales and technical
literature.
There are two types of IPLV depending on whether it was calculated from the
COP/EER or kW/Ton, these are just slightly different ways to calculate the
efficiency but these will be stated by the manufacturer.
IPLV COP
IPLV kWTon
When the IPLV is rated for kW/ton then a lower value means more energy
efficiency. The same reciprocating chiller might have an IPLV kW/ton of 0.7645
whereas the Turbocor might have an IPLV kW/Ton of 0.3398 so the Turbocor is
2.25 time more efficient. (0.7645/0.3398)
chiller full
load kW/ton
Alternatively, if you have the COP rating you would simply divide the chiller
capacity, rated in kW, by the COP then multiply this by the operating hours per
year. So to compare two chillers rated at 1758 kW. The first, a reciprocating
chiller with a COP of 4.24 and the second a scroll chiller with a COP of 5.86,
both units run for 3000 hours per year, then the estimated annual consumption
would be equal to 1,245,035 kWh for the reciprocating chiller and 900,207 kWh
for the scroll chiller.
If you have the IPLV kW/Ton value then you can use the following method. To
calculate the estimated annual kWh consumption then take the cooling capacity
Ton rating of the chiller and multiply this by the annual operating hours per
year then multiply this by the efficiency IPLV kW/Ton value and then multiply
this all by the average loading factor which is likely around 0.6.
So, if we drop the numbers in, you can see the Turbocor comes out at 246,500
kWh/y whereas the reciprocating chiller comes out at 471,250 kWh/y resulting
in a saving of 224,750 kWh/y.
Chiller
energy efficiency COP
If you have the IPLV COP value then you can use the following method. To
calculate the estimated annual kWh consumption, take the cooling capacity
rated in kW and multiply this by the operating hours per year, then divide this
by the efficiency IPLV value and the multiply this by the average load factor.
To calculate this we need to take the chillers rated capacity (kW) and multiply
this by the run hours per year, then divide it by the IPLV COP efficiency and
multiply this by the average load factor.
Historic
Cooling Load Profile
From the chiller log we can obtain the daily cooling load in RT and see that the
chiller runs for 10 hours per day between 8am and 5pm. Then we need the
efficiency of both the existing and new chiller. In this example we’ll use kW/Ton.
By multiplying the efficiency by the cooling load, we get the hourly kWh
consumption.
Chiller
replacement, based on historic load kW/ton
Then we can see that the existing chiller would consume 1,378 kWh a day
whereas the new potential chiller would consume 980 kWh a day resulting in a
saving of 398 kWh. If the chiller runs 5 days a week for 52 weeks per year then
the replacement chiller would save 103,480 kWh per year compared to the
existing chiller.
If you have the cooling load in kW then you should use the chiller COP to
calculate the hourly electricity consumption. For this you carry out the same
analysis to find the chillers efficiency for the chiller loading from the chiller
manufacturer except this time you divide the cooling load by the COP value to
calculate the hourly consumption. Again, following this we can see that the
replacement chiller would produce significant savings.
Historic data
COP
As I said this is an overly simplified example, in the real world the chiller
load will change through the seasons and would likely run much longer hours so
you would need to account for this, basing the annual performance on a single
week is not sufficient.
Additional considerations
To calculate the financial savings, you need to consider the electricity
tariff of the building as this will most likely vary throughout the day
and year.
There might also be savings from reducing your peak load electrical
demands and reductions from associated carbon emissions penalty
charges.
More complex financial models should incorporate inflation rates for the
tariffs.
Savings can also be quantified for reduced pumping costs due to a
reduction in pressure drop across the chillers evaporator and
condenser.
Lastly you should obtain quotations for maintenance and materials of
the new chiller and include any reduction within the financial model.
For payback you need to account for the cost of the chiller as well as
the removal, disposal, installation and commissioning for the new unit
from a contractor.
Paul Evans
Jul 3, 2019
1
Chiller Expansion Valve. In this article we are going to be looking at the thermal
expansion valve on a chiller. We’re going to look at the three most common
types of expansion valves in typical modern commercial chillers, that being the
pilot operated thermal expansion valve. The thermostatic expansion valve, and
also the electronic expansion valve.
The expansion valve controls how much refrigerant flows between the
condenser and the evaporator. The valve responds to the suction line
superheat, which is entering the compressor. It will vary the amount of
refrigerant flowing into the evaporator to suit the change in cooling load. The
evaporator needs a certain amount of liquid refrigerant in it for sufficient heat
exchange to occur. If there’s a high amount of superheat on the suction line
then there’s a lot of vapour entering the compressor. If so, then some more
liquid refrigerant can be allowed to enter the evaporator from the condenser.
The expansion valve is keeping that balance between the right amount of liquid
refrigerant and the right amount of superheat.
The balance needs to be right. You only want vapor entering into the
compressor. If liquid refrigerant enters the compressor, it will severely damage
the compressor because liquids are not compressible.
Pilot Operated Expansion Valve
You will notice there is another, much smaller thermostatic expansion valve
shown in the image. This feeds the pilot of the main expansion valve, the flow
in this smaller expansion valve is what controls the main expansion valve.
Attached to the pilot expansion valve is a capillary tube, this rides up and
attaches to a thermal bulb. Which is placed on the suction line of the
compressor.
Looking at the side view of a water cooled chiller model. We can see the route
of the refrigerant from the condenser into the main expansion valve and into
the evaporator. The pilot valve is also connected to the condenser and feeds
into the main expansion valve and it controlled by the thermal bulb on the
suction line.
Thermal Bulb
The thermal bulb will be located on the suction line, and it looks something like
in the image above. A capillary tube will run between the bulb and the valve
head. The bulb is filled with a refrigerant. When the superheat increases, this
causes heat to transfer across, from the suction line, into the bulb.
As the bulb becomes hotter, the refrigerant inside starts to boil and expand. As
that expands it pushes refrigerant out through the capillary tube and that
causes a pressure increase in the capillary tube. That pressure pushes all the
way along the capillary tube to the top of the pilot valve. That pressure pushes
down on to the top of the valve, the pressure on the valve causes it to close or
open and we use this to control the flow of refrigerant through the chiller.
Looking at the drawing of the system. We can see that as the pressure
increases in the capillary tube, the pressure will travel down and force the pilot
thermostatic valve to open. The refrigerant will flow through this and lift the
main expansion valve up, opening it. The refrigerant will now flow from the
condenser and into the evaporator.
Notice on the valve there is a thin capillary tube coming off the top of the valve
(the valve is on it’s side) this runs off the the suction line to measure the
superheat and react to it. This particular valve also have a thicker equalisation
tube coming out of the side of the valve but that’s a different subject we’ll look
at at a later point.
This type is basically what we saw being used as the pilot operated valve in the
previous expansion valve type, except it’s being used to directly control the
chiller. There is no “main expansion valve”, it is the main valve in this design.
With this design we use a thermal bulb to measure the temperature of the
superheat at the suction line of the chiller. As the bulb heats up the refrigerant
inside boils which creates pressure in the capillary tube. The pressure travels
down the capillary and pushes down on the head of the valve. As the head is
pushed down, it will open the valve to allow more refrigerant to flow into the
evaporator. When the superheat decreases the pressure also decreases and so
the valve begins to close.
The third expansion valve we’re going to look at is the electronic expansion
valve. This type of expansion valve gives the best performance because the
valve uses a stepper motor in the body. The stepper motor precisely controls
the positioning of the valve, allowing a very accurate and precise flow of
refrigerant.
You can see in the illustration above. The stepper motor on the far left. In the
centre of this is a shaft which attaches to the needle. The needle pushes against
a seat in the valve. The stepper motor pushes and pulls the shaft backwards
and forwards. As the shaft moves it opens or blocks the valve seat to allow or
restrict the flow of refrigerant from the condenser to the evaporator. The
controller measures the pressure and the temperature of the refrigerant to
determine how far to open/close.
Paul Evans
45
Cooling Load Calculation
Cooling Load Calculation for cold rooms. In this article we’ll be looking at how to
calculate the cooling load for a cold room. We’ll first look at the heat sources
and then we’ll look at a worked example of how to perform a cold room cooling
load calculation in a simplified example. Scroll to the bottom to watch the
video tutorial.
To remove the heat we use a refrigeration system as this allows accurate and
automatic control of the temperature to preserve the goods for as long as
possible.
To remove the heat we need to know what the cooling load will be. The cooling
load varies throughout the day so in most cases the average cooling load is
calculated and the refrigeration capacity is calculated to suit this.
Produ
ct Load
Then we have Product loads which account for typically 55-75% of the cooling
load. This accounts for the heat that is introduced into the cold room when new
products enter. Its also the energy required to cool, freeze and further cool
after freezing. If you’re just cooling the products then you only need to consider
the sensible heat load. If you’re freezing the product then you need to account
for the latent heat also as a phase change occurs. During this time energy is
used but you will not see a temperature change while the product changes
between a state of liquid and ice. There is additional energy required to further
chill this food down below the freezing point which is again sensible heat. You
also need to account for the packaging as this will inherently be cooled also.
Lastly if you’re cooling fruit and vegetables then these products are alive and
they will generate some heat so you’ll need to account for the removal of this
too.
Intern
al load
The next thing to consider is the internal loads which account for around 10-
20%. This is the heat given off by people working in the cold room, the lighting
and equipment such as fork lifts trucks etc. So for this you’ll need to consider
what equipment will be used by the staff members in order to move the
products in and out of the store, how much heat will they and the equipment
give off and the daily duration.
Equip
ment Load
Then we need to consider the refrigeration equipment in the room which will
account for around 1-10% of the total cooling load. For this we want to know
the rating of the fan motors and estimate how long they will run for each day,
then we want to also account for any heat transferred into the space from
defrosting the evaporator.
Infiltr
ation heat load
The last thing we need to consider is infiltration which again adds 1-10% to the
cooling load. This occurs when the door opens so there is a transfer of heat into
the space through the air. The other consideration is ventilation. Fruit and
vegetables give off carbon dioxide so some stores will require a ventilation fan,
this air needs to be cooled down so you must account for this if it’s used.
Transmission load
The dimensions of our cold store are 6m long, 5m wide and 4m high.
The ambient air is 30°c at 50% RH, The internal air is 1°C at 95% RH
The walls, roof and floor are all insulated with 80mm polyurethane with
a U value of 0.28W/m2.K
The ground temperature is 10°C.
Just to note the manufacturer should tell you what the u value is for the
insulation panels, if not, then you will need to calculate this.
Then we can run these numbers in the formula we saw earlier, you’ll need to
calculate the floor separately to the walls and roof as the temperature difference
is different under the floor so the heat transfer will therefore be different.
Floor
If the floor isn’t insulated then you will need to use a different formula based on
empirical data.
Remember if your cold room is in direct sunlight you’ll need to account for the
suns energy also.
For this example we’ll be storing apples, we can look up the specific heat
capacity of the apples but do remember if you’re freezing products then the
products will have a different specific heat when cooling, freezing and sub
cooling so you’ll need to account for this and calculate this separately, but in
this example we’re just cooling.
There are 4,000kg of new apples arriving each day at a temperature of 5°C and
a specific heat capacity of 3.65kJ/kg.°C.
Q = kWh/day
CP = Specific Heat Capacity of product (kJ/kg.°C)
m = the mass of new products each day (kg)
Temp enter = the entering temperature of the products (°C)
Temp store = the temperature within the store (°C)
3600 = convert from kJ to kWh.
Calculation
For this example I’ve used 1.9kJ/kg per day as an average but this rate changes
over time and with temperature. In this example we’re using a rules of thumb
value just to simplify the calculation since this cooling load is not considered
critical. If you were to calculate for a critical load you should use greater
precision. In this example the store maintains a hold of 20,000kg of apples.
Q = m x resp / 3600
Q = kWh/day
m = mass of product in storage (kg)
resp = the respiration heat of the product (1.9kJ/kg)
3600 = converts the kJ to kWh.
Q = m x resp / 3600
Q = 20,000kg x 1.9kJ/kg / 3600
Q = 10.5kWh/day
For the product section we’ll sum together the product exchange of 16kWh/day
and respiration load of 10.5kWh/day to get a total product load of 26.5
kWh/day.
We’ll estimate 2 people working in the store for 4 hours a day and we can look
up and see at this temperature they will give off around 270 Watts of heat per
hour inside.
Q = kWh/day
people = how many people inside
time = length of time they spend inside each day per person (Hours)
heat = heat loss per person per hour (Watts)
1,000 just converts the watts into kW
Calculation:
Q = kWh/day,
lamps = number of lamps within the cold room
time = hours of use per day
wattage = power rating of the lamps
1000 = converts the Watts to kW.
If we have 3 lamps at 100W each, running for 4 hours a day, the calculation
would be:
For the total internal load we then just sum the people load (2.16 kWh/day) and
lighting load (1.2kWh/day) to get a value of 3.36kWh/day.
Q = kWh/day
fans = the number of fans
time = fan daily run hours (hours)
wattage = the rated power of the fan motors (Watts)
1000 = convert from watts to kw.
In this cold room evaporator we’ll be using 3 fans rated at 200W each and
estimate that they will be running for 14 hours per day.
Calculation:
Q = fans x time x wattage / 1000
Q = 3 x 14 hours x 200W / 1000
Q = 8.4kWh/day
Q = kWh/day,
power = power rating of the heating element (kW)
time = defrost run time (Hours)
cycles = how many times per day will the defrost cycle occur
efficiency = what % of the heat will be transferred into the space.
In this example our cold room uses an electric heating element rated at 1.2kW,
it runs for 30 minutes 3 times per day and the estimate that 30% of all the
energy it consumes is just transferred into the cold room.
The total equipment load is then the fan heat load (8.4kWh/day) plus the
defrost heat load (0.54kWh/day) which therefore equals 8.94 kWh/day
Infiltration load
Now we need to calculate the heat load from air infiltration. I’m going to use a
simplified equation but depending on how critical your calculation is then you
may need to use other more comprehensive formulas to achieve greater
precision. We will use the formula:
Q = kWh/d
changes = number of volume changes per day
volume = the volume of the cold store
energy = energy per cubic meter per degree Celsius
Temp out is the air temperature outside
Temp in is the air temperature inside
3600 is just to convert from kJ to kWh.
We’ll estimate that there will be 5 volume air changes per day due to the door
being open, the volume is calculated at 120m3, each cubic meter of new air
provides 2kJ/°C, the air outside is 30°C and the air inside is 1°C
Safety Factor
We should also then apply a safety factor to the calculation to account for errors
and variations from design. Its typical to add 10 to 30 percent onto the
calculation to cover this, I’ve gone with 20% in this example so well just
multiply the cooling load by a safety factor of 1.2 to give us our total cooling
load of 86.7 kWh/day