Category Archives: Chiller Repair

Chilled Water System Repair

Chilled Water System Repair of Condenser

Chilled Water System Condenser Beyond Repair

The condenser on the chilled water system had been deemed to be beyond repair by the customer. The previous company had been chasing leaks round in a circle so the customer had decided to buy a new condenser. This was our first job with a new Maintenance Contract so we wanted to make a good impression

Condenser Removal on the Chilled Water System

There was no refrigerant in the chilled water system so our engineer cut the discharge and liquid line to the condenser. He then drilled out the rivets so the frame could be taken apart. Lifting shackles were fitted to the old condenser to aid the removal. Then, slings were fitted and a forklift truck removed the old condenser

Condenser Replacement on the Chilled Water System

Our engineer supervised the condenser replacement on the chilled water system. He found that the new condenser did not fit correctly. The new condenser was 5mm thicker than the old one. It was decided to lift it back out and angle grind the frame to make more room. Once this was completed, the new condenser fitted correctly and was bolted in place

Chilled Water System Pipework Repair

The pipework had to be repaired and brazed in on the chilled water system. Then, the standard practice of a pressure test to ensure the integrity of the system

The Evacuation Process

Having passed the pressure test, our engineer set up the vac pump and started the evacuation process. This is to dehydrate the system by pulling a vacuum of less than 2 Torr. Any moisture in the system will boil away and leave the system dry

Recharge and Test Operation

The refrigerant is R410a. Our engineer put around half the charge in, then trimmed the remaining charge according to the superheat and subcooling values. He monitored the chilled water system for the rest of the day. He was looking for leaks as the plant was at operating pressures of 30 Bar. All was well, so the customer signed off the paperwork as he was pleased with the efficient professionalism of our engineer

Read more about air cooled condenser installation at the Institute of Refrigeration Click Here


Chiller Controller Replacement and Refurbishment

Chiller Refurbishment

Chiller Refurbishment

Chiller refurbishment is cost effective because the main cost of a large screw or centrifugal chiller is mostly in the fixed plant. That is to say: the two main heat exchangers and the compressor. Therefore, this is the most environmentally friendly option as the carbon footprint of building new chilling plant is very high. This is not mentioned when you purchase a new chiller. With chiller controls replacement, this kind of plant lasts for 30 years. One of our competitors has been carrying this out to a chilling plant that dates back to the 1970s and is still in service!

Refurbishment of the Chiller Evaporator

Chiller refurbishment of broken tubes can be performed by plugging the tubes on either end. Larger scale chiller replacement of the tubes can be carried out by cutting a door in the shell to access the tubes. This is a major overhaul at a fraction of the cost of replacing the water chiller

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Refurbishment of the Chiller Compressor

We strip the chiller compressor down for refurbishment in our workshop. It is made from heavy castings so will last a very long time. We provide a 12 month warranty on all our chiller compressors. Read More about centrifugal compressor remanufacturing on our web page

Refurbishing the Chiller Controls

Refurbishing the chiller controls can be carried out by fitting state of the art controls. These will surpass the controls fitted by the builders of the chiller. The controls that come with the chiller are made 'in house' so they often are prone to spurious trip outs which can loose you production. A control panel, designed specifically for that chiller comes ready built. All you have to do, is wire in the various sensors and transducers. The run signal, compressor soft start, remote loading and monitoring can be easily integrated

Chiller refurbishment at Maximus Chillers | Centrifugal, air cooled and water cooled chillers | National and Global | Click Here

Read more about the chiller controls we fit to existing chillers


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