Chilled Water System Maintenance

Chilled Water System Flow Switch Maintenance

Chilled Water System Maintenance

Maintenance of the Chilled Water System Flow Switch

The chilled water system flow switch requires regular maintenance due to a to build up of contaminants on the sensor. Over time, slime accumulates giving false readings. The problem is relatively easy to sort out: a wipe with a cloth

Retrieving the sensor

The more difficult part is deciding how the retrieve the sensor. It is fixed with a bolt into the chilled water system being maintained. Therefore there is pressure inside. The textbook way to do the job is to valve off the section of pipework, then drain the glycol into a vessel. There are other ways known to an engineer

Snatching the Flow Switch!

Although not text book: snatching the flow switch is a considerably easier way of maintaining the chilled water system! One of our seasoned engineers unscrewed the bolt whilst holding the flow switch in. He whipped it out- gave it a quick wipe and stuck it back in! Only a small amount of the secondary coolant was lost (which shot out- loosing no height) He re-tightened the bolt and the job was done

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Checking the Fault Out Level

As you can see from the picture: there is a green light on 0. This indicates that the pump is off. Not to be confused with pressure, as there will be a couple of bar on a roof an 6 bar or so in a basement. The higher pressure in a basement is due to the head of water pushing down. With the pump on: the green lights go all the way up to 9 with the fault out level showing red on 7

Maintaining the Chilled Water System Fault Out Level

Maintaining the chilled water system flow switch can be achieved with a terminal driver. Using the manual that comes with the flow switch: the buttons can pressed a number of times to 'self test' Also, the fault out level can be set

Testing the Flow Switch

As part of the maintenance, the flow switch is manually tested using one of two methods. This ensures that the switch will function correctly when it needs to

Read more about flow measurement on Wikipedia


Air Cooled Glycol Chiller Maintenance

Chiller Maintenance Schedule Air Cooled Glycol

Air Cooled Chiller Maintenance Schedule Bodger Watch

A chiller maintenance schedule is usually very good, but this is bodger watch!

We maintain the air cooled chillers in an office building. The customer told me there had been this guy who used to come who spent most of his time in the canteen- reading manuals on his lap top! Not even the manuals for that site either! You couldn't make it up could you? What kind of a chiller maintenance schedule is that? They said he used to fix everyone's bathrooms in the evening to make up his pay! This is bodger watch!

Dosing Glycol Chillers

Our junior engineer rang me from a job the other week. Struggling to carry out glycol chiller maintenance. Get your refractometer out I said before you ring. We are teaching how to think for himself instead of just ringing everybody up. He came back with the result- too much glycol. The customer uses propylene even though the site is heavy industrial. This is because the price is narrowing between propylene and ethylene and propylene is not toxic

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Customer Dosing of Glycol

The customer adding glycol is the usual course. It means their onsite chiller maintenance engineer can keep on top of things on site. This onsite engineer was a little too keen though: he had been putting too much in

Glycol Removal

The glycol chiller was performed by telling my engineer to get half of it out into the empty drums that were still on site. The glycol can be used again in the future maintenance of the chilling plant. He then topped up the water system with water

For the efficient running of your chilling plant- choose Maximus Chillers to service & maintain Click Here for more info

Clear Site

Last but not least all off our engineers give the machine a wipe down and the chiller location a sweep. Good house husbandry is a part of expert chiller maintenance

Visit Refcom for industry guidance and advice


Float valve on an industrial refrigeration machine

Industrial Refrigeration Maintenance

Industrial Refrigeration Maintenance of Float Valve

On a recent visit to a site in the South East, the industrial refrigeration maintenance of float valve was carried out. It was an easy job as the electronic part can be easily removed and replaced without breaking into the system. It works by detecting a level in the float chamber and operating the expansion valve solenoid coil

High Head Pressure

The call out had been to investigate a high head pressure issue. Our engineer arrived on site about 9 o clock and started to investigate the industrial refrigeration fault- a cup of coffee in hand. The machine started to load up and at around 70% it backed off with high lift warnings on the display. There was a low temperature drop on the liquid line between the float valve and the expansion valve- float valve failure. The float valve is stand alone as it will let anhydrous ammonia liquid through when it builds up- that is if it works of course

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Industrial Refrigeration Maintenance of Electronic Parts

Industrial refrigeration maintenance was carried out to the electronic parts with a straight swap

Slide Valve Sensor

A common kind of slide valve sensor on an industrial refrigeration system works by converting the length of the slide arm into 4-20mA. 4 being closed and 20 being open. To get it to work you have to set the minimum position on the slide arm with a lock nut- then set that to 0 in the program

Failed Slide Arm Electronics

A common fault is when the slide arm electronics fail, giving a stuck reading on the display. The chiller controls notice the abnormality and shut down the plant

Calibration

If the slide arm is okay, calibration can sort out the problem. In the program, the minimum and maximum positions can be set to ensure the smooth running of the plant, therefore maintenance can be kept to a minimum

Are you concerned with high maintenance costs and a tight budget? Maximus Chillers can relieve the stress- Click Here

Visit the Institute of Refrigeration for industry publication resource


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