Common Factors Affecting Working Efficiency of Industrial Water Chiller

In the process of using industrial water chiller, it is common that the efficiency is low. What are the causes?
How to solve quickly? This article is for reference.
In the field of industrial manufacturing, precision processing and laboratory temperature control, water chiller unit, as the core temperature control equipment, its operating efficiency directly affects the production energy consumption and equipment life.
The industrial water chiller refers to the refrigeration equipment used for cooling industrial equipment or products. The unit compresses the refrigerant through the compressor for gas-liquid conversion. The refrigerant releases heat in the condenser, absorbs heat in water or other cooling medium in the evaporator, and turns it into a cold source. The pump circulates the cold source in the industrial equipment or products to be cooled to achieve cooling and cooling.

Water chillers are often inefficient in use, and there are many reasons for this. This is not only due to the environmental change of refrigeration equipment, but also due to the consumption of equipment components in long-term use. In general, for refrigeration, we need to understand the causes of equipment efficiency reduction and find solutions.

1. Human error in operation
Although most refrigeration equipment does not have too many tedious procedures in use, some basic contents are often ignored in long-term use. That is, some customers operate for the first time, so he has no experience applying any equipment. Therefore, refrigeration equipment operators shall be trained in professional skills before operating the equipment and pass all tests before operating the equipment.

2. Fouling of critical parts of equipment, i.e. inefficient equipment due to improper maintenance e.g. when chillers of chillers are heavily fouled, heat transfer is affected, resulting in inefficient overall equipment operation. In addition, in addition to the cooler and other parts prone to fouling, there will be serious damage to the transmission mechanism. In other words, the compressor impeller, transmission mechanism, high and low speed bearings and other important moving parts will be worn during long-term use, which will easily lead to insufficient operation efficiency of the equipment.

3. The equipment has a very high load during the operation period, because the equipment is often overloaded in the production process. Generally, the load operation rate of the refrigeration equipment is preferably 80% to obtain the highest efficiency, but it is often difficult to achieve in the specific production process, so it is very likely that the efficiency is low.
4. Refrigerant state and charging amount Refrigerant is the "blood" of refrigerating cycle, and its physical state directly determines the system COP (energy efficiency ratio). When the charge is lower than 15% of the design value, the superheat at the end of the evaporator will rise abnormally, which will cause the suction pressure of the compressor to drop, and the attenuation of the refrigerating capacity can reach 30%. On the contrary, excessive filling will lead to liquid accumulation in the condenser, increasing the condensate pressure by about 20%, and increasing the power consumption of the compressor. It is recommended to use an electronic scale for quantitative filling and observe the flow state through a liquid sight glass to maintain the liquid level in the 1/3-2/3 range of the sight glass.

5. Excessive transition of operating temperature
The operating factors to be paid attention to for refrigerating equipment at different temperatures, such as the temperature of cooling water, are different. In general, air conditioning and ventilation systems are provided in chiller plants to cool the environment, so as to keep the refrigeration equipment in a constant temperature environment. However, if there is a problem with this type of equipment that controls the operating temperature, it will eventually cause problems with the operating efficiency of the equipment.
6. Establishment of three-level maintenance mechanism for preventive maintenance system can improve equipment life cycle efficiency:
Daily patrol inspection: record operating current, vibration value and other basic parameters;
Quarterly maintenance: clean the filter screen, detect the insulation resistance and calibrate the sensor;
Annual overhaul: replacement of wearing parts, analysis of refrigerant composition and calibration of control system.