The Basics of Chillers

The Basics of Chillers

Chillers are essential components in HVAC systems, utilized across various industries for climate control. They remove heat from a liquid via a vapor-compression or absorption refrigeration cycle, essentially cooling the air or equipment that needs temperature regulation. For those handling claims or installations involving chillers, understanding their intricate operations is crucial.

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Water pipes for a chiller system

How Do Chillers Work?

Chillers remove heat from a designated space, similar to traditional HVAC systems, but they use water or a water solution instead of air to transfer the heat. There are two primary types of chillers: water-cooled and air-cooled. They operate similarly until the refrigerant reaches the condenser, and differences arise, which we will explore in subsequent sections.

Water-Cooled Chillers

The cooling process for water-cooled chillers starts with water entering the evaporator from the primary return, where heat is exchanged from the water to the refrigerant.

The chilled water is then sent to the water tank via the primary supply, where it is distributed to various climate-controlled spaces by the water pump. As per the second law of thermodynamics, the chilled water absorbs the ambient heat from the air handler's conditioned space. A fan forces the cooled air into the space through ductwork. The warmer water returns to the chiller to be cooled again.

Simultaneously, the refrigerant absorbs heat at the evaporator and moves to the compressor, increasing its pressure and temperature. In the condenser, water-cooled chillers use water to cool the refrigerant by surrounding its pipes and drawing in the heat. This heat is then released in a cooling tower. The refrigerant is then expanded to lower its pressure and temperature before returning to the evaporator to start the process anew.

Air-Cooled Chillers

Similar to water-cooled chillers, the process begins by bringing warm water to the chiller through the primary return. The evaporator transfers heat to the refrigerant, which is then sent to the cooled space via the primary supply. The refrigerant moves through the compressor, increasing its pressure and temperature, then reaches the condenser. Here, fans circulate outside air through the condenser, absorbing heat from the refrigerant before expelling the heat into the ambient air. The refrigerant then passes through an expansion valve and returns to the evaporator.

Where Are Chillers Used?

Chillers are widely used in various applications due to their efficiency in heat transfer with water. Water-cooled chillers are favored in medium to large facilities like airports, hospitals, hotels, shopping malls, and commercial buildings. They are more consistent and have a longer lifespan, provided there's a sufficient water supply.

Air-cooled chillers are more common in small to medium facilities where space or water may be limited. They are often used in restaurants, corporate and sporting events, and temporary structures, providing lower installation and maintenance costs but a shorter lifespan compared to water-cooled chillers.

Chillers also serve industrial or medical purposes, such as maintaining operational temperatures for assembly equipment, construction sites, lasers, MRI machines, and other high-powered equipment.

Common Problems That Affect Chillers

Corrosion

Chiller systems use metal tubes (usually copper or carbon steel) to transfer water. Corrosion can occur due to the presence of oxygen in the water. Proper treatment can significantly reduce this risk, but inadequate treatment can lead to sediment, mineral, and bacterial buildup. Such buildups can cause oxygenation level differences, leading to metal corrosion, leaks, reduced efficiency, and potential damage to the chiller and surrounding areas.

Poor Maintenance

Proper maintenance is crucial for chillers to function efficiently. Without it, chillers can suffer from corrosion, clogging, and efficiency loss. Inadequate water treatment or dirty open cooling towers can introduce sediment and particulates, causing clogged pipes and poor heat transfer. Air-cooled chillers' condensers can also become blocked by debris or dirt, decreasing efficiency.

Electrical Issues

The electrical systems in chillers are as complex as their mechanical components. They can be affected by high voltage surges, wear, and tear. Grounding issues or power supply failures can trigger automatic shutdowns. Overloading the chiller can lead to overheating and failure. Loose or damaged wires and cables after maintenance can cause malfunctions.

We Can Help Settle Your Chiller Claims

Chiller claims can be daunting due to the system's complexity and the many potential points of failure. Accurate diagnosis and expert opinions are often necessary. Our trained technicians can document damages and provide comprehensive reports detailing causes, losses, and repair or replacement costs.

Make settling chiller claims easier. Submit your claim today!

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