Top 10 Techniques to Maintain High Efficiency Chiller..
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Arctic Mount
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Jan 17,
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Chiller Systems are part of every industry and companies in UAE, climatic conditions of Middle East makes it unavoidable from daily Life. So we can say indirectly Professional Chiller System Maintenance providers keep the life of Middle East People cool and happier. Growing demands for chiller service have to be solved in a timely Manner.
Chiller Repairing, maintenance and Servicing industries in UAE, especially in Dubai and Sharjah are on the path of providing high quality service with fastest techniques and methods.Chillers often represent a plant&#;s single largest electric load. Operating chillers at their peak performance will save energy and maintenance costs.
Here are the top 10 techniques to Maintain High Efficiency Chiller systems.
1. Keep a daily log
The daily log is still the first step toward maintaining an efficiently-run chiller plant and it allows you to easily generate trend reports that help to identify maintenance needs before they become an issue.
2. Keep tubes clean for efficient heat transfer
Heat transfer efficiency has the greatest single effect on chiller performance, so clean heat transfer is fundamental to maintaining high efficiency.Condenser tubes should be brush cleaned at least annually, or per your demand maintenance schedule to keep them free of contaminants.
3. Treat condenser water to prevent scale, corrosion
All condenser water loops using open cooling sources (such as atmospheric cooling towers) require water treatment of some sort to eliminate scale, corrosion and biological growth.Inspect chilled water loops once a year or regularly with remote monitoring for general water quality and evidence of corrosion.
4. Lower entering water temperature
Lowering the temperature of the entering condenser water will improve the chiller&#;s efficiency.
5. Keep chilled water flow rate between 3 to 12-ft per second
Changing the chilled water flow rate affects a chiller&#;s performance. Too low a flow rate lowers the chiller efficiency and ultimately leads to laminar flow.The maximum recommended flow rate is typically around 12 FPS.
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For more information, please visit Custom Chiller System.
6. Maintain adequate refrigerant charge
The actual amount of cooling a chiller provides depends on how much refrigerant it moves through the compressor. Refrigerant leaks, as well as air and moisture introduced into the system, will decrease efficiency and the reliability of the system. A low refrigerant charge will cause the compressor to work harder for less cooling effect.
7. Prevent inefficiencies caused by non-condensates
Non-condensates can lower the real efficiency of the chiller from the rated performance by as much as 4% at 60% load and 7% at 100% load. Purge units minimize the effect of non-condensates.
8. Analyze compressor oil
Send a sample of the lubrication oil to a laboratory for a &#;spectrometric&#; chemical analysis once a year.Check oil filters for pressure drop and replace them if the oil charge is replaced.Inspect chilled water loops once a year or regularly with remote monitoring for general water quality and evidence of corrosion.
9. Check operation of starters and motors
For efficient operation of starters and motors, check the safety and sensor calibrations on microprocessor controls.To prevent insulation faults, test electrical motor windings for insulation resistance to ground and winding-to-winding.
10. Install variable speed drives
The chiller motor is typically the largest single electrical load in a building. With the right operating conditions, variable speed drives (VSD) can offer significant energy savings.
Chiller systems are a Solution to larger Environmental Problem also ,with cooling expenses accounting for 30% to 50% of your total energy costs and rising fast, and the impending phaseout of chlorofluorocarbon (CFC) and hydro chlorofluorocarbon (HCFC) refrigerants, there is a rapidly growing need to replace large commercial air conditioning and refrigeration systems with a modular chilling system.
Chilled water-based cooling systems account for significant energy consumption and maintenance costs in large commercial premises. As an individual component of the HVAC system, even a super-efficient chiller plant cannot meet ambitious energy targets on its own. A robust chiller plant optimization system driven by a smart building platform is the key to achieving peak efficiency and performance.
Chiller Plant Efficiency Calculation
Improving efficiency requires understanding how efficient your equipment is currently. This is accomplished by calculating the coefficient of performance (COP)&#;the ratio of the refrigeration effect produced by the chiller to the amount of electrical energy consumed for refrigeration. Each chiller has a different COP and varies with the cooling load.
Most chiller plants run more efficiently at part load and at optimum efficiency at 40-60% of their peak capacities. However, many variables impact efficiency, including:
- Design concept: Anticipating the operating conditions, including load profile, and selecting the right quantity, type, and configuration of chillers is critical to the efficiency of the plant.
- Components: Efficient individual components such as pumps, chillers, and fans can go a long way toward improving the overall full- and partial-load efficiency of the plant.
- Installation and operation: Proper installation of a chiller plant, along with an established commissioning process, is critical to realize the potential efficiency of the system.
Calculating COP and evaluating the impact of these variables in your building is a good starting point for building owners seeking to reduce energy consumption.
Strategies for Improving Efficiency
Different buildings present different opportunities for improvement, but there are common threads. Some of the best chiller plant optimization system strategies include:
- Staging: A staged chiller can ramp up and scale depending on the demand. Staging up provides sufficient cooling even at times of high demand, and staging down keeps chiller operations running while avoiding power surges and poor performance. Staging based on measured load vs. chiller capacity allows the staged chiller to be turned off when the remaining chillers have the capacity to meet the load.
- Using a virtual power plant: A cloud-based virtual power plant (VPP) can remotely integrate several independent energy resources from different locations into a network that provides reliable power throughout the day. By creating a demand response-based system, a VPP optimizes chiller operations when the cooling load is dropping and frees up power that can potentially be used to generate additional revenue.
- Integration: Building owners and facility managers tend to rely on a separate chiller plant management system to optimize efficiency, but such arrangements have major drawbacks. These include a lack of data sharing between the chiller plant management system and the BMS that controls other building operations. Integrating chiller controls with a smart BMS opens up valuable new opportunities for efficiency-focused automation, data-driven maintenance, and elevated performance.
Creating a Smart Chiller Plant Optimization System
The objective of a chiller plant optimization system is to control the cooling load. Most modern chiller control panels provide detailed operating data on cooling loads and operational efficiency. But the potential this data holds can only be fully unleashed through integration and advanced analytics. Integrated smart building platforms that continuously analyzes energy usage, correlate chiller performance with other building functions, identify areas of concern, and recommend solutions that should be the heart of any chiller plant optimization system.
onPoint is a cloud-based smart building platform that gives you greater insight and control over the cooling load and the complex variables that affect it. By analyzing historical and real-time data from all connected equipment, this powerful software will:
It can also play a central role in transforming chiller plants into revenue-generating pieces of equipment via VPPs.
Advances in technology are making siloed systems a thing of the past. When you embrace integration and smart building software, you are making a wise investment in the future of your building.
Buildings IOT offers the state-of-the-art services and products you need to create a smart chiller plant optimization system. Contact our team of experts to learn more about what we can do for you.
Contact us to discuss your requirements of Small Temperature Difference in Chillers. Our experienced sales team can help you identify the options that best suit your needs.
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