Do you own an air cooled chiller? If so, you might want to be using it more efficiently. In your average plant, the chiller will usually be the largest electric load. For example, a 500-ton chiller will draw approximately 0.547kW per ton. With an electricity cost of $0.08 per kWh, the chiller will set you back over $200,000 in operating costs on an annual basis. 

Once you include variables such as faulty tubes, you’re looking at another $20,000 per year.

How to save on energy and maintenance costs? Well, you can ensure that the chiller always operates at peak performance. Here are some tips that will help you achieve that.

1. Install a Purge Unit

Noncondensables such as moisture often leak into low-pressure chillers, decreasing their efficiency.

Additionally, moisture can lead to acid formation. In the long run, the acid will cause a lot of damage to motor windings and bearings.

If you’re looking to minimize the presence of noncondensables, look into installing a purge unit on your chiller. Modern purge units are quite effective at separating the noncondensables from the refrigerant.

2. Keep Your Air Cooled Chiller Clean

Did you know that large chillers often have over five miles of evaporator and condenser tubes?

This means that fouled tubes can greatly affect the performance of your chiller. Contaminants such as minerals will increase thermal resistance, reducing heat transfer efficiency.

If you want to check the heat transfer levels, look at your compressor’s approach temperature. A high approach temperature is a sign that heat transfer rate is dropping.

To keep the tubes free of contaminants, clean them with an automatic rotary machine once a year.

3. Maintain Refrigerant Charge

As you might know, the refrigerant is an integral part of any air cooled chiller. Without maintaining the correct level of refrigerant, a chiller won’t provide an adequate amount of cooling.

Become More Energy Efficient

It’s our responsibility to look for ways to help cut down on greenhouse gasses and reduce our carbon footprint. A plant or manufacturing facility can have a positive effect on the environment by ensuring that your chiller plant operates at peak performance. As we’ve seen, this also carries the benefit of lower energy costs and better operational efficiency.

Envirosep provides solutions for air cooled chiller plants and more. Contact us here on the website or connect with us through Linkedin to learn more.