Improve Chiller Efficiency via Automatic Tube Cleaning Systems

You probably know that HVAC systems are often the largest energy consumer in a facility during the cool-down period, often consuming 30-50% or more of the total energy consumption of the building. Additionally, you may know that the US Department of Energy has stated that many chillers are using 30% more energy than they need due to operational disruptions, and may even have taken some of the first steps to optimizing the efficiency of the cooling system: the building envelope. , Use of the building's energy management system, cold water recovery, annual cleaning of the condenser tubes, etc.

However, they may not know that there is another method to further increase the efficiency of the chiller in the chilled water unit, a type of continuous chiller pipe cleaning system that is part of a system family of technologies called automatic chiller cleaning systems.

Dirty condenser tubes are the main cause of refrigerant loss and are also common in refrigerators with good water treatment. In fact, it's not uncommon to find refrigerators that appear to be in good shape and operate at high pollution rates, causing the compressor's power consumption to increase by 15% or more. Refrigerant manufacturers are also recognizing the impact of condenser tube contamination on the performance of the cooler, and a quick look at the instruction manual shows that a deposit of just 0.3mm can reduce condenser efficiency by 25%.

A 900-ton chiller can use 0.547 kW / ton, which at a rate of $ 0.09 per kWh adds over $ 150,000 per year to electricity costs. Remember, dirty pipes and running costs can easily increase by 10-15%, with an additional cost of $ 15,000 to $ 30,000 per year.

Curious about how the pollution in the pipes could affect your bottom line? You can use this free calculator to calculate how much it will cost to clog the condenser tubes in your refrigerator.

How Continuous Tube Cleaning Technology Improves Chillers Efficiency

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According to Carrier, "pipe contamination occurs as soon as a heat exchanger is switched on". Usually, a system cleans the condenser tubes out of season and turns on a cooler in spring. The pipes begin to get dirty immediately and over the course of several weeks the refrigerator will degrade, causing the refrigerator to perform inferiorly in the hottest months of July, August, or September - right when you need it most!!

Automatic pipe cleaning systems are installed and work under clean pipe conditions (before the cooler is commissioned on new systems or immediately after pipe cleaning on existing coolers) by periodically pulling sponges in the form of fins past the condenser tubes. Injection cycles are typically performed every 20 minutes, but the schedule is tailored to the specific needs of the site. The spheres are slightly larger than the diameter of the tube and prevent the formation of salts, biofilms, sediments, or other incrustations as they move through the tubes. The entire injection and collection process is fully automated and controlled by a single programmable logic controller. The controller also offers monitoring and alarm functions to ensure that the system is working continuously and optimally.

Read Also: Who is Tsur Ben David?