TopChiller can design and manufacture all types of Explosion proof chillers for you.

Explosion Proof Chiller-The Ultimate FAQ Guide by TopChiller.

What is an Explosion Proof Chiller?

Explosion Proof Chiller is a refrigeration system that can be utilized in hazardous environments. It is built with specified safety features and can adequate physical protection to keep your equipment and important machinery safe.

Explosion Proof Chiller is comprised of flame retardant features and hardware to prevent combustion. Its special composition provides space cooling against an explosive industrial environment.

Explosion proof chiller

What are the Components of Explosion Proof Chiller?

All of the components of an Explosion Proof Chiller are made up of explosion-proof material such as stainless steel.

All of its components are housed in a single explosion-proof housing. The main components of an Explosion Proof Chiller are a follow:

1. Compressor
2. PLC system
3. Condenser
4. Expansion Valves
5. Evaporator

Explosion proof chiller control panel

What is the Working Principle of an Explosion Proof Chiller?

You can customize your normal chiller into Explosion Proof Chiller by adding or replacing explosion-resistant devices.

Its working is dependent on its design as it is highly capable of protecting your equipment from mechanical damage when they are in a working position.

An Explosion Proof Chiller is specially designed to ensure performance in various environments that are exposed to gases, combustible, and dust clouds.

Working principle of an explosion proof chiller

What are the Outstanding Features of Explosion Proof Chiller?

Some outstanding features of an Explosion Proof Chiller are listed below:

• It has advanced temperature alarms technology that notifies you about excessive temperature changes.
• The high-quality stainless steel housing of an Explosion Proof Chiller keeps the internal components safe from shocks.
• There are disconnecting switches that are used for emergency power supply cut off to avoid hazardous conditions.
• Equipped with a redundant system that controls lead and lags.
• Rotolock compressor connections for easy and combustion-free compressor change-outs.
• High-end coil coating in a system with the air-based condenser.

What are the Advantages of Explosion Proof Chiller?

Some of its outstanding advantages are as follow:

• An Explosion Proof Chiller has higher cooling efficiency than other systems.
• Higher protection against the hazardous environment.
• High precision temperature regulators.
• Easy to operate and maintain.
• Provides rapid cooling where required.

What are the uses of Explosion Proof Chiller?

An Explosion Proof Chiller is used in a vast range of hazardous environments.

The purpose of using it in chemical processing plants, oil and gas refineries, coal plants, and other conditions that utilize vapors and flammable gases.

Its usage depends on its divisions, discussed in the next sections.

What are the Types of an Explosion Proof Chiller?

There are different types of Explosion Proof Chiller, including:

• Scroll Explosion Proof Chiller (Compressor-based type)
• Screw Explosion Proof Chiller(Compressor-based type)
• Air Cooled Explosion Proof Chiller(Condenser type)
• Water Cooled Explosion Proof Chiller(Condenser type)

What are the Applications of an Explosion Proof Chiller?

Expl0sion-proof chiller designed by Topchiller widely used in below hazardous environments:

• Refineries
• Sample or Process Analyzers
• Granaries
• Laboratories
• Chemical Plants
• Petrochemical Plants
• Cooling Flammable Liquids

How an Explosion Proof Chiller Cools the Process in Hazardous Environment?

Many large-scale industries use flammable or volatile substances, heavy machinery, and other electrically classified devices.

All these things are operating with high power and can damage your assets and employees too. They required a precise and rapid temperature controlling chiller.

Here an Explosion Proof Chiller is used to provide cooling to the equipment. It is used like other chillers but it is built with heavy-duty components that protect your equipment from failure and explosion.

Explosion Proof Chiller can be air-cooled or water-cooled. You can request customizations according to your requirements.

It has greater cooling efficiency than other HVAC systems. It can control the temperature in various applications.

Such as Sample and process analyzers, refineries, granaries, petrochemicals, chemical plants, and laboratories, etc.

 What Type of Computerized System is Installed in an Explosion Proof Chiller?

A Programmable logic control system is installed in an Explosion Proof Chiller.

This system is capable of operating all the operations of the chiller. It is used for making Temperature adjustments.

This system also tells if there is something wrong with the machine by displaying the code on the screen.

The PLC system is a user-friendly system installed in it.

Explosion proof chiller computerized LCD

What is the Importance of Explosion Proof Chiller?

Explosion Proof Chiller is an important solution for regulating temperature in hazardous environments.

It is a source of cooling and protection for the safety of employees and equipment. It reduces the factor and risk of spark ignition in electrically classified locations.

Many large-scale industries are using an Explosion Proof Chiller to meet their cooling requirements safely.

This is suggested by law in many countries for locations having flammable materials. As in case of any hazardous condition, it can prove as a lifesaving chiller.

What Additional Things can be supplied Along with Explosion Proof Chiller?

Some additional things that can be supplied along with Explosion Proof Chiller are as follow:

• Paddle flow switch
• Delay starting protection devices
• Overload relay
• Protection switch

How to Keep your Explosion Proof Chiller Clean?

Cleaning of your Explosion Proof Chiller includes the following steps:

• Carry out a daily dusting of your Explosion Proof Chiller it should be included in your daily inspection.
• Clean all the tubes periodically to, remove mud, algae, and sludge from the tubes. Flush all the tubes with freshwater this is called Mechanical cleaning
• Removal of scale from pipes and tanks must be done properly periodically by using different chemicals and detergents. This is called chemical cleaning.

What are Some Protection Devices of an Explosion Proof Chiller?

Following are some protection devices used to protect your Explosion Proof Chiller.

• Fuses and circuit breakers to control current.
• Fire alarm system.
• Thermal overload protection relay for the compressor.
• Thermostat anti-freezing.
• High and low-pressure cutoff switches.
• Over-temperature alarm system.
• Sight glass on moisture absorber.
• Flow switch in the compressor.
• A low refrigerant alarm.
• Oil safety switch.
• Fire resistance wires and cables.

Explosion proof chiller pressure sensors

What is the Composition of Compressor used in an Explosion Proof Chiller?

The compressor of an Explosion Proof Chiller is composed of the following parts:

• Electric Motor

Its body is made up of stainless steel with copper winding it provides the pumping power to the compressor.

• Compressor Pump

The compressor pump compresses the air and directs this compressed air to the receiver, two-stage compressing is used to achieve the pressure145 -175 PSI.

• Receiver

The receiver is a container to store compressed air. A check valve is installed on the receiver to protect compressed air in the receiver to escape to the compressor.

• Pressure Switch

Once the pressure inside the receiver will reach to a factory set level the pressure switch will automatically shut down the motor.

Explosion proof chiller compressor diagram

How to Choose the Right Explosion Proof Chiller for your Application?

While going to buy an Explosion Proof Chiller always select the best product manufacturer for your application.

First of all, conduct a feasibility study to find which chiller will be best to match your requirement.

In this study, you have to figure out your cooling requirement, available budget, and the space available for installation.

Availability of spare parts and all other necessary information and then prepare a report that which Explosion Proof Chiller will be best for your application.

What are Some Safety Measures that you can take while using your Explosion Proof Chiller?

Safety Instructions:

• Follow all the warnings, instructions, and precautions mentioned in the manufacturer manual.
• The fire extinguisher must be placed close to your Explosion Proof Chiller to deal with any emergency. All the concerned must know that how to operate the fire extinguisher and the fire extinguisher must be operational.
• All the electrical cables or wires should be properly routed and secured.
• All the moving parts must be protected by guards.
• Train the people to operate the equipment safely.
• Check your emergency shutdown system for proper function at least once after two or three years.

Explosion-proof chiller emergency switch

What is the Role of Evaporator in Explosion-Proof Chiller?

The Explosion Proof Chiller uses a vapor compression mechanical refrigeration system that is connected to a process water system through an evaporator.

The refrigerant circulates through an evaporator, condenser, and expansion device.

The evaporator function as a heat exchanger in such a way that it heats captured by coolant flow is transferred to the refrigerant.

As the heat transfer occurs, the refrigerant evaporates to change into vapor from low-pressure liquid.

What Are Some Technical Parameters of an Explosion Proof Chiller?

Some technical parameters of an Explosion Proof Chiller are as follow:

• Cooling capacity
• Power consumption
• Running current
• Freeze water flow
• Compressor type
• Pump
• Refrigerant
• Evaporator type
• Condenser type
• Safety protection devices
• Dimensions
• Fan
• Weight

Is the Explosion Proof Chiller using a High-Quality Compressor?

Of course, the compressor of an Explosion Proof Chiller is equipped with a high-quality compressor inside an explosion-proof electrical cabinet.

Its compressor is highly corrosion resistant and good for harsh working environments. It is durable and produces very low nice.

The compressor of an Explosion Proof Chiller performs efficiently and is reliable too.

There are two main types of compressors used in it. It can be a screw compressor or a scroll compressor.

Explosion proof chiller low noise high quality compressor

What is the Role of an Explosion Proof Chiller in Petrochemical Refineries?

The chiller that is being used in hazardous areas is called an Explosion Proof Chiller.

The petrochemical refineries are also hazardous so an Explosion Proof Chiller is also used to maintain the temperature of refineries during the process.

Due to their robust and rugged designee, an Explosion Proof Chiller is preferred over other chillers.

Explosion proof chiller for petrochemical refineries

What are the Transportation Requirements of an Explosion Proof Chiller?

It is better to use a suitable container while transporting your Explosion Proof Chiller from one place to the other place.

During transportation must use the transport that bears the load of the Explosion Proof Chiller.

Must use a crane, or fork lifter to load the chiller on the truck, or it may also be towed behind the truck. Always drive slowly while transporting.

What is the Right Size of an Explosion Proof Chiller for your Application?

Explosion Proof Chiller comes in a variety of sizes and capacities. The sizing of the chiller depends on its type.

To determine the size of the Explosion Proof Chiller for your application you must know the following things:

• Decrement temperature
• Flow rate
• The fluid inlet and outlet temperature and their difference

When you will have the exact values of the above variables then you will be able to calculate its size by a general mathematical formula.

What are the NEC Hazardous Material Divisions of an Explosion Proof Chiller?

An organization with the name National Electricity Code (NEC) defines hazardous areas.

Including the area where the fire or explosion error may exist due to Flammable gasses vapors, flammable liquids.

It can be divided into three categories:

• Class I location. The location with gasses and vapors fumes.
• Class-II location. The location with flammable dust.
• Class III location. The location contains flame-able liquid.

Most of the time a fire may take place by ignition, temperature increase, or spark.

And mostly ignition is produced by electrical sparks that may cause an explosion; the hazardous areas of Explosion Proof Chiller are made safe to avoid explosion or fire hazards.

What to Expect from the Manufacturer While Buying an Explosion Proof Chiller?

There is a lot of manufacturer of Explosion Proof Chiller are available in the market. So visit all of them and always choose the manufacturer offering you with best facilities.

The facility may include an after-sale service facility, warranty, free sight delivery facility, affordable to your budget, the material used in manufacturing, and manufacturer repute in the market.

Is an Explosion Proof Chiller Reliable?

Yes, your Explosion Proof Chiller has a unique and drastic design it can be used in hazardous conditions without any danger of explosion.

So it is designed in a way that it should perform better in the worst-case scenario with optimum performance so it is a reliable chiller that can be used without any harm or risk factors.

How to Improve the Performance of an Explosion Proof Chiller?

Performance of Explosion Proof Chiller can be improved by keeping the following points in consideration:

• All the gauges and other equipment which required calibration or alignment process should be carried out as per schedule without any delay.
• Maintain a logbook to record the daily events.
• Carry out daily dusting and cleaning.
• Must be operated by a certified operator.

Maintain a logbook of your explosion proof chiller

How to Resolve the Problems of your Explosion Proof Chiller?

Explosion Proof Chiller has a coded system also known as PLC system. This system provides a direct interface between the machine and the user.

There is a code for every problem in the system .when the error code displays on its screen you need to check the solution for that code on the manual guide.

In this way, you can resolve the problems in Explosion-Proof Chiller.

What to look in when you are going to use Explosion Proof Chiller after Storage?

You are supposed to look into the following points after you are going to use your Explosion Proof Chiller after a long storage period.

• Look into the logbook if calibration of some components is due to get them calibrated.
• Unpack carry out the cleaning of the equipment properly.
• Check the logbook to whether lubrication oil was drained before storage; if yes fill in the lubrication oil before using it again.
• Check all the pipes for leakage.
• Check all the cables and wires for any damage.

How to Keep your Explosion Proof Chiller Safe from Harsh Weather Conditions?

To make your equipment safe in harsh weather conditions, ensure about following:

• Equipment must be fitted on the pedestal properly. No nut or bolt should be open or loose at all.
• All the panels must be closed properly and no fastener or panel screw is loose or missed.
• All the necessary equipment should be available to deal with an emergency.

How to Test your Explosion Proof Chiller before Startup?

Before starting your Explosion Proof Chiller ensure the following point:

• Check logbook if any component is removed from chiller for maintenance, if yes wait until the component is fitted back.
• Check for any leakage in oil or water.
• Check for leakage of air pressure.
• Make sure all safety equipment is available near the chiller.

Explosion proof chiller testing

How to Lubricate your Explosion Proof Chiller?

The compressor is filled with lubrication oil the compressor is done to minimize friction in the movement of mechanical parts of the compressor.

The user is to monitor for the proper level of oil in the compressor. The oil level can be monitored through sight glass on the compressor.

If the level is too low or too high it can be harmful t your system. The oil level must be well maintained as prescribed in the manufacturer manual.

Explosion proof chiller lubrication

What is meant by the Cooling Capacity of an Explosion Proof Chiller?

The cooling capacity of your Explosion Proof Chiller is the maximum amount of cooling that your Explosion Proof Chiller can provide efficiently. It is normally calculated in BTU /hour.

It can be converted into tons. To convert the BTU/hour into tons of cooling divide the BTU/ hour by 12000 and you will get the capacity into tons.

What is the Method of Filling the Refrigerant in Explosion-Proof Chiller?

When filling your Explosion Proof Chiller with refrigerant monitor the sucking and discharging pressure through sight glass for any leakage.

The refilling of refrigerant is done due to two reasons that are, leakage or system is required to be used after storage.

Following is the method to refill the refrigerant:

• Turn on all valves.
• Connect vacuum pump between low pressure and high pressure.
• Evacuate the system by using the vacuum pump.
• Check the nameplate for proper refrigerant and amount to be filled.
• Slowly fill the refrigerant into the system as per instructions given in the manual.

How to Uninstall the Compressor of an Explosion Proof Chiller?

Steps to uninstall the compressor:

• Turn off the unit power supply.
• Turn of inlet and outlet service valves on the compressor.
• Remove the bolts of sucking, and discharge flanges of a compressor.
• Take off power supply connections of the compressor.
• Remove the fixing bolts of the compressor.
• Take out the compressor.

What is the Purpose of a Drier Filter in an Explosion Proof Chiller?

The drier filter used in an Explosion Proof Chiller is for two purposes.

Firstly, it is used to absorb system contaminants like water vapors and its second function is to provide physical contamination filtration.

It is also used to prevent any physical contaminants to enter your Explosion Proof Chiller System which may create a problem.

Explosion proof chiller drier filter