TopChiller can design and manufacture all types of water chillers for you

Water Chillers: The Ultimate FAQ Guide

This guide covers everything you need to know about water chillers.

Whether you want to learn about specification, parts, working principle, function, or improving efficiency – everything is in this guide.

Keep reading to learn more.

What are Water Chillers?

Water chillers are closed systems that you will install in a building or industry to help in controlling the temperatures.

In most cases, you will use the water chillers to eliminate high temperatures thus cooling the environment.

Energy saving water chiller designed by TopChiller

Which Type of Liquid Do You Use in the Water Chillers?

Just from the name of the water chilling system, you can assume that the system uses water as the main chilling liquid.

Well, that is true because water is the main liquid that you will use in a water chiller system.

Apart from water, you can use a mixture of other liquids such as:

· Mixture of Water and Glycol

Water and glycol mixture is the best liquid for water chillers because it works well even in environments experiencing freezing temperatures.

With this type of liquid, you can easily install the water chillers outside the building as it offers freeze protection.

The ratio of mixing glycol and water will also vary depending on the type of water chiller you are using.

· Glycol

Glycol also makes a very good liquid for water chillers since it helps lubricate the system and prevent corrosion.

The different types of glycol coolants that you can mix with water include propylene and ethylene glycol.

· Water

Using water as the main liquid in the water chillers is the most energy-efficient and economical type of liquid.

You should be careful when using water as the main liquid in the water chillers as it should not contain minerals.

Water that has different minerals might lead to corrosion on the machines or clog the fluid channels.

The main types of water that you can use include reverse osmosis water and deionized water.

· Specific Type of Oils

In this application, you will use specific types of oils or emulsions that must have high viscosity.

It will help in cooling the smallest type of footprints in different applications such as recirculation of cooling machinery.

Apart from that, you can use it in applications such as cooling hydraulics as well as automation components.

Water chiller glycol

What are the Main Components of the Water Chiller?

Water chillers are made of different parts that perform different functions to enable the proper cooling of different applications.

Here are the main parts of the water chillers that perform different functions.

· Compressors

You can identify the compressor as the most significant mover which creates a pressure difference and enables the movement of refrigerants.

There are different types of compressors in the machine such as scroll, centrifugal, screw, and reciprocal compressors.

· Expansion Valves

You can locate the expansion valve between the evaporator and the condenser of the water-cooled chillers.

It is responsible for the expansion of refrigerants thus reducing the pressure and increasing the volume.

As that happens, the refrigerants will pick up the unwanted heat within the environment thus cooling it all together.

· Condensers

You can locate the condensers between the expansion valve and the compressors.

It will help in the elimination of heat from the refrigerants of the water-cooled chillers.

· Power Unit

The power unit is the part of the water chillers that will supply and control the amount of power.

You can mount the power unit either on the machine or separately on the wall of the installation plant.

· Evaporator

You will locate the evaporator between the compressor and the expansion valve.

It is the main part that will collect the heat from the building or room and transfer it to the refrigerant.

· Water Boxes

You will find the water boxes on the evaporators as well as the condensers on the water chillers.

The water boxes will help in directing the flow of water within the water chillers.

Apart from that, the water boxes separate the exit from the entrance of the water chillers.

· Controls

You will use the control unit to configure and program the water chillers to perform specific functions.

It is the same unit that will assist in is monitoring the whole water chilling process.

Water chiller compressor

What are the Benefits of Using the Water Chiller?

Water chillers play a very significant role in our lives as it makes most applications operate with minimal hitches.

Here are the main advantages that you will derive from using water-cooled chillers.

• High Durability Levels

Water chillers will not require frequent replacements just like the other types of chillers like air chillers.

Since you will install it indoors, there is minimal exposure to weather elements such as snow, heat, and rain.

• Produces Minimal Noise

Water chillers do not produce a lot of noise during their operations since they lack vents and ducts.

Water flowing through the system does not produce as much noise as you would hear in the air chillers.

This makes it the best chiller that you will use in very quiet environments including hospitals as well as schools.

• Saves on Energy

Water chillers use very little energy in transferring heat more efficiently in comparison to air-cooled chillers.

You will save a lot of money that you could use to pay high energy bills just by using water chillers.

• Does Not Require Open Spaces

You do not require open spaces to install the water chillers as you will install them within a mechanical room in the building.

It is the most ideal chiller that you can use in companies that do not have a lot of outdoor spaces.

• High Safety Levels

Water chillers use very safe liquids such as water as the main refrigerant thus eliminating the possibility of intoxication.

It also comes complete with safety mechanisms that will warn you in case of imminent danger that might cause damages.

Are there Disadvantages of Using Water Chillers?

Well, water chillers may develop a few issues that may discourage you from using them.

Here are some of the limi9tations that you might experience when using water chillers.

• Higher Cost of Purchasing and Installation

Well, you will have to pay quite a lot of money to simply purchase and install the water chillers.

This is because the machines are expensive with the inclusion of other parts including condenser water pumps and cooling towers.

• Requires More Maintenance

You will have to increase the maintenance levels of the machines since they have more parts than other chillers.

You have to be ready to pay for frequent inspections, treatment of water, and cleaning of the machine which is costly.

• Requires A Mechanical Room

You must also prepare a room or a mechanical room in the building where you will install the water chillers.

It will ensure that the water or cooling towers and other components of water chillers are highly durable.

• Installation Complications

You will also experience a lot of installation complications due to the presence of the additional parts of the chillers.

In that case, you must hire extra personnel which will definitely increase the cost of installation.

• Not Applicable in Drought-Stricken Areas

You may not install the water chillers in areas that experience frequent drought episodes since it requires a lot of water.

How Does the Water Chiller System Operate?

There are quite several different types of water chillers that have different working principles.

You will differentiate the water chillers from the different types of compressors in the industry.

Here is a step-by-step process on how the centrifugal water chiller works.

1. Refrigerant Passes through the Compressor

Basically, the centrifugal chiller works in a complete cycle beginning with the refrigerant passing through the compressor.

The refrigerant gas will flow from the evaporator and into the center of the centrifugal impeller.

The vanes in the impeller will such vapors and allow it through the radial passages thus making the impeller rotate.

As it rotates, it increases the speed of the gas resulting in the proper stability of the compressors at particular angles.

Apart from that, it will help in the distribution of vapor that enters the compressor thus adjusting the overall load.

Finally, the gas will undergo compression and then move straight into the condensers.

2. Refrigerant in the Condensers

Here, the hot vapor will flow into the condenser where it will cool down through the aid of water from cooling towers.

As the water flows through the tubes in the condensers, it collects the heat from the flowing hot vapor.

With the help of the condenser pump, the flow of water through the tubes will continue as it collects the heat.

It will flow all the way to the cooling tower where it will release the heat that it had collected into the air.

The process proceeds up to a point where the room with high temperatures cools down.

What is the Difference Between the Water Chiller and Air Chiller?

There are two main chillers in the industry which include the water and the air chillers.

Here is a difference between the two types of chillers.

· Water Chillers

Water-cooled chillers use water as the main cooling agent thus helping in the elimination of excess heat.

It comes complete with additional components such as water towers that help in improving its efficiency.

You will install the water chillers in the mechanical room which will protect it from damage from external weather elements.

· Air Chillers

Air chillers use air as the main agent that will help in the elimination of heat from the system.

It is one of the simplest chillers that do not have additional features such as the water towers.

You will install the air chillers outside the building which allows plenty of air to flow through.

It is, however, vulnerable to a lot of damage that comes as a result of exposure to external elements.

Air chiller manufactured by TopChiller

How Do You Maximize the Efficiency of the Water Chiller System?

The most significant mode of maximizing the efficiency of the water chillers is to do proper maintenance.

Maintaining the water chillers will go through a few processes which include:

· Ongoing Maintenance

You should ensure that you maintain your water chillers daily through proper inspection and cleaning of condenser coils.

Apart from that, you should also charge the main refrigerant to ensure a constant supply of the refrigerant through the system.

You should also maintain proper levels of the condenser water thus maintaining the proper flow of water.

· Predictive Maintenance

You should also purchase modern machines that come complete with automatic features such as artificial intelligence.

This feature will help in predicting any maintenance requirements on the machine.

It will inform you of any type of maintenance requires that you need to perform within a particular time frame.

· Optimization of Operations

You will also maximize the operations of the water chillers by optimizing all the main functions of the machine.

You will program the machine accordingly from the control panel and ensure the programming is optimized.

What are the Main Applications for Water Chillers?

You can use the water chillers in quite a several applications within different industries.

Here are some of the industries that use water chillers to cool off different applications.

Industrial Applications

You will use the water chillers to control the high temperatures of different products by cooling them.

It also helps in the cooling of the industrial mechanisms and machinery within the factory in different industries.

In the plastic industry, the water chillers will control blow molding and injection, welding equipment and die casting among others.

Commercial Buildings

You can use the water chillers in commercial buildings to help in cooling the rooms thus creating a proper working environment.

Apart from that, it helps in maintaining the cooling systems within such buildings thus keeping materials fresh.

Pharmaceutical Industry

You will also use the water chillers to help in keeping pharmaceutical products such as medicine cool.

In addition to that, it helps in maintaining proper temperatures within the hospital buildings for patient comfort.

Food Industry

Water chillers help in maintaining the freshness of food products for a very long time.

It is the most efficient way of keeping food products in a cool and dry environment or storage facility.

Water chiller applications

What is the Best Place for Locating a Water Chiller?

The best place where you should place your water chiller is inside the mechanical room of the building.

While inside the room, the chiller will be under proper protection from other weather elements.

This will increase the durability of the water chillers thus increasing the overall service life.

Which Features Must You Consider When Purchasing Water Chillers?

When purchasing the water chillers, you must know the features you want.

Here are some of the features that you need to think about before you purchase a water chiller.

· Size of the Machine

You will look at the size of the machine in terms of its dimensions of length, height, and width.

The size of the machine is relative to the size of the installation facility and cooling requirements.

· Housing Features

When looking at the housing features, you must consider the room where you will install the machine.

You must have a mechanical room with proper ventilation and space for installing the water chillers.

· Cooling Capacity

The cooling capacity of the water chillers often varies according to the size of the installation facility.

You will purchase water chillers with a greater cooling capacity if the installation facility is big.

How Many Types of Compressors Do We Have in the Water Chillers?

Well, there are four main types of compressors that you can use in water chillers.

Here are the main types of water compressors.

· Reciprocating Compressors

You can refer to it as the piston compressor because it uses pistons with crankshaft drives that deliver the refrigerant into high pressure.

In other words, reciprocating compressors are positive displacement compressors that use pistons to increase refrigerant pressure.

· Scroll Compressors

You can also identify the scroll compressor as the spiral compressor, scroll vacuum pump, or scroll pump.

It uses single scrolls that remain stationary while the other orbits around it through a swing link to increase refrigerant pressure.

· Screw – Driven Compressors

The screw or rotary-driven compressors depend on two meshed motors to trap air to change the volume of air.

The change in volume of the air will lead to an increase in pressure as the air moves through the rotors.

·  Centrifugal Compressors

Centrifugal compressors usually add kinetic energy as the fluid flows continuously through the impeller or rotor.

It will then convert the kinetic energy and result in an increase in pressure that pushes the refrigerants through the system.

Water chiller screw compressor

How Does Absorption Technology in Water Chillers Work?

Absorption technology in water-cooled chillers uses any of the four compressors together with steam, gas turbines, or electric motors.

It will, however, require you to install a bigger cooling tower to help in the proper operations of the machine.

The technology will employ the use of water as the main refrigerant and then lithium bromide as the main absorbent.

The strong affinity between the water and lithium bromide makes the entire process of absorption technology work well.

Apart from that, the entire operation will occur most conveniently in a complete vacuum.

Which Specifications Must You Consider When Looking for Water Chillers?

When shopping for an industrial water chiller, there are specific factors that you must take under your consideration.

Here are the main factors that you have to look at.

· Type of Compressors

There are four main types of compressors that you can choose from including reciprocating, scroll, screw-driven, and centrifugal compressors.

Here, your choice for the compressors will dictate the type of technology the water chiller will work with.

· Source of Power

You must also consider the source of power that will help in powering the compressors of the water chillers.

Here, you can either choose to use gas turbines, steam, or electric motors to power up the compressors.

What is the History of the Water Chillers?

The first water chiller was patented by Willis Carrier in 1921.

Initially, water chillers were depending on the reciprocating compressors to help in moving the refrigerant through the entire system.

The name of the centrifugal compressor is a result of the design which resembles centrifugal blades in water pumps.

Since then, a lot of technological advancements have been made in water chiller technology thus increasing its efficiency.

How Do the Direct-Fired Absorption Chillers Compare to Indirect-Fired Absorption Chillers?

There are two main types of absorption chillers that you can use which include the direct and indirect fired absorption chillers.

Here is a comparison between the two types of absorption chillers.

· Direct-Fired Absorption Chillers

It is the most cost-effective mode of absorption chillers especially when the cost of fuel is favorable.

You can either use it for cooling or heating purposes making it easily identifiable as a heater or a chiller.

· Indirect – Fired Absorption Chillers

You can operate this type of chiller using hot water or steam to power up the main operations.

In the recent past, there have been developments that will see the machine operate with solar power.

It has a cooling capacity ranging from 15 kW to 425 kW and the sizes range between 200 kW to 5000 kW.

What is the Difference Between Engine-Driven Water Chiller and Electric-Driven Water Chiller?

You can either have a water chiller driven with electric power or another that is driven with engine power.

Engine-driven chillers usually use rotary, reciprocating, or centrifugal compressors thus providing mechanical refrigeration.

In this case, the main source of power is the gas-fired engine or turbines that run the entire system.

Although it is costly, this type of chiller has very large capacities reaching about 15, 000 kW.

On the other hand, the electrically driven water chillers use centrifugal, reciprocating, and rotary compressors like the engine-driven water chillers.

All electric-driven water chillers depend on the mechanical vapor compression cycle to help in their operations.

They have varying chilling capacities depending on the type of compressor within the electric-driven water chillers.

Electric-driven water chiller

Do You Supply Solar-Powered Water Chilling Systems?

Absolutely, we do supply solar-powered water chilling systems that depend on the energy from the sun.

It is the most cost-effective type of water chilling system that you can choose from especially in sunny regions.

You will save on the cost of using fuel or electric power to power up the water chillers.

Solar-powered water chilling system

What is the Function of the Cooling Towers in Water Chillers?

Cooling towers are large heat exchanging units that will supply cooling water to help in the elimination of heat from chillers.

You must ensure a constant supply of cooling water through the system thus the need of having a good water source.

What are the Common Water-Chiller Problems and their Causes?

You might experience a few issues during the operations of the water chillers.

Here are some of the problems and the possible causes of these problems.

· Chiller Refuses to Power Up

The chiller might refuse to power up due to loss of connection or improper voltage in the main supply.

Apart from that, you might have an incorrect phase connection or blown fuse if the switch is not off.

· Insufficient Flow of Fluids or Failure to Pump

This can be a result of the improper flow of power or very little supply of fluids within the fluid reservoir.

Apart from that, there may be a pinch in the process line or partially closed valves within the system.

The pump can also fail thus leading to problems with enough power to push the fluid.

In addition to that, the process piping can also be too small thus leading to process restrictions.

· Insufficient or No Cooling

This can happen due to an improper supply of power or clogs in the air condensers and filters.

The coolant fluid can also be unsuitable for the temperature ratings and the refrigerant may also leak.

High ambient temperatures and iced-up evaporators may also be the leading cause of the problems.

Which Initial Steps Should You take to Isolate the Above Problems?

You can isolate the issues above by taking proper precautions before you proceed with the normal operations.

First, you have to conduct a proper inspection of the machine before you begin its operations.

This will help you identify the problems that might arise within the entire system and fix them early.

Apart from that, it will also give you the chance of refilling the reservoirs to optimum capacities.

Secondly, you have to maintain the machine regularly.

Proper maintenance of the machine will help in keeping the machine in perfect working condition for a long.

It will also help in getting rid of the debris that might block the filters through proper cleaning routines.

Depending on your unique requirements, TopChiller offers a range of water chiller systems.

Contact us now for a custom solution for water chiller systems.

Maximizing Your Water Chiller Efficiency Through Proper Maintenance

The basic components for chillers may be the same for all types and all of them need proper maintenance to ensure optimized operation according to its specification.

Different chiller manufacturers strongly advise their customers to holistically perform autonomous preventive maintenance on the components to always maximize the efficiency of the whole operation.

Knowing the basics of chiller operation is important before anyone could proceed to the proper maintenance of their equipment. Below is a comprehensive background for chillers and their components.

In chiller systems, cool fluid (water, water-glycol solution, or refrigerant) is pumped into the process to result in a cooling effect. This cool fluid absorbs heat from the processes and will go back in the cycle to be recirculated.

The refrigeration system starts with a low-pressure refrigerant entering the evaporator. In the evaporator, external heat from the process will boil the refrigerant, which transforms it from low-pressure liquid to low-pressure vapor.

The low-pressure vapor then enters the compressor to be compressed to high-pressure vapor. The high-pressure vapor enters the condenser where ambient air/condenser water will cool the refrigerant and undergo a phase change from high-pressure vapor to a high-pressure liquid.

After that, the high-pressure liquid will pass through the expansion valve wherein the flow to the evaporator will be controlled. This marks the start of the cycle again.

Condensers for chilling systems have different types -these are air-cooled and water-cooled. The air-cooled condenser of an air-cooled chiller uses ambient air to cool the refrigerant as it passes through the condenser.

On the other hand, the water-cooled condenser in a water-cooled chiller uses water to cool and condense the refrigerant. The water used in this process usually is cooled from a cooling tower.

Water chiller cooling tower maintenance

Below are the Key Components for Chiller Maintenance

Condenser:
Condenser coils should be always maintained to have a free passage and prevent any blockage. This component is an important part of the chiller’s heat transfer.

Refrigerant:
The performance of the chiller would highly depend on the refrigerant used. Improperly charged refrigerant can cause damages to the compressor and the whole refrigeration system.

Water:
Water used for cooling has to meet the requirements for the proper water flow. Any contaminants in the water may cause issues such as contamination, blockage, and scaling.

Reservoir Check:
For optimum operational efficiency of a chiller, all its reservoirs should be regularly monitored to be sure that they always have an adequate supply of fluids.

Temperature Check:
Unforeseen surges of temperature change on chillers can be harmful to the operating system. To prevent unforeseen temperature changes, regular monitoring of the fluid inlet and outlet temperatures should be done.

Cleaning:
Regular cleaning of equipment is recommended to prevent damages brought by the accumulated dust and dirt through the processes.

For maximized efficiency, the filter should be regularly cleaned to avoid clogging and ensure smooth fluid flow.

Other Optimization Initiatives:
Many initiatives can be made to boost the performance of the chiller and these are chiller sequencing, load balancing peak demand management, and cooling tower management.

In addition to the mentioned above, chiller performance can be optimized further through the installation of IoT widgets and accessories necessary for providing real-time monitoring.

Summary:

TopChiller is a leading manufacturer and supplier of all kinds of chillers, chiller units, and chiller systems.

With over 20 years of experience, we ensure our customers worldwide of high-quality chillers of compact design, high cooling performance, energy efficiency, easy operation, and low maintenance.

We also provide custom chiller designs depending on our customer’s application.
A water chiller or chiller system is essential for cooling in a wide range of industrial processes and commercial applications.

It is a refrigeration system that supplies cooling water to different units that need temperature control or lowering.

After the cooling water has extracted the heat from different units, the cooling water returns to the refrigeration loop where a refrigerant cools it again.

Working Principle of a Water Chiller

The water chiller works on the principle of vapor-compression or vapor absorption refrigeration cycle to provide a consistent supply of cooling water to various process units.

In the vapor-compression refrigeration cycle, the refrigerant circulates through an evaporator, a compressor, a condenser, and an expansion device.

The refrigerant absorbs the heat of the cooling water in the evaporator until it becomes a low-pressure vapor.

The vaporized refrigerant will then pass through the compressor where its temperature and pressure will be increased.

At the condenser, the high-pressure refrigerant will then return to its liquid state as it transfers heat to a condensing medium.

Lastly, the liquefied refrigerant lowers its pressure upon passing through an expansion device. The low-pressure liquid refrigerant then flows to the evaporator, and the cycle repeats.

On the other hand, in the vapor absorption refrigeration cycle, an absorber, a pump, and a generator are used instead of a compressor.

In addition, vapor absorption systems use a heat source to circulate the refrigerant around the system for cooling.

Working principle of a water chiller

Vapor Absorption Refrigeration Cycle

Types of Water Chillers

Water chillers can be classified based on the condenser type used.

Water-Cooled Chiller

Water-cooled chillers use water coming from a cooling tower to condense the refrigerant.

The cooling tower is a type of heat exchanger that facilitates water cooling by bringing hot water and cold air into contact. They supply the cooling water to the condenser unit.

Water-cooled chillers are commonly used in medium to large applications where an adequate supply of water is readily available.

Successful operation of this type of chiller does not depend on ambient temperature fluctuations.

Because of its constant cooling performance, it is ideal for use in commercial and industrial conditioning.

Water-cooled chillers can be further classified based on the type of compressor used.

Centrifugal Water Chiller. Centrifugal water chillers use centrifugal compressors and are suitable for use in large applications. They have a higher coefficient of performance at peak loads than other types of water chillers.

Screw Water Chiller. Screw water chillers use screw compressors and are perfect for use in small to medium applications. They have high partial-load efficiency and are used in applications with varying cooling demands. They are also easy to install and operate with little to no noise.

Scroll Water Chiller. Scroll water chillers use scroll compressors. They are commonly used in small to medium applications like screw water chillers. Speed control and variable displacement control are some of the methods to control refrigerants at different cooling loads.

Scroll water chiller

Air-cooled Water Chiller

Air-cooled water chillers use ambient air as the condensing medium.

Typically, an air-cooled condenser unit has finned coils to provide an efficient heat transfer between the air and the refrigerant.

The addition of air fans to the condenser unit helps speed up the cooling process.

Air-cooled water chillers are simpler and cheaper to install than water-cooled water chillers because additional infrastructures such as cooling towers and cooling water supply lines are not needed.

However, they are only suitable for use in applications where a considerable amount of heat discharged to the environment will not be an issue.

Like in water-cooled water chillers, centrifugal, screw, and scroll compressors are also used in air-cooled water chillers.

To learn more about TopChiller’s offerings, visit our website. For any concerns, do not hesitate to contact us.

Air cooled water chiller