ما هي المشاكل الأكثر شيوعًا في المبردات الصناعية وكيفية إصلاحها؟

In modern industrial production, equipment without industrial chillers cannot be considered irrelevant since it is the industrial chiller that provides a steady-cooled environment for many pieces of equipment and processes within production. Most advanced المبردات الصناعية might break down after prolonged use, thereby affecting their performance and efficiency. The article shall thus bring out very common problems with industrial chiller systems together with effective solutions that would go a long way in ensuring that there is stable operation of the equipment and increasing its service life.

I. Core Power System Problems

Compressor & Refrigerant. Indeed, the core power system of an industrial chiller is made up of both a compressor and refrigerant, which basically enable the refrigeration cycle to function well. In most cases, just like the heart of any other body, the compressor drives the circulation of refrigerant while increasing its pressure; on the other hand, refrigerant absorbs and then releases heat to create a cooling effect. This will throw the whole system out of whack if these key components go south.

1. Frequent Compressor Start-Stops or Complete Shutdowns

If the compressor stops shortly after starting or trips frequently, the chiller won’t provide stable cooling. This can happen for several reasons. One reason is that the condensing pressure is too high. This might be because the cooling system isn’t working properly. Another reason is that the suction pressure is too low. This usually means there’s not enough refrigerant. Also, if the power supply voltage is unstable, it can cause problems.

To correct such problems, first check if the supply voltage is balanced and make sure that all electrical connections are well secured against damage to the compressor emanating from voltage fluctuations or problems in connections. Measure high and low pressures since this is a condensing unit. If the condensing pressure is too high, clean the condenser so as to ensure that the cooling system is operating normally.

2. Refrigerant Leakage and Insufficiency

Cooling capacity decreases significantly, evaporator temperature drops excessively or even freezes, and low-pressure alarms occur frequently. Refrigerant leakage is the main cause of reduced system efficiency. As the refrigerant decreases, the evaporating pressure decreases, and the evaporating temperature drops, resulting in insufficient cooling output. Leaks typically occur at pipe connections, valve interfaces, or corroded areas of the heat exchanger.

The key to refrigerant problems lies in accurate leak detection. Use an electronic leak detector or fluorescent tracer to thoroughly inspect the system and accurately locate the leak. After repairing the leak, perform a thorough vacuum treatment of the system to remove non-condensable gases (such as air and moisture) and ensure system cleanliness. Finally, strictly adhere to the refrigerant type and charge quantity specified by the manufacturer to avoid affecting system efficiency due to overcharging or undercharging.

II. Heat Exchange Efficiency Issues: Condenser and Water Circulation System

Heat exchange efficiency is a key performance indicator for industrial chillers. Any obstruction or contamination in the condenser and water circulation system will significantly increase energy consumption and reduce cooling performance. These problems are easily overlooked in routine maintenance but have a profound impact on the long-term operation of the system.

1. Condenser Scaling or Contamination

Abnormally high pressure increases the compressor load, resulting in a significant decrease in the energy efficiency ratio. Scale easily forms on the inner wall of the copper tubes in the condenser of the water chiller. The thermal resistance of scale is much higher than that of metal, severely affecting heat exchange. The fins of air-cooled chillers are easily covered by dust, oil, and lint, obstructing airflow and reducing the heat exchange area.

Solving condenser problems requires regular maintenance. For water-cooled chillers, regular chemical cleaning or physical descaling can thoroughly remove scale. Simultaneously, optimize the water quality management of the circulating water, using qualified corrosion and. In dusty environments, consider installing high-efficiency filters or dust covers to reduce dust contamination of the fins.

2. Insufficient Cooling Water Flow

If the temperature difference between the evaporator or condenser outlet and the return water is too big, it will also show a low water flow. The pump might have failed, the coupler could be damaged, the valve not fully opened, water filters are clogged; these are all reasons for low water flow. When there is low water flow, the chilled water cannot exchange heat with the refrigerant properly inside the evaporator, resulting in ineffective cooling.

To resolve insufficient cooling water flow, check if the water pump is operating normally and if the impeller is damaged, ensuring the pump can provide sufficient flow. Regularly clean the Y-type filter or strainer to remove impurities from the pipeline and ensure smooth water flow. Finally, check the settings of the flow switch or differential pressure switch to ensure they are correct and functioning properly to avoid system shutdown due to false alarms.

III. Electrical and Control System Issues

The electrical and control system is the “brain” of the industrial chiller, ensuring precise operation and stable functioning. However, aging electrical components or malfunctioning control logic can lead to abnormal equipment operation or even malfunctions.

1. Loose Electrical Connections and Aging Components

Chillers sometimes have problems. The main contactor or thermal relay might overheat or burn out. Sometimes the control panel shows wrong data. In factories, vibration and humidity can make electrical connections loose. This creates high resistance and can cause overheating or even fires. Also, parts like contactors and relays wear out over time. They can become eroded from being used frequently, which affects how well they conduct electricity.

Troubleshooting electrical problems requires a thorough “power-off check,” using a multimeter to check the tightness of all main and control circuit connections. For high-wear components, such as contactors and circuit breakers, a lifespan log should be established, and preventative replacement should be implemented to avoid failures due to component aging.

2. Controller and Sensor Drift

When a chiller starts and stops a lot within its set temperature range, or when the actual water temperature is very different from what’s shown, it can cause signal drift. This happens a lot with NTC or PT100 temperature sensors that are in humid places for a long time. Also, if the controller’s settings are wrong, it can mess up how the chiller works. This affects how well it works and how long it lasts.

To address these issues, temperature sensors need to be calibrated regularly to ensure accuracy and reliability. Simultaneously, controller parameter settings should be checked to ensure they meet operational requirements, preventing system malfunctions due to incorrect settings.

IV. The Importance of Preventive Maintenance

Preventive maintenance is a key strategy for ensuring the efficient operation of industrial chillers. Regular maintenance, digital monitoring, and professional service support can effectively reduce equipment failures, improve operating efficiency, and extend equipment lifespan.

1. Regular Maintenance Plan

Regular maintenance is the foundation of preventative maintenance. Maintenance includes: checking the compressor’s operating status, including oil level, oil quality, and motor insulation; checking refrigerant charge and leaks to ensure system sealing; cleaning the condenser and evaporator to ensure heat exchange efficiency; checking the cooling water quality and flow rate to ensure the normal operation of the water circulation system; and checking the aging of electrical connections and components to ensure the safety of the electrical system.

2. Digital Monitoring and Predictive Maintenance

Digital monitoring is an important means of modern industrial maintenance. Sensors and controllers are used to monitor equipment operating parameters in real time, such as temperature, pressure, and flow rate. Data analysis tools are used to analyze the monitoring data and predict potential equipment failures. Based on the data analysis results, maintenance plans are arranged in advance to avoid sudden equipment failures.

3. Professional Service Support

Professional service support is an important guarantee for ensuring the long-term stable operation of equipment. Professional technicians are regularly invited to conduct comprehensive equipment diagnoses to identify potential problems. Technical training is provided to operators and maintenance personnel to improve their professional skills. A spare parts inventory is established to ensure the timely replacement of critical components.

Ⅴ. الخاتمة

The maintenance of industrial chillers needs a complete plan. We have to check the compressor, refrigerant, heat exchanger, water system, and electrical and control systems. Quick repairs and preventive care can cut down on breakdowns. They also make the equipment work better and last longer. Keeping up with maintenance ensures steady production and lowers costs. So, investing in preventive maintenance is the key to running industrial chillers well.