Chiller or water cooling systems are used for temperature control in many applications, from industrial manufacturing to food and beverage to commercial applications for hospitals and medical. In many cases, the integrity of the final product and the process itself are reliant on precise heat management to ensure quality as well as safe, efficient and reliable operation. Operations managers and engineers will select and install a process chiller system for precision cooling of low viscosity and industrial cooling fluids.
Featuring a unique design, Parker's range of Hyperchill water chillers provide precise and highly accurate temperature control of cooling fluids (water, water-glycol mixture, low viscosity fluids). High-quality components in the hydraulic and refrigerant circuits ensure continuous operation and deliver energy efficiency, even at partial loads, resulting in cost savings and carbon footprint reduction for an improved environment.
Engineering considerations
When designing a cooling system, a number of variables must be evaluated. The chiller location, positioning and distance from the application are important considerations. The application type and the number of chillers needed to serve a process also have a bearing on the system design.
Parker's engineers share the following key points that facilities managers should consider for the successful installation and performance of a chiller and cooling system:
- Chiller location and positioning
- Frost protection
- Chiller water circuit
- Fill options kit
- Electrical connection
- Remote control panel
- Chiller start-up
Chiller location and positioning
The location and positioning of the chiller is critical for achieving and maintaining the correct cooling performance. In general, most of the chiller range can be located both internally or externally. Parker's Hyperchill and Hyperchill Plus range of precision water chillers offer a robust and reliable cooling solution whether internal or external locations. Reviewing rating is part of our recommended guidelines:
Internal installation
Chiller models ICEP002, ICEP003 & ICEP005 have an Ingress Protection (IP) rating of 33 and must be located and installed internally.
Internal and external installation
Hyperchill Plus models from ICEP007 and above possess an IP54 rating and are suitable for installation both internally and externally. This is also the case for the Hyperchill product range.
Chiller positioning
Ventilation around the chiller is essential for maintaining system performance. The fundamental purpose of the chiller is to remove a heat load from the water circuit to the local atmosphere. If the local environment is inadequately ventilated, heat will build up in the circuit and the chiller will sound an alarm. Consider the following:
- Position the chiller in a well-ventilated area.
- Ensure the chiller has adequate free air space at the sides, rear and above the unit (please refer to the operation and maintenance manual for specific clearance details).
Frost protection
Exposing a water-cooled system to low temperatures can result in frost damage to the chiller and water circuit. Frost protection should be considered in the following circumstances:
- When the chiller is installed externally (exposed to low ambient temperature).
- Water temperature set point is configured at < 7oC (45oF).
Two options to prevent frost damage:
1. Include the antifreeze heating option in the chiller specification.
- Applicable for the ICEP007 and above.
2. Addition of antifreeze (ethylene glycol) solution to the cooling water.
- The minimum acceptable glycol content is 20% V/V.
- The total volume of glycol should not exceed 40% V/V.
In instances where a chilled water temperature of < 7oC (45oF) is required, an antifreeze solution must be added to the cooling process water.
The table below provides guidance on the glycol % required to meet specific outlet water temperatures:
When using ethylene glycol in the chilled water system, it is important to consider these 6 key factors:
- Do not use automotive antifreeze products. These products often have additives that can reduce heat transfer efficiency and potentially damage the chiller.
- Only use inhibited glycol products. Uninhibited products can be corrosive to the water cooling system.
- Do not mix different glycol solutions and brands. Different products can contain a range of incompatible inhibitors that can separate out and cause filtration and pump issues.
- Check local regulations and environmental policy. Disposal, groundwater contamination and drainage may have to be considered.
- Regular tap water can be used in most installations. However, the use of de-ionised, de-mineralised or distilled water may be preferable when using glycol to eliminate the risk of any impurities affecting the efficiency of the glycol inhibitors.
- System hygiene and maintenance is important. The chilled water system should be flushed, cleaned and sanitised before adding a new glycol/water mix.
Chilled water circuit
When designing the complete chilled water circuit, these points should be followed:
- Isolating valves should be fitted at the inlet and outlet of the chiller.
- A regulating valve should be fitted in flow pipework (refer to installation diagrams).
- A manual bypass with flow regulating valve should be installed to maintain appropriate flow through the process and chiller.
- A filter should be considered/installed in the flow pipework entering the process.
- The fill kit type (manual ambient or pressurized) should be correct for the application.
- The pipework minimum diameter is critical to achieve design flowrate.
- The pipework material is critical in cases where a non-ferrous system is required.
- Trace heating of external pipework may be required if glycol is not installed.
- Auto-air vents should be installed at a high point in the water circuit.
- Care should be taken when connecting pipework to the threaded connections on the chiller. Ensure adequate retention of the chiller connections when tightening to prevent damaging the chiller.
- Pipework should be flushed, then leak tested with water prior to re-filling with an appropriate antifreeze mix.
Water fill kit options
The appropriate water fill kit should be selected based on the chiller installation requirements. The following options are available:
Pressurized water fill kit
This option allows for the installation of the chiller in a closed water circuit. The kit contains an expansion vessel, pressure relief valve, pressure reducing valve, pressure gauge and drain cock.
The chiller can be configured with the water fill kit already installed. Alternatively, the kit can be supplied separately to the chiller.
NOTE: After commissioning, the main water supply can be isolated locally.
Ambient water fill kit
The ambient water fill kit can be used in open water circuit systems. The fill options are:
- Open circuit version design of models ICEP002 to ICEP005 includes water filling on the top cover and a visual external indicator.
- Models from the ICEP007 and above can be supplied with an externally fitted water fill kit. Alternatively, the kit can be supplied loose.
Electrical connection
Electrical work should be undertaken by a qualified technician. Please review the manual prior to completing the electrical commissioning of the chiller and follow these guidelines:
- A local isolator should be installed close to the chiller.
- The power supply should be protected using an appropriately sized D rated fuse/breaker.
- After the installation, the unit should be checked for the correct phase rotation.
Remote control panel
The Hyperchill range has the option to include remote control. The chiller can be controlled remotely through two control levels:
Base level control
- Chiller on/off control
- Chiller on/off signal
- General alarm signal
Advanced control
- Allows all control options on the advanced microprocessor board.
Chiller startup
Please consult the operation and maintenance guide and follow the appropriate steps. Fundamental checks include:
- Ensure pipework is fully leak tested and flushed prior to filling with water (or glycol mixture).
- Check the phase protection device in the electrical panel. Green and orange indicators should be visible on the device.
Conclusion
Parker Hyperchill water chillers maintain maximum quality and cleanliness of the cooling fluid, resulting in improved process efficiency and productivity as well as reduced maintenance costs and downtime. Following the above recommendations from Parker's engineers will ensure the successful installation and performance of a Hyperchill water cooling system.
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View the interactive for detailed information on the chilling process, chiller solutions, operation and system design
This post was contributed by James Brown, compressed air and gas treatment/analytical gas sales manager and Filippo Turra, product manager, Parker Gas Separation and Filtration Division EMEA
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