How to select the right industrial chiller

It is an established fact that industrial chillers are an essential part of manufacturing procedures, especially where production downtime, due to excess heat, is not an option. In recent times there have been major advances and innovations in the design, performance, and efficiency of industrial chiller concepts. The significance of these developments is included in this guide.

Industrial Cooling

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Why the right choice of chiller is important

Among the most compelling reasons for a chiller installation is minimising downtime through the continuous protection it provides in removing heat from valuable and temperature-sensitive process equipment. At the same time, a chiller saves water and associated costs by recirculating and re-using the plant’s own water supply. The cost of cooling water can add up quickly, especially if process equipment is running for several shifts a day. When a chiller is introduced into the system, it can bypass the costs and need for a monitored, municipal water supply and wastewater discharge, and contribute to substantial savings within production budgets. Furthermore, with the latest developments in chiller technology, capital investment payback can be realised over a very short period of the equipment lifetime.

Specifying a chiller installation

When specifying a chiller installation, a working knowledge of chiller performance factors is crucial to obtaining the right product fit. What needs to be determined is: the type of process fluid that will be used; the process cooling temperature; the flow and pressure requirements; the operating environment; ambient temperature; the chiller size needed and the spatial constraints of its location.

Process fluid performance

The main factors to bear in mind when considering the appropriate cooling fluids for a process are their performance characteristics and their equipment compatibility. The performance of a cooling fluid is based upon its properties at a given temperature. The relevant parameters are specific heat, viscosity, and freezing/boiling points. There is a direct relationship between specific heat and cooling capacity. In order to maintain system integrity and prolong optimum performance, mixing a percentage of ethylene or propylene glycol with water (typically in the 10 to 50% range) is recommended when low or high setpoint temperatures are required. In terms of compatibility, the potential for corrosion and the early degradation of seals are common failure modes for incorrectly sized systems. That is why the materials of construction and the nature of fluids should be an important consideration, and why inclusion of a corrosion inhibitor in the cooling fluid is recommended. However, in the latest developments of chiller technology, the storage tank and hydraulic parts of centrifugal pumps are constructed in stainless steel to prevent process water contamination with rust particles, as well as provide higher levels of reliability and temperature control. Similarly, state-of-art, all-aluminium microchannel condensers are designed to provide long life without corrosion and require 30% less refrigerant charge in comparison to other types of heat exchanger.

Cooling fluid temperature

The setpoint temperature will affect the cooling capacity of a chiller. Decreasing the temperature will put more load on the refrigeration system, and vice versa for increasing it. There is a direct relationship between the temperature at which the chiller has been set and its total cooling capacity. Therefore, it is important to review the chiller’s published performance data for relevance to the proposed installation. At the same time, if the chiller is destined for an exposed site, it is equally important to establish the level of freeze protection required, i.e., the coldest leaving fluid temperature of the chiller during operation.

Process flow and pressure requirements

While pump life is a primary consideration when configuring an industrial cooling system, pressure loss across the system and the necessary flow rate must first be determined by the pump size and performance.
Pressure: An undersized pump will reduce the fluid flow rate through the entire cooling loop. If the chiller has been equipped with internal pressure relief, the flow will be diverted around the process and back into the chiller. If there is no internal pressure relief, the pump will attempt to provide the necessary pressure and run at what is referred to as dead-head pressure, or limit. When this state occurs, the pump’s life can be drastically reduced; liquid ceases to flow and the liquid in the pump becomes hot, eventually vaporising and disrupting the pump’s ability to cool leading to excessive wear to bearings, seals, and impellers. Determining the pressure loss across a system requires siting pressure gauges at the process’s inlet and outlet, then applying pump pressure to obtain values at the desired flow rate.
Flow rate: Inadequate flow through the process will yield inadequate heat transfer so the flow will not remove the heat necessary for safe operation of the process. As the fluid temperature increases beyond the setpoint, the surface/component temperatures also will continue to rise until a steady-state temperature that is greater than the initial setpoint is reached. Most chiller systems will detail the pressure and flow requirements. When specifying the necessary heat load removal as part of the design, it is important to account for all hoses, fittings, connections, and elevation changes integral to the system. These ancillary features can significantly increase pressure requirements if not sized appropriately.

Chiller operating environment

Ambient Temperature. An air-cooled chiller’s ability to dissipate heat is affected by the ambient temperature. This is because the refrigeration system uses the ambient air/refrigerant temperature gradient to induce heat transfer for the condensation process. A rising ambient air temperature decreases the temperature differential (ΔT) and, subsequently, reduces the total heat transfer. If the chiller uses a liquid-cooled condenser, high ambient temperatures can still have negative effects on key components such as the compressor, pump, and electronics. These components generate heat during operation, and elevated temperatures will shorten their lifetime. As a guideline, the typical maximum ambient temperature for non-exterior rated chillers is 40°C.
Spatial Constraints: In order to maintain the proper ambient air temperature, it is important to provide adequate air circulation space around the chiller. Without proper airflow, recirculation of an inadequate volume of air rapidly heats it up. This affects chiller performance and potentially can damage the chiller unit.

Why size is important

Selecting a correctly sized chiller is a crucial decision. An undersized chiller will always be a problem – never able to properly cool the process equipment and the process water temperature will not be stable. In contrast, an oversized chiller will never be able to run at its most efficient level and prove more costly to operate. To determine the correct size of unit for the application it is necessary to know the rate of flow and the heat energy that the process equipment is adding to the cooling medium, i.e., the change in temperature between the inlet and outlet water, expressed as the ∆T. The formula for calculation purposes is: heat energy per second (or more commonly known as power) = mass flow rate × specific heat capacity × change in temperature (∆T)’. The specific heat capacity of the water is nominally expressed as 4.2 kJ / kg K but if it contains a percentage of glycol additives that value is increased to 4.8 kJ / kg. K Note: 1K = 1°C and the density of water is 1 i.e.,1l of water volume = 1kg of water mass. Here is an example of the formula application to determine the correct kW sized chiller to handle a water flow rate of 2.36 l/s (8.5 m3/hr) with a temperature change of 5°C: heat energy per second (kJ/s or kW) = 2.36 l/s (Flow Rate) X 5°C (∆T) X 4.2 kJ /kg K (Specific Heat Capacity of pure water), chiller size required = 49.6 kW. Alternatively, the heat load to be cooled may already be known in which case the formula can be re-arranged to determine the temperature difference (∆T) that can be attained with different flow rates (achievable with different pump sizes). There may be other circumstances that can influence size choice. Planning for future plant expansion, exposure to high ambient temperatures, or location at high altitudes, could all lead to the specification of a different size of unit.

Maintenance, safety, and control

In the latest, advanced generation of industrial chillers, ease of maintenance, operational safety, and intelligent control and connectivity are prominent features of their designs. For example, they are constructed with IP54-rated, sound-attenuated canopies that allow chillers to operate indoors or outdoors, even at ambient temperatures down to -45°C. They are specifically designed for easy access to the installed components − refrigeration systems in the front and the cooling water circulation assembly in the back. Wide canopy doors and intelligent layout reduces maintenance time and allows for easy inspection to prevent breakdowns. Innovative new models on the market feature a wide range of safety devices, such as flow and level switches, thermal probes, pressure probes, crankcase heating and strainers which allow the chiller to operate securely. Additionally, a fully hermetically sealed refrigeration system prevents refrigerant gas from leaking and requires zero maintenance. UK FGAS Regulations do require an annual, and on larger refrigeration systems, bi-annual inspection by a FGAs certified engineer. The provision of a phase sequence relay ensures no risk of compressor damage in case of incorrect wiring. In these new designs, a touch screen controller operates with energy-efficient algorithms, combines all the chiller sensors into one system and issues timely warnings in case of deviation from the operating parameters. Full connectivity is achieved with built-in smart remote monitoring capability on chiller sizes 11 Kw and above. This provides user’s machine data, in real time, in a clear format to ensure optimum efficiency.

Conclusion

In general, potential users of an industrial chiller system are advised to take into account the conditions in which the process chiller will be used, and the process for which it will be used. This will help to identify the features most needed in the system.

It is also wise to consider the possibility of expansion in the future. If the amount of heat output by one machine is increased, then the cooling power of the chiller has to be increased accordingly. If there is a variable heat rate, choose the kW rating that can handle the highest heat output.

In summary, taking all of these considerations on board, recognising the important technological advances, and the availability of chiller suppliers who incorporate them in their product offering, all helps in determining the optimal industrial cooling system for any particular application. 

Hydraulic Oil Chiller: The Ultimate FAQ Guide

I know you’re looking for a high-performance hydraulic oil chiller.

Or, you would like to learn more about hydraulic chillers.

That’s why in this guide, I will answer all questions you have been asking about hydraulic oil chillers.

Let’s dive right in.

What is a Hydraulic Oil Chiller?

Hydraulic oil chillers are special types of chillers that you will use to chill, regulate, or control hydraulic oil temperatures.

Hydraulic oil chiller manufactured by TopChiller

Which Specifications should you Consider When Choosing a Hydraulic Oil Chiller?

Whenever you intend to make a purchase, there are particular specifications that you ought to consider.

Here are some of the specifications that you need to pay close attention to.

· Quantity of Heat

You should consider the amount of heat that you intend to eliminate from the system.

The higher the amount of heat, the bigger the type of hydraulic oil chillers you will need.

· Desired Oil Temperature

In addition to that, you should also look at the oil temperature that you desire for your applications.

You will look at specific factors such as the oil temperatures that you desire to know the desired temperature range.

· Ambient Air Temperature and Water Temperature

You must also look at the ambient air and water temperatures that you will use for cooling.

The machine should have the capability of setting the ambient temperatures of air and water for cooling purposes.

· Oil Viscosity

Here, you will look at the ability of the fluid to flow from one point to the next.

You have to choose a chiller that will help in maintaining the viscosity of the oil fluid.

· Desired Water to Oil Flow Ratio

You ought to consider the water to oil flow ratio that you desire during the cooling process.

In other words, you have to choose a hydraulic chiller that will maintain the desired water to oil flow ratio.

What are the Benefits of Using the Hydraulic Oil Chillers?

When you use the hydraulic oil coolers, you will get stable filtration and cooling performances.

Apart from that, there are other benefits that you will enjoy by using hydraulic oil chillers.

Here are the main benefits of using hydraulic oil chillers.

· Flexibility of the Hydraulic Oil Chillers

You have the freedom of choosing from different variants of the hydraulic oil chillers available in the market.

Apart from that, you will not go through the long lead costs and tooling variations when choosing other variables.

· Reliability of Hydraulic Oil Chillers

Hydraulic oil chillers are highly reliable with very simple designs and no moving parts that can lead to damages.

It allows for heat elimination from the system without placing stress on the other parts of the hydraulic oil chillers.

· Great Performance

It has control panels which you can use to increase or decrease the performance of the hydraulic oil chillers.

It will also help in controlling the number of passes within the hydraulic oil chiller tubes thus increasing the performance.

· Ease of Service

The process of maintaining and servicing the hydraulic oil chillers is easy and will not require a lot of professionalism.

Apart from that, you can simply purchase and maintain the machine parts at very low and affordable prices.

How does Hydraulic Oil Chiller compare to Coolant Chiller?

You can use both the hydraulic oil chillers and coolant chillers for cooling services of different parts.

The hydraulic oil chillers are the most suitable type of chillers for cooling hydraulic fluids in different industries.

On the other hand, coolant chillers will help in maintaining the temperatures of a device by continuously rejecting heat.

In hydraulic oil chillers, you can use air or water as the main types of cooling agents.

On the other hand, you will use water or oil as the main cooling agent in the coolant chillers.

Which is the Best Location for Installing the Hydraulic Oil Chiller?

You can install the hydraulic oil chillers next to the equipment that you intend to chill.

The close the hydraulic oil chillers are to the equipment, the higher the cooling efficiency of the chillers.

In addition to that, you can install the water-cooled hydraulic oil chillers in a mechanical room within the industrial setup.

In some cases, you can simply install the air-cooled hydraulic oil chillers on the outside of the industrial setup.

Air-cooled hydraulic oil chillers have components that are strong enough to withstand the weather elements.

Apart from that, you should install it outside to help in noise elimination as well as to have proper access to air.

Air cooled hydraulic oil chiller

Do Hydraulic Chillers Exhibit Any form of Limitations?

Yes, hydraulic oil chillers also have particular disadvantages that might prevent them from proper functions.

Here are some of the disadvantages of using hydraulic oil chillers.

· High Energy Consumption

Hydraulic oil chillers consume a lot of energy in the process of cooling off different oil equipment.

You will spend quite a significant amount on the operation of the machine due to the high cost of energy.

· Difficult to Clean

You will also find it hard to clean the machine and replace the parts especially due to the hermetic design.

It has a hermetic design that is difficult to open up and clean thus increasing the difficulty of cleaning the machine.

What are the Main Components of the Hydraulic Oil Chiller?

Hydraulic oil chillers will work best with the help of the numerous components on the machine.

Here are the main components of the hydraulic oil chillers that you need to know more about.

· Oil Reservoir

Hydraulic oil chillers have reservoirs that will store the oil that is responsible for the cooling operations.

· Cooling Fan

You will depend on the cooling fan to provide the cooling air that blows away the heat from the system.

There are different sizes and designs of the cooling fans that you can choose from depending on the hydraulic oil chillers.

· Relief Valve

The hydraulic chillers have a relief valve that will help in releasing the pressure from the system.

It will also help in controlling the amount of oil, water, or air that passes through the valve.

· Oil Level Sight Glass

You will use the oil level sight glass to check the level of the oil in the hydraulic oil chiller.

It will help you determine the period when you will have to refill or change the oil in the system.

· Filter Block Indicator

This is an indicator that will inform you of a blockage in the filtration system of the hydraulic oil chillers.

You will know that it is time for you to change the filters or clean the filters together.

· Compressor

This is the part of the hydraulic oil chillers that will compress the refrigerant to increase the pressure and speed.

You can choose from the different types of compressors such as centrifugal, scroll, and screw compressors.

· Evaporator

The evaporator will help in getting rid of the heat from the hydraulic equipment or fluid carrying the heat.

It will also change the fluid or liquid status of the refrigerants to a gas state after feeding them with the heat.

It also has perfect antifreeze properties that will prevent the fluids in the hydraulic oil chillers from freezing.

· Condensers

Hydraulic oil chillers have condensers that will absorb the heat from the refrigerant using cool air or water.

It will also help in condensing the refrigerant from a gas state to a liquid state after removing the heat.

· Expansion Valve

You will use the expansion valve to reduce the pressure of the refrigerant to manageable levels for the compressor.

· Digital Thermostat

You will use the digital thermostat to control or adjust the on and off cooling of the machine.

It also has a keypad lock that will lock the system from potential control in case of a problem.

Hydraulic oil chiller scroll compressors

What is the Working Principle of the Hydraulic Oil Chillers?

Just like the other chillers, you will similarly operate the hydraulic oil chillers.

Here is a step-by-step process that you can follow when operating the hydraulic oil chillers.

1) Compression Process

You will pass the refrigerant through the compressor of the hydraulic oil chiller which will compress the refrigerant.

It will compress the refrigerant thus increasing the pressure and speed of the refrigerants as it flows.

It will flow easily to the evaporator with very high speed and pressure.

2) Heat Absorption

Here, the refrigerant will pick up the heat from the system and change its state from liquid fluid to gas fluid.

After that, it will maintain the pressure and speed with the heat within and flow to the condenser.

It will also leave the flowing water within the evaporator tubes in a chilled manner to flow and collect more heat.

3) Heat Elimination

The refrigerant will go to the condenser unit where the air or water will eliminate the heat from the system.

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It will dwell within the condenser for a while until the air or water eliminates all the heat from the system.

You will also realize that it will change its state from the gaseous state to the liquid state.

4) Pressure Reduction

Finally, the liquid refrigerant will pass through the expansion valve which will reduce the pressure.

The expansion with feeds the compressor with the refrigerant liquid as the whole process continues.

How do you Maintain a Hydraulic Oil Chiller?

You should perform regular maintenance on the hydraulic oil chillers based on the operational and surrounding conditions.

You should verify the performance of the equipment and prevent the failure of the components prematurely.

Here are some of the maintenance tips that you need to know more about.

· Proper Inspection

You need to do a proper inspection of the hydraulic oil chillers regularly and note down parts that require maintenance.

With this information, you can plan on the right specifications that you will have to maintain when the right time comes.

· Lubrication of Moving Parts

You will also apply enough lubricants on the moving parts of the hydraulic oil chillers to reduce damage from friction.

You should maintain the lubrication process regularly or have an automated lubrication system.

· Filling the Reservoirs

You must also fill the oil and water reservoirs regularly to maintain a proper level of fluids.

Properly filled reservoirs will ensure that the machine does not lack enough fluid to help in the cooling process.

· Cleaning the System

It is also very important to clean the entire system of the hydraulic oil chillers to get rid of debris and mold.

The cleaning process also involves disinfecting the fluids to prevent the growth of mold within the fluid passages.

· Replacement of Parts

You should replace the worn-out parts regularly to maintain the good working properties of the hydraulic oil chillers.

Lubrication of hydraulic oil chiller moving Parts

Which Hydraulic Fluids can you use in Hydraulic Oil Chiller?

There are different types of hydraulic fluids that you can use in hydraulic oil chillers.

Here are some of the hydraulic fluids that will come in handy when using the hydraulic oil chillers.

• Biodegradable hydraulic fluids
• Anti-wear hydraulic fluids
• Brake Fluids
• Power Steering Hydraulic Fluids

What are Some of the Signs of a Failing Hydraulic Oil Chiller?

You can notice that there are issues with your hydraulic oil chillers by looking at specific signs and symptoms.

Here are some of the signs that should warn you of a failing hydraulic oil chiller.

· Oil Leaks

You will notice that oil leaks are coming from the hydraulic oil chillers.

· Presence of Oil in the Cooling System

You may also find traces of oil in the cooling compartments of the hydraulic oil chillers.

· Refrigerant or Coolant in the Oil

There are particular instances where you will find the refrigerant right in the hydraulic fluid or oil.

What are the Main Causes of Overheating in Hydraulic Oil Chillers?

The main causes of overheating in the hydraulic oil chillers are inefficiencies in the operation of the hydraulic oil chillers.

The inefficiencies usually lead to loss of input power which usually converts to heat energy.

This often contributes to the high heat systems within the hydraulic oil chillers.

In addition to that, friction between the moving parts without proper lubrication also contributes to overheating.

How Many Types of Compressors Can You Use in the Hydraulic Oil Chillers?

There are three main types of compressors that you can use in hydraulic oil chillers.

Here are the three main types of compressors that you can use in the hydraulic chiller classification process.

• Screw Compressors
• Centrifugal Compressors
• Scroll Compressors

You can use the classification of the compressors to classify the hydraulic oil chillers accordingly.

Hydraulic oil chiller screw compressor

Which Quality Certifications Do Hydraulic Oil Chillers Adhere to?

You must also confirm that the hydraulic oil chillers have the right quality specifications.

These international quality specifications will ensure that you get the right quality of hydraulic oil chillers.

Here are the main quality standards that you have to be on the lookout for.

• DIN Quality Certifications such as DIN EN ISO - for quality management systems
• JIS B Quality Certifications such as JIS B :
• ANSI Quality Certifications such as ANSI/AHRI 560 and ANSI/ASHRAE 182 –
• VDI Quality Certifications such as VDI -2
• RoHS Quality Certifications

What are Some of the Applications of the Hydraulic Oil Chillers?

You can use the hydraulic oil chillers for several applications to cool the hydraulic system.

Here are some of the applications where you can use hydraulic oil chillers.

• Chemical and Pharmaceutical Industry
• Laser Technology Industry
• Welding Engineering Industry
• Injection Moulding Machines
• Plastics Processing
• Factory Furnaces
• Blow Mold Machines
• Aeronautical Testing Facilities

Hydraulic oil chiller applications

What are Some of the Features to Look at When Choosing a Hydraulic Oil Chiller?

There are quite a lot of features that you need to look at when choosing a hydraulic oil chiller.

Here are some of the features that you should refer to before choosing a hydraulic oil chiller.

· Superior Reliability

You should choose hydraulic oil chillers which have very high levels of reliability in terms of cooling hydraulic systems.

· High Energy Efficiencies

The ultimate goal is to reduce the overall cost of production by saving on energy.

In that case, you will look for a machine that has very high levels of energy efficiency.

· High Durability Levels

Here, you will decide on a machine that will serve you for a very long time in terms of long equipment life.

· Variable Frequency Drive Options

The drive options on the hydraulic oil chillers should be variable with different frequencies that control the system.

· Easy Interface

You should consider having a human-machine interface for proper and easy control and configuration of the machine.

· Main Manufacturing Materials

Here, you will also look at the main manufacturing materials which can be galvanized steel or stainless steel.

· Reliable and Desirable Design

The design of the hydraulic oil chillers must have a proper level of functionality and attractiveness for a proper working environment.

· Environmentally Friendly

In this case, you should consider reducing pollution by using refrigerants and other fluids that are ozone friendly.

Hydraulic oil chiller control system

Which Specifications Do You Require in Manufacturing of Custom Hydraulic Oil Chillers?

As a customer, you will have to dictate how you want your hydraulic oil chillers to work or to look.

You can dictate such details through proper selection and identification of the right specifications.

Here are some of the specifications that you will dictate to the manufacturer.

• Desired Cooling Capacity
• Desired Cooling Fluid Flow Rates
• Maximum Ambient Temperature and Liquid Leaving Temperature
• Operation Ambient Temperature Range
• Electricity Control Logic Systems
• Proper Configuration of the Cooling System
• Overall Design of the Hydraulic Oil Chillers
• Power Supply in terms of Frequency and Voltage

Which Verification Documents do you need after Purchasing the Hydraulic Oil Chillers?

After purchasing your hydraulic oil chillers, you will have to confirm the quality of the hydraulic chillers.

You will receive a few verification documents from the manufacture after conducting a few tests on the machine.

Here are the main verification documents that you will get after performing the quality tests.

Hydraulic oil chiller system

· Factory Acceptance Test Verification Documentation

You will receive a FAT verification document after testing the machine while at the factory level.

The manufacturer will give you the FAT verification certificate after testing the machine in your presence.

· Installation Qualification Verification Documents

You will receive an IQ verification document immediately after installing the hydraulic oil chillers.

It will prove enough that your hydraulic chillers are in good condition after the installation process is complete.

· Operation Qualification Verification Documents

Here, you will get an operational qualification verification document after confirming that the machine works well.

You will have to run tests on the machine according to the product specifications you desire for the chillers.

How Much Does the Hydraulic Oil Chiller Cost?

Well, the cost of the hydraulic chillers will vary due to the different types and sizes available in the market.

You will also look at the minimum order quantity of the hydraulic oil chillers before you make a purchase.

The cost of the hydraulic oil chillers will vary between to 80,000 US Dollars.

In addition to that, the higher the quality of the hydraulic oil chillers, the high the cost of the chillers.

Low price hydraulic oil chiller

What are the Safety Features of Hydraulic Oil Chillers?

One of the major factors that you ought to pay close attention to is the safety of the hydraulic oil chillers.

You should consider having the safest mode of hydraulic oil chillers operations by installing safety features.

Here are some of the safety features that you should have on the hydraulic oil chillers.

· Automatic Sensors

Your hydraulic oil chillers should have automatic sensors that will detect any form of anomaly and send warning signals.

Apart from that, these automatic sensors can also detect serious issues with the machine and then shut them down automatically.

· Alarm Signals

You can also depend on the alarm signals which will warn you of any pending safety misconceptions.

· Proper Housing

Hydraulic oil chillers also have very good housing or covers that will protect you from accessing sensitive parts.

It should have perfect heat insulation properties that will protect you from getting burnt on the skin.

Hydraulic oil chiller automatic sensors

What are Some of the Problems that You Might Experience in High-Temperature Situations?

High-temperature operations within the hydraulic oil chillers can lead to particular problems on the machine.

Here are some of the problems that you might experience when you use hydraulic oil chillers.

· Degradation of Oil

An increase in temperatures within hydraulic oil chiller systems will lead to an increase in the rate of degradation.

· Reduction of Oil Viscosity

As the temperature of oil within the hydraulic oil chillers increases, the viscosity of the oil also reduces significantly.

At TopChiller, we have a range of chiller systems such as air chiller, water chiller, portable chiller, glycol chiller, scroll chiller, screw chiller, and centrifugal chiller, amongst others.

For more information, please visit water chiller cooling system.