Water Chillers 93

Likewise, water chillers have a critical range of flow rates in

which they will safely operate. If the designer chooses to vary the
flow through the chiller to save on pumping energy at any con-
dition less than full load, the control system must be properly
designed to operate safely. Because of these design limitations
and safety concerns, chillers are usually designed for constant
water flow. However, there is an energy-saving opportunity if the
chiller pump is variable flow.
Cooling equipment is normally designed for a 10°F tempera-
ture difference or delta T (∆T). For example, chillers and cooling
coils might be designed to operate with a supply water tempera-
ture of 45°F and a return temperature of 55°F, while the cooling
tower (tower range) and water-cooled condenser (condenser rise)
operate between 85°F and 95°F.

PLANT MAINTENANCE AND OPERATION

Good maintenance and the proper operation of plant equip-

ment cannot be overemphasized. Proper maintenance helps en-
sure efficient operation of equipment and systems (thereby
reducing energy usage) and helps prolong equipment life. The
following maintenance procedures can help in the optimization of
chiller plant equipment and determine the cause of any abnor-
malities and correct them as needed.

Compressors and Motors

Follow manufacturer’s guidelines for compressor and motor
maintenance and observe compressor operation. Frequent stop-
ping and starting or continuous running may indicate inefficient
operation. It is also important to listen to the compressor. A high
noise level may be a sign of a loose drive coupling or excessive
vibration. Next, inspect the compressor for oil leaks and use a
leak detector to check for refrigerant leaks. Establish normal op-
erating pressures and temperatures for the system. Routinely
record operating temperatures and oil pressures in a log. Be sure
94 HVAC Fundamentals

to compare readings with manufacturer’s specifications to ensure

normal operation.

Pumps and Motors

Follow manufacturer ’s guidelines for pump and motor
maintenance. Observe and listen to the pump operation. Keep the
pump and motor properly lubricated; lubricate motor bearings
and all moving parts according to manufacturer’s recommenda-
tions. Keep pump and motor properly aligned. Water balance
pumps for proper flow quantity; change impellers as needed.

Fans and Motors

Follow manufacturer’s guidelines for fan and motor mainte-
nance. Lubricate motor and fan bearings and all moving parts
according to manufacturer’s recommendations. Keep fan and
motor drives properly aligned. Inspect condition of belt(s) and
check belt tension. Observe and listen for any unusual noise or
vibration.

Condensers and Cooling Towers

Clean tubes on water-cooled condensers and keep condenser
coil faces clean on air-cooled condensers. Perform chemical treat-
ment to determine if desolved solids concentrations are being
maintained at acceptable levels on evaporative condensers and
cooling towers. Monitor effectiveness of water treatment pro-
gram. Keep the tower clean to minimize drops in air and water
pressure. Check overflow pipe clearance for proper operating
water level. Clean intake strainer. Determine if there is air re-cir-
culation from tower outlet back to tower inlet. Inspect towers for
proper nozzle performance.

Plant Retrofit
The biggest energy users in chilled-water plants are the
motors driving the chiller compressors, pumps, and fans. There-
fore, significant energy savings can be achieved by: