Chiller Maintenance Checklists

Chiller maintenance checklists
Routine maintenance of industrial chillers is required to maintain high uptime and extend
the useful life of the asset. A nice bonus is that well-maintained chillers have a reduced
power consumption.
Below, we outline daily, weekly, monthly, and annual maintenance steps you should
consider to keep industrial chillers in good operating condition at all times.
Daily chiller maintenance checklist

Daily tasks to be performed involve checking the chiller’s regular operation:
 Check the temperature of chilled water entering and leaving the chiller
system.
 Check and verify the temperature of condenser water entering and leaving
the system.
 Check the power and current drawn by the compressor.
 Check sump oil level and temperature.
 Check condenser and evaporator pressure.
 Inspect and record oil pressure readings.
 Check for any abnormal noise and vibration from the chiller system.
Weekly chiller maintenance checklist

Some of the weekly maintenance tasks to be performed are:
 Check the sump oil level and top-up if required.
 Check the liquid level using site glass.
 Inspect pipes and coils for visible leakages.
 Check the exterior condition of the condenser.
 Observe chiller operation for unusual sounds or vibration.
 Check and record all operating temperatures and pressures. Ensure that all
the numbers match normal operating conditions.
Monthly chiller maintenance checklist

Common monthly maintenance tasks to be performed on your chillers include:
 Check components for wear and tear.
 Check the level of lubrication in the centrifugal pumps and motors. Top up
the lubrication if required.
 Check the condenser and clean the coils.
 Clean condenser water strainers.
 Run the chiller on full load and check the liquid level in the evaporator.
 Inspect the compressor motor for operational temperature. Ensure motors
are not overheating.
Annual chiller maintenance checklist

In addition to daily, weekly, and monthly maintenance checks, you should schedule
planned downtime to:
 Chemically wash condenser coils.

 Change all oil filters.
 Change all oil. Make sure to use only approved oil.
 Straighten fins and fans of air-cooled condensers.
 Check the liquid line filter. If required, change it.
 Check the health of water strainers. If needed, replace them.
 Check the quality of circulating water for water-cooled condensers. Change
the water if required.
 Inspect the health of isolating valves. Lubricate the moving parts of the
isolating valve.
 Inspect and verify the operation of the valve limit switch.
 Inspect and verify the operation of the vane damper.
 Inspect the physical condition of the starter panel.
 Check the contactors and tips of electrical components.
 Check the condition of terminal lugs. Replace them as needed.
 Inspect loose connections in electrical circuitry and its components.
Best practices for maintaining industrial

chillers
Over the years, maintenance professionals have tried and tested various approaches to
chiller maintenance. Here are some best practices recommended by the industry:
 Cleanliness: Keep the chiller and its surrounding environment clean. This
helps to reduce inefficiency and improve overall performance.
 SOPs and checklists: Create standard operating procedures (SOP) for all
chiller maintenance activities. Create preventive maintenance checklists out
of the SOPs. Use them to ensure that maintenance tasks are performed up
to the required standard.
 Maintenance records: Keep record of all maintenance activities and
measurements (such as temperature and pressure readings). You can
use cloud platforms like CMMS to store that data in an easily accessible
place.
 Preventive schedules: Create preventive schedules for chiller
maintenance. The schedule created has to be in alignment with OEM
recommendations and inputs from experienced technicians. You can use
a CMMS like Limble to automate and organize maintenance work and stay
on top of your spare parts inventory.
 Treated water: Regular water causes corrosion. Use treated water to
reduce the chances and impacts of corrosion, as well as to reduce scale
formation inside conduits.
 Oil testing: Regularly test the quality of oil and lubricants used in chillers
via spectrometric analysis. Replace the oil as soon as degradation in oil
quality is detected.

Keep in mind that these are just rough recommendations. You will have to adjust
maintenance frequency based on the age/condition of your asset, operating conditions,
and the type of chillers you run.
Keeping your industrial equipment in check

Industrial chillers are critical components in industrial operations. The maintenance of
industrial chillers has to be done diligently, adhering to industry conventions. If possible,
you should use a CMMS system to manage all industrial maintenance activities, chiller
maintenance included.
If you want to learn more about Limble CMMS, do not hesitate to request a
demo, contact us, or start a free trial.
Heating and cooling are basic processes that are required in virtually every industry. This
is why industrial boilers and chillers have seen widespread adoption across many
different sectors.
As an important part of smooth day-to-day operation of your facility, it is paramount to
understand what chiller maintenance includes and how to keep chillers in good operating
condition through proactive maintenance.
The purpose and importance of industrial

chillers
Industrial chillers play a key role in setting up a temperature-controlled environment. Just
as a boiler heats fluid in its chamber, chillers remove heat from fluids. The cooled fluid is
circulated through a heat exchanger to cool equipment or parts of the process stream.
Industrial chillers have 3 broad use cases:
1. Air conditioning: Water mixed with ethylene glycol is used as a coolant for
air conditioning purposes. The chilled coolant is distributed to heat
exchangers to cool spaces in buildings.
2. Controlled cooling: Chillers are used for controlled cooling in various
industrial processes. They are used in:
o Injection and blow molding
o Chemical processing
o Pharmaceutical manufacturing
o Printing press
o Plastic industry
o Power generation stations
o Food processing units
o Die-casting and machine tooling
o Welding process
o Rubber manufacturing
o Laser applications
o Semiconductor manufacturing
3. Dehumidification: Cooling condenses the moisture in the air. Air can be
effectively dehumidified with industrial chillers.
There are many industrial processes where maintaining specific environmental conditions
is essential.
For example, pharmaceutical production often happens in air-conditioned environments.
Production carried out without adequate air-conditioning will be defective and can even
harm lives. Having a reliable air-conditioning system is critical.
Chillers are also used in processes that require controlled cooling. A great example
is injection molding. Molten plastic is poured into molds to form plastics of different
shapes. Chillers help maintain the right temperature to hold the shape. If the chiller
breaks down, the complete injection molding process has to be halted.
Types of industrial chillers

There are many ways to categorize industrial chillers. Based on the basic working
principle, chillers can be classified as:
1. Vapor compression chiller: A mechanical compressor powered by
electricity, steam, or a turbine. It is used to compress coolant in vapor form.
2. Vapor absorption chillers: These types of chillers use heat that is generated
as waste in other industrial processes for the thermodynamic process to chill
the coolant.
Vapor compression vs Vapor absorption chiller. Source: The Engineering Mindset

Based on how the heat is removed, vapor compression chillers can be classified into:
1. Air chillers: As the name indicates, air is used to remove heat. Additional
fans are set up to expel heat. Air chillers are easy to install, but they consume
more energy in comparison to water chillers.
2. Water chillers: Heat is removed by pumping water to the cooling tower. The
high heat capacity of water makes it an energy efficient chiller.
Air cooled and water cooled industrial chillers. Source: HVACWAVETECH

Chiller maintenance is intricately connected with how chillers work. Each type of
industrial chiller has its nooks and crannies you will need to watch out for.
When creating a preventive maintenance plan for any asset, we always recommend you
combine personal experience with OEM-provided guidelines, and take the operating
conditions of your facility into consideration.
This should be enough to build a decent initial plan. If you use maintenance software,
you can also pull historical maintenance information before assigning frequencies to
specific maintenance tasks.
Circuit Breaker maintenance checklist
Description, Types and maintenance checkpoints.
 Home
 Documents
 Circuit breaker maintenance checklist.
Contents
1. Circuit breaker maintenance checklist.
2. Format of circuit breaker maintenance checklist.
3. Types of circuit breaker maintenance checklist.
4. Safety precaution for circuit breaker PPM activity.
5. Details of circuit breaker maintenance activity checkpoints.
1- Circuit breaker maintenance checklist:
Circuit breaker is a costly electrical device which is used for power supply
making and breaking as switched On or switched Off. Preventive maintenance
is a important activity for keeping good health of motor starter. Many type
maintenance activity is carried out as monthly, quarterly, half yearly and yearly.
These all activities is carried out according maintenance checklist which is
written step by step maintenance process.
2-Format or template of circuit breaker PPM checklist:
3 - Types of circuit breaker maintenance checklist:
 Monthly
 Quarterly
 Half Yearly
 Annually or Yearly
4-Details of safety guideline for circuit breaker PPM activity:
During PPM activity we should follow safety guideline for stopping any
misshaping. Safety related some points below mentioned.
 Rack out circuit breaker from electrical panel.
 Use lock out and tag out on the electrical panel.
 Use insulated tools.
 Use personal protective equipment as safety shoes, helmet etc.
 After completion activity remove tools and tackles.
 After completion remove safety lock and signboard or tag.
5-Circuit breaker maintenance activity checkpoints:
 Ensure and check no power supply before starting PM activity.

 Clean properly fixed and moving contact in arch chamber.
 Check and clean contact holding mechanism like as spring charging etc.
 Check and adjust breaker protection relay setting as short circuit, earth
fault and OL.
 Check all release in functional mode like as shunt coil, UV and spring
charge.
 Check auto and manual function.
 Check earth connection with panel body.
 Check any abnormal sound on load condition.

Parameters status :
After carried out maintenance activity we should check parameters for

equipment better health.
 Incoming Voltage
 Check load according capacity.
 Check parameters according default limit.
 Check any abnormal sound.
Electrical Equipment Logbooks

Description, Types of logbooks and Why it is used.
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 Documentation
 Logbooks
Contents
1. Equipment Logbooks
2. Schematic diagram.
3. Types of technical system logbooks.
o HT panel logbook.
o Transformer logbooks.
o LT panel logbook.
o UPS logbooks.
o Chiller plant logbook.
o Diesel generator logbook.
o Water treatment plant logbook.
1- Equipment Logbooks:
Log book is a record book which is used for manual storing parameters data
of equipment, events and machines. The parameters of equipments are
mentioned in it. Parameters data is taken in a frequency according
requirement as a hourly, 2 hourly, 4 hourly or per day.
Different types log books are used in a different formate are used according
equipments. Here we are going to discus electrical log books like as UPS log
book, transformer logbook, HT panel log book etc. Electrical equipments
parameters are logged as voltage, current, frequency, temp etc.
2- Tech Logbook format :
3- Types of logbooks :
Different types logbooks are used in technical system like as transformer log
book, chiller plant logbook which below mentioned.
1- HT panel logbook.
HT panel logbooks are used in industries, residential societies, commercial

buildings, and substations. The parameters are not down for observation and
future reference. The parameters details are below mentioned.
Parameters detail:
 Date and time.
 Energy consumption in KVAh and KWH.
 R, Y, B phase high voltage
 All three phase current.
 Maximum demand
 Power factor
 Auxiliary voltage
 Control supply voltage

2- Transformer logbook
Transformer is an electrical equipments which is used for voltage

transformation. It is costly electrical equipment so for better health we have to
follows it's parameters so that we can prevent from any fault.
Parameters:
 Date and time.

 Transformer input voltage
 Transformer out put voltage
 Transformer current
 Transformer winding temp
 Transformer oil temp.
 transformer oil level.
 Dry type transformer temp

3- LT panel logbook.
LT panel is electrical power distribution center in a premises where electricity

board supply and backup supply is received and distributed to feeders so
parameters are important for LT panel health.
Parameters:
 Date and time.
 All phase incomer voltage.
 all phase current.
 frequency.
 Power factor.
 All feeders current

4- UPS logbook.
UPS is an electrical device which is used for receiving backup supply without
any interruption. So parameters are very important for knowing the status of
UPS.
Parameters:
 Date and time.
 Incoming voltage.
 Outgoing voltage.
 Current in Amp
 Load in percentage of capacity (KVA)
 Energy load in KW.
 Battery voltage.
 Battery charging current.
 Temp and humidity.

5- Chiller plant logbook.
Chiller plant is an Airconditioning machine which is used for high rise offices,
premises, malls. It is costly machines so parameters are very important for its
health.
Parameters:
 Date and time:
 Running hours.
 Voltage
 Current
 Energy in KW.
 Chilled water in and out temp.
 Condenser water in and out temp
 Oil temp and pressure.
 Refrigerant discharge, suction pressure and temp

6- Diesel generator logbook.
Diesel generator is a mechanical and electrical device which is used for back
up power generation. It converts mechanical energy into electrical energy so
record parameters are important for its better health.
Parameters:
 Date and time:
 Running hours.
 Voltage
 Current
 Energy in KW.
 Oil pressure.
 Water temp
 Coolant temp.
 Battery charger voltage.

 Fuel level.
7- Water treatment plant logbook.
WTP is a water control center where the water is received, storage, filtered and
distributed for utilization. So parameters are very important for knowing the
status of water plant.
 Date and time.
 Fire tank water level.
 Raw tank water level.
 Domestic tank water level.
 Softener tank water level
 Softener plant hardness value.
 RO plant TDS value.
 All type pump water pressure.
HT Panel Logbooks
Description and Types of parameters.
 Home
 Documentation
 Log Book
 HT panel Logbooks
Contents
1. HT panel logbook.
2. Log book formate.
3. Types of parameters.
1- HT panel logbooks:
HT panel log book is a parameters note book where the required parameters
are noted down in manually. The all parameters data is noted down in a
frequency base according requirement as a hourly, 2 hourly, 4 hourly or per
day.
We can observe the HT panel status on daily basis, monthly basis, quarterly
basis and annually basis. If any parameters is not functioning according
default value then we can check and find out the problem. If any fault is
occurred suddenly then we can check log book data related fault.
2- Logbook formate :
3- Types of logbook parameters. :
 Date and time.
 HT energy consumption.
 Maximum demand.
 Incoming HT voltage.
 Load according phases.

 Power factor.
 Control supply voltage.

1- Date and Time:
Date and time is the most important in log book. If we want to know about
exact parameters from last week then we can easily find out.
2- HT energy consumption:
HT energy consumption is taken from HT meter in the format of KVAh. Many

reading are available in HT meters but billing is processed in KVAh formate.
3- Maximum demand.
Ones time recorded highest load limit is called a maximum demand. It should
be low in against of section load. Section load is the highest load of premises
which has to be approved from electricity board authority.
4- Incoming HT voltage.
HT voltage is received from electricity board according HT connection like as

11KV or 33KV. If the voltage is receiving as low or high against 11KV or 33 KV
then we will have to increase or decrees from substation.
5- System Load in Amp.
Premises total load is checked in HT panel through amp meter. R , Y and B

phase amp are taken for checking load and unbalance load.
5- Power factor.
Line power factor should be .98 of .99 . If the power factor value is low as .85
then energy consumptions will be 100 present but actual energy will be used
only.85 % . It means 15 % energy losses so power factor value is important for
system.
6- Control supply voltage.
Control supply is used for all protection relay auxiliary supply, ON and OFF
TNC switch, Circuit breaker shunt and closing coil. The UPS or battery is used
for control supply. If the battery voltage then 12 volt is used. If the UPS supply
then 230 V AC is used.
7- Temp and humidity.
Temp and humidity meter are used in HT room because high temp and high
humidity is very dangerous for technical system. So temp and humidity
parameters are required.
Transformer logbook
 Home
 Documentaion
 Logbook
 TR Logbooks
Contents
1. Transformer logbook.
2. Logbook format.
1- Transformer logbooks:
Transformer logbook is a parameters note book where the required
parameters are noted down in manually. The all parameters data is noted
down in a frequency base according requirement as a hourly, 2 hourly, 4
hourly or per day.
We can observe the transformer condition on daily basis, monthly basis,

quarterly basis and annually basis. If any parameters is not functioning
according default value then we can check and find out the problem. If any
fault is occurred suddenly then we can check logbook data related fault.
2- Transformer logbook format :
Different types parameters are noted down in logbooks in technical system as

per requirement. which below mentioned.
 Date and time.
 Transformer oil level.

 Dry type transformer temp.
1- Date and Time:
Date and time is the most important in logbook. If we want to know about
2-Transformer input voltage:

3- Transformer out put voltage.
4- Transformer current.

5- Transformer winding temp.

5- Transformer oil temp.
system.
6- Transformer oil level.
7- Dry type transformer temp.
LT Panel Logbook
Template and Types of parameters.
 Home
 Documentaion
 Log book
 LT panel logbooks
Contents
1. LT panel logbook.
2. Logbook format.
1- LT panel logbooks:
LT panel logbook is a parameters note book where the required parameters
are noted down in manually. The all parameters data is noted down in a
frequency base according requirement as a hourly, 2 hourly, 4 hourly or per
day.

fault is occurred suddenly then we can check log book data related fault.
2- LT panel logbook format :

 Date and time.
 All phase current.
 Frequency.
 Power factor.
 All feeders current.

1- Date and Time:
2-All phase incomer voltage.

3- All phase current.
4- Frequency.

5- Power factor.
Premises total load is checked in HT panel through amp meter. R, Y and B

5- All feeders current.
system.
UPS Logbooks
 Home
 Documentation
 Logbook
 UPS Logbook
Contents
1. UPS logbook.
2. Logbook formate.
1- Transformer logbooks:
UPS logbook is a parameters note book where the required parameters are
noted down in manually. The all parameters data is noted down in a frequency
base according requirement as a hourly, 2 hourly, 4 hourly or per day.

fault is occurred suddenly then we can check log book data related fault.
2- Transformer logbook format :

 Date and time.
 Current in Amp

1- Date and Time:
2-Incoming voltage.

3- Outgoing voltage.
4- Current in Amp.

5- Load in percentage of capacity (KVA)

5- Energy load in KW.
system.
6- Battery voltage.
7- Battery charging current.
8- Temp and humidity.
Equipment Health Checklist
Template, Types of Checklist and Checkpoints.
 Home
 Documents
 Equipment checklist
Contents
1. Equipment health checklist.
2. Checklist format or template.
3. Types of checklist.
4. Equipment technical checkpoints.
5. Why it is used?
1- Equipment health checklist :
Equipment checklist is a formate of checkpoints which is used for equipment

status checking. Checklist is used in daily basis or weekly basis. We can check
any electrical or technical equipment properly according checkpoints like as
abnormal sound, any heating, vibration, efficiency. leakage, filter condition,
bearing play etc.
2- Checklist format or template:
3- Types of checklist:
Different type checklist are used according equipment characteristic. Different
types checklist are available in electrical, mechanical, HVAC, WTP, BMS system.
Types of checklist below mentioned.
 Health status checklist.
 Maintenance checklist.
 Parameters checklist.
 Testing checklist.
1- Health status checklist.
Health status checklist is used for knowing currently status of running

equipment. Health status points below mentioned. running hours, over load or
under load, abnormal sound, Vibration, Any fault status. filter condition etc.
 Check current load condition.
 Check abnormal sound.
 Check vibration.
 Check filter condition.
 Check any fault as currently and twenty four hours in history.

2- Maintenance checklist.
Maintenance checklist is used during maintenance period. Maintenance

activity is carried out according checklist points like as below mentioned.
LOTO procedure, tight loose connection,
 Use LOTO procedure.
 Check all connections and tight properly.
 Change any heat or faulty parts.
 Clean dust properly inside and outside.
 Remove any vibration.

3- Equipment parameters checklist.
Some electrical equipment parameters are very important for knowing its
status.
 Input supply.
 Output supply.
 Load according capacity

4- Equipment testing checklist.
Equipment testing is carried out with time as after commissioning or yearly.
 Check default setting parameters.
 Use safety LOTO procedure during electrical high voltage equipment.
 Test default setting through test instrument.
 Calibrate equipment according default setting like as meters, pressure
gauge.
 Connect the electrical testing Instrument with earth.
4- Types of equipment checklists:
 HT panel checklist.
 Transformer checklist.
 LT panel checklist.
 WTP plant checklist.
 Chiller plant checklist.
 DG checklist as A check, B check, C check and D check.
 AHU checklist.
 Starter panel checklist
 Capacitor panel checklist
 Production machine checklist.
 fir equipment checklist.
 Electrical equipment checklist
 Access control status checklist.
5- Why it is used?:
Check list is a important part for health of any equipment. Checklist activity is
performed on daily basis, weekly or monthly basis. If checklist activity is
carried out per day then we can know about equipment actual status. If any
type problem is present in equipment then we can resolve or repair of
problem. So in this way we can say checklist activity is carried out equipment
health and performance.
HT Panel Health Checklist

Format and Types of checkpoints.
 Home
 Documentation
 Checklist
 HT Panel Checklist
Contents
1. HT panel checklist
2. Checklist format template.
3. Types of checkpoints
1- HT panel checklist:
HT panel checklist is a observation type checklist where the all parts of HT

panel is inspected visibly. Status of all parts and efficiency are noted down in
checklist. Here some points are focused as a high voltage status, load,
maximum demand, measuring meters, circuit breakers and protection relay
are used.
2- HT panel checklist format :
3- Types of checkpoints :
Different types checkpoints are executed on the HT panel during daily check.
which below mentioned.
 Date and time.
 Check all protection relay.
 Check all indicators.
 Check auxiliary control supply.
 Check HT circuit breaker SF6 and vacuum kit.
 Check all measuring instrument.
 Panel all covers should be locked properly.
 Check temp and humidity in HT panel room.
 Check body earth connection
ransformer Health Checklist

 Home
 Documentaion
 Checklist
 Transformer checklist
Contents
1. Transformer checklist.
2. Format and template of transformer checklist.
3. Points of checkpoints.
1- Transformer health checklist:

Transformer checklist is a inspection type checklist where the all parts of
transformer is inspected visibly. Status of all parts and efficiency are noted
down in checklist. Here some points are focused as a input and output voltage
status, load, Tap changing tap status, measuring meters, OTI, WTI and
buckholze relay.
2- Transformer checklist format :
3- Checkpoints of transformer checklist. :
Different types checkpoints are executed on the transformer during daily

check which below mentioned.
 Input and out put voltage.
 Voltage tap counter status
 Silica gel color status.
 Transformer oil level status.
 Winding temp status.
 Oil level temp status.
 Check any leakage in transformer body.
 Abnormal sound in transformer body.

Observation and action taken.
First of all we should check abnormal sound, any oil leakage from oil tank.
Check the color of silica gel if the color is pink then silica gel will be replaced.
LT Panel Health Checklist

 Home
 Documentaiton
 Checklist
 LT panel checklist.
Contents
1. Health checklist of LT panel.
2. Format or template of checklist.
3. Points of checkpoints.
4. Observation according checklist.
1- LT Panel checklist:
LT panel checklist is a observation type checklist where the all equipment of LT

panel is inspected visibly. Status of all parts and efficiency are noted down in
checklist. Here some points are focused as a input voltage status, load, power
factor, measuring meters and protection relay.
2- Transformer checklist format :
3- Checkpoints of LT panel checklist. :

Different types checkpoints are executed on the transformer during daily
check which below mentioned.
 Input voltage.
 Power factor relay controller.
 Check all feeders output current.
 Abnormal sound in LT panel.
 auxiliary power supply status.
 DG incomer control panel.
 Check any error in Measuring meters.
 Check any fault in protection relay.
 Check all indicators.
 Check visibly any hot spot or heat thimble in panel.
4- Observation according checklist :
First of all we should check abnormal sound, power factor value. Check critical
feeders load according capacity like as UPS, Server etc. LT panel circuit breaker
should be working condition. All supported equipment like as
meter,indicators, selector switch, protection relay should be check visibly if any
err found then find out.
Water Treatment Plant health Checklist

Format, important points of checklist and observation.
 Home
 Documentaion
 Checklist
 WTP checklist.
Contents
1. WTP health checklist.
2. Format of WTP checklist.
3. Details of checkpoints.
1- Health checklist of WTP- (water treatment plant) :
WTP health checklist is a inspection type checklist where the all equipment of
water treatment plant is inspected visibly and on load condition so that the
health condition of equipment could be check properly. If found any problem
then we can note down for rectification. Status of all parts and efficiency are
noted down in checklist.
Here some points are focused as health status of water MGF filter, pumps and
motors, RO and softener plant etc.
2- WTP health checklist format :
3- Details of checkpoints in WTP. :
Different types checkpoints are executed in the WTP plant during daily check
which below mentioned.
1- Checkpoints
 Water flow meters.
 Water level sensor of water tank.
 Any leakage in water line.
 Status of water multi grade filter .
 All water pump health status as abnormal sound, leakage problem etc.
 All water pump motor health status as abnormal sound, load capacity,
heating etc.
 Check the condition of water as TDS and hardness value.
 Check the softener plant salt charging and water hardness.
 Check the RO water TDS value.

2- Observation:
During inspection of above mention points if we find any problem in WTP

plant just like as abnormal sound in pump, motor or any leakage in water line
or across required limit of water hardness and TDS value.
3- Action taken:
according health checklist we should make a fault or err list according its
severity. We can categorized the fault list as normal and major. The normal
fault is rectified by inhouse team and major fault is rectified in weekend by
inhouse team or OEM vendor.
Standard Operating Procedure (SOP)

Description, Types and Why it is used.
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 Documentation
 SOP
 SOP
Contents
1. SOP- Standard operating procedure.
2. Format or templates.
3. Types of SOP .
4. Safety guideline for SOP.
5. Why it is used?
1- SOP- Standard operating procedure. :
SOP is an instructed guideline template which is written for describing any

work process in step by step format in organization. It is approved by
authorized organization management team or gov authority. Any type work
process is written in step by step format as start to end so that all team
member could be follow.
Policies, processes ans standard is a very important part of any organization

for getting success in broadly because one SOP will be followed by all workers
and error free output will be received. Different types of SOP can be written in
different format.
It communicates to across all levels and team members in a organization and

both business owners and employee are also involved. It can be followed by
departmentally, managers etc.
2- SOP format or template:

3- Types of SOP:
Different types SOP are used but we can categorized in two types as technical
and management. Technical SOPs are used for technical process and technical
equipment operating and management SOPs are used for management work
flow process according organization policies.
 Technical SOP.
 Management SOP.
1- Technical SOP:
Technical SOP is a two type as one is digital technical process and second is
operating of technical equipment.
 Technical process
 Technical equipment.
A- Technical Process:
B- Technical equipment:
2- Management SOP:
Management SOP is a polices and work process standard template which is

followed by all label members in organization.
 Core SOP.
 Training SOP.
 Production SOP.
A- Core SOP:
Core SOP is the important part of organization for getting success.
 Creation.
 Revision.
 Approval.
 Publishing.
 Distribution.
B- Training SOP.
Training SOP is the important role of improving employee skill. Working role,
responsibilities and work process is executed through training SOP. Working
efficiency of skilled person is more in comparison of unskilled employee.
C- Production SOP.
Production SOP is the important role for increasing production with good
quality. A process is followed step by step by employee for getting required
production according production SOP.
4- Benefits of SOP:
 Employee safety.
 Time saving.
 Maintained compliance standard
 Improved accountability.
 Increased consistency.
 Available guiding hand every time.
 Improved communication with organization.
5- Why it is used?:
HT Panel Operation SOP

Process of Manual Start Procedure.
 Home
 Documentation
 SOP
 HT start SOP
Contents
1. HT panel manual start SOP
2. Format of HT panel start SOP.
3. Procedure of HT panel manual starting.
1- HT panel manual operation SOP:
HT panel is a high voltage power center where the high voltage power supply
is received and distributed for power utilization. If we want to start and stop
this panel then we will have to follow standard operating procedure which was
written as step by step process with safety instruction so that any operation
mistakes could not activate.
First of all we will have to take safety precautions then we can start and stop
HT panel. details of SOP given below mentioned.
2- Format of HT panel SOP:
3- Procedure of HT panel manual start SOP:
1- Object:
HT panel manual start and stop standard operating procedure.

2- Responsibility:
Technicians, technical supervisors, electrical engineers.

3- Safety instruction:
Before starting we must follow safety instruction.
 Check and verify auxiliary control supply of HT panel.
 Check and verify HT incoming supply voltage.
 The voltage should be required limit in each phase.
 Check circuit breaker should be charged.
 Check related transformer should be healthy condition.
 Check any pending work on HT panel.
 All protection relay should be healthy condition.
 All measuring meter should be in health condition.

 If any problem don’t open any panel cover without shutdown.
4- Procedure of starting HT panel.
 Press the circuit breaker ON button.
 Check the all three phase voltage on volt meter.
 Check the load of each phase on ampere meter.
 Check the power factor value if the low then start the capacitor.
 Check the maximum power according maximum demand.
Transformer Voltage Regulation SOP

Description and procedure of voltage regulation.
 Home
 Documentation
 SOP
 TR Voltage Regulation
Contents
1. Transformer manual voltage regulation SOP.
2. Format of Transformer manual voltage regulation SOP.
3. Procedure of Transformer manual voltage regulation SOP.
o Voltage regulation through transformer OLTC.
o Voltage regulation through RTCC panel or motor.
1- Transformer manual voltage regulation SOP.:
Transformer is a high voltage static device where the high voltage is increased
and decreased and distributed for power utilization. If the voltage is low as per
requirement then we will have to increased voltage through manually
operated voltage regulation mechanism in OLTC of transformer. These voltage
regulation process will be followed Under standard operating procedure which
was written as step by step process with safety instruction so that any
operation mistakes could be remove.
First of all we will have to take safety precautions then we can regulate the
voltage as increased or decreased. Details of SOP given below mentioned.
2- Format of voltage regulation SOP:
3- Transformer voltage regulation procedure:
1- Object:
Transformer manual voltage regulation SOP- standard operating procedure.

2- Responsibility:

 Use HT gloves for using this process.
 Use safety shoes.

4- Voltage regulation through transformer OLTC:
 Open the OLTC cover.

 Connect the handle into tap mechanism.
 Move the forward handle for voltage increasing.
 Move the backward handle for voltage decreasing.
 Check the required voltage on display.
 If the voltage is as required then stop the function.
 If the voltage is not as required then again start the procedure.

5- Voltage regulation through RTCC panel or motor:
 Select the selector Switch in manual mode.
 Press the up push button for voltage increasing.
 Press the down push button for voltage decreasing.
 Check the required voltage on display.
 If the voltage is as required then stop the pressing push button function.
 If the voltage is not as required then again start the pressing push
button function.
LT Panel changeover SOP

Description and procedure of changeover procedure.
 Home
 Documentation
 SOP
 LT changeover SOP
Contents
1. LT panel changeover SOP
2. Format of changeover SOP.

3. Procedure of LT panel changeover SOP.
1- LT panel manual changeover SOP:
LT panel is a low voltage power control center where the power is received
and distributed. It has two power incoming sources one is EB source and
second is DG source. One time one source can be used when power supply
switched off then DG backup supply is used. If the EB power supply available
then the supply source is replaced as DG to EB source through changeover
process.
If we want to change source EB to DG or DG to EB then then we will have to

follow standard operating procedure which was written as step by step
process with safety instruction so that any operation mistakes could be
remove.
First of all we will have to take safety precautions then we can start
changeover process as DG to EB source. The details of SOP given below
mentioned.
2- Format of LT panel changeover SOP:
3- Procedure of LT panel changeover SOP:
1- Object:
LT panel manual changeover standard operating procedure.

2- Responsibility:
 Check and verify auxiliary control supply of LT panel.
 Check and verify LT incoming supply voltage.
 The voltage should be required limit in each phase.
 Check circuit breaker should be charged.
 Check related transformer should be healthy condition.
 Check any pending work on LT panel.
 All protection relay should be healthy condition.
 All measuring meter should be in healthy condition.
 If any problem don’t open any panel cover without shutdown.

4- Procedure of LT panel changeover:
 Switch off the DG incomer circuit breaker.
 Switch ON the transformer air circuit breaker.
 Connect the other section through buscuppler.
 ON required feeder load one by one.
 Switch ON the capacitor bank panel.
 Check the power factor value.
UPS Manual Operating SOP

Description of Manual Operation procedure.
 Home
 Documentation
 SOP
 UPS Operating SOP
Contents
1. UPS manual operation SOP
2. Schematic diagram of format.
3. Procedure of UPS operation SOP.
1- UPS manual operation SOP:
UPS is a uninterrupted power supply which is used for backup supply sources.
When electricity power source is not available then it is used for backup which
is available in single phase and three phase. Low capacity UPS is used for
domestic used but high capacity UPS is used for industrial and IT sectors as 50
KVA to 500 KVA.
If we want to start and stop high capacity UPS then we will have to follow
standard operating procedure which was written as step by step process with
safety instruction so that any operation mistakes could be remove.
First of all we will have to take safety precautions then we can start ON and
OFF procedure. The details of SOP given below mentioned.
2- Format of UPS start and stop operation SOP:
3- Procedure of UPS start and stop operation SOP:
1- Object:
UPS start and stop standard operating procedure.
2- Responsibility:

3- UPS manual switched ON procedure:
For starting UPS we must follow below mentioned procedure.
 Switch ON the UPS bypass supply breaker.
 After display ON, switched ON battery breaker.
 Check the battery voltage on display as per battery bank.
 Switched ON the UPS input supply breaker.
 Check and verify the input voltage as default value.
 Switched ON the out put breaker.
 Check the all three phase load current.
 Check and note down all parameters.

4- UPS manual switched OFF procedure:
 Switch Off the load breaker.
 Switch Off the battery circuit breaker.
 Switch Off the input breaker.
 Switch Off the bypass breaker.
PPM Maintenance Checklist

Types of Checklist and Checkpoints.
 Home
 Documentation
 PPM Checklist
 Equipment PPM-Checklist
Contents
1. Equipment PPM checklist ?
2. Format of PPM checklist.
3. Safety guideline for PPM.
4. Types of PPM checklist.
5. Details of maintenance checkpoints.
1 - Equipment maintenance checklist:
Here we are going to discussing about equipment maintenance activity like as

PPM- planned preventive maintenance, breakdown maintenance , schedule
maintenance etc. Maintenance checklist is a written document which is
followed step by step during maintenance activity. It is written as below
mentioned points.
 Safety precaution points.
 PPM activity points
 After PPM activity points.
2 - Format of maintenance checklist:
3 - Maintenance safety guideline:

 Disconnect energy sources like as electrical, hydraulic or mechanical.
 Use lock out and tag out procedure.
4 - Types of maintenance checklist:
 Weekly
 Monthly
 Fortnightly
 Quarterly
 Half Yearly
5 - Details of preventive maintenance checklist:
1- Maintenance activity points:
 Clean with air blower and clothes.
 Check and tight all terminal connections

 Clean air filter through water.
 Check any vibration and rectify it.
 Check any abnormal sound, if available then rectify it.
 Check all connection on visibly.
 Check any heat or hot spot in connections, thimbles or terminal if yes
then replace it.
 Check body earth connection

2- After maintenance equipment testing :
Transformer preventive Maintenance Checklist

Description, activity procedure and checkpoints.
 Home
 Documentation
 PPM Checklist
 TR PPM Checklist
Contents
1. TR maintenance checklist.
2. Format of TR maintenance checklist.
3. Types of TR PPM checklist.
4. Safety precaution for TR PPM activity.
5. Details of TR maintenance activity checkpoints.

1- Transformer preventive maintenance checklist:
Transformer is a costly electrical static device which is used for voltage

transformation als low to high and high to low. Preventive maintenance is a
important activity for keeping healthy of transformer. Many type maintenance
activity is carried out as monthly, quarterly, half yearly and yearly.
2-Format or template of TR PPM checklist:
3 - Types of transformer maintenance checklist:
 Monthly
 Quarterly
 Half Yearly
4-Details of safety guideline for TR PPM activity:
 Isolate electrical energy source from HT panel.

 Use lock out and tag out on the HT panel transformer feeder output
source.
5-Transformer maintenance activity checkpoints:
 Ensure no leakage current is present in the transformer after
discharging.
 Change silica gel from breather.
 Check buchholz relay alarm and trip setting.
 Check buchholz relay alarm and trip setting.
 Check and adjust winding temp alarm and trip setting.
 Check and adjust oil temp alarm and trip setting.
 Check and adjust oil temp alarm and trip setting.
 Check any crack in transformer bushing.
 Check any overheating sign on input and output cable terminals.
 Check abnormal sound in transformer body.
 Check poor contacts of terminals at the tap changer of the winding.

Parameters status :
Electrical Panel PPM- preventive maintenance

checklist format and checkpoints.
 Home
 Documents
 PPM checklist
 Elect panel PPM checklist
Contents
1. Electrical panel PPM maintenance checklist.
2. Format of electrical panel PPM maintenance checklist.
3. Types of electrical panel maintenance checklist.
4. Safety precaution for electrical panel PPM activity.
5. Details of electrical panel maintenance activity checkpoints.
1- Electrical panel PPM maintenance checklist:
Electrical panel is a costly electrical device which is used for power receiving
and distribution. Preventive maintenance is a important activity for keeping
good health of electrical panel. Many type maintenance activity is carried out
as monthly, quarterly, half yearly and yearly.
2-Format or template of electrical panel PPM checklist:
3 - Types of electrical panel maintenance checklist:
 Monthly
 Quarterly
 Half Yearly
4-Details of safety guideline for electrical panel PPM activity:
 Isolate electrical energy source from incoming electrical panel.
 Use lock out and tag out on the electrical incoming source panel.

5-Electrical maintenance activity checkpoints:
 Check all busbar connection properly.
 Check panel earth connection properly.
 Check panel earth connection properly.
 Check all measuring meters as volt meter, amp meter etc.
 Check all indicators, selector switch and push button.
 Check circuit breaker input and output terminal hot spots.
 Check circuit breaker protection settings as overload, short circuit and
earth fault.
Parameters status :

Electrical Motor PPM checklist

 Home
 Documentations
 PPM checklist
 Motor PPM checklist
Contents
1. Electrical motor maintenance checklist.
2. Format of electrical motor maintenance checklist.
3. Types of electrical motor maintenance checklist.
4. Safety precaution for electrical motor PPM activity.
5. Details of electrical motor maintenance activity checkpoints.
1- Electrical motor maintenance checklist:
Electrical motor is a costly electrical device which is used for electrical power
into mechanical power. Preventive maintenance is a important activity for
keeping good health of electrical motor. Many type maintenance activity is
carried out as monthly, quarterly, half yearly and yearly.
2-Format or template of electrical panel PPM checklist:
3 - Types of electrical motor maintenance checklist:
 Monthly
 Quarterly
 Half Yearly
4-Details of safety guideline for electrical motor PPM activity:
 Isolate electrical energy source from motor starter panel.
 Use lock out and tag out on the electrical starter panel.
5-Electrical motor maintenance activity checkpoints:
 Check terminal connection, thimble and connection plate.
 Check both side bearing for any play or loose condition.
 Check all winding insulation value if value is low then use insulation
varnish.
 Check rotor ends rings loose or tapper condition.
 Check and fill greasing in air ventilation fan and both bearings.
 Check earth connection with motor body foundation.

 Clean with air blower and clothe properly.
Parameters status :

ircuit Breaker maintenance checklist

 Home
 Documents
 Circuit breaker maintenance checklist.
Contents
1. Circuit breaker maintenance checklist.
2. Format of circuit breaker maintenance checklist.
3. Types of circuit breaker maintenance checklist.
4. Safety precaution for circuit breaker PPM activity.
5. Details of circuit breaker maintenance activity checkpoints.
1- Circuit breaker maintenance checklist:
Circuit breaker is a costly electrical device which is used for power supply
making and breaking as switched On or switched Off. Preventive maintenance
is a important activity for keeping good health of motor starter. Many type
maintenance activity is carried out as monthly, quarterly, half yearly and yearly.
2-Format or template of circuit breaker PPM checklist:
3 - Types of circuit breaker maintenance checklist:
 Monthly
 Quarterly
 Half Yearly
4-Details of safety guideline for circuit breaker PPM activity:
 Rack out circuit breaker from electrical panel.
 Use lock out and tag out on the electrical panel.

5-Circuit breaker maintenance activity checkpoints:
 Clean properly fixed and moving contact in arch chamber.
 Check and clean contact holding mechanism like as spring charging etc.
 Check and adjust breaker protection relay setting as short circuit, earth
fault and OL.
 Check all release in functional mode like as shunt coil, UV and spring
charge.
 Check auto and manual function.
 Check earth connection with panel body.
 Check any abnormal sound on load condition.

Parameters status :


Monthly Management Reports
 Home
 Documentation
 Reports
 MMR
Contents
1. Equipment Logbooks
3. Types of technical system logbooks.
o HT panel logbook.
o Transformer logbooks.
o LT panel logbook.
o UPS logbooks.
o Chiller plant logbook.
o Diesel generator logbook.
o Water treatment plant logbook.
1- Equipment Logbooks:
Log book is a record book which is used for manual storing parameters data
of equipment, events and machines. The parameters of equipments are
mentioned in it. Parameters data is taken in a frequency according
requirement as a hourly, 2 hourly, 4 hourly or per day.
Different types log books are used in a different formate are used according
equipments. Here we are going to discus electrical log books like as UPS log
book, transformer logbook, HT panel log book etc. Electrical equipments
parameters are logged as voltage, current, frequency, temp etc.
2- Tech Logbook format :
3- Types of logbooks :
1- HT panel logbook.
HT panel logbooks are used in industries, residential societies, commercial

buildings, and substations. The parameters are not down for observation and
future reference. The parameters details are below mentioned.
Parameters detail:
 Date and time.
 Energy consumption in KVAh and KWH.
 R, Y, B phase high voltage
 All three phase current.
 Maximum demand
 Power factor
 Auxiliary voltage
 Control supply voltage

2- Transformer logbook
Transformer is an electrical equipments which is used for voltage
transformation. It is costly electrical equipment so for better health we have to
follows it's parameters so that we can prevent from any fault.
Parameters:
 Date and time.
 transformer oil level.
 Dry type transformer temp

3- LT panel logbook.
LT panel is electrical power distribution center in a premises where electricity

board supply and backup supply is received and distributed to feeders so
parameters are important for LT panel health.
Parameters:
 Date and time.
 all phase current.
 frequency.
 Power factor.
 All feeders current

4- UPS logbook.
UPS is an electrical device which is used for receiving backup supply without
any interruption. So parameters are very important for knowing the status of
UPS.
Parameters:
 Date and time.
 Current in Amp

5- Chiller plant logbook.
Chiller plant is an Airconditioning machine which is used for high rise offices,
premises, malls. It is costly machines so parameters are very important for its
health.
Parameters:
 Date and time:
 Running hours.
 Voltage
 Current
 Energy in KW.
 Chilled water in and out temp.
 Condenser water in and out temp
 Oil temp and pressure.
 Refrigerant discharge, suction pressure and temp

6- Diesel generator logbook.
Diesel generator is a mechanical and electrical device which is used for back
up power generation. It converts mechanical energy into electrical energy so
record parameters are important for its better health.
Parameters:
 Date and time:
 Running hours.
 Voltage
 Current
 Energy in KW.
 Oil pressure.
 Water temp
 Coolant temp.
 Battery charger voltage.
 Fuel level.
7- Water treatment plant logbook.
WTP is a water control center where the water is received, storage, filtered and
distributed for utilization. So parameters are very important for knowing the
status of water plant.
 Date and time.
 Fire tank water level.
 Raw tank water level.
 Domestic tank water level.
 Softener tank water level
 Softener plant hardness value.
 RO plant TDS value.
 All type pump water pressure.
https://electricaltopic.com/MMR.html
Electrical Safety
Description, Types and functions.
 Home
 Electrical Safety
 Electrical safety
Contents
1. Electrical safety.
2. Types of electrical safety.
o Electrical earthing.
o Maintenance LOTO procedure.
o Electrical rubber mat.
o Electrical safety display posters.
o Electrical safety sign board.
o Safety tools and tackles.
o Electrical PPE- Personal protective equipment.
1 - Electrical safety:
Electrical system is very useful to human. The life of human is very comfortable
with use of electricity. Many equipments are using according requirement as
fan, motor, blower, AC etc. During operate and maintenance of these
equipments, we will have to keep in mind for electrical safety. Different types
electrical safeties are used as PPE, insulated tools, LOTO procedure, earthing
and many more.
1 - Types of electrical safety:
 Electrical earthing.
 Electrical LOTO procedure.
 Electrical safety rubber mat.
 Electrical safety display posters.

 Electrical safety sign board.
 Safety tools and tackles.
 Electrical PPE- Personal protective equipment.

1 - Electrical earthing:
Electrical earthing is the important safety system and it prevents from leakage
current in equipment body. Earth wire is connected to equipment body and
leakage current is circular into ground through earthing. So in this way when
any human touch the equipment body then the leakage current will not be
affected.
 Plate earthing.
 Pipe earthing.
 Chemical earthing.
 Rod earthing.
 Conductor earthing.
READ MORE
2 - Electrical LOTO procedure.:
When a equipment fails then maintenance activity is carried out. During

maintenance activity the incoming energy source is disconnected for safety. If
the primary source is not locked during maintenance activity then by mistake
other person can switch on the energy source so this situation may be
dangers for maintenance worker.
So for stopping this mis- happening incident the LOTO procedure is used. In
this system incoming energy source is switched Off and locked so that any
one can not start. A DO Not Operate tag is also installed on it with authorized
name and phone no.
READ MORE
3 - Electrical safety rubber mat.:
Electrical safety rubber is called as insulation safety mat. It is protected to us

from electrical shock. It is used infront of electrical panel. During panel
operation leakage electrical current may be dangerous for technical person. It
is comes in market according panel voltage ratings. The details of mat below
mentioned as per voltage ratings.
 Panel voltage 3.3 KV = 2mm thickness of Mat
 Panel voltage 3.3 KV = 2.5mm thickness of Mat
 Panel voltage 3.3 KV = 3.0mm thickness of Mat

4 - Electrical safety display posters.:
Electrical system is a boon for human but due to wrong use it can be
danger.For electrical safety, the display poster are very important for
increasing safety awareness. Safety instructions are mentioned on it step by
step. It is installed on electrical room, transformer, HT room, substations etc.
5 - Electrical safety sign board.:
Electrical safety sign board is a important part for safety. It is called another
name as danger sign board and danger word is mentioned on it. It is installed
on electrical panels, substations, high voltage transformers etc.
6 - Electrical safety tools and tackles.:
During maintenance activity the tools should be insulated properly like as all
type pliers, screw driver set etc.
7 - Electrical PPE- Personal protective equipment.:
Three Phase Energy Meter

Connection Diagram, Working Principle and Features.
 Home
 LT Power
 Meters
 Energy Meters
 Three phase energy meter
Contents
1. Digital Three phase energy meter.
2. Connection diagram
3. Working principle
4. Parameters of 3P energy meters
5. Applications of TP energy meter.
1 - Digital Three Phase Energy Meter:
Three phase energy meter is a measuring instrument device which is used for
measuring the utilizing power of three phase. many types of meter are used as
details below mentioned.
 Electromechanical induction type.
 Electronic energy meter.
 Smart digital energy meter
Here we are going to discuss about electronic or digital three phase energy
meter.
2 - Connection Diagram:
3 - Working Principle:
Computerized signal processor or elite execution microchips are utilized in

advanced electric meters. Like the simple meters, voltage and current
transducers are associated with a high goal ADC. When it switches simple
signs over completely to computerized tests, voltage and current examples are
increased and incorporated by advanced circuits to gauge the energy
consumed.
Microchip additionally works out stage point among voltage and current, so it
likewise gauges and shows responsive power. It is modified so that it
computes energy as per the duty and different boundaries like power factor,
greatest interest, and so on and stores this multitude of values in a non
unpredictable memory EEPROM.
It contains ongoing clock (RTC) for working out time for power reconciliation,
most extreme interest computations andfu rthermore date and time stamps
for specific boundaries. Moreover it collaborates with fluid precious stone
showcase (LCD), specialized gadgets and other meter yields. Battery is
accommodated RTC and other huge peripherals for reinforcement power.
4 - Parameters of three phase digital energy meter. :
 Voltage:- RY, YB, RB, RN, YN, BN
 Current:- R, Y, B, R, Y, N
 Phase wise load in % : three current in % of full load.
 Unbalance load in % : Current and voltage unbalance in %.
 Power factor:- pf1, pf2, pf3
 Power: VA, W, VAR, per phase and total.
 Energy:VAh, Wh, + VARh.
 CT polarity check.
5 - Applications of TP Energy Meter:
Three phase energy meter is used as widely in industrial, Commercial high rise
buildings, Residential societies etc.
lectrical Earthing
Parts, Types and Why it is used.
 Home
 LT Power
 Earthing
 Electrical Earthing
Contents
1. Electrical earthing
3. Parts of earthing.
4. Types of earthing.
5. Importance of electrical earthing.
1- Electrical Earthing:
Electrical earthing is a safety system which is protects humans and equipments

from leakage current. Electrical earthing is connected to the body of
equipments. During current leakage, the current should be immediate
discharge into ground through low resistance earth wire and earth electrode.
This process is called electrical earthing. Different types electrical earthing are
used.
2- Electrical earthing connection diagram.:
3- Parts of Earthing
1- Earth Pit:
Earth pit is the main part of ground where earth electrode is connected to the
distribution earth wire or strip.
2- Earth pipe or Strip:
Earth pipe or strip is connected to the earth plate for current discharging.
3- Earthing Plate:
Earthing plate is used for discharging the current quickly into ground.
4- Earthing wire:
Earthing wire is used for current discharging from equipment to earth pit.
4- Types of Earthing:
A- Construction type:
 1- Pipe Earthing
 2- Rod Earthing
 3- Plate earthing
 4- Chemical Earthing
 5- Conductor Earthing
B- Connection type
 1- Neutral earthing
 2- Equipment Earthing.
5- Importance of electrical earthing:

Earthing is most essential part of electrical system so it has more importance
points as per below mentioned.
 Protect any human from electrical shock during leakage current
equipment body.
 Protect to the electrical equipment form any short circut before
insulation failure.
 protect to the high rise building and electrical system from sky lightning.
 protect to the electrical equipment from fire case.
We have published a more recent article about water treatment tips, read on here.
————
Brent Hall, Technical Manager offers his top six tips for prolonging a chiller’s life to help
keep it working as efficiently as possible.
Chillers are the backbone of commercial and industrial cooling systems across the
country. However, they are not a ‘fit and forget’ solution, and there are some easy ways
to look after your chiller to ensure it lasts 10 years and more.
Water treatment is a fundamental part of a chiller’s operating and maintenance. Most

maintenance engineers know that if a chiller’s water and glycol mix is incorrect, the
effects can be rapid and disastrous, leading to corrosion, system deterioration, and
leaks, as well as the build-up of rust, scale, algae and debris. However, having a simple
‘watch list’ will help to avoid a crisis.
1. Don’t forget inhibitors
Glycol is an essential element of any heat transfer fluid used as part of a chilled water
system, as it allows the fluid to be sufficiently chilled without freezing. However, an
uninhibited glycol system can pose even more of a risk than plain water due to the
highly corrosive nature of most glycols, so inhibitors must be used at all times.
For those operating in areas where there is a risk of incidental human contact, such as
the food processing industry, the wrong inhibitors in an MPG solution creates a serious
contamination risk, but an NSF-accredited glycol overcomes that.
2. Take regular water samples from various parts of the system.
Corrosion and degradation can happen anywhere within a system and it’s not enough to
take water samples from just one location. Samples need to be taken from available
access points around the system and especially from high risk areas such as heat
exchangers, cooling jackets and any other sensitive product-fluid interfaces.
3. Test fluid pH levels
Not taking pH level readings as part of routine water sampling can have a major
negative impact on a system’s performance. While chiller pH tolerances will vary slightly
depending on the materials used, I would recommend limits of 8.0 – 8.5. Incorrect pH
levels may indicate that either not enough inhibitors have been used, or the glycol levels
are too concentrated. Both scenarios can very quickly cause high levels of corrosion
throughout a system if left unchecked, leading to costly maintenance bills and
unplanned downtime.
4. Check the clarity of the sample
Not all tests are as in-depth as pH level, and one of the most obvious signs that a chiller
system is degrading or corroding internally is when there’s visible debris in the water
sample. A water sample from a chiller operating correctly should be clear and if it’s not,
then there’s already some internal system damage. This needs to be addressed
immediately as the debris can soon lead to blockages in key areas of operation such as
the heat exchanger, which will rapidly decrease the chiller’s efficiency.
5. Chemically flush your system and chiller immediately after installation
As soon as a new chiller is installed, the whole system should be flushed immediately to
ensure the fluid is completely free from contaminants and at the highest quality
possible, with no legacy debris or surface contamination present to cause damage to
the fluid, the pipework and the new equipment. This golden rule should be followed
whether it’s a permanent or temporary installation for planned or reactive maintenance.
6. When in doubt, consult the experts
Given the intricacies of taking a thorough and correct chilled water system sample,
sometimes it pays to call in an expert. Regular water sampling and off-site laboratory
analysis is available as part of some chiller manufacturer’s aftersales and servicing
packages – including Planned Preventative Maintenance Packages (PPM) from ICS
Cool Energy.
Water cooling system specification and

requirements
Last Updated: 2021-03-01
Learn about the specific water treatment procedures and requirements that are needed for
situations where the facilities water system (FWS) water or the technology cooling system (TCS)
water can be used to directly cool the datacom equipment.
Overview
The datacom equipment cooling system (DECS) is a water loop in which the water comes in
contact with the components to be cooled. There are cases where the DECS water is supplied by
an in-rack CDU or can be supplied by an external CDU that service multiple racks. For details of
potential liquid cooling systems and loops within a data center and the terminology that is used,
see Figure 1.
The water quality standards that are specified pertain only to the DECS water loop that comes
into contact with compute components. The ongoing monitoring and maintenance procedures are
also described.
The cooling loop hardware consists mainly of corrosion resistant alloys, such as copper alloys
and stainless steels. EPDM rubber must form the inner lining of all the hoses in the system. The
chemistry of the cooling water must be properly maintained to avoid system disruption or
shutdown due to any of the four common water-related problems of corrosion, microbiological
growth, scale formation, and fouling.
The details of the water treatment depend on whether the local municipality allows the disposal
of water that contains some cleaning chemicals down a sanitary drain. If the local municipality
does not allow the disposal of contaminated water down a sanitary drain, a deionizing bypass can
be included in the water cooling loop to allow the cleaning of the water to purity levels
corresponding to resistivity > 0.1 MΩ.cm (conductivity < 10 μS/cm) before pouring the water
down the drain. You are responsible for verifying the local regulations before you dispose any
water.
Figure 1. Example of liquid cooling systems and loops within a data center
Water-related problems
Proper treatment of the water is necessary to avoid the following common water-related
problems: corrosion, microbiological growth, scale formation, and fouling. Any of these
problems can significantly reduce the cooling efficiencies and increase the risk of system
downtime.
 Corrosion - corrosion can take on many forms. The common forms of corrosion that are
relevant to the cooling loop include the following forms:
o Uniform corrosion, also referred to as general corrosion, is the spatially uniform
removal of metal from the surface. It is the typical expected mode of corrosion.
o Pitting corrosion is a localized attack of a metal surface that in the case of copper
tubes can lead to water leaks with a typical mean time to failure of around 2 years.
o Galvanic corrosion arises when two metals that are wide apart in the galvanic
series are in electrical contact and immersed in the same water environment. The
potential difference that arises between the two metals in contact, forces electrons
to flow from the less noble to the more noble metal. On the less noble metal
surface, corrosion occurs, giving off electrons that are consumed on the more
noble metal surface by a reduction reaction that can take many chemical forms.
Examples are the reduction of metal ions or the consumption of oxygen and water
to form hydroxyl ions. Even when not in electrical contact, aluminum can be
galvanically attacked by copper because of dissolved copper ions in low
concentrations that deposit on the aluminum surface forming the galvanic
corrosion couple.
 Microbiological growth - microbiological growth in water cooling systems can lead to
deposition, fouling, and corrosion within the cooling loop. Prevention of microbiological
growth involves making sure that the cooling loop hardware is assembled from
components that are free of biological organisms and treatment with biocides to control
the bacteria population. To avoid biological growth, the water cooling loops must be
shipped and stored dry. Every effort must be made to blow out the water and dry the
water cooling loop as much as possible before shipping and storage.
 Scale formation - scaling is the deposition of dense, adherent material on the cooling loop
surfaces. Scaling occurs when the solubilities of salts in water are exceeded because of
high concentrations or because of increased temperature.
 Fouling - fouling of cooling loops is the deposition of non-scale-forming substances such
as corrosion products and organics. Fungi, such as Fusarium sp, are known to grow, foul,
and plug filters and fine finned heat sinks. They generally grow at the water line in
cooling tower basins or sumps.
Avoiding water-related problems

The following best practices can be used to avoid water-related problems:
 Design clean - Restrict the water-wetted metallurgies to copper alloys and stainless steels.
Avoid the use of plain-carbon steel hardware that can rust and foul the water cooling
loop.
 Build clean - Ensure that the cooling loop components are clean and free of bacteria and
fungi. The cooling loop assembly must be free of soldering, brazing fluxes, or both.
Clean water must be used in the assembly operations. Any residual water must be blown
out of the assembly. The finished assembly must be clean and dry.
 Ship clean - Any residual water from the assembly, testing operations, or both must be
blown out from the cooling loop before any shipping to avoid corrosion and
microbiological growth. As a final step, use nitrogen gas to dry the system. Plug ends and
ship the system with the cooling loop pressurized with nitrogen gas.
 Install clean - The cooling loop must be kept clean during the installation step. Brazing is
preferred over soldering. Problem with soldering is porous joints that keep leaching out
flux residue. All flux residues must be cleaned off. Fill the system with clean water and,
if possible, include a secondary step to deionize the water in the cooling loop before the
addition of biocide and corrosion inhibitors.
 Maintain clean - Monitor and maintain the pH, water conductivity, bacteria count, and the
corrosion inhibitor concentration.
Water quality requirements

Use the following requirements to plan for the water quality in your system:
 The water that is required to initially fill the system side cooling loop must be reasonably
clean, bacteria-free water (less than 100 CFU/ml), such as demineralized water, reverse
osmosis water, deionized water, or distilled water.
 The water must be filtered with an in-line 50 μm filter.
 If reasonably clean water is not available, the following guidelines are recommended. It
is especially useful for large cooling loops: In this method, the water is deionized before
any of the racks are connected to the water loop.
o It is important to ensure that the system water is cleaned before any chemicals are
added to the water. This can be accomplished by deionizing the water by using
deionizing cartridges that are installed in the cooling loop. Even if deionized
water is used to fill the system, a deionizing step is prudent for two reasons: the
first is to ensure that the starting water is deionized and the second is to remove
any ions that might leach off the walls of the cooling loop.
o When the water needs to be deionized, the valves V2 and V3 can be opened and
valve V1 partially closed to bypass some of the water through the deionizing
canister.
o During this deionizing step, the cooling loop and the computers can keep
operating normally.
o When the deionization is complete, the V2 and V3 valves must be closed and V1
fully opened.
o The deionization step raises the resistivity of the water greater than 1 MΩ.cm.
o Under normal operation, the V2 and V3 valves are closed and V1 valve is fully
open.
Figure 2. Deionizing the water using deionizing cartridges installed in the cooling loop
Water quality chemical requirements

The following measurements must be performed before you add any chemicals to the water
loop. It is the starting point that defines a clean water base.
 All metals less than or equal to 0.10 ppm
 Calcium less than or equal to 1.0 ppm
 Magnesium less than or equal to 1.0 ppm
 Manganese less than or equal to 0.10 ppm
 Phosphorus less than or equal to 0.50 ppm
 Silica less than or equal to 1.0 ppm
 Sodium less than or equal to 0.10 ppm
 Bromide less than or equal to 0.10 ppm
 Nitrite less than or equal to 0.50 ppm
 Chloride less than or equal to 0.50 ppm
 Nitrate less than or equal to 0.50 ppm
 Sulfate less than or equal to 0.50 ppm
 Conductivity less than or equal to 10.0 μS/cm. Conductivity must be measured at 20°C -
25°C (68°F - 77°F). Conductivity increases approximately 5% for every degree Celsius
rise in temperature
 pH 6.5 – 8.0
 Turbidity (NTU) less than or equal to 1
Plumbing materials requirements

All piping must be composed of specified materials to prevent scaling and to allow proper
reactions with the chemistry of the water within the system. Threaded joints must not be sealed
with polytetrafluoroethylene tape, as particles from the tape may enter the water stream and
create clogs. Instead, a thread sealant, must be used to seal threaded fittings. Piping must be large
enough, as dictated by industry best practices, to avoid excessive water velocity as well as undue
pressure drop.
Material selection and installation is a complex issue that is governed by building codes and
other local requirements. You are encouraged to consult with appropriate authorities that have
jurisdiction (such as building inspectors, fire departments, insurance providers, and code
compliance officers) before you plan and install cooling distribution systems. The following
information is provided for chemical compatibility purposes.
The following alloys must be avoided in the plumbing system:
 Aluminum and aluminum alloys.

 Brass with greater than 15% zinc.
 Free-cutting brasses, especially brasses that contain lead. One example of such brass is
copper alloy C36000 called free-cutting yellow brass.
 High lead brasses are especially a concern because of stress corrosion cracking when
subjected to high tensile stress.
 Steels that are not stainless steel.
 Stainless steels that are not properly solution treated.
The following materials are preferred:

 Copper alloys:
o Lead-free copper alloys with less than 15% zinc.
 Stainless steels:
o Low carbon stainless steels are preferred.
o Must be solution that is treated. Stainless steel that is solution-treated undergoes a
specific heat treatment to improve its resistance to corrosion.
o Passivation is desirable as long there is low possibility of acid entrapment in
crevices.
o Avoid sensitization during welding.
o Avoid brazing; welding is preferred.
 Polyvinyl chloride (PVC) (not allowed inside IBM® products due to flammability
concerns, but can be used at a facility level. Appropriate authorities that have jurisdiction
must be consulted).
 EPDM rubber is the preferred material for hoses:
o Flammability rating must be CSA or UL VW-1 or better.
o Peroxide cured hoses are preferred because they do not absorb triazoles.
Metal joining operations:
 Solder joints that come in contact with water must be avoided. Solder joints are porous
and they leach flux residue into the cooling loop. Solder joints might pass inspection and
pressure tests as manufactured, but still might be unreliable.
 Brazed joints are preferred for joining copper plumbing pieces.
 Braze joints must not be used to join stainless steels. Tungsten inert gas (TIG) and metal
inert gas (MIG) welding are preferred for joining stainless steels. Sensitization must be
avoided. Welded assembly must be cleaned and, if possible, passivated if there is a low
possibility of acid entrapment in crevices.
Deionizing equipment
Deionizing equipment is optional. It is recommended for use in large cooling loops. When the
water needs to be deionized, some of the water can be bypassed to flow through the deionizing
cartridge.
Dosing Equipment
The following equipment is used to dose the cooling loop:
 Recommend using a stainless steel or fiberglass chemical shot feeder.

 System volumes less than 378.5 liters (100 gallons) use a 0.38 liter (0.1 gallon) size
feeder
 System volumes less than 3875 liters (1000 gallons) use a 3.8 liter (1 gallon) size feeder
 System volumes greater than 3875 liters (1000 gallons) use a 9.5 liter (2.5 gallon) size
feeder.
 Chemical pump according to Nalco or another water treatment contractor specification.
Monitoring equipment
The following equipment is used to monitor the cooling loop:
 3D TRASAR® Controller (#060-TR5500.88) for systems larger than 250 gallons to

enable precise and continuous monitoring of system water chemistries: conductivity, pH,
corrosion rate, and turbidity.
 Azole test kit
o Nalco P/N 460-P3119.88 – Triazole Reagent Set, 25 mL
o Nalco P/N 500-P2553.88 – UV Lamp with power supply, 115 VAC
o Nalco P/N 400-P0890.88 – Nalco DR/890 Colorimeter
o Nalco P/N 500-P1204.88 – 25 mL graduated cylinder
 Nalco bacteria test kit
o Nalco P/N 500-P3054.88 – Bacteria dip slides
 Water resistivity monitor with 0-10 MΩ.cm range
o Nalco P/N 400-C006P.88
Required materials and equipment

The following items must be available to properly and safely complete the initial system start:
 De-ionizing cartridges of appropriate capacity (optional).

 Nalco treatment chemicals in appropriate quantities.
o System with 75.7 liters (20 gallons) or less coolant: Use a suggest prepackaged
cleaner and inhibitor solution: Nalco 460-CCL2567 or Nalco CCL2567 and Nalco
460-CCL100 or Nalco CCL100. If exposure to bacterial is suspected or a concern,
biocides such as Nalco H-550 or Nalco 73500 can be used. If fungi are suspected
or a concern, Nalco 77352 can be used.
o System with greater than 75.7 liters (20 gallons) of coolant: Use a suggest using
concentrated chemicals. The cleaner in concentrated form is Nalco 2567. The
inhibitor in concentrated form is Nalco 3DT-199. If exposure to bacterial is
suspected or a concern, biocides such as Nalco H-550 or Nalco 73500 can be
used. If fungi are suspected or a concern, Nalco 77352 can be used.
 A method to add chemicals: Use an installed system chemical shot feeder, an
appropriately sized chemical feed pump, or both.
 Source of demineralized water, reverse osmosis water, deionized water, or distilled water.
 Proper personal protective equipment.
 Approved drainage to drain pre-cleaning waters (for example, sanitary sewer). You are
responsible for the drainage process according to local regulations.
 Appropriate test kits to monitor Nalco 3DT-199 residual and bacteria count after Nalco
H-550, Nalco 73500 or Nalco 77352 addition.
 Water resistivity monitor with 0-10 MΩ.cm range.
Initial treatment for systems smaller than 75.7 liters (20 gallons)
Use the following procedure to clean your system:
Note: This procedure must be performed on the cooling loop before any computer racks are
connected to the system.
1. System must be empty. If it is not empty, you must drain the system completely.
2. Remove all the filters from the filter housings.
3. Ensure that bypass hoses are connected between the supply and return portions of the
cooling loop to ensure the cleaning of all sections of the system.
4. One of the following two cleansing procedures can be used:
a. Chemical cleaning - This method is the most effective way for cleaning the
plumbing loop.
i. Fill the system with cleaning solution. The suggested cleaning solutions
are Nalco 460-CCL2567 or Nalco CCL2567.
ii. Circulate the cleaning solution for a minimum of 30 minutes (longer if
time permits) to ensure that it reaches all sections of the system.
iii. Drain the system completely, disposing of the cleaning solution according
to local regulations
iv. Refill with demineralized water, reverse osmosis water, deionized water,
or distilled water.
v. Circulate the water for 15 minutes.
vi. Drain the system completely, disposing of the cleaner according to local
regulations.
vii. Immediately proceed to fill the system with water that contains premixed
inhibitor and preservative.
b. Cleaning with deionized water. This procedure can be used if the cleaning
chemical cannot be obtained or if local laws prevent the disposal of the chemicals.
i. Completely fill the system with demineralized water, reverse osmosis
water, deionized water, or distilled water.
ii. Deionize the water by bypassing some of the water flow through the
deionizing cartridge or cartridges and circulate the water normally through
the complete system until the resistivity of the water increases above 1
MΩ cm.
iii. Proceed to the inhibitor dosing procedure.
Use the following procedure for chemical dosing:
1. Install a new or cleaned 50 μm filter in the filter housings.

2. One of the following two dosing procedures can be used:
a. If the system was cleaned by using cleaning solution Nalco 460-CCL2567 or
Nalco CCL2567 and if at the end of the cleaning step, the system was empty with
no water in it, complete the following steps:
i. Fill the coolant reservoir with Nalco 460PCCL100 / Nalco CCL100. Add
120 ppm of Nalco 3DT-199 to raise the azole concentration to 40 ppm.
ii. If bacteria or fungi is suspected or is a serious concern, add one of the
following biocides:
 100 parts per million (ppm) of Nalco H-550 (glutaraldehyde)
 200 ppm of Nalco 73500 (glutaraldehyde)
 100 ppm of Nalco 77352 (isothiazolone)
The choice of biocide depends on the expected microbiological material in
the cooling loop. Glutaraldehyde biocide is more effective against
anaerobic bacteria. Isothiazolone is more effective against aerobic
bacteria, fungi, and algae. When in doubt, use the isothiazolone biocide.
iii. Confirm azole residual using Nalco azole test kit.
If the system was cleaned by using deionized water only and the system is full of
deionized water, complete the following steps:
iv. Add one of the following biocides:


v. Add 120 ppm of Nalco 3DT-199 to achieve 40 ppm azole concentration.

vi. Confirm azole residual using Nalco azole test kit.
Initial treatment for systems larger than 75.7 liters (20 gallons)
Use the following procedure to clean your system:
Note: This procedure must be performed on the cooling loop before any computer racks are
connected to the system.
1. System must be empty. If it is not empty, you must drain the system completely.
2. Remove all the filters from the filter housings.
3. Ensure that bypass hoses are connected between the supply and return manifolds of the
cooling loop to ensure the cleaning of all surfaces of the cooling loop.
4. One of the following two cleansing procedures can be used:
a. Chemical cleaning - This method is the most effective way for cleaning the
plumbing loop.
i. Fill the system with demineralized water, reverse osmosis water,
deionized water, or distilled water.
ii. Add the required volume of cleaning solution Nalco 2567 according to the
manufacturer recommendation.
iii. Circulate the cleaning solution for a minimum of 4 hours.
iv. Drain the system completely utilizing all drain ports available, disposing
of the cleaning solution according to local regulations
v. Refill with demineralized water, reverse osmosis water, deionized water,
or distilled water.
vi. Circulate the water for 1 hour.
vii. Drain the system completely utilizing all drain ports available, disposing
of the cleaning solution according to local regulations
viii. Refill with demineralized water, reverse osmosis water, deionized water,
or distilled water.
ix. Circulate for 15 minutes.
x. Immediately proceed to the inhibitor dosing procedure.
b. Cleaning with deionized water. This procedure can be used if the cleaning
chemical cannot be obtained or if local laws prevent the disposal of the chemicals.
i. Completely fill the system with demineralized water, reverse osmosis
water, deionized water, or distilled water.
ii. Deionize the water by bypassing some of the water flow through the
deionizing cartridge or cartridges and circulate the water normally through
the complete system until the resistivity of the water increases above 1MΩ
cm.
iii. Proceed to the inhibitor dosing procedure.
Use the following procedure for chemical dosing:

Note: The dosing procedure for systems larger than 75.7 liters (20 gallons) is the same regardless
of the cleaning technique.
1. Install a new or cleaned 50 μm filter in the filter housings.

2. One of the following two dosing procedures can be used:
a. If the system was cleaned by using cleaning solution Nalco 460-CCL2567 or
Nalco CCL2567 and if at the end of the cleaning step, the system was empty with
no water in it, complete the following steps:
i. Fill the coolant reservoir with Nalco 460PCCL100 / Nalco CCL100. Add
120 ppm of Nalco 3DT-199 to raise the azole concentration to 40 ppm.
ii. If bacteria or fungi is suspected or is a serious concern, add one of the
following biocides:

iii. Confirm azole residual using Nalco azole test kit.
If the system was cleaned by using deionized water only and the system is full of
deionized water, complete the following steps:
iv. Add one of the following biocides:


v. Add 120 ppm of Nalco 3DT-199 to achieve 40 ppm azole concentration.

vi. Confirm azole residual using Nalco azole test kit.
System monitoring and maintenance

Use the following guidelines for system monitoring and maintenance:
 It is important to conduct a bacteria test on a quarterly basis and add 100 ppm of Nalco
H-550 or 200 ppm of Nalco 73500 biocide if the bacteria count is greater than 1000
CFU/ml. Nalco 77352 fungicide can be added if fungi have been a concern in the past.
o Fungi might not be detected in the water, even though it can grow and cause
blockage of cooling channels in cold plates that are used to cool the computer
processors. Reduced coolant flow rate through the cold plates might be an
indication of blocked channels due to fungi growth.
 On large systems that have more than 250 gallons of water, Nalco 3D TRASAR®
controller must be installed on the system cooling loop to enable precise and continuous
monitoring of system water chemistries, conductivity, pH, corrosion rate, and turbidity.
 It is important to conduct an azole test on an annual basis and add Nalco 3DT-199 to
bring the azole concentration to the wanted 40 ppm level or any other desirable ppm
level.
Multiple racks
Use the following guidelines when adding additional racks:
 Racks arrive from IBM ready for installation.

 Install rack or racks and open flow from existing system.
 Make sure that the automated water make up on the chiller coolant reservoir is activated.
If there is no automated water make up feature, top off the system side reservoir.
 Within 2 hours of installing the new rack or racks, add one of the following biocides:
o 100 parts per million (ppm) of Nalco H-550 (glutaraldehyde)
o 200 ppm of Nalco 73500 (glutaraldehyde)
o 100 ppm of Nalco 77352 (isothiazolone)
The choice of biocide depends on the expected microbiological material in the cooling
loop. Glutaraldehyde biocide is more effective against anaerobic bacteria. Isothiazolone
is more effective against aerobic bacteria, fungi, and algae. When in doubt, use the
isothiazolone biocide.
 Add 120 ppm of Nalco 3DT-199 to achieve 40 ppm of azole concentration. The amount
of inhibitor dosage is calculated based on the volume of the makeup water.
 Confirm azole residual using Nalco azole test kit.
Refreshing the water

Situations might arise where the water must be refreshed (for example, the system must be
cleaned and the biocide and corrosion inhibitor is added again). To refresh the water, use one of
the two following procedures:
If you prefer that no water goes down the sanitary sewer, use the following procedure:
1. Remove the inline 50 μm filter from the filter housing.

2. Insert new deionization cartridges into the canisters and bypass some of the water
through the deionizing cartridges until the resistivity of the water increases above 1
MΩ.cm. During this period, the systems and cooling system can be left on and be fully
functional.
3. Stop the bypassing of the water flow through the deionizing filter and add a new or
cleaned 50 μm filter to the inline filter housings.
4. Add one of the following biocides:
o 100 parts per million (ppm) of Nalco H-550 (glutaraldehyde)
o 200 ppm of Nalco 73500 (glutaraldehyde)
o 100 ppm of Nalco 77352 (isothiazolone)
The choice of biocide depends on the expected microbiological material in the cooling
loop. Glutaraldehyde biocide is more effective against anaerobic bacteria. Isothiazolone
is more effective against aerobic bacteria, fungi, and algae. When in doubt, use the
isothiazolone biocide.
5. Circulate for 30 minutes.

6. Add 120 ppm of Nalco 3DT-199 to achieve 40 ppm of azole concentration.
7. Circulate for 30 minutes.
8. Confirm azole residual using Nalco azole test kit.
If the water can be poured down the sanitary sewer, use the following procedure:
1. Pour the water down the drain with the permission of the local municipality.
2. Fill the system by using one of the following procedures:
o Systems less than 75.7 liters (20 gallons): Initial treatment for systems smaller
than 75.7 liters (20 gallons).
o Systems larger than 75.7 liters (20 gallons): Initial treatment for systems larger
than 75.7 liters (20 gallons).
Moving or storing the system

If you need to move your system or put it into storage, the water in the system must be drained.
You can drain the water in one of two ways:
 The water can be deionized to a purity corresponding to resistivity greater than 0.1
MΩ.cm and then can be poured down any municipal drain.
 The water can be poured down a sanitary drain with the permission of the local
municipality.
Disposal of water and cartridges

The deionizing cartridges must be disposed off in accordance with local municipality ordinances.
IBM is not responsible for the disposal of water. You are responsible for determining the local
regulations that govern the disposal of water.
Troubleshooting
If you encounter any problems with your water-cooled system, use the following table to
troubleshoot your problem.
Problem Solution
Poor cooling performance Contact IBM Service
Reduced water flow Contact IBM Service.
Chemical pump issues (where Follow procedures that are provided by installer, contact your
installed and used) site water treatment contractor or local Nalco office, or both.
3D TRASAR® alarms or
Contact the local Nalco office.
operational issues
Might be an indication of corrosion and or microbiological
Discolored water
issues. Refresh the water supply.
Might be an indication of corrosion and or microbiological
Slime in flow meter areas
issues. Refresh the water supply.
 For systems of smaller than 75.7 liters (20 gallons),
refresh the water supply.
 For systems of larger than 75.7 liters (20 gallons), add
100 parts per million (ppm) of Nalco H-550 or Nalco
Elevated microbial counts 73500 biocide. Retest the bacteria content between 24
– 48 hours after biocide dosing. If the bacteria level is
not less than 100 CFU/ml contact Nalco or your water
treatment company.
Fungi Contact Nalco or your water treatment company.

Any other problems Contact IBM Service.
Table 1. Troubleshooting
Parent topic:
Planning for water cooling
Parent topic:
Planning for water cooling
Last updated: Tue, February 02, 2021

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maintaining user understanding, are sometimes required. As other industry leaders join IBM in embracing the use of
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Injection Molding Chille Chiller (10℃）
Model Injection Injection Injection Injection Injection Injection Injection Injection Inj
Molding Molding Molding Molding Molding Molding Molding Molding Mo
Chiller Chille Chille Chille Chille Chille Chille Chille Ch
3.1ADT 5.1ADT 8.1ADT 10.1ADT 12.1ADT 15.1ADT 20.1ADT 20.2ADT 25
KW 1.3 7.3 1. 11 14.6 16.5 20.8 27.9 29.3 33
10′ Kc a
Cooling Capacity 1. 2 1. 5 1. 10 1. 11 1. 13 17.9 24 25.2 28
1/h
TR 12. 31 1. 1 3.7 1. 3 1. 3 1. 4 1. 6 1. 7 1. 8
Total Current A 1. 4 1. 7 1. 11 15 16.6 22.5 29.6 28.3 32
Compresso
Quantity Set 1 1 1 1 1 1 1 2 2
r
Power kW 0.19 0.42 0.38 0.84 0.84 0.84 12. 31 12. 31 12

Axial Fan
Current A 0.5 0.85 1 1.7 1.7 1.7 3 3 3
Flow Rate m’/ h 13 21 37 42 47 59 80 84 94
Evaporator
Pipe
DN 20 20 25 25 25 32 32 32 32
Diameter
Water Power kW 0.37 0.37 0.37 0.55 0.55 0.75 0.75 0.75 12
Pump Head M 15 20 21 18 16 23 22 22 21
Water Tank L 70 75 100 115 145 250 270 270 32
Length mm 950 950 1200 1350 1400 1600 1950 1950 21
Diament Width mm 700 700 850 850 850 1000 1250 1250 12
Height mm 1050 1050 1550 1550 1550 1600 1600 1600 16
Weight kg 150 200 285 350 450 600 830 830 10
Why Choose Geson Injection Molding

Chiller?
If you are finding industrial injection molding and blow molding chillers for your plastic
process cooling system.
Geson water cooled chiller for injection molding machine can meet all your varied of
requirements.
Here, you will have the ultimate economical injection mold chiller solution.
From the professionally experienced R&D team, you will satisfy the industrial water
cooled chiller system.
We can supply the following types of industrial water chiller:
Screw Chillers
Centrifugal Chillers
Rotary Screw Chillers
Scroll Chillers.
You can get the following services:

Customize chiller types, compressor types.
Precious proper cooling temperature.
The most suitable economical refrigerant.
The OEM brand for your brand.
Stable operation with 40000 hours failure-free.
Customize the voltage as your need.
Contact our engineer, to get the right solution for your plastics industry injection molding
applications.
CONTACT WITH EXPERTS
REQUEST FOR CATALOGUE
GESON Chillers for the Plastic Industry

Chillers for Extrusion Application
Plastic extrusion manufacturing is that the melted thermoplastic material is fed through
a hole.
Creates a continuous length of uniform section of the part.
Two different types of plastic can be extruded.
Film blowing extrusion, compressed air passes through holes to create air bubbles with
plastic and form plastic film.
The process of plastic extrusion requires the use of chillers, because the temperature of
plastic needs to be controlled at all times during production.
Chillers are used to cool down the temperature of hot molten plastic in order for it to
become solid and flowable.
If the temperature is too high, then there will be problems with adhesion and other
defects in the final product.
Chiller for Injection Molding Machine
Melted plastic (jetting) enters the mold through a nozzle.
Thermoplastics are generally used, and thermosetting plastics are used individually
Metal parts can be inserted
Producing simple and complex parts
The cooling process of plastic injection molding machine is a key factor in the success
of products. Without proper cooling, the product can be deformed and has reduced
mechanical strength. The cooling process is also important because it helps maintain
the dimensional accuracy of the product.
An effective way to cool down the heated plastic is by using a chiller for injection
molding machine. It has many advantages such as:
– Reducing heat load on downstream equipment
– Improving mold filling and ejection
– Reducing cycle time

Chillers for Blow Molding Application
The melted plastic is called a blow-molded parison before it is formed.
Compressed air forces the plastic to coat the mold cavity
Use usually thermoplastic.
Injection Blow Molding – Blow-molded parisons are cast into a mold and then blown into
shape.
Production of bottles with smaller openings and hollow-shaped objects
The use of chillers in the blow molding process is essential for the quality of the finished
product. The blow molding process requires a plastic that can be heated to its melting
point and then cooled quickly. This cooling has to happen fast enough so that the plastic
does not have time to cool too much before it is injected into a mold.
Blow molding is an industrial process by which hollow, semi-solid objects are formed in
a shape, typically by extrusion or injection, and then cooled. Blow molded products are
very common in everyday life, such as food containers, bottles, toys and cups.
Chillers for Compression Molding Application
Forming a plastic mixture under hot pressing.
Plastic is pressed into the mold.
Before pressing, it is formed into a certain shape by preheating.
Thermoset plastic is usually used.
Sundries, Parts, Durable Rigid Thermoset PlasticsChillers are used in plastic

compression molding for cooling and solidifying the plastic. They can be used for both
continuous and batch production.
The following are some of the most common types of chillers:
– Air-cooled chillers
– Water-cooled chillers
– Oil-cooled chillers
– Gas coolers
Chillers for Transfer Molding Application
Preheated shaped items are placed in the transfer chamber.
The plunger turns the plastic into a liquid that flows into the mold cavity.
Usually use thermoset plastic.
The major use of chillers is for cooling liquids in the plastic transfer molding process.
The chiller removes heat from the liquid and transfers it to a cooling surface. The cooled
liquid then cools the plastic parts being transferred into the mold cavity.
Chillers for Rotational Molding Application
Plastic melts in bidirectionally rotating mould.
Plastic coating on the inner surface of the mold.
The rotating mold is cooled.
Production of hollow parts without openings.
Generally use thermosetting plastic.

Rotational molding is a process that involves the use of heat and pressure to produce
hollow plastic parts. The most common type of rotational molding is called “injection
molding”.
A rotational molding machine has a barrel in which molten plastic is injected and rotated
to cool it evenly. The cooled, solidified part is then ejected from the machine.
In order to produce high quality parts, the temperature of the liquid plastic inside the
barrel has to be maintained at a certain level throughout the entire injection process. If it
gets too hot or too cold, it will affect how well the finished product turns out. This can be
done by using a chiller system that cools or heats as needed.
Chillers for Thermoforming Application
Soften thermoformed sheets by heating.
Plastic extends to mold.
Plastic enters the mold under vacuum and takes shape.
Plastic thermoforming is a process which involves the heating of plastic sheets and
shaping them over a mold. The shape of the mold determines the final product.
The main objective of a chiller is to maintain the temperature of the plastic at an optimal
level by cooling or heating it, depending on requirements. A chiller may be used as an
alternative to water baths in some cases.
Chillers are mainly used in Plastic Thermoforming for applications like:
– Injection Molding
– Blow Molding
– Vacuum Forming
Top Brand Components

Ensure Your Top Quality Chiller
Top Quality Screw Compressor With Certificate
Adopts Famous Brand Compressor;
Semi-hermetic 5:6 Screw Compressor;
Compressor Energy Efficiency is 20%~30% Higher;
Available with R134A/R407C/R410A/R510A and etc.
40000 Hours of Trouble-free Operation
Screw Compressor has Approved ISO9001, CRAA、CE、PED、UL Certification;
Reliable Microcomputer Control System

PLC Programmable Controller
LCD Touch Controller
Automatic Detection of Cold Water Outlet Temperature;
Automatic Detection of Operating Conditions;
Automatically Record the Alarm and Send Trouble Alarm;
Can Realize Remote Control;
Reserve RS-485 Communication Interface, or Ethernet Port;
Customize Display Language: Chinese, English, Russian, Spanish；
High-efficiency Shell and Tube Heat Exchanger

Low Maintenance Cost, Easy Operation;
Long Cleaning Cycle and Convenient Cleaning;
Fast Heat Exchange Speed;
High-Temperature Resistance 400℃;
High-Pressure Resistance 2.5Mpa;
Can be Used Under High Temperature and High Pressure
Adopts Copper Tube with Rolled Fins on the Outer Surface,
Which Has High Thermal Conductivity and Large Heat Exchange Area;
Long Service Life Up to More Than 20 Years;
Brand Refrigeration Components：

Famous Brand Expansion Valve;
Brand Filter Drier
Has Electronic Expansion Valve
Or Thermoexpension Valve
Ensure the Stable Operation of the Industrial Water Chiller Unit.
Top Quality Electrical Components：

Famous Brand A.C Contactor, Relay, Thermal Protector,
Brand Pressure Controller, Filter Drier to Ensure the Reliability of the Industrial Water Chiller
Unit
High-Efficiency Copper and Aluminum Fins

Condenser：
Heat Transfer Performance is Good, Stable, Air Resistance is Small.
Enhance the Efficiency of the Heat Exchanging
Injection Molding Chillers Manufacturer |

Geson Chiller
This information will help you in getting the best Injection Molding Chiller.
Indeed, it identifies everything.
That you have been searching for.
Hence, it includes version, kind, advantages, price, and maintenance, among other
important points.
So before you buy a Chiller Plant For Injection Molding machine, go through this guide.
The working principle of the injection molding chiller units:
After the plastic pellets are injected into the mold after heating and melting in the
injection molding machine to condense, the mold is opened to eject the molded plastic
workpiece.
In the continuous production process, the chilled water system of the chiller is required
to cool the mold to shorten the plastic condensing time and improve the dimensional
accuracy of the workpiece.
Molding quality and surface quality, this is the working principle of injection molding
water chillers, injection molding water cooled chillers generally use water-cooled box
chillers.
If the chiller is applied to the cooling cycle of molding molds of plastic processing
machinery, it can greatly improve the surface finish of plastic industry products, reduce
the surface marks and internal stress of plastic industry products, make the products do
not shrink or deform, facilitate the demolding of plastic products, and accelerate product
shaping.
Thereby greatly improving the production efficiency of the plastic molding machine;
Portablechiller for injection molding
What is a Chiller?
A chiller is an appliance that eliminates heat from a fluid through different methods.
They include vapor-compression, adsorption refrigeration, or absorption refrigeration

cycles.
Moreover, this fluid can then be transferred through a heat exchanger to cool
processing equipment or another process stream. i.e., air or process water
Chiller For Injection Molding Machine
· What are the components of a Chiller?
Following are the major components of a Chiller

1. Compressor,
2. Condenser,
3. Evaporator,
4. Expansion Valve,
5. PowerPanel,
6. Control unit,
7. WaterBox,
Chiller system basics
· What is the principle of an Injection Molding Chiller?
A chiller performs on the principle of vapor-compression or vapor absorption closed

loop.
Thus, the heat transfer takes place, the refrigerant evaporates, changing from a low-
pressure fluid into a vapor.
While the Blow Molding and Molding Water proper cooling temperature of the process
coolant decreases.
The refrigerant then moves to a compressor, which executes multiple functions.
How does Water Chiller Units cool the Mould.
The injection mold chiller is cooling cycle device for the injection mold machines.
The blow molding and injection molding machine cooling requirements chilled water
flow rate with precise proper cooling temperature.
Injection mold coolers inject the cooling water into the mold body.
The low temperature chilled water flow rate is generated by the small process chillers.
Low-temperature water is pressurized and poured into the mold body through the
booster pump to improve the cooling efficiency.
There is a pressure regulating valve on the booster pump,
The pressure regulating valve can adjust the pressure of the water flow into the injection
mold, So that the cooling effect can be control;
The cooling temperature can be controlled.
· What are the kinds of a Chiller?
There are two kinds of a Chiller.
They are:
 Compression Chillers
 Absorption Chillers
Air Chiller Diagram
What is Drooling in Water Cooling System For Molding?
When nozzles are pushed away from the mold after injection, blow molding has been
processed out.
Thus, the drizzle of plastic from the sprue gate occurs.
Hence, this drizzle of plastic is usually called drooling.

Moreover, it is caused by residual pressure stored in the sprue and runner.
Water Chiller For Injection Molding Machine
How to do the water treatment in the plastic injection molding system?
When the efficiency of the chiller cooing is low, it is possible because of the scale
formation.
You need to do the water treatment for the plastic injection molding chiller.
· Can ABS be injection molded?
ABS is a thermoplastic matter.
Thus, it is known for its high impact resistance and rigidity.
Furthermore, it has good resistance to scratching and toughness with excellent

dimensional reliability.
However, due to these thermoplastic features, ABS is easily plastic injection molded.
Chiller Plant
General Plastic Manufacturing Mold Cooling

Mold Chiller
· What is the switchover position in an Injection Molding Chiller?
The switchover position is the ram position where the injection position switches to the
packing part.
However, the cushion length is the distance from the switchover position to the farthest
place that the end of the screw can reach.
· What is mold temperature controller in blow molding and Injection

molding?
For injection-molding processing of PTT melt， and blow molding Water Temperature
Control, recommend being between 232–260°C and 88–121°C, respectively.
· What is tonnage in an Chiller?
The “tonnage” is the calculation of energy needed to keep the tool closed during the
injection.
Thus, this energy is the main component in determining the molding appliance size
needed for producing the processing equipment.
· How do you calculate tonnage in Plastic Chillers?
The foremost step in calculating accurate clamp tonnage is to measure the surface area
of the part.
However, this means achieving the space’s square inch area by multiplying the length
by the width.
Moreover, if it is a multi-space mold?
Then, multiply the number by the number of cavities.
· How do you modulate air bubbles in an Injection Molding Machine?
In contrast, use a heat gun or something familiar.
Then as you gently heat the area of the component where the bubble is formed.
Thus, the state of the bubble should change.

So, if it is a gas bubble?
The gas will heat up and expand.
Moreover, it raises the surface and often will pop as the part surface gets smooths.
How To Calculate Btu/hr For Chiller?
How to convert the hp and btu of the chiller? The conversion relationship of the cooling
capacity unit is as follows:
1 kcal/h (kcal/hour) = 1.163W, 1 W = 0.8598 kcal/h;
1 Btu/h (British thermal unit/hour) = 0.2931W, 1 W = 3.412 Btu/h;
1 USRT (United States cold tons) = 3.517 kW, 1 kW = 0.28434 USRT;
1 kcal/h = 3.968 Btu/h, 1 Btu/h = 0.252 kcal/h;
1 USRT = 3024 kcal/h, 10000 kcal/h = 3.3069 USRT;
1 horse = 2.5 kW (for air-cooled units), 1 horse = 3 kW (for water-cooled units)
Description:
When “hp” is used as a power unit, it is expressed by Hp (imperial horses) or Ps (metric

horses), also known as “horsepower”, 1 Hp (imperial horses) = 0.7457 kW, 1 Ps (metric
horses) = 0.735 kW;
· How do you set specifications of an Injection Molding Chiller?
 Set injection velocity from slow

 Fixed screw revolving velocity from low
 Set mold open/close velocity slowly at first
 Set injection proportion from a short position.
 Set prolonged pressure holding time of molding appliance at first
 Set a long cooling time at first.
Figure 1 Injection Molding Chiller
· How do you calculate clamping force in an Injection Molding Machine?
Clamping force is often calculated in the following ways:
1. Empirical FormulaClamping force (T) = clamping force constant Kp * product projected

area S (CM * CM).
2. Empirical Formula 350bar*S(cm^2)/1000.
3. It is calculated using CAE software.
· What are the disadvantages of an Molding?
Disadvantages of an Molding are:
 High tooling expenses and long set up lead times:
Up-front expenses are high due to the style, assessing, and tooling needed.
Firstly, there is the initial creation and prototyping.
Then the design of a prototype mold tool to produce copies of the component in
proportion.
Lastly, and only after massive testing during both steps, you can finally get injection
mold a component.
 Part design limitations:
Components must be created with injection molding consideration and must follow the
fundamentals of injection molding.
For instance:
 Prevent undercuts and sharp borders as much as possible
 Use regular wall thicknesses to avoid inconsistencies in the cooling process resulting in
issues like sink marks.
 Draft angles are recommended for better de-molding.
 Small runs of components can be expensive:
Due to the intricacy of processing equipment, and the need to rid the appliance of all
previous material before the next product can be produced, the setup time can be too
long.
Therefore small runs of parts have typically always been thought of as too costly to
injection mold.
· Why is hydraulic heat exchanger used in an Chiller?
Injection Molding Chillers have a hydraulic heat exchanger mechanism.
Thus, that must give reliable execution through many years of constant, around-the-
clock production cycling.
Moreover, there is also a requirement for energy control sub-circuits.
Thus, to keep the nozzle against the sprue of the mold and to keep the mold closed.
· What polymers are used in an Injection Molding Machine?
Generally, plastic injection molders use thermoplastics.
However, regular polymers used by molders are:
 Acrylonitrile Butadiene Styrene (ABS),

 Polyethylene,
 Polycarbonate,
 Polyamide
 Polypropylene.
What Are Portable Chillers For Injection Molding?

Plastic Chiller For Injection Mold Cooling
The use of a chiller for injection molding machines is one of the technological
breakthroughs in the plastic industry. It is crucial to be able to mass-produce the
components of plastic furniture.
In order to succeed with this manufacturing process, it requires precision and accuracy.
Speed is also important.
The cooling process with the help of a small water cooled chiller chiller is crucial. In fact,
experts believe that the use of water cooling system for injection molding makes up
80% of the molding process.
The use of an efficient water cooled chiller can significantly reduce the amount of time
spent for each batch. It is important to evaluate your cooling needs so you can invest in
the right system.
How Do You Choose Chillers For Injection Molding?
The process of cooling molten plastic is straightforward and easy to comprehend.

However, it has many variables.
The main objective for choosing water cooled chiller industrial use is to find the right fit
for the job. Different sized jobs have different cooling requirements.
There are 1 ton chiller, 2 ton chiller, 3 ton chiller, 10 ton chiller, 20 ton chiller, 50 ton
chiller, 60 ton chiller, 100 ton chiller, 200 ton chiller, 500 ton chiller.
You can maximize your time by choosing the right chillers for injection molding.
The most important factors to consider when choosing which portable air chiller to
invest in are: melting point, heat distortion temperature (HDT), desired mold
temperature controller, cooling power, and the availability of space.
Portable Chiller Unit
Why Is Melting Point Important When Selecting Chiller For Injection Molding
Machine?
The melting point of the plastic is an important factor to consider when choosing water
mold cooling system for injection molding.
You need to understand that there are different melting points for every type of plastic.
The first step is, therefore, to know what type of plastic you are working with.
It is something that you need to evaluate prior to starting the cooling process. To give
you an idea, it is important to look at the types of plastic and their corresponding melting
points.
Polypropylene is one of the most common types of plastic in the market. It has a melting
point of 160 degrees Celsius.
Low-density polyethylene is another common type of plastic for injection molding. It has
a very high melting point that can go up to 240 degrees Celsius.
Next is the high density polyethylene plastic with a melting point of up to 270 degrees
Celsius.
Polycarbonate is the type of plastic with the highest melting point at 287 degrees
Celsius.
It is also important to note that the melting point of plastic might vary from one
manufacturer to another. Before you handle with these plastic materials, it is important
to consult the manufacturer first.
Aside from knowing the heating needs of the plastic, you need to know about your goal
temperature so you can decide the right portable chillers for injection molding.
Why Do You Need To Know The Heat Distortion Temperature?
The heat distortion temperature is another factor that must be taken into account when
choosing air cooled portable chiller.
You need to research on the HDT range for your plastic to help you choose the right
small portable chiller for the job.
Ideally, you need to chill plastic components before they reach the HDT range. If not,
then the plastic components could easily deform once you take it out of the injection
mold.
There are many factors within the plastic components themselves that would determine
the HDT such as the composition of the plastic itself, pressure in the mold, and the
molten density.
You need to talk with the plastic manufacturer so you can get the exact gauge on this
and choose the right portable chillers for injection molding.
Chiller For Injection Molding
What Is The Importance Of Your Goal Temperature?

To help you decide on the best water cooling system for injection molding, you need to
know the desired temperature for heating.
There is more to plastic chilling than just blasting your plastic components with cooling
as soon as possible. You need to be able to optimize your temperature targets in the
most efficient manner possible.
Again, you must refer to the plastic manufacturer, to learn the ideal heating and cooling
temperature for the components.
This information is vital in putting together a chiller plant for injection molding machine
or buying injection molding chillers.
Knowing your temperature target will enable you to select the right mold temperature so
you can select your portable air chiller accordingly.
By knowing and achieving the ideal mold temperature controller, you can match that
with the injecting molding chillers that can deliver such cooling capacity.
As a result, the plastic can cool and crystallize efficiently once it is molded. This will
prevent cracking, seeping plastic, deformities, cavity formation, and other defects with
the injection molding process chiller.
What Is The Cooling Power For In Injection Molding Chillers in the Injection
Molding Process?
There are several different sizes and injection mold cooling process capacities available
with portable chillers for molding cycle. They are often measured out in “tons”.
You need to look at the “tons” when comparing chiller sizes for molding cycle with
plastic. It does not refer to the actual weight of the industrial chiller units.
Instead, tons indicate the horsepower of the portable chillers industrial molding. It refers
to the refrigeration cooling capacity of the unit.
For example, 1 ton of injection mold cooling process power can deliver safe ejection
temperature for 35 lbs per hour for polypropylene plastic or 65 lbs per hour for
polycarbonate plastic.
As a general rule, 1 ton of cooling power should be enough to cool and complete the
molding cycle for most types of plastic. It is something to consider when shopping
around for portable chillers for injection molding process.
How Much Space Is Available?

Just as there are different sizes of injection molding chillers, they also differ in terms of
actual size.
The injection molding process equipment is bulky. It can take up a lot of floor space in
the factory. This is something to think about when choosing portable air chiller systems.
You need to know how much space is available for injection molding process so that
you can size the chiller accordingly.
Water cooling system for molding cycle take up more space than air cooled portable
chiller. This is because the former will require the use of cooling towers.
It is also the reason why a portable air chiller makes most sense in this injection molding
applications. Since it is not fixed into position, you can free up the space once you are
done with injection molding.
Chiller Package Unit Small Space
What Else Require Cooling During Injection Molding?
Relying on portable chillers for injection molding has its own benefits that will facilitate
ease of plastic manufacturing.
There are also certain limitations to the cooling capacity of a portable air chiller. It might
not be enough to provide the cooling you need.
You need to keep in mind that during the plastic processing, the injection molding
equipment is not the only one that will require chilled water injection mold cooling
process. There will be other processing equipment that will be in use that will generate
heat in the water loop.
During plastic molding, refer to the temperature to the process, the following equipment
must be cooled as well: hydraulic heat exchanger motor, feed throat, thermometer,
dryer aftercooler, and hot runners.
It is important to determine how much the equipment would heat up during plastic
molding. This will enable you to choose the best chiller plant for plastic molding machine
and other equipment.
Chiller Plant
What Features Do You Look For In Portable Chillers For Injection Molding
Process Cooling?
General Plastic Manufacturing Mold Cooling
The best way to choose the best portable chillers for plastic molding is to look at the
features you need.
Make sure that the small portable chiller you buy has the following features: quiet
compressor, Screw compressor, scroll compressor, recirculation, efficient cooling fluids,
precise temperature controls, customization, and flexible temperature ranges.
Screw Compressor
A quiet compressor is a must when choosing the best portable chillers for plastic
molding. This is important so you can reduce the noise within the plastic molding facility.
If you are looking for injection molding chillers with a quiet compressor, make sure to
avoid reciprocating compressors. They are the loudest to operate when compared to
other types of compressors.

Scroll Compressor
The ability to precisely control temperature is another important factor to consider when
buying injection molding chillers.
It goes without saying that getting your temperature right is vital to the success of
injection molding in plastic. You will be able to be efficient with plastic molding if you
control the temperature correctly.
The efficiency of the cooling fluids for water or air-cooled chiller is also important. The
best cooling fluids for this purpose, are those with water and glycerol since they
facilitate in effectively removing waste heat.
Chiller System Basics

Flexible temperature ranges is also an important consideration when buying chiller for
injection molding machine. There are several areas that plastic molding can go wrong.
However, these variables are highly dependent on the temperature.
The ability to control the temperature during the plastic cooling process is important.
This will enable you to achieve the optimum cooling requirement based on the plastic
selection.
Finally, you want a water chiller for injection molding machine that can be easily
customized. Each injection molding job is unique. Make sure you can tweak the controls
and the function of the chiller to suit your needs.
Industrial Water Chiller
What Are The Benefits Of Plastic Cooling With Chillers?
The use of cooling technology is definitely a game-changer when it comes to the

plastics industry.
This innovation has brought about many benefits in terms of how plastic products are
manufactured.
First off, it has helped reduce cooling times so that it can speed up the manufacturing
process cooling. With less cooling time, it means you can mold more plastic in the same
amount of time.
Water Cooling Towers
It can also deliver better quality for your molded components. By efficiently cooling the
plastic, you can reduce the possibility of having defects on the plastic material once you
take it out of the mold.
The final advantage of using water cooled chiller for injection molding is the reduced
costs and higher efficiency. There will be less waste and the processes can be
accomplished using a shorter amount of time.
Is Water Or Air Chilled Cooler Better For Injection Molding?
There are two systems to choose from when it comes to choosing a water cooled chiller
for injection molding machine: water- or air-cooled chiller, also can use cooling towers.
The decision on which of the two systems to buy will depend on your own needs as
there will be certain benefits and drawbacks for each system.
Air Cooled Chiller Diagram
Injection molding is a complex process, one of the basic requirements of plastic

injection molding is proper cooling, for which we mainly use water. Chilled water is often
the preferred coolant because of its low cost, excellent heat transfer properties, and
easy availability.
– The water used to cool our injection molding machines must be chemically treated to
prevent bacterial growth, scaling or contamination of the entire system.
Two water treatment methods: The first is a tower system that maintains the water
temperature around 70 o – 90 o F. This system is used to keep the machine at a safe
operating temperature. The machine must be cooled to maintain maximum oil
temperature and reduce feed inlet temperature. The feed port is where the plastic is fed
into the heated barrel, and the temperature needs to be controlled to prevent premature
melting of the plastic as it transitions from solid to molten plastic.
The second is the cooling water system, which is maintained at a more stable 50 o F
temperature. The system is used to cool tools. Chilled water is directed through molds
and tooling to remove heat from the injected plastic as quickly as possible. Cooling is
often the longest part of a production cycle, so reducing wait times is beneficial. In most
cases, we try to bring the plastic down from about 500 o F to 100 o F to 140 o F as
quickly as possible.
GESON 120 ton chiller system to improve cold water distribution throughout the plant.
This system helps maintain a consistent 50 o F water temperature distribution
throughout the facility and provides our tools when needed.
To achieve the optimum mold temperature, possibly higher than the chilled water supply
temperature, we use a mold thermostat, which increases the water temperature in a
small closed loop system that pumps water through the mold. Using these, we can run
different temperatures at each machine location. Each thermostat has a separate valve
that lets in a small amount of cold water and releases some hot water to maintain a
stable temperature.
The process water temperature is different for each mold and is determined by a
number of variables. The wall thickness of the part, dimensional requirements, the type
of resin used, and dimensional factors in the mold design can all affect the process
water temperature.
Extreme conditions sometimes call for temperatures too high to use tap water safely. In
these cases, we would use a hot oil thermostat and then use chilled water to maintain
the temperature of these oil units through a heat exchanger.
The water cooled chiller is the more cost-efficient of the two. While the air-cooled
chiller costs less to initial setup, the water cooled chiller will offer more savings in the
long run.
It is also important to note that water cooled chillers will require the installation of a
cooling towers. Take this additional cost to mind when choosing what water cooled
chiller system to use for plastic molding.
Air Chilled Cooler
How do I choose a chiller for injection molding machine?

Use the following five steps and general sizing formula:
1. Calculate Temperature Differential (ΔT°F) ΔT°F = Incoming Water Temperature
(°F) - Required Chilled Water Temperature. ...
2. Calculate BTU/hr. BTU/hr. = ...
3. Calculate tons of cooling capacity. Tons = BTU/hr. ...
4. Oversize the chiller by 20% ...
5. You have the ideal size for your needs.
6. Which type of chiller is best?

7.
8. Water-cooled chillers are typically more efficient than air-cooled chillers. Using
water evaporation to dissipate heat uses significantly less energy than blowing
air across a hot surface. This is thanks to water's high heat capacity. Additionally,
water chillers tend to last longer than air-cooled chillers.
hat to Know When Selecting an Injection Molding Chiller
Cooling molten plastic is a complex science with many variables. However, there are
certain questions that will guide you when selecting an injection molding chiller.
What are my melting points?

Plastic melting temperatures vary greatly depending upon the type of plastic required
for the job. Knowing the molten temperature of your plastic in the nozzle is the first
step in selecting a chiller that will cool it before ejection. Here are some common
plastic melting points and ranges:
 Polypropylene (PP): 320° F (160° C)

 Low Density Polyethylene (LDPE): 356-464° F (180-240° C)
 High Density Polyethylene (HDPE): 410-518° F (210-270° C)
 Acrylonitrile Butadiene Styrene (ABS): 374- 518° F (190-270° C)
 High Impact Polystyrene (HIPS): 356-518° F (180 – 270° C)
 General Purpose Polystyrene (GPPS): 338-536° F (170-280° C)
 Polyoxymethylene: (POM): 347° F (175° C)
 Acetal: 356-410° F (180-210° C)
 Acrylic: 428-482° F (220-250° C)
 Thermoplastic Polyurethane (TPU): 374-428° F (190-220° C)
 Polycarbonate: 550° F (287° C)
These melting points and ranges may vary depending upon the plastic manufacturer.
Be sure to thoroughly research your plastic’s heating needs so you know what your
goal temperatures are.
What are my HDTs?

Next, research the Heat Distortion Temperature (HDT) of your plastic selection.
Plastic components need to be chilled below their HDT in order to avoid deformation
when ejected from the mold. HDTs differ depending upon the plastic’s composition,
the molten density, and the pressure in the mold. Again, consult your plastics
manufacturer to ensure you know your chosen material’s temperature ranges.
What is my desired mold temperature?

Proper plastic chilling is more involved than just cooling as quickly as possible…it
involves carefully hitting temperature targets. Your plastic manufacturer will also be
able to provide the ideal mold temperature for your plastic selection. Achieving your
mold temperature allows your plastics to cool and crystallize properly in the mold.
Proper crystallization prevents cavity formation, stress cracking, creeping and seeping
plastic, and other deformities.
How much space do I have?

Injection molding equipment can take up a large amount of space on the factory floor.
Because chilling equipment can greatly add to that footprint, you will need to know
how much room you have to work with. Water cooled chillers use a cooling tower that
takes up more space than air cooled chillers, so select an industrial chiller that will
meet your space requirements.
How much cooling power do I need?

Chiller sizes are traditionally listed according to “tons.” Tons does not refer to the
actual weight of the chiller, but instead is a historical reference to a time when blocks
of ice were harvested for cooling. Just like engines are still measured according to
“horsepower”, the term “tons of refrigeration” stuck around. 1 ton of cooling power =
12,000 btus per hour.
Cooling power for your injection mold
As a general rule of thumb, 1 ton of cooling power is sufficient to cool the following
flow rates of molten plastics to a safe ejection temperature:
 30 lbs/hour of HDPE
 35 lbs/hour of LDPE
 35 lbs/hour of PP
 50 lbs/hour of HIPS and GPPS
 50 lbs/hour of ABS
 65 lbs/hour of Polycarbonate
Cooling power for additional equipment
In most cases, the injection mold will not be the only piece of equipment in need of
cooling. There are other pieces of auxiliary equipment that require process cooling in
order to extend your machine’s duty cycle.
 Hydraulic motor (additional .1 tons of cooling per horsepower)

 Feed Throat (additional .5 tons of cooling)
 Thermolator (additional .2 ton per pump horsepower)
 Hot Runners (additional .15 ton cooling per kilowatt hour)
 Dryer Aftercooler (consult your dryer manufacturer to determine how
much additional cooling is required)
What Should An Injection Molding Chiller Have?

Portability
Portable industrial chillers give you a greater amount of flexibility and save valuable
floor space.
Quiet Compressors
Anytime you install additional equipment on an injection mold factory floor, you
increase the operational noise in your facility. Your chilling unit should be powered
by compressors that operate efficiently but quietly. In general, chillers with
reciprocating compressors are much louder than centrifugal, scroll, or screw
compressors.
Flexible Temperature Ranges

The plastic cooling process will vary depending upon many factors: size and thickness
of the plastic part being made, type of plastic, etc. Installing an industrial chiller with
the flexibility to hit a range of temperatures broadens your manufacturing
capabilities.
Recirculation
Save money and protect our precious resources by installing a recirculating chiller.
Recirculation greatly reduces water consumption and will help you save on utility
bills in the future.
Precise Temperature Controls

Molten plastic can behave in unpredictable ways unless you hit precise temperature
targets during the heating and cooling process. Smart thermostatic controllers give
you peace of mind with greater access to cooling time frames and temperature ranges.
Customization
Some injection molding operations require specific components and specifications to
meet their cooling needs.
For example, plastic products made for the food and beverage, bio and
pharmaceutical, industries must meet FDA standards for food-grade materials.
Facilities that manufacture these plastics must maintain clean-room conditions and all
equipment must be easy to wipe down and sanitize. Injection mold chillers for these
facilities should contain corrosion resistant components. They should also be
contained inside easy-to-clean enclosures to help maintain factory cleanliness.
Efficient Cooling Fluids

Injection mold chillers must produce cooling power that is able to penetrate through
the mold and efficiently remove heat from the plastic. Fluids such as water/glycol
mixes remove waste heat more efficiently than water alone.
North Slope Chillers Injection Mold Chilling Solutions
At North Slope Chillers, we are proud to offer portable and powerful injection mold
chilling solutions. Easy to install and use, our chillers come with a wide range of
cooling temperatures. In addition, our customization process is the fastest on the
market and can provide you with the exact specifications you require.
5 Sizing Steps for Chillers in Plastic Process

Cooling


 Share
By Bob Casto, Cold Shot Chillers®
No matter what your application, there is a single formula for determining the size of chiller you
need. Before you begin, you must know three variables:
1. The incoming water temperature

2. The chilled water temperature required
3. The flow rate
For our example, we will calculate what size chiller is required to cool 40 GPM (gallons per minute)
from 70 °F to 58 °F? Use the following five steps and general sizing formula:
1. Calculate Temperature Differential (ΔT°F)
ΔT°F = Incoming Water Temperature (°F) - Required Chilled Water Temperature.
 Example: ΔT°F = 70°F - 58°F = 12°F
2. Calculate BTU/hr.
BTU/hr. = Gallons per hr x 8.33 x ΔT°F
 Example: 40 gpm x 60 x 8.33 x 12°F = 239,904 BTU/hr.
3. Calculate tons of cooling capacity

Tons = BTU/hr. ÷ 12,000
 Example: Ton capacity = 239,904 BTU/hr. ÷ 12,000 = 19.992 tons
4. Oversize the chiller by 20%

Ideal Size in Tons = Tons x 1.2
 Example: 19.992 x 1.2 = 23.9904
5. You have the ideal size for your needs
 Example: a 23.9904 (or 25-Ton) chiller is required

A 20 ton cooling-capacity chiller from Cold Shot Coolers
Plastic Process Cooling Applications

There also industry-specific, rules-of-thumb for chiller sizing. These may vary depending upon the
application. The below guidelines and formula may be used for sizing chillers for plastic process
cooling applications. In our example, we will calculate what size chiller is needed for a polypropylene
molding operation that incorporates a 6oz. "Shot Size" and a 18 second cycle time with a 3 H.P.
hydraulic motor. We will use Charts 1 and 2 as references.
1. Calculate the pounds of material per hour being processed.
 Example: 6 oz. / 18 sec. = 19.99 oz/min (20.00 oz./min)

 20 oz. / min x 60 min. = 1200 oz/hr
 1200/16 = 75 lbs. / hr
2. Determine how many pounds per hour are required for each ton of cooling capacity using Chart 1.
 Example: Polypropylene requires 1 ton of cooling capacity for every 35 lbs./hr processed
 75 lbs. ÷ 35 lbs. = 2.14 tons of cooling
3. Determine if the extruder or any auxiliary equipment will require chilled water using Chart 2. If not,
go to step #5.
 Example: A hydraulic motor requires 0.1 ton/HP of cooling capacity

 3 HP x 0.1 ton/HP = 0.3 ton of capacity
4. Combine the process and auxiliary equipment cooling requirements.
 Example: 2.14 tons + 0.3 ton = 2.44 tons

5. Size your chiller by rounding up to the closest standard unit.
 Example: This application will require a 3-ton unit
Chart 1: Plastic Material Process Cooling Requirements
Injection Molding 30#/hr H.D. Polyethylene 1 ton
35#/hr L.D. 1 ton

Polyethylene/Polypropylene
40#/hr Nylon 1 ton
50#/hr Polystyrene or ABS 1 ton
65#/hr PVC or Polycarbonate 1 ton
70#/hr P.E.T 1 ton
Extrusion
50#/hr 1 ton
Polyethylene/Polypropylene
75#/hr Polystyrene 1 ton
80 #/hr PVC 1 ton
Blow Molding 35#/hr Polyolefins 1 ton

Source: www.waterchillers.com
Chart 2: Auxiliary Equipment and Extruder Cooling Requirements
Extruder Cooling Gear box cooling 1 ton/100

hp
Feed throat: 3” screw or less 1 ton
Feed throat: larger than 3” 2 ton

screw
Barrel or screw cooling (per 1 ton/inch

inch of screw diameter)
Auxiliary Equipment
Cooling
Air compressor (no 0.16
aftercooler) ton/hp
Air compressor (with 0.2 ton/hp

aftercooler)
Vacuum pump 0.1 ton/hp
Hydraulic cooling 0.1 ton/hp
Hot runner mold 0.1 ton/hp
Water pump in circuit 0.1 ton/hp
Feed throat: less than 400 0.5 ton

ton
Feed throat: greater than 400 1 ton

ton
Source: www.waterchillers.com
About Cold Shot Chillers®

Based in Houston, Texas, Cold Shot Chillers® manufactures economical, ruggedly dependable
industrial air cooled chillers, water cooled chillers, portable chillers and central chillers. Our industrial
water-cooled chillers and air-cooled chillers serve a variety of different industries and applications.
Cold Shot Chillers® began in the late 1970s as an HVAC repair company in Houston, Texas. In
1980, the company began manufacturing new chillers for the plastic process industry and
refurbishing used chillers for an assortment of industries. As our new chiller sales grew the company
emphasis shifted from service to 100% manufacturing. Primary industries served include plastic
processing, food & beverage, and metal finishing.
What causes pinholes in copper tubing?
When the potable water flowing through your plumbing system has a pH value that is
less than 6.5, it can harm your copper water pipes. As the water moves through your
copper pipes, it causes internal pitting of the pipe. Once those pits penetrate entirely
through the copper, a pinhole leak develops.
What causes copper pipes to crack?
If the water flowing into the building through the copper pipes is acidic or contains a lot
of dissolved solids, the acidic nature of the water can corrode the copper pipes, creating
pits, cracks, and holes.
How to Prevent Pinhole Leaks

in Copper Pipes
February 15, 2018
Pinhole leaks are unique to copper pipes and are caused when corrosion inside the pipe eats
through to the outside, creating a leak. And they’re the last thing any homeowner wants for
their copper pipes.
So, how can you prevent your copper pipes from getting pinhole leaks?
Well, that depends:
If your pipes are 20+ years old and you’ve already noticed pinhole leaks, you really can’t
prevent them from happening elsewhere in your piping. The most cost-effective option is
to have a professional re-plumb your home.
If your pipes are LESS than 20 years old and you haven’t had any pinhole leaks (or have had
very few), you can have a professional:
1. Reduce turbulence in your pipes
2. Install a whole-home water softener
We’ll go into both of those situations in more detail...
Hopefully if you’re reading this you don’t already have pinhole leaks. But if you do, just give us a
call, and we can help walk you through your options to fix them.
Situation #1: Your pipes are
20+ years old
Copper pipes typically last 20–50 years, so if your plumbing system is older than 20 years, it’s
generally not worth trying to save your pipes—especially if you already have pinhole leaks.
You see, as copper ages, the inner linings of the pipe become weaker, which makes them
more prone to pinhole leaks.
So if you find yourself in this situation, we recommend repiping your home with PEX pipes.
PEX piping is a lot less susceptible to pinhole leaks, plus they’re less expensive to install.
For more information about PEX pipes and re-piping your home, read our article, “What’s the
Average Cost of Re-plumbing a House in Florida.”
Situation #2: Your pipes are

under 20 years old
If you find yourself in this situation, you can hire a professional to do 2 things to prevent
pinhole leaks:
1. Reduce turbulence in your pipes
2. Install a whole-home water softener
Let’s look at both of those preventative measures in more detail…
#1: Reduce turbulence in your pipes

The biggest reason copper pipes leak is due to turbulence (when water travels through the
pipe at unstable speeds).
You see, as minerals in the water supply are pushed at high speeds inside your pipes, they can
wear out the inner lining of the pipe, especially in areas where water is forced to change flow
direction quickly (like fittings and elbows). Once this lining is worn out, small pinhole leaks
can form.
A plumber can do 3 things to lower turbulence in your pipes:
1. Lower the water velocity. According to standard plumbing practices, water velocity
should be kept at a fixed speed of 8 fps (for cold water) and 5 fps (for hot water) in copper
pipes. If water is traveling faster than that, your pipes will experience greater turbulence.
Contact a plumber to check your water velocity and make sure it’s not too fast.
2. Make sure you have the right size pipe. Smaller pipes increase the friction of the water
moving against the lining of the pipe. If you hear banging noises, or get frequent clogs, those
could be signs your pipes are too small.
Since it requires specialized calculations, you’ll need a professional to inspect your pipes to
make sure they’re the right size. In the worst case scenario, the pipes are too small which
means they’ll need to be replaced.
3. Check your pipe fittings to make sure they’re not too close together. Copper pipe
fittings change the direction or flow of water in your system and join pipes together. If they’re
placed too close together it increases turbulence, which means water grates harder against
the inner lining of the pipe. However, adequate space between fittings on a line of pipe
reduces turbulence, which could prevent pinhole leaks from forming.
You should contact a plumber to check your fittings and make sure they’re spaced apart
properly.
#2: Install a whole-home water

softener
A whole-home water softener can prevent pitted corrosion, which is another cause of
pinhole leaks in copper pipes. Pitted corrosion is an extremely localized type of corrosion that
attacks small areas on the inside surface of copper pipes. Areas with hard water, like Florida,
often see higher risk of pitted corrosion, as do older homes (pre-1970).
So what is “hard water” and why does it corrode your copper pipes?
Hard water is water with a high concentration of dissolved minerals like calcium, magnesium
and other metals. Over time, these metals can wear out the inner lining of copper pipes,
eventually creating pinhole leaks.
Luckily, a whole-home water softener removes dissolved minerals from your home’s water so
that these metals don’t buildup or react negatively with your pipes. To reduce your risk for
pitted corrosion, you’ll need to hire a water specialist to provide a soft water treatment
system for your home.
Need plumbing help from
7 Ways to Fix a Copper

Pipe Leak: Temporary
and Long-Term
Solutions
Written by Mariel Loveland
Contributing Writer
Updated September 12, 2023
Photo: BigshotD3 / iStock / Getty Images Plus / Getty Images
 Is My Leak Serious?
 Signs of a Pipe Leak
 Short-Term Solutions
 Long-Term Solutions
 Leak Prevention
 When to Hire a Pro
 FAQs
No soldering iron, no problem
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Enter a zip below and get matched to top-rated pros near you.
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Is there a small leak in your copper pipe? Help is on the way. If

you have some plumbing experience and are comfortable
cutting pipes, you can solve the problem on your own. If not,
you can temporarily fix your pipe until your plumber comes to
save the day. This guide will show you how to fix a copper pipe
leak like a pro—whether or not you have a soldering iron.
Gauging the Seriousness of a Leak

Copper pipes can leak for a number of reasons. The most
damaging is typically when a copper pipe bursts in freezing
temperatures. If you’re not home to turn off your water, this
can lead to significant water damage. Other types of leaks
generally start slowly, but even the common type of pinhole
leaks caused by corrosion can eventually widen and become
serious without repair.
Older pipes are especially prone to corrosion if you have hard

water, acidic water (water with a high pH), or water that is
very basic (water with a low pH). This compounds with high
water pressure, as minerals can wear against the inner lining
of the pipe. The most vulnerable areas are around fittings and
elbows. Other common causes of copper pipe leaks include:
 Clogs
 Damaged joints
 High water pressure
 Turbulent water flow
 Uneven or shoddy plumbing work
 Loose connections
 Age
How Much Does It Cost to Fix a Copper Pipe Leak

The cost to fix a leaking pipe is usually between $150 to
$850, with the average homeowner spending $500 on a
professional job. You can expect to spend more if you need to
repair the drywall or flooring because the pipes aren’t easily
accessible. Burst pipe repair costs tend to be the highest.
Expect to spend up to $5,000 if you have significant water
damage.
Signs a Copper Pipe Is Leaking
Photo: BanksPhotos / iStock / Getty Images Plus / Getty Images
In your home, copper pipes are typically found inside your

walls, under your floors, in utility closets, connected to water
heaters and boilers, or exposed in unfinished basements. One
set of pipes will carry hot water, and another set of pipes will
carry cold water. Because they’re well hidden, you may not
notice a leak until it’s been leaking for a while. That said, there
are some signs to look out for:
 Water stains on walls, ceilings, or floors

 Green corrosion around pipes
 Water collecting on the outside of pipes
 A mold or mildew smell
Related Article
How Much Does Water Heater Replacement and Installation
Cost? [2023 Data]
Temporary Copper Pipe Leak Fixes
Photo: Тимур Конев / Adobe Stock

Want to learn how to fix a leaking copper pipe without
soldering? Try a temporary fix. Temporary fixes tend to be
more DIY-friendly, but you’ll eventually need to bring someone
in to replace a portion of your pipe. The good news is that a
quick temporary fix can save you on the cost of an emergency
plumber.
Before you attempt to fix a leaky pipe, make sure you turn off
the water using your home’s main water shut-off valve. If not,
both you and your home will end up pretty wet. Water damage
remediation is never fun.
Attach a Repair Clamp

Repair clamps are sold in hardware stores and create a tight
seal around a small pipe leak using a rubber gasket. Make sure
you purchase a clamp that’s the same size as your leaking
pipe, then:
1. Line up the gasket with the leak. The gasket is the

rubber, rectangular part of the clamp.
2. Fit the metal portion of the clamp around the gasket.
3. Tighten the bolts until they will no longer tighten, and the
clamp sits snugly against the pipe.
Solder the Hole Shut

If you only have a pinhole leak, you can temporarily solder the
copper pipe to close it. You’ll eventually need to replace the
damaged portion of the pipe, but this fix will buy you time.
Follow these steps:
1. Clean and smooth the pinhole using an abrasive pad.

2. Apply flux to the pinhole.
3. Heat the flux gradually until it changes color.
If this didn’t solve the problem because the pinhole expanded,
use electrical wire to create what’s essentially a pipe Band-
Aid. Just wrap the electrical wire tightly around the pipe and
solder the wire in place over the small hole.
Wrap the Pipe With Adhesive Tape

Pipe repair tape—or polypropylene adhesive tape—can provide
a quick, temporary fix for a copper pipe leak. These tapes are
a great solution for residential pipes because they can
withstand more than 100 PSI of water pressure, and you can
apply them to a wet pipe. All you have to do is tightly wrap the
tape over the hole and around the pipe. Make sure you choose
a non-toxic tape if the pipe provides your drinking water.
Use Epoxy Putty

Epoxy putty, which is common in pipe repair kits, is another
temporary solution. Keep in mind that the putty is a little hard
to remove when you need to replace the pipe. You’ll have to
sand it off later down the line. Regardless, it doesn’t require
much plumbing know-how to use. Follow these steps:
1. Put on latex or nitrile gloves to protect your hands from

the putty. It heats up during application, so it could hurt
your hands.
2. Mix the putty per the manufacturer’s instructions.
Generally, you’ll have to knead it between your fingers
until the dark part of the epoxy mixes with the lighter part
of the epoxy.
3. Once the epoxy is light gray in color, wrap it around the
leaking pipe in a 1/2-inch layer.
4. Taper the ends and create a watertight seal.
5. For an extra-secure seal, apply adhesive tape to the
edges of the epoxy.
6. Let the putty set for five to 10 minutes before turning your
water back on.
Long-Term Copper Pipe Leak Solutions
Photo: RZ / Adobe Stock
There are a few different ways you can go about fixing a

copper pipe leak long-term. Most methods require you to cut
out a portion of the pipe, add a fitting, and/or use a soldering
iron. Before you start, make sure you turn off the water at your
home’s main water shut-off valve.
Solder Repair Couplings Onto the Pipe

Even if you have a larger leak, you can still solder a copper
pipe to fix the issue. You’ll just need to cut out the damaged
portion, and solder in a new piece with a pipe fitting called a
repair coupling. If your hole is on the smaller side, the coupling
may be long enough to cover the gap on its own. Use these
steps:
1. Cut out the damaged portion of the pipe using a tubing

cutter and discard it.
2. If you’re using a new piece of pipe because the coupling
isn’t large enough to cover the gap you just created, cut
your new pipe to size.
3. Smooth the sharp, freshly cut edges of the pipes using a
pipe deburring tool.
4. Add flux to the end of the pipes and repair coupling. This
will create a stronger bond.
5. Slide the repair coupling onto the pipes. If you have a
larger gap, you can use one repair coupling on each side
and then install a new pipe between them.
6. Solder the couplings and pipes together.
Once you’ve securely patched the pipes using the repair
coupling, you can turn back on your water.
Put On a Sharkbite Slip Coupling

If you’re not comfortable soldering pipes, use a slip repair
coupling (sometimes called a sharkbite slip). This method
can fix a hole in water pipes made of copper, PEX, and PVC.
Follow these steps:
1. Measure the sharkbite slip coupling and record the

measurement.
2. Mark this measurement on your piping with the hole you
want to repair at the center. This is where you’ll install
the coupling.
3. Use a tube cutter to cut away the pipe within your marked
measurements.
4. Deburr the edges of the existing pipe.
5. Install the coupling between the gap in the existing pipes.
6. Make sure the coupling and the existing pipes are aligned
properly and fit snugly together.
7. Depending on the model, tighten the coupling using your
hands or a wrench.
Once you’ve tightened the coupling and it feels firmly
connected, you can turn on your water.
Use Compression Couplings
A compression coupling (or compression fitting) is another
type of pipe fitting you can use to patch your leaky copper
pipe. It’s similar to a slip coupling or the type of repair
coupling you need to solder. Use these steps to fix the copper
pipe leak:
1. Use a tube cutter to cut away the damaged portion of

your pipe.
2. Deburr the edges of the existing pipe.
3. Slip a compression coupling on each side of the existing
pipe.
4. Apply a pipe sealant to the couplings (this helps make a
tighter seal between the pipes and coupling)
5. Cut a new piece of pipe that fits in the gap of the section
you removed.
6. Deburr the edges of the pipe.
7. Install the new piece of piping between the compression
couplings.
8. Tighten the couplings with a wrench.
Once the couplings are secure, you can turn on the water. If
you still have a leak, make your couplings even tighter.
How to Prevent a Copper Pipe Leak

Photo: Тимур Конев / Adobe Stock
Well-maintained plumbing systems can last 20 to 50 years,

provided you prevent your pipes from freezing and deal with
hard or soft water. The older they get, the more likely they are
to spring a leak. Typically, age leads to smaller pinhole leaks,
but corrosion can speed along the process. To prevent a
copper pipe leak:
 Prevent freezing by installing the proper pipe insulation.

 If you have hard water, install a water-softening system.
 Always use the right size pipes and make sure fittings
aren’t too close together.
 Check the fittings and replace them as necessary.
 Lower the water velocity in your home.
To preserve the lifespan of your pipes, a plumber can test and
adjust your home’s water velocity. Aim for the following fixed
water velocities:
 Cold water: 5–8 fps (feet per second)

 Hot water (below 140 degrees F): 4–5 fps
 Hot water (above 140 degrees F): 2–3 fps
Related Article
What to Do If Your Pipes Freeze and How to Unfreeze Them

There’s no need to panic if those temps plummet
When to Get Professional Help for Leaking

Copper Pipe
When you’re doing plumbing work, it’s better to be safe than
sorry. A simple mistake can lead to thousands of dollars worth
of water damage. That said, you’ll save a good chunk of
change by handling minor leaks (think: pinholes that require a
simple patch) if you’re comfortable cutting a pipe.
If it’s an emergency, you can always patch the pipe with a

temporary fix and then hire a plumbing repair service
or faucet repair specialist near you during business hours.
This will save you from emergency plumbing charges. In
general, budget $45 to $200 per hour for a pro, and always
consider hiring a pro if your pipes are old enough to need a
larger replacement. You may want to consider replacing your
copper pipes with PEX pipes, and larger plumbing jobs
typically require a permit.
You should also call in a professional if your leaking pipe is

coupled with some other issue or abnormality, like pipes
making noise when your water is turned off—called water
hammer—or a water heater that isn’t working properly.
Frequently Asked Questions

Can you patch a leaking copper pipe?
You can temporarily patch a leaking copper pipe using epoxy
putty or adhesive tape. These are not permanent solutions,
and you will eventually need to remove and replace the
damaged portion of the pipe.
For a smaller pinhole, you can actually solder it closed using

plumbing flux. Again, this is only a temporary solution, but it
will give you time to hire a plumber and go over your options.
8 METHODS FOR REPAIRING COPPER
PIPING
October 4, 2021
INTRODUCTION –
Water leaks can be a very frustrating experience, whether it’s from a toilet or a copper
pipe that needs repair. In this how-to article you will find out how to stop leaks in your
copper pipes, how to get the job done fast and efficiently with minimal tools and cost
involved.
If a copper pipe is leaking it’s important to find the source of the leak and take steps to
repair it as soon as possible.
The longer you allow the leak to persist, the more likely it will damage your home, or
worse yet cause injury by flooding an area of your house that could potentially cause
harm.
If unsure how to do these repairs, contact your local plumber for assistance.
A ruptured copper water pipe is a common problem for many homeowners. You can
easily repair copper pipes by using a few different techniques, but if you’re not
comfortable getting your hands dirty it may be best to call a plumber from Plumbing
Express.
Some homes have copper pipes in the walls, which can cause a bit of a hassle to get
too.
So, the DIY repairs we suggest are primarily for easily accessible copper pipes with
large holes
If you’re experiencing water leaks from pinholes in copper pipes, then one of these
solutions might provide some short term relief. However, pinhole leaks are often a sign
of complete failure to your plumbing system. You can read more about that on our
article: Pinhole Leaks in Failing Copper: An Atlanta Problem
TURN OFF WATER

Regardless of which repair method you choose, the first thing you need to do is shut
off the water supply before doing any repair work.
Once you have turned off the water supply, begin removing sections of piping around
where you suspect there may be a problem. Take extra care not to remove too much
piping so that you can easily replace each section once they are exposed.
This type of repair will be easier if there is a large tear or hole in the piping. If you’re
experiencing pinhole leaks in the copper piping, then you’re likely experiencing
a complete failure of the entire piping system.
8 METHODS FOR REPAIRING COPPER PIPING

1) Soldering two couplings & piece of pipe (code approved / permanent)
2) compression couplings (code approved / permanent)
3) Sharkbite slip coupling (code approved if done correctly / permanent)
4) repair clamp (not code approved / temporary)
5) soldering hole shut (not code approved / temporary)
6) copper wire fix (not code approved / temporary)
7) Alfa tape (not code approved / very temporary)
8) Freeze Fix epoxy compound (harsh chemicals will come in contact with drinking
water / not code approved / temporary)
METHOD #1: SOLDERING TWO COUPLINGS & A PIECE OF PIPE

This is by far the most common and up to code method. This should be your go to
method for repairing a small section with pinhole leaks or with an area with a large
hole.
1. Determine the area of the pipe to cut.

2. Mark areas to cut
3. Use a pipe cutter to remove damaged section of pipe
4. Use the removed piece of pipe to determine the length to cut the new piece of
pipe that will replace it
1. Cut new piece of pipe
5. deburr the inside and outside of the pipe that is still installed
1. You can use a sharp utility knife for the inside
2. You can use a file for the outside
6. Slip couplings over each section of the cut pipe
1. These couplings do not have stops
2. This will allow you to easily slip on to the existing pipe and then over onto
the new section of pipe
3. The couplings will need to be the same size of the pipe
7. Hold the piece of the replacement pipe up to the section that’s missing
8. Slide one coupling at a time over the new section so that half of the coupling is
on the original pipe and half is on the new pipe.
9. Repeat for other side
10. Then, proceed to solder both couplings and on both ends of the coupling.
11. Remove the excessive plumbing flux and test for leaks
Pros:
 Long term solution

 Low cost
Cons:
 Requires soldering
 Not for beginners
 Requires sufficient access to the pipe
METHOD #2: USING COMPRESSION COUPLINGS

This is probably the most user-friendly method for a do-it-yourselfer.
1. Determine the area of the pipe to cut.

4. Use the removed piece of pipe to determine the length to cut the new piece of
pipe that will replace it
1. Cut new piece of pipe
5. Starting on one side, slip on the retainer nut.
6. Slip on the sleeve
7. Repeat the process for the same side of the new pipe
8. Before tightening the retainer nut onto the coupling, be sure to apply some
plumbing pipe dope on the sleeve.
9. Tighten the retainer nut on each side of the coupling
10. Repeat steps 5 – 9 for the other side
11. If water leaks from the coupling, then you probably did not tighten the retainer
nuts enough.
If done correctly, this is a permanent and code approved solution.
Pros:
 Good for beginners

 No soldering required
 Permanent solution
Cons:
 Might leak if not installed properly

 Not as robust as soldering
METHOD #3: SHARKBITE SLIP COUPLING
1. Use the fitting itself to determine the area of the pipe to cut.
4. Deburr the inside and outside of the pipe
1. You can use a sharp utility knife for the inside
2. You can use a file for the outside
5. Identified the slip end of the fitting
6. Then use an adjustable wrench to push the fitting back over the other end of the
exposed pipe, until you can see your marks
This method is code approved if done correctly. It’s best for repairing a single hole in a
pipe.
Pros:
 No soldering
 Good for beginners
Cons”
 Not good for pipes exposed to sunlight
 Not as robust as soldering
 Might leak if improperly installed
METHOD #4: REPAIR CLAMP
1. Determine size of the pipe that is damaged

2. Select the correct size clamp
3. Open the clamp
4. Secure clamp over the hole in pipe
5. Snap clamp closed
This is a temporary fix. It’s a great option if you have a single hole in your copper pipe,
and a plumber can’t come to make the repair right away.
However, this repair is not to code. So, it is only for temporary repairs.
Pros:
 Very easy
 Great for any skill level
 Best temporary option
 No soldering
Cons:
 Not to code
 Temporary
METHOD #5: SOLDERING HOLE SHUT

This only works if you have a singular small hole. This would be roughly the size of a
pencil tip.
1. Clean pipe using an abrasive pad

2. Apply some plumbing flux around the hole
3. Apply some heat to the flux and the area around the hole with your portable
blow torch
4. You’ll see the plumbing flux begin to change color
5. Apply the solder to patch the hole
This is not a code approved fix. It is only temporary. It’s a possible solution to allow you
to continue to use your water, while you wait for a plumber to come and do a proper
repair.
Pros:
 Allows you to continue using water while waiting for plumber to arrive
Cons:
 Involves soldering
 No one should really do this
 Will probably not stop leak
 Not a solution for pinholes
METHOD #6: COPPER WIRE FIX
1. Clean the damaged area of the pipe with an abrasive material like Scotch-Brite
pad
2. Tightly wrap copper wire around the hole in the copper pipe and secure it in
place
3. Then solder the wire to the pipe
Pros:
 Allows you to continue using water while waiting for plumber to arrive
Cons:
 Involves soldering
 No one should really do this
 Will probably not stop leak
 Not a solution for pinholes
METHOD #7: ALFA TAPE
1. Begin wrapping the pipe with the tape

2. After you get your initial start, it is critical that you pull tightly on the tape, for
each additional wrap around the pipe
Pros:
 No soldering
 Easy for beginners
Cons:
 Extremely temporary fix

 Might not stop leak
 No to code
METHOD #8: FREEZE FIX EPOXY COMPOUND

There are really two ways to use epoxy to fix a leaking copper pipe.
You can either use an epoxy putty to plug the hole, or you can use epoxy to create a
bandage that’s similar to a cast put on a broken arm.
THIS IS HOW TO FIX COPPER PIPING BY USING AN EPOXY

PUTTY.
This is most similar to using a piece of chewing gum to stop a leak in a dam. It’s most
commonly used for multiple holes in a pipe – most likely related to defective pipe or
pipe that has reached the end of its life expectancy.
This is probably the most popular repair method for copper pipes with pinholes.
However, it’s important to remember that this is temporary & toxic.
Step 1: The epoxy will be separated into two different compounds. You will need to
combine the compounds thoroughly. This will create a chemical reaction, which will
create a new compound. Be sure to wear protective gloves.
Step 2: Apply this compound to the visible holes in the pipe. Allow this to fully dry.
Step 3: Wait for everything to fully dry and harden

This is not an ideal method, because the harsh chemicals will enter into the drinking water.
This method is not code. It should only be used temporarily, until the pipe can be properly
fixed.
Pros:
 No soldering
 Temporary solution
Cons:
 Toxic
 Not good for pinhole leaks
THIS IS HOW TO FIX COPPER PIPING BY USING AN EPOXY

SLEEVE.
One of the most common ways to fix copper piping is by using an epoxy sleeve. Epoxy
sleeves are encased around the damaged area and then allowed to dry in order to
create a watertight seal. You can think of this as being the equivalent of an arm cast for
pipes.
Step 1: The epoxy will be separated into two different compounds. You will need to
combine the compounds thoroughly. This will create a chemical reaction, which will
create a new compound. Be sure to wear protective gloves.
Step 2: Apply this compound to the large hole in the pipe. Allow this to fully dry.
Step 3: Soak the bandage material in water.
Step 4: Wrap tightly around the the epoxy compound
Step 5: Wait for everything to fully dry and harden
This is not an ideal method, because the harsh chemicals will enter into the drinking water.
This method is not code. It should only be used temporarily, until the pipe can be properly
fixed.
Pros:
 No soldering
Cons:
 Toxic
 Not good for pinhole leaks
 Temporary
CONCLUSION:
You’ve probably heard of a few different options for repairing leaks in copper pipes.
But, what is the best solution?
The answer to this question depends on where and how big your leak is. If you have a
single hole or if it’s localized to one area, then there are many solutions that could work
well for you.
However, if the problem has spread throughout most of your plumbing system, then
you’ll need more than just a quick fix-and we’re here to help with that!
We offer comprehensive services from diagnostics to repairs so that our customers can
get their systems up and running as quickly as possible without having any major
issues down the road. Give us call today at 770-691-5837
Air-Cooled Condenser Coil Leaks Problem

By Thomas L. Jacobs
June 6, 2011
Some years ago it was common for air-cooled condensers to develop leaks, resulting in unpredictable
shorter service life. By studying the causes of the problem, it’s possible to come up with solutions. It
became obvious that vibration was the major culprit, and thermal expansion/contraction creates some
specific problems where the hot gas first enters the coil. To discuss this, we’ll look first at leaks at the
tube sheets caused by vibration - by far the major culprit - then leaks at the discharge header, a result of
either vibration or thermal expansion/contraction or both.
VIBRATION CAUSED LEAKS AT TUBE SHEETS

The most frequently reported leaks have been at the intermediate tube sheets. While all leaks are
problems, these are particularly troublesome since they are almost impossible to repair. As you’ll see in
the specific examples discussed later, these are all caused by vibration. If they were caused by thermal
expansion/contraction, they would appear in the top row since that’s where the greatest changes in
temperature occur (the hot discharge gases enter the coil here and the majority of all heat loss, or
exchange, occurs in the top row). However, almost totally, leaks are reported in the bottom row of tubes
where the temperature is the most stable. Let’s look at the two types of leaks in more detail.
Condenser coil with special feeds and return bend pattern.

1.The most common type of leak occurs on the bottom of the tube where it passes through the tube sheet.
These do not occur when the tube is expanded to a tight fit but when there is a clearance between the
expanded tube and its matching through-hole in the tube sheet. Studies show that it does not matter
whether the tube sheet is steel or aluminum, or the holes formed with collars, clean punched, or even
fitted with bushings. With vertical vibration, the tubes bounce on the tube sheet holes and start to work
harder at the point of contact. When the vibration is strong enough and lasts long enough, stress cracks
develop and become leaks.
But there is very little wearing on the tubes. These most often happen on the bottom row of a coil. This
bottom row carries the greatest weight (the refrigerant is now liquid). This bottom row is also where the
flexing of the corrugated fins allows the tubes to make greatest contact with the tube sheet during
bouncing. These failures happen at the intermediate tube sheets since these carry twice the weight of end
sheets.
2.A second cause of leaks is due to flexing of the coil bundle when vibration is present. The possibility of
this happening is magnified by having fewer rows of tubes and/or a wide span between supports.
Engineering figures show that a 25 percent reduction in rows (four rows to three rows) results in about a
60 percent increase in flexing. Similarly, a 15 percent increase in span (from 48 to 55 inches, for example)
results in about a 50 percent increase in flexing. This type of leak shows up as a fatigue crack across the
top of the tube at the support point and can eventually result in the tube totally breaking off at the tube
sheet.
Multiple circuits in typical condenser coil.
LEAKS IN THE DISCHARGE HEADER

There are generally three causes of leaks in the area of the discharge header:
1.Thermal expansion/contraction of the tubes in contact with the tube sheet.
2.The discharge header itself expands/contracts, bending the tubes and creating fatigue.
3.Improper support of field piping amplifies vibration.
Leaks can occur if the tube sheet makes contact with the tubes that are attached to the discharge header.
Thermal expansion/contraction of the tubes causes wear. Most manufacturers have solved this problem by
having clearance holes in the tube sheet at these locations (essentially the top row).
Leaks can be caused by the thermal expansion/contraction of the discharge header itself. Because the
expansion coefficient is linear, a long header expands more than a short header. The outermost tubes
connected to the header will therefore bend the most. Headers over 4 feet long can cause fatiguing of the
outermost tubes. In an actual application field manifolding should be configured so that some of the
expansion/contraction can be absorbed at the manifolds.
Leaks also result from improper support of field piping connected to either the discharge or liquid
headers. Piping with multiple bends very quickly amplifies compressor pulsations or any other vibrations.
The resulting stress is concentrated at the core tubes that tie into the header, right at the point where these
tubes pass into the core bundle. Small circuits with only one, two, or three tubes into the header are
particularly susceptible to leaks from this cause.
CAUSES OF VIBRATION
As you can see, most leaks result from vibration. There are many sources of vibration, most out of the
control of the condenser manufacturer. Examples include:
• Over-the-road shipping vibration;

• Compressor pulsation;
• Motor bearing failure;
• Bent, broken, or dirty fan blade;
• Dirty condenser;
• Broken motor mounts;
• Loose bolts;
• Fan cycling; and
• Blocked or frozen dampers.
If you want your cooling tower to be as efficient as possible, pH levels

must be maintained to ensure that TDS concentrations remain low. If
TDS levels are high, scale could form on the interior walls. Equipment
could also become corroded.
Is TDS or pH more important?
A very low concentration of TDS produces undesirable taste of water, as many people
buy mineral water, which has natural levels of dissolved solids. Increased
concentrations of dissolved solids can also have technical effects. CONCLUSION: pH is
one of the most important operational water quality parameters.
What is the relation between pH and TDS?
Total Dissolved Solids (TDS) correlates positively with conductivity and affects pH. The
higher the TDS, the higher the conductivity and the lower the pH, towards acidity. The
presence of dissolved solids in water may affect its taste (4)
What is the TDS for chillers?
Cooling water quality (i.e., TDS & pH levels), very important parameter the desired TDS
should be in the range of 1000-1200 ppm & pH should be between 6.5 to 7.5.
What is the best pH and TDS for drinking water?
The ideal TDS for drinking water should be between 150 to 250 while it is completely
acceptable to drink water with TDS up to 500. The ideal pH of water is between 6.5 to 8.
Drinking too alkaline or too acidic water can be harmful to the body.
What is difference between TDS and pH value?
The following are the primary distinctions between pH and TDS: Definition - pH: The
acidity or alkalinity of a solution is determined by pH. It shows how many hydrogen ions
(H+) are present in the solution, whereas the total amount of inorganic and organic
compounds dissolved in a solution is measured by TDS.
How can I improve my chiller efficiency?
3 Ways To Increase Chiller Efficiency
1. Consider variable speed retrofits. Most components within a chilled water system
will benefit from variable speed drives. ...
2. More is less: Running multiple parallel devices optimizes savings. ...
3. Increase supply temperatures.
4. How do you clean a chilled water system?

5. Chilled Water Systems: Circulate for 48 hours, then drain systems as quickly as
possible. Refill with clean water, circulate for 24 hours, then drain. Refill with
clean water and repeat until system cleaner is removed.
What is the evaporator in a chiller?

Evaporator – Available in coil, shell and tube, and plate, a chiller evaporator's
role is to absorb heat when water from your industrial processes enters this
component. This process heat boils the refrigerant in the evaporator, converting it
from a low-pressure liquid to a low-pressure gas, or superheated vapor.
Energy savings from replacing a

chiller
Energy savings from replacing a chiller
By
Paul Evans
May 30, 2018
3
How to estimate the energy savings from replacing a chiller. In this article we’ll
be looking at how to estimate the potential energy savings from replacing a
chiller. We’ll look at why to replace an existing chiller, when to replace an
existing chiller, how to calculate the savings as well considerations for advanced
calculations.
Scroll to the bottom to watch the free video tutorial
See the wide range of Danfoss chiller solutions

at http://bit.ly/SolutionsForChillers
Danfoss has a wide portfolio of products to help you boost efficiency in

whatever chiller system you’re working with. Their products include
compressors, AC drives, system protectors, heat exchangers, valves,
electronics, and sensors.
They’re committed to helping you build better chillers — from the inside out.
Learn more at http://bit.ly/SolutionsForChillers
As you probably know, chillers are typically the single largest energy consuming
piece of equipment within a commercial building. There’s growing pressure on
building owners, the building and facilities managers as well as engineers and
contracted service companies to reduce energy consumption, carbon emissions
and operating costs. As the chiller is typically the largest single energy
consumer within the building, it is often looked at for energy efficiency
improvements, and rightly so.
In our previous chiller article, we discussed different ways to improve the
efficiency of an existing chiller, you can learn about this by clicking here, but in
this article we’ll look at replacing a chiller for a newer, more efficient, option.
Why and when to replace a chiller?

Chillers have a typical operational life span of 10-25 years. Their age, condition,
criticality and reliability usually play the big part in deciding when to replace a
chiller. What should also be considered is the huge savings that can be achieved
from the improved efficiency of a replacement chiller with newer technology and
also the reduced maintenance costs.
For example, replacing an existing chiller for a Turbocor chiller in many cases is
able to cut the annual energy consumption by around 30%, sometimes even
higher. The maintenance costs are around 50% less because the Turbocor
compressor is oil free so the only maintenance requirements are to change out
the capacitors once every five years, tighten the electrical connections once
quarterly, and annually dust off and clean the electronic cards. That’s it, no oil
replacements, no periodic teardowns, no major overhauls.
We’ve previously discussed how refrigerants work as well as the new

regulations coming into effect which will see refrigerants being phased out due
to their potential to damage the atmosphere. Some chillers can be
retrofitted with alternative refrigerants but the capacity is often hindered
because it was not designed to operate at the performance of the new
refrigerants which means you’ll almost certainly need to replace some of the
components within the system.
How to quantify the energy savings from replacing a

chiller
Chiller IPLV NPLV
There are many ways to compare the chillers performance, one of the most
common ways is to compare the (IPLV Integrated Part Load Value) or NPLV
(non-standard partload value) rating. This is supplied by the chiller
manufacturer on request or can usually be found in their sales and technical
literature.
The IPLV or NPLV is the weighted efficiency of a chiller operating at 100%,

75%, 50% and 25% against a typical amount of time per year at specified
conditions defined by ASHRAE in AHRI Standard 550/590. When a chiller is
unable to operate at these specifications then it will be rated as NPLV.
There are two types of IPLV depending on whether it was calculated from the
COP/EER or kW/Ton, these are just slightly different ways to calculate the
efficiency but these will be stated by the manufacturer.
IPLV COP
For example, a chiller with a reciprocating compressor might have an IPLV

COP rating of 4.6 where as an equivalent Turbocor might have an IPLV COP
rating of 10.35. As COP is based on kW of electricity input per kW of cooling
output then a higher COP rating means a more energy efficient chiller. So the
Turbocor is 2.25 times more efficient than the reciprocating. (10.35/4.6)
IPLV kWTon
When the IPLV is rated for kW/ton then a lower value means more energy
efficiency. The same reciprocating chiller might have an IPLV kW/ton of 0.7645
whereas the Turbocor might have an IPLV kW/Ton of 0.3398 so the Turbocor is
2.25 time more efficient. (0.7645/0.3398)
How to estimate annual energy consumption from a

replacement chiller
There are a few ways to calculate this and it depends firstly what the calculation
will be used for and what data you have.
It is not recommended to use IPLV or NPLV ratings to estimate the energy

consumption for a buildings cooling system as these do not represent the load
of the building, only the test data for specific conditions. It is recommended to
use building energy analysis programs which are compliant with ASHRAE
standard 140, these can model the buildings construction as well as weather
data and reflect how the chiller will react.
However, if you’re simply wanting to perform some calculations to obtain a

rough estimate of annual consumption for comparative purposes then you can
use one or all of the following calculations and we’ll look at examples for each.
 Chiller operating at mainly full load kW/Ton

 Chiller operating mainly at Full load COP
 Chiller operating mainly at part load kW/Ton
 Chiller operating mainly at part load COP
 Chiller based on actual cooling load logs kW/Ton
 Chiller based on actual cooling load logs COP
Fully loaded chiller – estimate the energy savings from

replacing a chiller
If you have a chiller that runs at full loading then you can use the following
calculations.
To calculate the estimated energy consumption simply multiply the rated

capacity of the chiller Tons with the efficiency at full load being in kW/Ton and
multiply this by the annual run hours.
chiller full
load kW/ton
For example, if we compare a reciprocating chiller with a full load efficiency of

0.83 kW/Ton to a scroll chiller with an efficiency of 0.6 kW/Ton, both rated at
500 Tons capacity and run for 3000 hours per year. We see that the
reciprocating chiller consumes 1,245,000 kWh/y whereas the scroll chiller
consumes 900,000 kWh.
chiller full
load COP
Alternatively, if you have the COP rating you would simply divide the chiller
capacity, rated in kW, by the COP then multiply this by the operating hours per
year. So to compare two chillers rated at 1758 kW. The first, a reciprocating
chiller with a COP of 4.24 and the second a scroll chiller with a COP of 5.86,
both units run for 3000 hours per year, then the estimated annual consumption
would be equal to 1,245,035 kWh for the reciprocating chiller and 900,207 kWh
for the scroll chiller.
Variable load chiller – estimate the energy savings from

replacing a chiller
If you have a chiller with a variable load, which is far more likely, then you can
use the following method.
Chiller
energy saving kW/ton
If you have the IPLV kW/Ton value then you can use the following method. To
calculate the estimated annual kWh consumption then take the cooling capacity
Ton rating of the chiller and multiply this by the annual operating hours per
year then multiply this by the efficiency IPLV kW/Ton value and then multiply
this all by the average loading factor which is likely around 0.6.
For example we’ll compare a Turbocor chiller with an IPLV of 0.34 to a

reciprocating chiller with an IPLV of 0.65. Both units are rated at 250 tons with
an average load factor of 0.58 and operate for 5000 hours per year.
So, if we drop the numbers in, you can see the Turbocor comes out at 246,500
kWh/y whereas the reciprocating chiller comes out at 471,250 kWh/y resulting
in a saving of 224,750 kWh/y.
Chiller
energy efficiency COP
If you have the IPLV COP value then you can use the following method. To
calculate the estimated annual kWh consumption, take the cooling capacity
rated in kW and multiply this by the operating hours per year, then divide this
by the efficiency IPLV value and the multiply this by the average load factor.
For example, we’ll compare a turbocor chiller with an IPLV of 10.35 to a

reciprocating chiller with an IPLV of 5.409. Both have an average load factor of
0.58 and a run time of 3,000 hours per year.
To calculate this we need to take the chillers rated capacity (kW) and multiply
this by the run hours per year, then divide it by the IPLV COP efficiency and
multiply this by the average load factor.
Dropping these numbers in we can see the reciprocating chiller consumes

343,957 kWh/y per year whereas the Turbocor consumes 153,000 kWh/y.
Historic data modelling – estimate the energy savings

from replacing a chiller
For a better and more accurate comparison for replacing an existing chiller you
can log the cooling load profile and energy consumption at intervals, hourly
should be fine, and record this over a number of months or a year. The longer
the better. Then using the part load efficiency data for any potential
replacement chiller, you can calculate and compare the estimated energy
consumption of different chillers to see the potential savings. Lets have a look
at a simplified example for a daily load profile.
Historic
Cooling Load Profile
From the chiller log we can obtain the daily cooling load in RT and see that the
chiller runs for 10 hours per day between 8am and 5pm. Then we need the
efficiency of both the existing and new chiller. In this example we’ll use kW/Ton.
By multiplying the efficiency by the cooling load, we get the hourly kWh
consumption.
Chiller
replacement, based on historic load kW/ton
Then we can see that the existing chiller would consume 1,378 kWh a day
whereas the new potential chiller would consume 980 kWh a day resulting in a
saving of 398 kWh. If the chiller runs 5 days a week for 52 weeks per year then
the replacement chiller would save 103,480 kWh per year compared to the
existing chiller.
If you have the cooling load in kW then you should use the chiller COP to
calculate the hourly electricity consumption. For this you carry out the same
analysis to find the chillers efficiency for the chiller loading from the chiller
manufacturer except this time you divide the cooling load by the COP value to
calculate the hourly consumption. Again, following this we can see that the
replacement chiller would produce significant savings.
Historic data
COP
As I said this is an overly simplified example, in the real world the chiller
load will change through the seasons and would likely run much longer hours so
you would need to account for this, basing the annual performance on a single
week is not sufficient.
Additional considerations
 To calculate the financial savings, you need to consider the electricity
tariff of the building as this will most likely vary throughout the day
and year.
 There might also be savings from reducing your peak load electrical
demands and reductions from associated carbon emissions penalty
charges.
 More complex financial models should incorporate inflation rates for the
tariffs.
 Savings can also be quantified for reduced pumping costs due to a
reduction in pressure drop across the chillers evaporator and
condenser.
 Lastly you should obtain quotations for maintenance and materials of
the new chiller and include any reduction within the financial model.
 For payback you need to account for the cost of the chiller as well as
the removal, disposal, installation and commissioning for the new unit
from a contractor.
Chiller Expansion Valve

By
Paul Evans
Jul 3, 2019
1
Chiller Expansion Valve. In this article we are going to be looking at the thermal
expansion valve on a chiller. We’re going to look at the three most common
types of expansion valves in typical modern commercial chillers, that being the
pilot operated thermal expansion valve. The thermostatic expansion valve, and
also the electronic expansion valve.
Scroll to the bottom to watch the YouTube tutorial video on chiller

expansion valves
The expansion valve controls how much refrigerant flows between the
condenser and the evaporator. The valve responds to the suction line
superheat, which is entering the compressor. It will vary the amount of
refrigerant flowing into the evaporator to suit the change in cooling load. The
evaporator needs a certain amount of liquid refrigerant in it for sufficient heat
exchange to occur. If there’s a high amount of superheat on the suction line
then there’s a lot of vapour entering the compressor. If so, then some more
liquid refrigerant can be allowed to enter the evaporator from the condenser.
The expansion valve is keeping that balance between the right amount of liquid
refrigerant and the right amount of superheat.
The balance needs to be right. You only want vapor entering into the
compressor. If liquid refrigerant enters the compressor, it will severely damage
the compressor because liquids are not compressible.
Pilot Operated Expansion Valve
Above is an image of a real world pilot operated expansion valve. The

refrigerant is going to flow as a liquid from the condenser, through the while
pipe, into the expansion valve and then into the evaporator. The large block
attached to the bottom of the white pipe is known as a king valve. This can be
used to isolate the condenser.
You will notice there is another, much smaller thermostatic expansion valve
shown in the image. This feeds the pilot of the main expansion valve, the flow
in this smaller expansion valve is what controls the main expansion valve.
Attached to the pilot expansion valve is a capillary tube, this rides up and
attaches to a thermal bulb. Which is placed on the suction line of the
compressor.
Looking at the side view of a water cooled chiller model. We can see the route
of the refrigerant from the condenser into the main expansion valve and into
the evaporator. The pilot valve is also connected to the condenser and feeds
into the main expansion valve and it controlled by the thermal bulb on the
suction line.
Thermal Bulb
The thermal bulb will be located on the suction line, and it looks something like
in the image above. A capillary tube will run between the bulb and the valve
head. The bulb is filled with a refrigerant. When the superheat increases, this
causes heat to transfer across, from the suction line, into the bulb.
As the bulb becomes hotter, the refrigerant inside starts to boil and expand. As
that expands it pushes refrigerant out through the capillary tube and that
causes a pressure increase in the capillary tube. That pressure pushes all the
way along the capillary tube to the top of the pilot valve. That pressure pushes
down on to the top of the valve, the pressure on the valve causes it to close or
open and we use this to control the flow of refrigerant through the chiller.
Looking at the drawing of the system. We can see that as the pressure
increases in the capillary tube, the pressure will travel down and force the pilot
thermostatic valve to open. The refrigerant will flow through this and lift the
main expansion valve up, opening it. The refrigerant will now flow from the
condenser and into the evaporator.
Thermostatic Expansion Valve

The next expansion valve we are going to look at is the thermostatic expansion
valve. These are quite common on air cooled chillers which are smaller in
cooling capacity. These provide the same function at the previous expansion
valve, they just work a little different.
Notice on the valve there is a thin capillary tube coming off the top of the valve
(the valve is on it’s side) this runs off the the suction line to measure the
superheat and react to it. This particular valve also have a thicker equalisation
tube coming out of the side of the valve but that’s a different subject we’ll look
at at a later point.
This type is basically what we saw being used as the pilot operated valve in the
previous expansion valve type, except it’s being used to directly control the
chiller. There is no “main expansion valve”, it is the main valve in this design.
With this design we use a thermal bulb to measure the temperature of the
superheat at the suction line of the chiller. As the bulb heats up the refrigerant
inside boils which creates pressure in the capillary tube. The pressure travels
down the capillary and pushes down on the head of the valve. As the head is
pushed down, it will open the valve to allow more refrigerant to flow into the
evaporator. When the superheat decreases the pressure also decreases and so
the valve begins to close.
Electronic Expansion Valve
The third expansion valve we’re going to look at is the electronic expansion
valve. This type of expansion valve gives the best performance because the
valve uses a stepper motor in the body. The stepper motor precisely controls
the positioning of the valve, allowing a very accurate and precise flow of
refrigerant.
You can see in the illustration above. The stepper motor on the far left. In the
centre of this is a shaft which attaches to the needle. The needle pushes against
a seat in the valve. The stepper motor pushes and pulls the shaft backwards
and forwards. As the shaft moves it opens or blocks the valve seat to allow or
restrict the flow of refrigerant from the condenser to the evaporator. The
controller measures the pressure and the temperature of the refrigerant to
determine how far to open/close.
Cooling Load Calculation – Cold

Room
How to calculate
By
Paul Evans
Dec 26, 2017
45
Cooling Load Calculation
Cooling Load Calculation for cold rooms. In this article we’ll be looking at how to
calculate the cooling load for a cold room. We’ll first look at the heat sources
and then we’ll look at a worked example of how to perform a cold room cooling
load calculation in a simplified example. Scroll to the bottom to watch the
video tutorial.
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What is a cold room?

A cold room is used to store perishable goods such as meat and vegetables to
slow down their deterioration and preserve them as fresh as possible for as long
as possible. Heat accelerates their deterioration so the products are cooled
down by removing the heat.
To remove the heat we use a refrigeration system as this allows accurate and
automatic control of the temperature to preserve the goods for as long as
possible.
Refrigeration system – Cold Room
To remove the heat we need to know what the cooling load will be. The cooling
load varies throughout the day so in most cases the average cooling load is
calculated and the refrigeration capacity is calculated to suit this.
Cold Room Heat Sources

Where does all the heat come from that we need to remove?
Trans
mission load
Typically 5-15% is through transmission loads. This is the thermal energy

transferred through the roof, walls and floor into the cold room. Heat always
flows from hot to cold and the interior of the cold room is obviously a lot colder
than its surroundings, so heat is always trying to enter the space because of
that difference in temperature. If the cold store is exposed to direct sunlight
then the heat transfer will be higher so an additional correction will need to be
applied to allow for this.
Produ
ct Load
Then we have Product loads which account for typically 55-75% of the cooling
load. This accounts for the heat that is introduced into the cold room when new
products enter. Its also the energy required to cool, freeze and further cool
after freezing. If you’re just cooling the products then you only need to consider
the sensible heat load. If you’re freezing the product then you need to account
for the latent heat also as a phase change occurs. During this time energy is
used but you will not see a temperature change while the product changes
between a state of liquid and ice. There is additional energy required to further
chill this food down below the freezing point which is again sensible heat. You
also need to account for the packaging as this will inherently be cooled also.
Lastly if you’re cooling fruit and vegetables then these products are alive and
they will generate some heat so you’ll need to account for the removal of this
too.
Intern
al load
The next thing to consider is the internal loads which account for around 10-
20%. This is the heat given off by people working in the cold room, the lighting
and equipment such as fork lifts trucks etc. So for this you’ll need to consider
what equipment will be used by the staff members in order to move the
products in and out of the store, how much heat will they and the equipment
give off and the daily duration.
Equip
ment Load
Then we need to consider the refrigeration equipment in the room which will
account for around 1-10% of the total cooling load. For this we want to know
the rating of the fan motors and estimate how long they will run for each day,
then we want to also account for any heat transferred into the space from
defrosting the evaporator.
Infiltr
ation heat load
The last thing we need to consider is infiltration which again adds 1-10% to the
cooling load. This occurs when the door opens so there is a transfer of heat into
the space through the air. The other consideration is ventilation. Fruit and
vegetables give off carbon dioxide so some stores will require a ventilation fan,
this air needs to be cooled down so you must account for this if it’s used.
Cooling load calculation – Cold room worked example

Lets consider a simplified example of a cooling load calculation for a cold room.
Now If you’re doing this for a real world example then I recommend you use a
design software such as the Danfoss coolselector app for speed and accuracy.
Download here –> http://bit.ly/2Ars6yF
Transmission load
 The dimensions of our cold store are 6m long, 5m wide and 4m high.
 The ambient air is 30°c at 50% RH, The internal air is 1°C at 95% RH
 The walls, roof and floor are all insulated with 80mm polyurethane with
a U value of 0.28W/m2.K
 The ground temperature is 10°C.
Just to note the manufacturer should tell you what the u value is for the
insulation panels, if not, then you will need to calculate this.
To calculate the transmission load we will be using the formula
Q = U x A x (Temp out – Temp in) x 24 ÷ 1000.
 Q= kWh/day heat load

 U = U value of insulation (we already know this value) (W/m 2.K)
 A = surface area of walls roof and floor (we will calculate this) (m 2)
 Temp in = The air temperature inside the room (°C)
 Temp out = The ambient external air temperature (°C)
 24 = Hours in a day
 1000 = conversion from Watts to kW.
To calculate “A” is fairly easy, its just the size of each internal walls, so drop the
numbers in to find the area of each wall, roof and floor.
Side 1 = 6m x 4m = 24m2
Side 2 = 6m x 4m = 24m2
Side 3 = 5m x 4m = 20m2
Side 4 = 5m x 4m = 20m2
Roof = 5m x 6m = 30m2
Floor = 5m x 6m = 30m2
Then we can run these numbers in the formula we saw earlier, you’ll need to
calculate the floor separately to the walls and roof as the temperature difference
is different under the floor so the heat transfer will therefore be different.
Walls and roof
Q = U x A x (Temp out – Temp in) x 24 ÷ 1000

Q = 0.28W/m2.K x 113m2 x (30°C – 1°C) x 24 ÷ 1000
Q = 22 kWh/day
[113m2 = 24m2 + 24m2 + 20m2 + 20m2 + 30m2 + 30m2 ]
Floor
Q = U x A x (Temp out – Temp in) x 24 ÷ 1000

Q = 0.28W/m2.K x 30m2 x (10°C – 1°C) x 24 ÷ 1000
Q = 1.8 kWh/day
If the floor isn’t insulated then you will need to use a different formula based on
empirical data.
Total daily transmission heat gain = 22kWh/day + 1.8kWh/day = 23.8kWh/day
Remember if your cold room is in direct sunlight you’ll need to account for the
suns energy also.
Product load – Product exchange

Next we will calculate the cooling load from the product exchange, that being
the heat brought into the cold room from new products which are at a higher
temperature.
For this example we’ll be storing apples, we can look up the specific heat
capacity of the apples but do remember if you’re freezing products then the
products will have a different specific heat when cooling, freezing and sub
cooling so you’ll need to account for this and calculate this separately, but in
this example we’re just cooling.
There are 4,000kg of new apples arriving each day at a temperature of 5°C and
a specific heat capacity of 3.65kJ/kg.°C.
We can then use the formula
Q = m x Cp x (Temp enter – Temp store) / 3600.
 Q = kWh/day
 CP = Specific Heat Capacity of product (kJ/kg.°C)
 m = the mass of new products each day (kg)
 Temp enter = the entering temperature of the products (°C)
 Temp store = the temperature within the store (°C)
 3600 = convert from kJ to kWh.
Calculation
Q = m x Cp x (Temp enter – Temp store) / 3600

Q = 4,000kg x 3.65kJ/kg.°C x (5°C – 1°C) / 3600.
Q = 16kWh/day
Product load – Product respiration

Next we calculate the product respiration, this is the heat generated by living
products such as fruit and vegetables. These will generate heat as they are still
alive, that’s why we’re cooling them to slow them down their deterioration and
preserve them for longer.
For this example I’ve used 1.9kJ/kg per day as an average but this rate changes
over time and with temperature. In this example we’re using a rules of thumb
value just to simplify the calculation since this cooling load is not considered
critical. If you were to calculate for a critical load you should use greater
precision. In this example the store maintains a hold of 20,000kg of apples.
To calculate this we’ll use the formula
Q = m x resp / 3600
 Q = kWh/day
 m = mass of product in storage (kg)
 resp = the respiration heat of the product (1.9kJ/kg)
 3600 = converts the kJ to kWh.
Q = m x resp / 3600
Q = 20,000kg x 1.9kJ/kg / 3600
Q = 10.5kWh/day
For the product section we’ll sum together the product exchange of 16kWh/day
and respiration load of 10.5kWh/day to get a total product load of 26.5
kWh/day.
Internal heat load – People

Next we’ll calculate the internal loads from people working in the cold room, as
people generate heat and we need to account for this.
We’ll estimate 2 people working in the store for 4 hours a day and we can look
up and see at this temperature they will give off around 270 Watts of heat per
hour inside.
We’ll use the formula:
Q = people x time x heat / 1000
 Q = kWh/day
 people = how many people inside
 time = length of time they spend inside each day per person (Hours)
 heat = heat loss per person per hour (Watts)
 1,000 just converts the watts into kW
Calculation:
Q = people x time x heat / 1000

Q = 2 x 4 hours x 270 Watts / 1000
Q = 2.16 kWh/day
Internal heat load – Lighting

Then we can calculate the heat generated by the lighting, this is fairly simple to
do and we can use the formula
Q= lamps x time x wattage / 1000
 Q = kWh/day,
 lamps = number of lamps within the cold room
 time = hours of use per day
 wattage = power rating of the lamps
 1000 = converts the Watts to kW.
If we have 3 lamps at 100W each, running for 4 hours a day, the calculation
would be:
Q= lamps x time x wattage / 1000

Q= 3 x 4 hours x 100W / 1000
Q= 1.2kWh/day
For the total internal load we then just sum the people load (2.16 kWh/day) and
lighting load (1.2kWh/day) to get a value of 3.36kWh/day.
Equipment load – fan motors

Now we can calculate the heat generation of the fan motors in the evaporator.
For this we can the use the formula of:
Q = fans x time x wattage / 1000
 Q = kWh/day
 fans = the number of fans
 time = fan daily run hours (hours)
 wattage = the rated power of the fan motors (Watts)
 1000 = convert from watts to kw.
In this cold room evaporator we’ll be using 3 fans rated at 200W each and
estimate that they will be running for 14 hours per day.
Calculation:
Q = fans x time x wattage / 1000
Q = 3 x 14 hours x 200W / 1000
Q = 8.4kWh/day
Equipment load – fan motors

Now we will calculate the heat load caused by defrosting the evaporator. To
calculate this we’ll use the formula:
Q = power x time x cycles x efficiency
 Q = kWh/day,
 power = power rating of the heating element (kW)
 time = defrost run time (Hours)
 cycles = how many times per day will the defrost cycle occur
 efficiency = what % of the heat will be transferred into the space.
In this example our cold room uses an electric heating element rated at 1.2kW,
it runs for 30 minutes 3 times per day and the estimate that 30% of all the
energy it consumes is just transferred into the cold room.
Q = power x time x cycles x efficiency

Q = 1.2kW x 0.5hours x 3 x 0.3
Q = 0.54kWh/day
The total equipment load is then the fan heat load (8.4kWh/day) plus the
defrost heat load (0.54kWh/day) which therefore equals 8.94 kWh/day
Infiltration load
Now we need to calculate the heat load from air infiltration. I’m going to use a
simplified equation but depending on how critical your calculation is then you
may need to use other more comprehensive formulas to achieve greater
precision. We will use the formula:
Q = changes x volume x energy x (Temp out – Temp in ) / 3600
 Q = kWh/d
 changes = number of volume changes per day
 volume = the volume of the cold store
 energy = energy per cubic meter per degree Celsius
 Temp out is the air temperature outside
 Temp in is the air temperature inside
 3600 is just to convert from kJ to kWh.
We’ll estimate that there will be 5 volume air changes per day due to the door
being open, the volume is calculated at 120m3, each cubic meter of new air
provides 2kJ/°C, the air outside is 30°C and the air inside is 1°C
Q = changes x volume x energy x (Temp out – Temp in ) / 3600

Q = 5 x 120m3 x 2kJ/°C x (30°C – 1°C ) / 3600
Q = 9.67 kWh/day
Total cooling load

To calculate the total cooling load we will just sum all the values calculated
Transmission load: 23.8kWh/day

Product load: 26.5 kWh/day
Internal load: 3.36kWh/day
Equipment load: 8.94 kWh/day
Infiltration load: 9.67 kWh/day
Total = 72.27 kWh/day
Safety Factor
We should also then apply a safety factor to the calculation to account for errors
and variations from design. Its typical to add 10 to 30 percent onto the
calculation to cover this, I’ve gone with 20% in this example so well just
multiply the cooling load by a safety factor of 1.2 to give us our total cooling
load of 86.7 kWh/day
Refrigeration cooling capacity sizing

The last thing we need to do is calculate the refrigeration capacity to handle this
load, a common approach is to average the total daily cooling load by the run
time of the refrigeration unit. For this I’m estimating the unit to run 14 hours
per day which is fairly typical for this size and type of store. Therefore our total
cooling load of 86.7kWh/day divided by 14 hours means our refrigeration unit
needs to have a capacity of 6.2kW to sufficiently meet this cooling load.

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Chiller maintenance checklists

Daily chiller maintenance checklist

Weekly chiller maintenance checklist

Monthly chiller maintenance checklist

Annual chiller maintenance checklist

 Chemically wash condenser coils.

Best practices for maintaining industrial

Keeping your industrial equipment in check

The purpose and importance of industrial

Types of industrial chillers

Vapor compression vs Vapor absorption chiller. Source: The Engineering Mindset

Air cooled and water cooled industrial chillers. Source: HVACWAVETECH

1. Circuit breaker maintenance checklist.

2. Format of circuit breaker maintenance checklist.

3. Types of circuit breaker maintenance checklist.

4. Safety precaution for circuit breaker PPM activity.

5. Details of circuit breaker maintenance activity checkpoints.

1- Circuit breaker maintenance checklist:

3 - Types of circuit breaker maintenance checklist:

4-Details of safety guideline for circuit breaker PPM activity:

 Rack out circuit breaker from electrical panel.

 Use lock out and tag out on the electrical panel.

 Use insulated tools.

 Use personal protective equipment as safety shoes, helmet etc.

 After completion activity remove tools and tackles.

 After completion remove safety lock and signboard or tag.

5-Circuit breaker maintenance activity checkpoints:

 Ensure and check no power supply before starting PM activity.

fault and OL.

 Check auto and manual function.

 Check earth connection with panel body.

 Check any abnormal sound on load condition.

After carried out maintenance activity we should check parameters for

 Check load according capacity.

 Check parameters according default limit.

 Check any abnormal sound.

Electrical Equipment Logbooks

3. Types of technical system logbooks.

o Chiller plant logbook.

o Diesel generator logbook.

o Water treatment plant logbook.

2- Tech Logbook format :

HT panel logbooks are used in industries, residential societies, commercial

 Date and time.

 Energy consumption in KVAh and KWH.

 R, Y, B phase high voltage

 All three phase current.

 Control supply voltage

Transformer is an electrical equipments which is used for voltage

 Date and time.

 Transformer out put voltage

 Transformer winding temp

 Transformer oil temp.

 transformer oil level.

 Dry type transformer temp

LT panel is electrical power distribution center in a premises where electricity

 Date and time.

 All phase incomer voltage.

 all phase current.

 All feeders current

 Date and time.

 Load in percentage of capacity (KVA)

 Energy load in KW.