Chillers are indispensable components of industrial cooling systems as they regulate temperatures across a diverse array of sectors, including manufacturing plants and commercial facilities. Whether it is maintaining optimal conditions for production processes or ensuring comfort in commercial spaces, the efficiency and reliability of chillers are crucial. However, over time, these essential systems can succumb to wear and tear, facing challenges such as fouling, scaling, and decreased performance. This is where proactive maintenance comes in as a preventive strategy to safeguard against these issues and ensure uninterrupted operation.
One such strategy involves integrating an automatic tube cleaning system (ATCS) , which offers a host of benefits in optimising chiller performance and longevity. Some of these benefits include:
1. Continuous Performance Optimisation
Fouling and scaling are common challenges faced by chiller condensers, compromising their efficiency and effectiveness. Fouling refers to the accumulation of deposits, such as dirt, debris, or biological growth on the surfaces of chiller tubes, while scaling involves the buildup of mineral deposits, typically calcium carbonate. These deposits can obstruct water flow and impede heat transfer efficiency within the chiller system.
An automatic tube cleaning (ATC) system is a routine maintenance and cleaning operation performed on clogged tubes. It is a continual hydro-mechanical cleaning system that cleans the heat exchanger, shell and tube by moving softballs throughout the tubes at predetermined time intervals. By continuously removing these deposits from the condenser tubes, an automated tube cleaning system prevents the accumulation of contaminants that hinder heat transfer efficiency.
Consequently, the chiller operates closer to its design specifications, maintaining optimal performance levels over time. This directly ensures that the chiller consistently delivers the required cooling capacity, enhancing overall operational performance.
2. Reduced Downtime and Increased Reliability
Unplanned downtime can be disruptive and costly for any organisation relying on chiller systems. As a solution to such costly problems (fouling and scaling), an automatic tube cleaning system for chiller condensers significantly mitigates the risk of unexpected breakdowns by keeping the tubes clean and free from obstructions. Through this process, the likelihood of equipment failure due to fouling-related issues is greatly reduced and as a result, the chiller operates more reliably, with fewer instances of unscheduled shutdowns or performance degradation. This improved reliability translates to increased productivity and uninterrupted operations, fostering a more resilient operational environment.
3. Extended Equipment Lifespan
The durability of chiller components is closely linked with the maintenance practices employed throughout their lifecycle. By preventing the buildup of fouling and scaling, the condenser tube cleaning systems eliminate the strain on various chiller elements, including compressors, condensers, and evaporators. With reduced wear and tear, the need for frequent component replacements decreases, resulting in substantial cost savings over time. Furthermore, preserving the integrity of chiller components coupled with preventive maintenance acts as a safeguard against premature equipment failures, further enhancing operational continuity.
4. Operational Cost Savings
The economic advantages of preventive maintenance with automatic tube cleaning are multifaceted and profound. Firstly, the energy savings derived from improved chiller efficiency are significant. A cleaner heat transfer surface requires less energy to achieve the desired cooling effect, leading to reduced electricity consumption and lower operating costs. Furthermore, by minimising the occurrence of fouling-related issues, such as reduced heat transfer efficiency or refrigerant leaks, repair expenses are substantially reduced. The extended lifespan of chiller components also translates to deferred capital expenditures on replacements, offering long-term cost-effectiveness.
5. Reduced carbon footprint
Singapore’s average Operating Margin Grid Emission Factor (OM GEF), which measures the carbon intensity of electricity generation, is 0.4168 kg CO2 per kWh as at 2022 according to the EMA’s website. Besides that, an independent assessment report for the HydroBall ATC system from a field-testing project funded by The Enterprise Challenge Unit (TEC Reference No: L00279/772) proves that with the HydroBall ATC system installed, the chiller-specific electricity consumption of a building can be reduced by 18.4%.
Hence, taking the example of an operational 600 RT chiller running 12 hours daily with a HydroBall ATC system installed, it can reduce carbon footprints by approximately 187,000 kg CO2 based on the above parameters. This underscores HydroBall ATC system’s commitment not only to operational efficiency but also to environmental sustainability.
As industries continue to prioritise operational efficiency and reliability, investing in these proactive maintenance strategies emerges as a strategic move for chiller operations. It is time for businesses to embrace preventive measures, not just to ensure the durability and reliability of their chiller systems, but also to reinforce their commitment to sustainable and cost-effective operational practices.
In Singapore, to optimise energy consumption at the systems level, Minimum Energy Efficiency Standards (MEES) have been introduced for water-cooled chilled water systems to encourage the adoption of energy-efficient chilled water operations by industrial facilities. Mandatory MEES requirements were introduced for new industrial facilities in 2020. This has helped new facilities each save an average of S$300,000 annually in electricity costs, recouping their initial outlay just after 3 years.
The Energy Conservation Act will be amended in 2024 to effect similar requirements for existing industrial facilities from December 2025. Existing industrial facilities can expect average energy savings of about S$1.25 million per year per facility across the system’s 15-year lifespan, and to recover retrofitting and operating costs within 5.5 years.
Looking for a chiller and condenser maintenance strategy? Reach out to HydroBall today and discover how our “Non-Powered” automatic tube cleaning systems with a “Dual Loop” design and “Water Resilient” mechanism benefit your company. With our energy & water efficient automatic tube cleaning systems in place, your chiller and condenser maintenance processes are streamlined, resulting in a great reduction in energy and water consumption. This also means substantial cost savings (capital and revenue expenditure) for your business, enhancing its overall efficiency and profitability while contributing to reduced carbon emissions.
