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North Slope Chillers

Industrial Water Chiller Systems

Archives for June 2018

Types of Chillers

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Different types of process chillers fall under two main categories: (1) Vapor Absorption  and (2)Vapor Compression. Vapor compression chillers are the most common and include (1) air chillers and (2) water/fluid chillers.  Chillers are further categorized by the type of compressor technology used: (1) centrifugal, (2) scroll, (3) reciprocating, and (4) screw. 

Chiller units are refrigerant systems that aid in cooling residential/commercial spaces, machines, industrial operations, and industrial chemicals. These units are energy efficient, cost-efficient, and time-efficient. Without these systems, production objectives often cannot be achieved.

Types of Chillers Diagram

Chillers fall under two main categories: vapor compression and vapor absorption chillers. vapor compression chillers use an electrically driven mechanical compressor to force a refrigerant around the system while vapor absorption chillers use heat to move the refrigerant around the system.

Vapor compression chillers are the most commonly used and fit into two subcategories: air chillers and water chillers. Let’s take a quick look at how each of these work, their applications, and the pros and cons of each.

How Air Cooled and Water Chillers Work

Both air and water chillers have the same components: an evaporator, a compressor, a condenser and an expansion valve. Furthermore, the mechanics for both are very similar. The compressor pushes a refrigerant around the inside of the chiller through the condenser, the expansion valve, the evaporator, and back to the compressor.

(Read more about how chillers work here.)

The primary difference between air and water chillers is how the unwanted heat is ejected. Air chillers us air to remove heat while water chillers use, you guessed it, water.

Air Chillers

Air cooled chillers use air to remove heat by using fans to force air across the exposed tubes of the condenser. While air chillers require more energy than water-cooled chillers, they can be a great option when it comes to stationary cooling. Air chillers are easy to instal and typically can be installed outside a building (no extra space requirements). Compared to water chillers, air chillers are more prone to blockages and recirculation issues.

Water Chillers

How a Chiller Works Diagram

Water chillers remove heat by pumping water through a sealed condenser and dispersing it through the cooling tower. 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.

Types of Compressor Technology

Air-Cooling and Water-cooling chillers are further categorized by the type of compressor technology used.

Centrifugal Chillers

The majority of centrifugal chillers are water chillers (It’s extremely rare that you’ll find a centrifugal system in an air chiller). Centrifugal chillers are often used for medium to large cooling loads (typically available from 150 up to 6,000 tons of refrigeration) This system offers high cooling capacity in a compact design. Centrifugal chillers operate by using rotating impellers to compress the refrigerant and force it around the chiller.

Reciprocating Chillers

These systems work by using a piston and chamber to compress the refrigerant. You’ll find a reciprocating compressor in any of the ½ ton models we sell at North Slope Chillers.engine pump

Scroll Compressor Chillers

Scroll compressors are used in both air and water coolers. These chillers operate by using two spiral plates (one stationary and one rotating) to compress the refrigerant. Our chillers use scroll compressors for the 1 and 2-ton models.

Screw Driven Chillers

Screw chillers are also used in both water and air chillers and are best for small to medium cooling loads. These chillers are typically available in 70 to 600 tons.  Screw compressors work by using two interlocking rotating helical rotors to compress the refrigerant.

North Slope Chillers are portable water-cooling chillers; they offer all the energy-efficiency and quick cooling of water chillers without intensive installation or bulky towers. If you need help determining which chiller type is best for your needs or would like to learn more about how North Slope Chillers work, shoot us an email at [email protected].

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Chiller Maintenance: Repairing or Replacing a Broken Chiller

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As much as we’d love technology to run at maximum efficiency 100% of the time, regular wear and tear can lead to malfunctions. If your business owns or regularly uses a chiller unit, it could be helpful to familiarize yourself with these chiller repairing and maintenance steps.

When it comes to process chiller repair and maintenance, it is necessary to know and understand how chiller systems work. Here are a few helpful tips that can help keep your chiller running efficiently:

Chiller Maintenance Guide

1. Track and Monitor Daily Operations Log

A daily operations log provides supporting data to help isolate problems and fix inefficiencies faster.  Details under the log should include flow rates, operating temperatures, and other crucial information. Keeping a detailed log takes just a few minutes a day and could be the key you need to get things up and running again should a problem arise.

2.Use Regular Water Treatments

There are many different types of chillers used in different situations, but the most common are water chillers, or water-cooled chillers. Water in the units must be frequently treated to prevent corrosion, scale accumulation, and algae growth. For closed water systems use regular chemical treatments. Filters should be cleaned every three months to prevent contaminant buildup.

3. Immediately Tend to Leaks

Small leaks in your chiller system can lead to more serious issues. Unwanted moisture could contribute to the formation of corrosive acids. Additionally, moisture could cause chiller parts to rust and stop working properly. Carefully check your unit at least once quarterly for leaks.

Tools Organized on bench top

4. Clean System Tubes

Overall system productivity depends upon the efficiency of heat transfer in the evaporator and condenser tubes. Keeping these tubes clean will help keep your chiller running smoothly. Cleanings are done through brushing or applying chemicals to remove algae and scale accumulation.

5. Regularly Conduct Oil and Refrigerant Analysis

Regularly analyzing the oil and refrigerant within your system can help prevent more complicated issues. Consistent refrigerant analysis can help detect contamination issues. Oil analysis can expose underlying problems such as problems with compressor wear or excess moisture content in the oil.

When chiller units malfunction or breakdown, try following these common chiller problems solutions:

  • If your pump runs irregularly, check that all valves are open to the chiller. Next, check for possible debris entering the pump. If everything looks clean, check that the pressure is within the normal range. If all looks well there, there could be a possible problem with the pump component that requires professional attention.
  • If there’s an irregularity with the switch contact, you can use a simple multimeter to check the contacts of the switch.

controller

  • Additional issues will likely require professional attention. If you’ve been experiencing issues with your chiller unit, give us a call at (866) 826-2993.

Replacing Your Chiller Unit

Industrial Chiller from North Sope Chillers

If you’re currently using a chiller unit that you’re unsatisfied with, it may be time to replace it! North Slope Chillers are a top-notch option. If you’d like more information on which North Slope Chiller will best replace your current system, give us a call at (866) 826-2993.

DOWNLOAD THE CHILLER SELECTION GUIDE

How EDM Cutting Technology is Helping to Create Innovative New Products

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What is EDM?

EDM (electrical discharge machining), also known as spark machining, is a manufacturing process used to obtain a specific desired shape in metal by applying electrical discharges(sparks). There are a few different types of EDM technology including sinker EDM, wire EDM, ram EDM and fast hole drilling EDM; all of which are primarily used for hard metals that would be very difficult to machine with alternative methods. Even though electrical discharge machining is ideal for hard-to-drill materials, it can also be used for softer metals.

EDM CNC

Photo: Advanced Machinery

Key components:

A typical EDM system consists of a CNC unit, a power supply with anti-electrolysis circuitry, automatic wire threading, a tank of dielectric fluid(deionized water), a filtration system and a spindle chiller to keep the fluid at a steady temperature. In order to control the spacing of the sparking gap between the electrodes and workpiece, the piece of metal that’s being cut is completely submerged under dielectric fluid or deionized water.

EDM Unit

Photo: Makino Resources

Water filtration and temperature

When it comes to using electrical discharge machining, the water serves as a key component. To get the best performance from an EDM machine, the water must be kept as clean as possible. During the EDM process, some of the metal goes into the water as small particles. The water is filtered and deionized(demineralized) in order to remove those metal atoms. Process cooling deionized water helps to promote a higher metal removal rate and enhances the machine’s capacity to deliver a more precise cut.

In addition to cleanliness of the water, the water temperature is important as well. In order to ensure that the deionized fluid maintains a consistent temperature of 60-70 degrees Fahrenheit, a water chiller is essential during the EDM process. The machine will fail to cut precisely, slow down processing, and not last as long if these standards are not met.

EDM cutting infographic from North Slope Chillers

Industries using EDM:

EDM is used everyday in various ways in a lot of familiar manufactory such as  3D printing, medical instruments, moulds, gears, jewelry, telecommunications, guns and many more.

3D Printing: Project Daniel

With the ability to create molds of any shape or size, 3D printing seems to be almost limitless. Similar to 3D printing, there are practically zero mechanical forces when using EDM because the sparks do the cutting. Since not all 3D printers can cut metal, EDM is used to shape the necessary metal pieces.  From using 3D printing to produce 3D ultrasounds–yes, it’s a thing– to providing prosthetic limbs for children, the innovative style 3D printing has obtained with the help of EDM is astonishing.

16 year old, Daniel Omar, is an inspiring example of the amazing things we are capable of accomplishing with the technology of 3D printing and EDM. After a traumatic accident in South Sudan, Daniel lost his arms at age 14. Thanks to Dr.Tom Catera, who partnered with Not Impossible Labs, Daniel is one of the first amputees in South Sudan to receive a prosthetic arm built by a consumer-grade 3D printer. Since not all 3D printers can cut metal, EDM shaped the necessary metal pieces. Not Impossible Labs creates low-cost prosthetic limbs that are known for being simple to use and affordable for anyone who needs one. Daniel is only one of more than 50,000 amputees in South Sudan whose story we have heard. Not Impossible Labs is creating better opportunities for thousands of people everyday with help from 3D printing and electrical discharge machines.

Daniel Omar

Daniel Omar Photograph: Not Impossible Labs

Sinker EDM: WET Advanced

WET is a manufacturing company based out of Sun Valley, California that designs some of the world’s most iconic fountains known to man. In order to create the specific molds required to transform a mediocre fountain into an art piece and music show, they must have EDM technology. WET is responsible for the Dancing Fountains of Bellagio in Las Vegas; as well as the 35 acre fountain in Dubai that greets the guests of the tallest building in the world known as Burj Khalifa. WET also accomplished the making of a water wall called Luminous, located in Guangzhou, China. It’s more than three stories tall and has 5,000+ LED lights. WET is using EDM in-house to make the specifically detailed P20 mold inserts required to make their sensational fountains possible. In house EDM cuts production time from six or more weeks down to two or less.

water fountains in Dubai

Dubai Fountain, Burj Khalifa. Image: Merek Kijevsk

Small Hole EDM Drilling: Valve lifters

Valve lifters are common and critical components in internal combustion car engines because they help regulate the opening and closing of valves. Small hole EDM drilling is used to make these valve lifters and make sure the valves in the engines are working properly. They use oil pressure to adjust their points of contact with the camshaft. Oil flows through hydraulic lifters using small hole EDM drilling.

valve lifters race cars

Randy Pobst Words, Manufacturer PhotosAugust, 201

Sources:

https://www.techspex.com/knowledgecenter/guide-to-buying-machine-tools/buying-a-wire-edm

https://www.mmsonline.com/zones/edm

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Keeping Chemicals Cool

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If your business or organization regularly works with, stores, or manufactures chemical products, you’re likely familiar with chemical hazards and proper safety protocol (We’re willing to bet you’ve been through one or two chemical safety courses as part of your training).

blue plastic barrels and drums

For those who aren’t as familiar with chemical handling and cooling, it’s important to remember that an important part of safe chemical use is safe storage, Generally, storing hazardous chemicals requires sorting by oxidation (chemical reaction), flammability, toxicity, explosive properties, etc., away from outdoor exposure, and, if applicable, out of reach of children. Safety guidelines also require the use of clear warning labels.

Not only does improper chemical storage pose a serious safety risk, it can also lead to some expensive material loss.  There are certain chemicals (like industrial chemicals) that degrade or oxidize in warm environments over time. In such cases, it’s important to make sure storage containers are kept the proper temperatures. Fortunately, there are a few different options for keeping both large and small scale chemical storage cool.

REFRIGERATED ROOMS

Refrigerated rooms are exactly what they sound like; they are essentially room-sized refrigerators.  These could be a good process cooling solution for large production facilities that need more space to accommodate a constant storage supply of chemical drum containers.

However,  refrigerated rooms have a few limitations:

  • Requires significant time to set up
  • Costly to design and construct
  • Not practical to operate when chemicals are in use at several points in the facility
  • Difficult  to scale up when more storage space is needed
  • Difficult to relocate once it’s set-up

CHILLER UNITS

A second option for cooling during storage are chiller units. Chemical chillers work by using localized cooling to draw excess heat from the contents of each drum container. Chillers require a separate heat exchanger to “connect” the chiller to the drum.

We’ll discuss the following two heat exchangers: the submersible coil unit, and the fluid cooling blanket.

North Slope Chillers Industrial Chiller

SUBMERSIBLE COIL UNIT

This unit is connected to a chiller and submerged directly into the chemical drum. Coils are most commonly composed of plastic and metal. While these units provide more flexibility, portability, and scalability than a refrigerated room, some drawbacks include:

  • Exposure to dangerous chemicals
  • Contamination of the chemical substances from the coil unit and air-transported fragments
  • Evaporation of drum contents
  • Potential localized freezing/ uneven cooling

FLUID COOLING BLANKET

This heat exchanger is connected to a chiller and wrapped around the storage drum. Fluid runs through the blanket and pulls heat from the drum. We’ve found that this solution is generally most effective for the following reasons:

  • Hazardous chemicals are fully contained
  • Less possibility of product contamination
  • Better insulation for the drum products
  • Provides even, consistent cooling (No localized freezing)
  • Easy to install and scale up or down
  • Can be used throughout a facility

If you are trying to decide which cooling solution is best for you and your needs, we’d love to answer any of your questions! Shoot us an email at i[email protected].