Optimize chiller efficiency with regular chiller tube cleaning

Ensuring that evaporator and condenser tubes are sparkling clean is absolutely crucial for maximizing chiller efficiency! When the interior surfaces of these tubes are tainted with even the slightest bit of scale, mud, algae, sludge, or other contaminants, it creates thermal resistance that forces the chiller to work overtime, causing energy efficiency to nosedive. Believe it or not, inefficient chillers can gulp down up to 30% more energy, as highlighted by the DOE.

Manufacturers typically recommend cleaning condenser tubes annually. Evaporator tubes should be cleaned about once every three years for closed systems, more often for open systems. There are two basic methods of cleaning chiller tubes: chemical and mechanical. In chemical tube cleaning, an acid solution is circulated through tube bundles to break down or soften calcium, lime, rust, and other deposits. This process should always be followed by a thorough mechanical cleaning. While chemical cleaning can be quite effective in many cases, it can be costly and time consuming.

Mechanical cleaning is highly effective for removing accumulated materials like mud, sand, and algae from smooth-bore tubes, offering several efficient methods. The traditional rod and brush technique is occasionally used, though it is labor-intensive and only moderately effective. The chiller tube cleaning gun is an excellent choice for lighter deposits, using brushes, rubber bullets, or scrapers propelled through tubes with compressed air and water, or high-pressure water alone, to effectively remove deposits. Rotary tube cleaners use a motor to rotate a flexible shaft equipped with various brushes and tools, making this method both affordable and highly effective. They are the optimal choice for internally-enhanced chiller tubes, which feature spiral grooves to enhance heat transfer.

Many new chillers are equipped with online tube cleaning systems, which can also be retrofitted onto existing chillers. One type uses brushes trapped in plastic baskets at both ends of each tube. The water flow direction is periodically reversed, propelling the brush to the opposite end of the tube. Another system type features sponge balls that circulate through the tubes, maintaining clean surfaces. With proper water treatment, these automatic systems are highly effective, eliminating the need for manual tube cleaning. Although retrofits can be costly to purchase and install, the payback periods are typically less than two years.

For more information about chiller tube cleaning, please contact Griffin Mechanical Services, LLC. Service@griffmech.com 609-388-1978