Testing and Commissioning of Chillers, Coolers and Thermoregulators
The assurance of performance and efficiency
It is insurance for the future of refrigeration, cooling and temperature control systems: chillers, coolers, thermoregulators must be tested in all their internal components, including electrical functionality. A serious, detailed ‘check-up’ that can take several hours. But which gives the end-user the guarantee that he has the expected performance and functionality and can concentrate on his key processes.
The Stages
FOR CHILLERS
Pressure test
After construction of the refrigerant gas circuit, which is treated in an inert atmosphere for the duration of the assembly, each circuit is subjected to pressure tightness tests in accordance with regulations. Once the test is passed, the circuits remain under nitrogen pressure until the next stage. In addition, at the end of the test (after the last phase), our technical staff carries out an additional check of all joints and braze welding in the circuit(s) (by means of an infrared "electronic nose") as yet another confirmation of the tightness of the workings.
FOR CHILLERS
Vacuum testing and drying
After passing the pressure test, the refrigerant gas circuit(s) is subjected to the vacuum test and the vacuum itself is maintained for the time necessary to achieve the appropriate degree of dehumidification. After complete drying of the gas circuit(s), the vacuum is 'broken' with a suitable refrigerant charge.
FOR ALL FRIGOFLUID SYSTEMS
Hydraulic test
When the power station is placed in the end-of-line test station, water or water/glycol is loaded into the hydraulic supply circuit. All hydraulic connections and joints are pressure tested, and with the help of electric pumps, the flow rate of the liquid is measured and the hydraulic pressure drops of each power unit are checked.
FOR ALL FRIGOFLUID SYSTEMS
Electrical test
The tightening of the electrical cables of both the switchboard and the motors are checked one by one. All safety devices are set and calibrated, and after checking the directions of rotation of the motors, the absorption and dispersion of the electrical system on board the machine and in the switchboard are measured.
FOR ALL FRIGOFLUID SYSTEMS
Thermodynamic test
Every chiller produced by Frigofluid enters our end-of-line area and undergoes a stability test under thermal load, from which we obtain all the necessary outputs to validate the product. Using an advanced data acquisition system, we certify the validity of the performance. Only at the end of this operation, all the traffic lights that allow passage between the different test phases are lit green and the product passes to the final activities that are completed with shipment to the customer.
FOR ALL FRIGOFLUID SYSTEMS
The machine is now tested
Only now does the company's management software receive the OK from the test centre: the refrigeration or temperature control system is ready to be installed!
The guarantee of performance and functionality
Industrial chillers are complex machines; the number of their internal components (refrigerant circuits, evaporator and condenser, valves) is quite large. Dry coolers, adiabatic coolers, and temperature controllers also require special care in manufacturing–and in component testing.
According to many interlocutors, one of the most qualifying points of the service that manufacturers of industrial chillers and thermal machines in general can provide is the guarantee on the required performance and correct functionality of each part: especially through meticulous pre-installation testing.
Tell us your needsTesting and commissioning in an advanced station
It is with this in mind that we have had a test and inspection laboratory at our headquarters for many years. Machine testing can take several hours and covers very different aspects of the machinery.
- All of our machines are tested before installation.
- Frigofluid’s business management system receives data that the machinery has been tested: otherwise, the job order itself is not validated.
- In the case of turnkey refrigeration systems, cooling systems supplied by MITA Cooling Technologies (as part of MITA Group) are also tested in the test laboratory.
Even before the testing station
However, validation of the components in the test station is not the only time for testing and acceptance of the machinery.
In fact, industrial chillers and dry coolers have already had their first “litmus test.” In fact, our products are designed following the thermodynamic calculations contained in a single selection software for all components-a choice intended to unify several otherwise dissected programs. The advantage is to have already tested a first time the constituent parts of the system in their interaction.
Testing by means of an equipped center is thus an additional guarantee of accuracy, already tested in the design phase.
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Turnkey Refrigeration Plants
A refrigeration system is more than a single chiller: heat exchangers, hydraulic connections, additional cooling devices also come into play to support your production process.
Air-Cooled Liquid Chillers
Temperature fluido in uscita da +1° a +30° CIn air-cooled liquid chillers, the cooling of the refrigerant gas is ensured by the ambient air itself. Frigofluid offers a wide range of this type of industrial chiller in its catalogue, including a solution with free-cooling.
Water-Cooled Liquid Chillers
Fluid outlet temperatures -8°C to +20° CCooling the refrigerant gas by means of a water exchanger: this is what characterises the water-cooled chillers, which use this feature to ensure high system efficiency. Frigofluid water chillers, with output temperatures down to -8° C, are ideal when air movement is not possible.
Industrial Dry Coolers and Adiabatic Dry Coolers
Industrial dry coolers are a useful solution where fluid outlet temperatures no lower than the external temperature are required. Adiabatic dry coolers are a version of these industrial coolers that can offer outlet fluid temperatures lower than the external temperature.
Industrial Thermoregulation Units
Water control temperatures from +90° to +140° CIndustrial termoregulation units manufactured by Frigofluid are designed to condition moulds and cylinders in various industrial processes. In plastic moulding, process fluids are kept at temperature, thus reducing the use of electrical power for heating and limiting the cooling power spent on cooling by self-stabilisation.
Remanufactured chillers for immediate delivery
Remanufacturing is a 'hot topic' in industrial production, especially in times of resource rationalisation: Frigofluid can supply its customers with remanufactured chillers. A totally sustainable solution.