How to Prevent Evaporator Leakage in Industrial Chillers
2026-01-23
How to Prevent Evaporator Leakage in Industrial Chillers
Introduction
Evaporator leakage is one of the most common and costly failures in industrial chiller systems. While leakage is often caused by multiple factors, most cases can be effectively prevented through proper system design, water quality control, and standardized operation and maintenance practices.
This article outlines practical measures to help reduce the risk of evaporator leakage and extend the service life of industrial chillers.
1. Maintain Proper Water Quality
Effective water quality management is the foundation of evaporator protection.
Circulating water should be regularly tested for pH value, chloride content, hardness, and impurity levels. Untreated or recycled industrial water should undergo proper filtration and chemical treatment before entering the evaporator.
Using corrosion inhibitors and scale inhibitors can significantly reduce the risk of tube corrosion and pitting.
2. Control Fouling and Scale Formation
Regular cleaning of the evaporator water side helps maintain stable heat exchange efficiency and prevents localized overheating.
Mechanical cleaning or chemical descaling should be scheduled based on water quality and operating conditions.
Early fouling control reduces thermal stress on heat exchange tubes and minimizes the likelihood of leakage caused by metal fatigue.
3. Implement Effective Freeze Protection
For chillers operating under low-temperature conditions, proper antifreeze protection is essential.
Ensure that antifreeze concentration meets the minimum required freezing point, and always drain water from the evaporator during long shutdown periods in cold seasons.
Maintaining sufficient water flow and avoiding dead zones within the evaporator can further reduce freezing risks.
4. Ensure Stable Operating Conditions
Avoid frequent start-stop cycles and sudden load fluctuations whenever possible.
Operating the chiller within its design parameters helps prevent pressure surges and liquid hammer effects, which can cause fatigue damage to tubes and welded joints.
5. Focus on Manufacturing Quality and Installation
Selecting evaporators manufactured with stable welding quality and reliable tube-to-tube-sheet connections is critical. Equally important is choosing a reliable and experienced supplier with proven manufacturing capability and strict quality control standards.
As an industrial chiller manufacturer, BOSIKAR works closely with qualified evaporator suppliers and applies rigorous inspection procedures throughout production, including material verification, welding quality control, and pressure testing, to ensure long-term reliability under industrial operating conditions.
During installation, proper alignment, effective vibration isolation, and balanced stress distribution should be ensured to prevent mechanical loads from being transferred to the evaporator and to reduce the risk of premature leakage.
6. Perform Regular Inspection and Preventive Maintenance
Routine inspection allows early detection of corrosion, fouling, and abnormal operating conditions.
Pressure testing, temperature monitoring, and water quality analysis should be incorporated into regular maintenance plans.
Preventive maintenance not only reduces the risk of leakage but also lowers total lifecycle costs.
Conclusion
Preventing evaporator leakage in industrial chillers requires a systematic approach that combines proper water treatment, freeze protection, stable operation, quality manufacturing, and regular maintenance.
By addressing these factors proactively, users can significantly improve system reliability, reduce downtime, and extend the service life of their chiller equipment.
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Analysis of Common Causes of Leakage in Chiller Evaporators (Heat Exchangers)
2026-01-23
Introduction
In industrial chiller systems, the evaporator (heat exchanger) is one of the most critical components. It is continuously exposed to refrigerant pressure, water-side corrosion, and repeated thermal cycling.
Once evaporator leakage occurs, it can lead to reduced cooling capacity, unexpected shutdowns, equipment damage, and even serious production disruptions.
Learn the common causes of leakage in industrial chiller evaporators, including water quality issues, fouling, freezing risks, pressure surges, and maintenance factors,to support proper equipment selection, operation, and maintenance.
1. Corrosion Leakage Caused by Water Quality Issues
Poor water quality is one of the most common causes of evaporator leakage in industrial chillers.
When circulating water contains high chloride levels, excessive hardness, impurities, or exhibits strong acidic or alkaline properties, corrosion is likely to develop on copper tubes or stainless steel surfaces. Over time, pitting corrosion and tube perforation may occur, eventually resulting in leakage.
Common scenarios include:
a. Untreated groundwater or industrial reclaimed water
b. Highly alkaline or high-salinity water conditions
c. Long-term lack of water quality testing or replacement
2. Freezing and Cracking Risk Under Low-Temperature Conditions
Under low-temperature operating conditions, insufficient antifreeze protection may cause water inside the evaporator to freeze and expand.
The resulting mechanical stress can easily damage heat exchange tubes or welded joints, leading to cracking and leakage.
Typical causes include:
a. Failure to drain water during winter shutdown
b. Insufficient antifreeze concentration
c. Inadequate water flow or localized blockage
3. Manufacturing and Installation Factors
Some evaporator leakage problems originate from manufacturing quality or installation issues, such as:
a. Inconsistent welding quality
b. Improper tube-to-tube-sheet expansion
c. Uneven mechanical stress or vibration transfer during installation
Although these issues may not be immediately visible, they often surface after prolonged operation.
4. Lack of Regular Maintenance and Inspection
As a concealed component, the evaporator is often overlooked during routine inspections.
Without regular cleaning, inspection, and maintenance, minor issues can escalate into serious leakage failures, resulting in higher repair costs and extended downtime.
Conclusion
Evaporator leakage in industrial chillers is rarely caused by a single factor. Instead, it is usually the combined result of water quality issues, operating conditions, structural design, and maintenance practices.
For industrial applications, proper evaporator selection, effective water quality management, and standardized operation and maintenance are essential to ensure long-term system reliability.Regular inspection and preventive measures are far more cost-effective than reactive repairs after leakage occurs.
For guidance on how to prevent evaporator corrosion and reduce leakage risks, please refer to our next article: How to Prevent Evaporator Leakage in Industrial Chillers.
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Industrial Chiller Condenser Types: Microchannel vs Copper Tube Fin
2026-01-23
Industrial Chiller Condenser: Microchannel vs Copper Tube Fin Comparison
Compare microchannel and copper tube fin condensers for industrial chillers. Learn efficiency, durability, maintenance, and best applications.
What Is an Industrial Chiller Condenser?
An industrial chiller condenser is a critical heat exchange component responsible for releasing heat absorbed from the cooling process. The condenser directly affects system efficiency, stability, maintenance cost, and service life of industrial cooling systems.
Industrial Chiller Condenser: Microchannel vs Copper Tube Fin Comparison
Comparison Item
Micro-Channel Condenser
(MCC)
Traditional Copper Tube Fin Condenser
Concern Explanation
Core Material
Aluminum alloy (fully aluminum brazed)
Copper + aluminum (copper tubes with aluminum fins)
MCC cost is affected by aluminum prices; traditional designs are affected by copper prices. Material price fluctuations are transparent and traceable.
Heat Exchange Efficiency
Very high
⭐⭐⭐⭐⭐
Good ⭐⭐⭐
MCC features micro-scale internal channels for larger heat exchange area, delivering higher COP and significant energy savings under the same cooling capacity.
Size & Weight
Small / Light (approx. 50% reduction)
Larger / Heavier
MCC is suitable for space-limited installations (e.g., workshop corners, roof tops) or weight-sensitive applications (e.g., mobile/vehicle-mounted chillers).
Resistance to Dust & Blockage
Weak (dense fins, easy to clog with dust/oil mist)
Strong (wider fin spacing, less prone to clogging)
Critical for industrial environments: In dusty/oily settings (e.g., injection molding, machinery factories), MCC is prone to clogging and hard to clean, while traditional designs offer higher fault tolerance.
Corrosion Resistance
Relatively weak (aluminum sensitive to salt spray/chemical gases)
Stronger (copper offers better corrosion resistance)
Critical for industrial environments: Traditional copper designs ensure longer service life in corrosive settings (e.g., coastal areas, chemical plants).
Maintenance Convenience
Difficult (integral brazed structure, not repairable on-site; full replacement required)
Easy (copper tubes can be welded on-site; simple cleaning)
Critical for industrial environments: Traditional designs feature lower maintenance costs and shorter downtime. MCC requires high replacement costs and disrupts production upon failure.
Resistance to Pressure/Shock
Relatively weak (thin walls, sensitive to liquid hammer/pressure fluctuations)
Strong (thick copper tubes, robust structure)
Traditional designs operate more stably under large industrial load fluctuations (e.g., simultaneous start/stop of multiple equipment) and are less prone to shock damage.
Initial Cost
Generally lower (depending on specific design)
Generally higher
MCC typically has lower material costs than copper, offering a lower initial purchase threshold.
Lifecycle Cost
Higher (high maintenance costs, service life heavily environment-dependent)
Lower (low maintenance costs, longer design life)
From a long-term operation perspective: Traditional designs are more "cost-effective and hassle-free," avoiding additional costs from frequent maintenance and replacements.
Choosing the Right Condenser for Dusty Industrial Environments
In industrial environments such as injection molding, extrusion, and machinery workshops, dust and oil mist are common challenges for cooling systems. These factors often lead to condenser clogging, reduced heat exchange efficiency, and increased maintenance frequency.
For such applications, traditional copper tube fin condensers are widely preferred. With wider fin spacing and a robust structure, they offer better resistance to dust accumulation, easier cleaning, and longer service life under continuous operation.
While microchannel condensers provide high efficiency in clean environments, their dense fin design makes them less suitable for dusty factories. Selecting the right condenser type based on actual working conditions is critical to ensuring long-term system reliability and lower lifecycle costs.
Need help selecting the right condenser for your factory?Send us your working conditions and get a free technical recommendation from our engineering team.
bskchiller.com
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Water-Cooled Chiller High-Pressure Alarm
2025-12-17
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A high-pressure alarm in a water-cooled chiller is typically associated with issues in the cooling water system. The following are common causes and corresponding solutions:
Cooling Water Valve Not Opened
The water-cooled chiller relies on a continuous supply of circulating cooling water from the cooling tower. If the cooling water valve remains closed during operation, water circulation to the chiller will be interrupted.
Solution: Ensure the cooling water valve is fully opened before startup.
Insufficient Cooling Water Flow or Elevated Cooling Water Temperature
Both conditions impair heat dissipation, preventing effective cooling of the refrigerant and leading to increased system pressure.
Solution: Verify that the piping diameter matches the chiller specifications, confirm normal pump operation, and ensure all valves are fully open.
Cooling Tower Failure
If the cooling tower malfunctions, it cannot supply adequately cooled water to the chiller, resulting in reduced heat rejection and potential high-pressure alarms.
Solution: Inspect the cooling tower for operational faults and perform necessary repairs or maintenance.
Scaling in the System
Prolonged operation without proper maintenance may lead to scale buildup and debris accumulation on internal pipe walls, significantly reducing condenser heat transfer efficiency.
Solution: Perform regular descaling and cleaning of the heat exchanger and water circuit to maintain optimal performance.
Note: Routine inspection and preventive maintenance of the entire cooling water system are essential to ensure reliable chiller operation and prevent unexpected downtime due to high-pressure conditions.
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Why Does an Air-Cooled Chiller Trigger a High-Pressure Alarm?
2025-12-17
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During hot summer months, many air-cooled chillers trigger high-pressure alarms, particularly in regions with extremely high ambient temperatures—often exceeding 45 °C—such as chillers in Saudi Arabia, the United Arab Emirates and Iraq.
Standard air-cooled chillers are equipped with comprehensive protective systems. When a high-pressure condition occurs, the protection mechanism is automatically activated, and the corresponding fault indicator light illuminates.
The primary cause of a high-pressure alarm is insufficient heat dissipation from the condenser. If this issue remains unresolved and the chiller continues to operate under high pressure for an extended period, it may lead to excessive current draw and ultimately result in compressor failure.
Common causes of high-pressure alarms include:
Air-cooled chillers rely on fans for condenser heat dissipation. When the ambient temperature exceeds 42 °C, the cooling efficiency decreases significantly, preventing effective removal of heat generated during refrigerant circulation.
Dirt accumulation or blockage on the condenser surface can severely impair heat transfer, leading to elevated pressure levels.
Recommended Solutions:
Inspect fan operation to ensure proper functionality.
Ensure adequate ventilation around the unit to allow efficient discharge of hot air.
In environments above 42 °C, consider auxiliary cooling methods such as external fans or shading structures to reduce surrounding temperatures.
Regularly clean the air filters and condenser fins using compressed air or appropriate cleaning tools.
For ambient temperatures near 42 °C, increase the condenser size by approximately 25%—a common practice for chillers using refrigerants such as R22, R407C, and R410A. For ambient temperature exceeding 45 °C, we recommend designing the system with R134a refrigerant, which supports operation at up to 55 °C. However, note that R134a has lower refrigeration efficiency, requiring a larger compressor to achieve equivalent cooling capacity, which increases overall system cost.
Note: Proper installation location is critical—air-cooled chillers should be installed in well-ventilated areas to ensure optimal airflow and long-term reliability.
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