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.