How to Prevent Evaporator Leakage in Industrial Chillers

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.