Turbocor Chiller

Common issues

• Refrigerant leaks at flanged or brazed joints, reducing capacity and EER over time
• Magnetic bearing controller fault trips from loss of rotor position sensing
• Fouled seawater-side condenser tubes raising head pressure and cutting efficiency
• Evaporator freeze-up from low refrigerant charge or reduced seawater flow
• VFD/electronics overheating in poorly ventilated machinery spaces
• Pressure/temperature sensor drift causing false trips or inefficient staging
• Seawater strainer fouling upstream, starving the condenser of flow

Inspection checklist

• Check refrigerant charge and discharge superheat (no lubricating oil to sample on this oil-free compressor)
• Inspect the compressor's touch-down (backup) bearing status via the controller's diagnostic log
• Clean/inspect seawater strainers and the condenser tube bundle for fouling or marine growth
• Verify condenser and evaporator approach temperatures against commissioning baseline
• Check electrical connections and VFD cooling fan operation
• Test high- and low-pressure safety cutouts
• Inspect refrigerant leak detection sensors in the machinery space
• Verify surge/anti-surge control behaviour at part load

Service intervals

Typical wear limits

Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.

Critical spares

• Touch-down (backup) bearing set for the compressor
• Pressure and temperature transducers
• Electronic expansion valve
• Condenser/evaporator gasket and O-ring set
• VFD cooling fan
• Correct-type refrigerant charge
• Compressor control board

Safety

• Refrigerant handling requires certified personnel and space ventilation - risk of asphyxiation in enclosed compressor rooms on a large leak
• High voltage present in the VFD and magnetic bearing controller even with the compressor stopped - lock-out/tag-out required
• Pressurised refrigerant system - risk of cold burns/frostbite from liquid refrigerant contact
• Do not bypass touch-down bearing diagnostics - the rotor runs on magnetic bearings at high speed with no mechanical backup lubrication

Class survey

Refrigeration plant normally falls under periodic rather than continuous survey. Class will typically check pressure vessel/receiver certification, safety valve testing, the refrigerant leak log, and machinery-space gas detection/ventilation arrangements for the refrigerant type fitted.

Estimated lifetime: Oil-free magnetic-bearing chillers of this type are typically designed for 15-20+ years of service with periodic sensor, bearing, and controller board renewal, since there are no lubricated bearings or reciprocating parts to wear the way a conventional compressor would.