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

Chiller Pressure Test

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.

Chiller Vacuum Test

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.

Hydraulic Testing of Industrial Chillers and Coolers

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.

Electrical Testing of Industrial Chillers and Coolers

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.

Test e Collaudo Refrigeratori e Raffreddatori Industriali

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.

Proven Refrigeration System

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.

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Testing 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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