TopChiller Explosion Proof Chiller & Hazardous Process Chiller

Explosion Proof Chiller-An Ultimate Buying Guide by TopChiller

Explosion Proof Chiller is an effective refrigeration solution for the safety and protection of your industrial machinery and workers.

In case you are searching for an effective water cooling system in petrochemical, oil, gas, or other industries, the Explosion Proof Chiller is a must-to-consider refrigeration option.

Air Cooled Explosion Proof Chiller or Water Cooled Explosion Proof Chiller? depending on the industry for which you are going to use it.

Before we buy, it is essential to understand the parts, features, and working of the Explosion Proof Chiller.

So, let’s get started.

What is an Explosion Proof Chiller?

The Explosion Proof Chiller is an effective refrigeration device that is primarily included inflammable and volatile environments.

Normally the cooling capacity of Explosion Proof Chiller is at a range of 10 to 200 Ton.

It plays a big part in aiding in the protection of industries where workers are dealing with volatile and flammable substances.

To improve the cooling efficiency, the Explosion Proof Water Chiller cools water at room temperature to a certain temperature using the compressor, evaporator, condenser, and other parts.

Moreover, a constructed fan is also present, which aids in heat dissipation.

The refrigerant circulation system, the water circulation system, and the electrical automatic control system are three interconnected systems you will find here.

Whether you want to install it in petrochemical industries, laboratories, or granaries, it will be efficient enough in dealing with excessive heat.

Also, the Explosion Proof Chiller is an effective solution for increased heat problems in process analyzer machines and industries.

It complies with all the basic manufacturing safety standards and considerations that are set by NEMA, so it is completely safe to use.

Even customization of the Explosion Proof Chiller is possible based on the needs of the consumer.

Explosion Proof Chiller Designed by TopChiller

What are the Major Parts of an Explosion Proof Chiller?

1. Compressor:

The compressor presented in the center of the  Explosion Proof Chiller, between the evaporator and the condenser will produce a pressure gap in the device to shift the refrigerant around.

Moreover, it is normally partially shielded, and the driving power is usually an electrical motor, which can be installed either internally or externally.

The hearing aid should be worn anywhere near the Explosion Proof Chiller because compressors can be particularly loud, producing a continuous low tuneless sound of an overlaying high pitch.

1. Expansion valve:

The expansion valve is between the condenser and the evaporator. It aims to extend the refrigerant, lowering its pressure and increasing its thickness, allowing it to absorb heat from the evaporator.

There are several different types of expansion valves, with the thermal expansion valve being the most common.

1. Evaporator:

The evaporator, which is situated between the expansion valve and the compressor, collects excess heat from the building and transfers it to the refrigerant, which is then sent to the cooling tower and discarded.

Then when the refrigerant starts taking this heat, the water cools down. Then, this cooled water is supplied to buildings for air conditioning purposes.

1. Power unit:

The power unit may be attached to the Explosion Proof Chiller directly or indirectly, connected to the plant room wall with power cables passing between them.

The power unit’s job is to control the flow of electricity to this machine. A starter, circuit breakers, speed controller, and power monitoring equipment are also normally included.

1. Condenser:

After the compressor, just before the expansion valve, is the condenser. The condenser’s job is to drain heat from the refrigerant that was collected in the evaporator.

Air-cooled and water-cooled condensers are the two major types of condensers.

1. Controls:

The Explosion Proof Chiller control device is typically fixed on it. Its purpose is to keep track of the different aspects of the efficiency of the machine and make corrections if needed.

To avoid damage to the device, the control unit can generate alarms for the safe shutdown of the system. Remote control and tracking of the Explosion Proof Chiller are normally possible because of the BMS connections.

Explosion Proof Chiller Power Unit

What are the Main Features of the Explosion Proof Chiller?

• Specific explosion-proof electric control box.
• Explosion-proof low-noise big flow pump.
• As per team management specifications.
• Fast to apply the sterile, anti-rust, and anti-vibration treatment.
• Low noise, high heat flow content, and high power output.
• To meet the special requirements of excellent refrigeration efficiency.
• A user-friendly interface, high-tech content.
• Intelligent control, flexibility, arbitrary, stability, and peace of mind are required.
• To provide secure and efficient operation of protection designed.
• Specifically for chemical and other inflammable and explosive sites.

Explosion Proof Chiller Low-Noise Big Flow Pump

How Does an Explosion Proof Chiller Work?

There are screw and scroll compressors, as well as air-cooled and water-cooled condensers, which alter the working of the Explosion Proof Chiller.

The components of the Explosion Proof Chiller alone do not make it explosion-proof. It is determined by the overall system’s configuration.

However, the components decide the final performance of it and the temperatures it will achieve.

The refrigerant is cycled through the components to pass heat from the cooled environment (or process fluid) from the outside.

It will lower the temperature of the refrigerant to below zero degrees Fahrenheit, depending on the cooling agent (refrigerant) used and the compressor form.

Explosion Proof Chiller is used in temperatures ranging from -40 to 20 degrees Fahrenheit.

The procedure begins with refrigerant in a liquid-gas mixture. Heat converts the refrigerant into a low-pressure gas in the evaporator, where the gas and liquid mix.

This gas enters the compressor, which compresses it into a high-pressure state using one of many means.

This gas travels to the condenser, which cools the refrigerant with either water or air.

The coolant gives off its heat in the condenser and condenses back into a vapor.

As this liquid goes through a control experiment, which determines how much of the cooled refrigerant passes through the evaporator to restart the loop, it is at high pressure.

And this is how the Explosion Proof Chiller completes its cooling process for dealing with extra heat production in various industries.

What are the Advantages of Explosion Proof Chiller for your Applications?

• It aids in reducing the chances of an explosion.
• It ensures the protection and safety of all workers and the industry from hazardous situations.
• Explosion Proof Chiller is a safety standard for many businesses.
• It reduces the chance of a spark from a machine igniting explosive or flammable objects.
• It is a small price to pay compared to the cost of lives lost in an industrial accident caused by incorrect machinery.
• The Explosion Proof Chiller is allowed by law in many places where flammable materials are present to prevent accidental fires.
• It plays a good safety role in the field where explosive gases, vapors, or highly alkaline liquids are present for normal machinery operation.

What are the Applications of Using an Explosion Proof Chiller?

• Refineries:

The materials used in oil and gas refining must be treated with strict care. The flammable vapors generated by power plants necessitate Class 1 Explosion Proof Chiller.

The room in which the plant requires the device will decide if Division 1 or Division 2 forms are required.

• Sample or Process Analyzers: 

Workers use sample or method analyzers to evaluate the chemical structure of different compounds. Explosion safety in the sample testing areas could save lives because the contents have uncertain compositions and could contain dangerous materials.

• Granaries: 

Flour is a highly hazardous substance. A tiny spark is all that is needed to fire the fine dust in the air. That is why Explosion Proof Chiller is needed in silos and granaries.

Even though the NEC’s article 506 provides a special category for places of ignitable dust, there are also limitations on electric appliances to avoid fire.

• Laboratories:

In laboratories, airflow is critical for worker safety and health. Fire protection and, if necessary, blast proofing are both critical considerations.

Anywhere there are explosive, flammable vapors or gases, special electric components are needed to prevent misplaced sparks from igniting them.

What are the Petrochemical and Offshore Oil Rig Usage of the Explosion Proof Chiller?

Petrochemical Plants: 

The petrochemical industries require working with dangerous materials. The flammability of certain petrochemicals, such as gasoline, is part of what makes them attractive.

Oil refineries are also at risk of fire because of this characteristic. In several areas at oil refineries, the NEC needs the Explosion Proof Chiller.

Offshore Oil Rigs:

All is riskier in an underwater setting because of the venue. Even if the room doesn’t necessarily require an Explosion Proof Chiller, the place in the center of the water, far from fire stations, does.

Furthermore, oil rigs frequently have uncovered oil that may vaporize and cause a dangerous condition if it sparks. The Explosion Proof Chiller keeps the staff on the rig safe, secure, and protected.

Petrochemical Plant where Explosion Proof Chiller is Used

What are the Energy Saving Options of Using the Explosion Proof Chiller?

Without base attachment, the device uses high-quality imported twin-screw compressors.

It comes with working parts that are only a tenth of the reciprocating compressors and vibration that is only a fifth of the rotating compressors.

One other good point is that the failure rate is just a tenth of that of the flow coefficient.

Moreover, the Explosion Proof Chiller is safe and reliable to be used in various industries. It is equipped with world-class brand monitoring systems to ensure long-term safety and stability.

What are the Conditions and Benefits of Remote Alarm and Alert Relays in the Explosion Proof Chiller?

A remote warning and remote alert operator control contacts may be added to the Explosion Proof Chiller.

At 24 volts, all relays attached to these contacts must be rated for a maximum power draw of 10 VA sealed and 25 VA inrush.

TB5-12 and TB5-13 will be used to link the warning relay, which indicates that the whole device has been turned off. You may also refer to the unit’s wiring diagrams or manual for more details.

A field supplied and mounted relay must be linked between MBBJ3-CH25-3 and TB5-13 for an alarm relay, showing that at least one circuit is off due to the alert.

Using the Reverse Alarms Relay setup, the operation of the alarm and warning relays can be changed from usually open to normal lock.

How to Choose a Suitable Explosion Proof Chiller for your Applications?

• To begin, you’ll need to know the Explosion Proof Chiller height, which does not necessarily apply to its measurements.
• To avoid wasting resources or selecting an unreliable device, you must carefully calculate the cooling ability.
• You’ll also need to know which group the device room belongs to according to NEC requirements.
• Moreover, the heat load that your machine can bear is essential to be kept in mind,
• Last but not least, the amount of energy your Explosion Proof Chiller uses, contributes a lot in making it reliable or unreliable for you.

How to Maintain your Explosion Proof Chiller?

• Water Treatment:

Since water is such an important component in the operation of the Explosion Proof Chiller, you must ensure that it is well handled.

The most important thing is to supply absolutely clean water to the machine. This is to avoid major problems like rust, rust, and biological growth.

It is preferable if the water system infrastructure should be handled as part of huge maintenance frequently. This thing will surely aid in the higher durability of your Explosion Proof Chiller.

• Chemical Analysis:

The chemical analysis must be seen in addition to water services. Regularly test the chemicals you use (such as oil and refrigerants) to avoid contamination or chemical mismatch.

Furthermore, knowing the amount of dirt, moisture, or acid in your Explosion Proof Chiller will help you avoid various problems.

• Heat-Transfer Efficiency:

The performance of an Explosion Proof Chiller is strongly influenced by heat transfer efficiency.

It could negatively impact the whole process and create expensive delays if it begins delivering subpar performance.

Ensure that the evaporators and condenser tubes are either manually or chemically washed. This means that the heat-transfer capability of your Explosion Proof Chiller does not fall below acceptable levels.

• Monitor Logs:

Finally, it’s necessary to keep track of your Explosion Proof Chiller working and efficiently regularly.

This allows you to stay aware of any problems that are probable to occur in the future. Which also aids in the creation of development and safety-improvement techniques.

Chemical Analysis to Maintain Explosion Proof Chiller

What are the Causes and Solutions for Compressor Failure in the Explosion Proof Chiller?

The compressor failure is much likely to happen because of overheating of the system that can be caused by given factors.

• High Compressor Pressure

The compressor is under so much pressure, so the overload action kicks in.

Possible causes include a strong cooling water temperature, excessive refrigerant injection, or the presence of a non-condensing gas such as air in the device.

All of these will overload the compression machine and result in high-pressure loss.

• High Compressor Load

Overload action of the compressor of the Explosion Proof Chiller is often caused by electrical loss.

The current or one-phase current is too high if the three-phase power supply voltage is too low or the three-phase is unbalanced.

Also, the AC contactor is weakened, the contact is ablated, and the contact current is too large, or the current is too large due to a loss of phase.

• Moistured Refrigerator

The compressor overheating malfunction can also be caused by moisture or damage to the refrigerator’s getting too hot safety module SSM.

The overheating malfunction can occur when the system is switched on if the intermediate relay is broken and the interaction is not sufficient, allowing the compressor to fail to start.

It can wrongly announce an overheating malfunction whether there is a device electronic board or contact failure.

• Congested space

The compressor can overheat if the Explosion Proof Chiller is placed in an area that is not well maintained, and some space is not left for the inlet and outlet seals to allow for airflow.

As a result, the location of the Explosion Proof Chiller is important. Attention must be paid to airflow, and no debris can be put near it; otherwise, its daily activity would be affected badly.

Explosion Proof Chiller Compressor Failure Inspection

FAQ of Explosion Proof Chiller

How Does the Compressor of the Explosion Proof Chiller Contribute to its Durability?

The Explosion Proof Chiller has a compressor made up of corrosion-resistant metal material that increases its life and durability.

What are Some Protection Devices Used in the Explosion Proof Chiller?

The Explosion Proof Chiller contains an overload and compressor’s overheat protector for its protection. Moreover, a safety valve is also present in it to deal with emergencies.

What are the Common Refrigerant Compressor Options Available in the Explosion Proof Chiller?

The refrigerant compressor options include the centrifugal, screw, scroll, and rotating compressors. Each type has its own set of advantages and disadvantages.

What are the Piping Options Available for the Explosion Proof Chiller?

You have two piping options when talking about the Explosion Proof Chiller. You are free to choose between the CVC or the stainless steel piping options depending upon your application.

What Reduces the Excess Power Consumption in the Explosion Proof Chiller?

The hot gas bypass contributes a lot to the reduction of the power consumption of the Explosion Proof Chiller.

What is the Condenser Type Mostly Used in the Explosion Proof Chiller?

Shell and tube-type condensers are mostly used in the Explosion Proof Chiller.

What is the Best Solution to Deal with Varying Loads of the Explosion Proof Chiller?

The best solution to deal with the varying loads of the Explosion Proof Chiller is to go for the dual refrigeration system.

What is the Control Mode of the Explosion Proof Chiller?

The Explosion Proof Chiller is controlled by the PLC mode (Programmable Logic Controller).

What are the Two Common Refrigerants Used in the Explosion Proof Chiller?

The three common refrigerants used in the Explosion Proof Chiller include the R-407c, R410a, and R-134a.

What is the Evaporator Type used in the Explosion Proof Chiller?

The Explosion Proof Chiller uses the shell and tube type flooded type evaporator for excellent performance. This evaporator contributes a lot to the efficient working of this machine.

100% Quality Tested Explosion Proof Chiller