Client: Industrial Brewery in Warrington
Location: Warrington, UK
Date: August 2024
Equipment Type: Water Chiller with Cast Aluminium Condenser Coils
Issue: Refrigerant Leak due to Mechanical Joint Failure
Sustainability Index Score: 85%
Amount of Carbon Saved: 52 kg CO₂
Background
In response to the market demand for improved coefficient of performance, efficiency, and reduced production costs, many chiller manufacturers have started using cast aluminium condenser coils. While these coils provide the desired performance benefits, they necessitate a mechanical joint where the aluminium coil connects to the copper refrigeration pipework.
At Lunar Refrigeration Ltd, our Planned Preventative Maintenance (PPM) practice and ISO9001 quality audits have identified a recurring issue where these mechanical joints fail, leading to refrigerant leaks and subsequent equipment downtime.
Problem Identification
In a recent case, we observed significant corrosion at the joint connecting the aluminium coil to the copper pipework, resulting in a refrigerant leak. The equipment was out of warranty, and the client sought a solution that would avoid the costly replacement of the entire condenser coil, which was otherwise functional.
Solution Implementation
To prevent further refrigerant loss and minimise repair costs, our team opted to replace the failed factory joint with a certified press-fit joint. This method allowed us to securely join the aluminium and copper without the need for complete coil replacement, offering the client a cost-effective and durable solution.
Outcome
By replacing the factory joint with a certified press-fit joint, we successfully mitigated the refrigerant leak and restored the chiller’s functionality without replacing the expensive condenser coil. The solution proved effective, and the client was satisfied with the minimal disruption and cost savings.
Conclusion
This case exemplifies the importance of proactive PPM and thorough quality audits in identifying potential points of failure. By implementing a certified press-fit joint, Lunar Refrigeration Ltd provided a practical solution that preserved the client’s equipment and avoided unnecessary replacement costs.