Chiller Systems Course

Lesson 1 • Basic Thermodynamic Principles

Covers heat transfer modes, enthalpy, and entropy as applied to cooling systems. Establishes the physical laws that govern all chiller equipment behaviour.

Lesson 2 • The Vapour Compression Cycle

Explains the four-stage refrigeration cycle and the role of each component. Provides the mechanical framework learners apply throughout the course.

Lesson 3 • Refrigerants: Properties and Selection

Examines refrigerant classifications, thermodynamic properties, and environmental impact ratings. Connects refrigerant choice to system efficiency and regulatory compliance.

Lesson 1 • Expansion Devices and Flow Control

Covers thermostatic, electronic, and fixed-orifice expansion devices and their control logic. Proper expansion device selection ensures stable superheat and system efficiency.

Lesson 2 • Ancillary Components and Safety Devices

Identifies oil management systems, purge units, and safety cutouts integral to chiller reliability. Connects each device to a specific failure mode it prevents.

Lesson 3 • Evaporators and Condensers

Details shell-and-tube, plate, and brazed heat exchanger designs used in chillers. Explains how heat transfer surface area and flow arrangement affect performance.

Lesson 4 • Compressor Types and Operation

Surveys centrifugal, screw, scroll, and reciprocating compressors and their operating principles. Compressor selection criteria are linked to chiller capacity and application.

Lesson 1 • Absorption Chiller Technology

Explains lithium bromide and ammonia absorption cycles driven by heat rather than electricity. Learners assess absorption chillers for waste-heat and combined-energy applications.

Lesson 2 • Chiller Plant Configurations

Analyses series, parallel, and primary-secondary plant arrangements and their hydraulic behaviour. Configuration choice directly impacts redundancy, efficiency, and control complexity.

Lesson 3 • Air-Cooled Chiller Systems

Examines air-cooled condenser design, ambient temperature effects, and installation constraints. Highlights trade-offs between simplicity and efficiency versus water-cooled alternatives.

Lesson 4 • Thermal Energy Storage Integration

Introduces ice and chilled water storage strategies that shift cooling loads to off-peak periods. Learners calculate storage capacity and evaluate economic and operational benefits.

Lesson 1 • Sensors and Measurement Devices

Covers temperature, pressure, flow, and power sensors used in chiller monitoring. Accurate sensor selection and placement are critical to reliable control and diagnostics.

Lesson 2 • Chiller Control System Architecture

Describes microprocessor-based chiller controllers, I/O modules, and communication buses. Establishes the hardware foundation for all subsequent control discussions.

Lesson 3 • Capacity Control and Staging Logic

Explains leaving water temperature control, guide vane modulation, and multi-chiller staging sequences. Proper staging minimises energy use while meeting variable load demands.

Lesson 4 • Safety Interlocks and Alarm Management

Details protective shutdown sequences, alarm prioritisation, and fault logging practices. Learners interpret alarm histories to distinguish nuisance trips from genuine faults.

Lesson 1 • Performance Curves and Operating Maps

Teaches interpretation of compressor maps, capacity curves, and efficiency surfaces across load and temperature ranges. Curves reveal optimal operating zones for energy savings.

Lesson 2 • Optimisation Strategies and Setpoint Tuning

Applies chilled water reset, condenser water optimisation, and sequencing improvements to reduce plant energy use. Learners implement and verify optimisation measures.

Lesson 3 • Energy Benchmarking and Monitoring

Establishes baseline energy consumption using interval metering and normalisation techniques. Benchmarking enables detection of performance degradation over time.

Lesson 4 • Efficiency Metrics and Rating Standards

Defines COP, EER, IPLV, and NPLV metrics and explains how rating conditions are standardised. Learners apply these metrics to compare equipment across manufacturers.

Lesson 1 • Cooling Load Calculation Methods

Applies heat gain calculation methods to determine design cooling loads for buildings and processes. Accurate load calculations are the foundation of correct equipment sizing.

Lesson 2 • Functional Testing and Commissioning Reporting

Executes functional performance tests, records measured vs. specified values, and produces commissioning reports. Commissioning confirms the system meets design intent before handover.

Lesson 3 • Equipment Selection and Sizing

Guides chiller, pump, tower, and piping selection based on load profiles and site constraints. Learners produce equipment schedules with performance and redundancy criteria.

Lesson 4 • System Design Documentation

Covers piping and instrumentation diagrams, sequence of operations, and control point schedules. Complete documentation enables accurate installation and future maintenance.

Lesson 1 • Electrical and Controls Inspection

Outlines motor insulation testing, connection torque checks, and controller diagnostic routines. Electrical integrity prevents the majority of unplanned chiller shutdowns.

Lesson 2 • Water Treatment and System Flushing

Explains chemical treatment programmes for chilled and condenser water loops to prevent scale, corrosion, and biological growth. Proper treatment protects heat exchangers and piping.

Lesson 3 • Heat Exchanger Cleaning and Inspection

Covers tube brushing, chemical cleaning, and eddy-current testing for evaporators and condensers. Clean heat exchangers are essential for maintaining rated efficiency.

Lesson 4 • Maintenance Programme Development

Guides creation of time-based and condition-based maintenance plans aligned with manufacturer requirements. A well-structured programme reduces unplanned downtime and warranty risk.

Lesson 1 • Diagnostic Methodology and Tools

Introduces structured fault-finding frameworks, diagnostic instruments, and data collection practices. A repeatable methodology reduces diagnostic time and prevents misdiagnosis.

Lesson 2 • Water-Side and Heat Exchanger Faults

Diagnoses low flow, fouling, freeze protection failures, and tube leaks on the water side. Water-side faults are frequently misattributed to refrigerant or compressor problems.

Lesson 3 • Refrigerant Circuit Faults

Diagnoses overcharge, undercharge, moisture contamination, and non-condensable gas faults using pressure-temperature analysis. Learners distinguish refrigerant faults from mechanical issues.

Lesson 4 • Compressor Faults and Failure Modes

Identifies surge, oil failure, motor overload, and bearing wear as primary compressor failure modes. Early detection prevents catastrophic damage and costly replacement.