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Chiller rebuild cost and frequency


MPdesign
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Reference: Chiller rebuild cost and frequency

What are "ballpark" chiller rebuild costs:

100 ton, 300 ton, 500 ton

How often should they be rebuilt?

What is recommended life. From experience I would say 40 years; but, is that really a good idea?

I assume that you are talking about a commercial type chiller?

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Reference: Chiller rebuild cost and frequency

What are "ballpark" chiller rebuild costs:

100 ton, 300 ton, 500 ton

How often should they be rebuilt?

What is recommended life. From experience I would say 40 years; but, is that really a good idea?

Depends on the type of chiller. We use to tear down 100 ton Trane recips once a year (for a local TV station). Replacement of the valve plates was done at that time as well as any other problems that might be found (the 100 ton Trane recips were dogs). We would also do eddy current testing on the chiller and condenser barrels. The labor on these would be typically be 2 men 2 days.

Centrifugal chillers were once every 4-5 years. The labor for the centrifugal was 2 men 2 weeks. Parts would vary with what we found wrong. Eddy current testing would also be done as well.

Back then 65.00 and hour would be a good target (late 90's)

When the screws were coming out I got out of the industry so I can not comment.

EDIT: We use to sub the eddy current testing out so that is not included in the hours. The testing was done by one tech with the machine. We would either punch the tubes or acid clean before the eddy current testing was done.

EDIT EDIT: A centrifugal, with good maintenance, may last 40 years and beyond but I doubt a recip will be able to hang in there for 40 years.

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I recently read an article in Buildings magazine about the phase-out of refrigerants that contain chlorine molecules and have ozone-depletion potential. The international treaty is called the Montreal Protocol. It was ratified several years ago, but was amended last fall to accelerate the phase-out schedule.

Older chillers use HCFC-123 or HCF-22 refrigerant. What I gleaned from the article is that the reduced availability and likely increased cost of chlorine-containing refrigerants should be entered into the equation of replacement vs. rebuild strategies.

Retrofitting the machines to use modern refrigerants isn't practicle because the operating pressure differences between the refrigerants is too great. Newer machines are more efficient and cost less to maintain, which is another factor.

A spokesman for Johnson controls estimated lifespan at about 30 years. A director of McQuay Intl. stated that he felt there was a benefit in replacing a 10-year-old centrifugal chiller now. He said full-load efficiences have increased in the past 10 years by 10-15% and part load efficiencies have increased by 25-30%, which computed to a payback of 3 years. These are computations from companies that sell new equipment, however.

No estimates of new equipment costs were given.

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Team,

Yes, I am talking about a commercial chiller.

My problem is that people normally say they have a life of 30 years but I see *MUCH* older chillers all of the time. They can last much much longer.

So it sounds like they should be rebuilt every 4-5 years.

Anyone have a budget for this? Does this sound right based on the above?

$125 per hour*2men*80hrs per man = $20,000 + say $5,000 for eddy testing?

Is this $5,000 reasonable for eddy current testing?

Would it cost about 50% more for a 300 ton?

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Team,

Yes, I am talking about a commercial chiller.

My problem is that people normally say they have a life of 30 years but I see *MUCH* older chillers all of the time. They can last much much longer.

So it sounds like they should be rebuilt every 4-5 years.

Anyone have a budget for this? Does this sound right based on the above?

$125 per hour*2men*80hrs per man = $20,000 + say $5,000 for eddy testing?

Is this $5,000 reasonable for eddy current testing?

You haven't said what type of chiller - recip, screw, centrifugal??

Your estimate sounds pretty good for a centrifugal however you need to add in X amount for materials. Liquid line dryers, refrigerant etc. Upon occasion we would send the impeller out to have it balanced and trued as well.

Would it cost about 50% more for a 300 ton?

As compaired too????

If it's a centrifugal then 300 ton is a baby.

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