Chiller Restoration
Recover lost tonnage and reduce head pressure through tube cleaning, tube sheet refurbishment, and epoxy resurfacing of water boxes.
Heat Transfer Efficiency
Even microscopic scale on chiller tubes can increase energy consumption by 15-20%. We target the fouling that standard maintenance misses.
Approach Temperature
Rising approach temperatures indicate fouled tubes and reduced efficiency.
Head Pressure
High head pressure forces compressors to work harder, shortening lifespan.
Corrosion & Pitting
Tube sheet degradation leads to leaks and catastrophic cross-contamination.
Epoxy Failure
Existing coatings on water boxes failing, leading to substrate corrosion.
Chiller Refurbishment SOP
Our process restores the entire heat exchange loop, from physical tube cleaning to protective coating application.
Rotary Brush & Descaling
Mechanical cleaning of copper tubes to remove mineral scale and biological fouling.
- Nylon/Brass brushing
- Chemical descaling circulation
- Borescope inspection
Tube Sheet Resurfacing
Abrasive blasting of tube sheets to expose white metal and remove corrosion.
- Grit blasting
- Surface profile verification
- Chloride testing
Epoxy Cladding
Application of 100% solids epoxy to tube sheets and water boxes.
- Ceramic-filled epoxy
- Edge-retention coating
- Holiday testing (Spark test)
Final Return to Service
Reassembly and pressure testing to ensure leak-free operation.
- Hydrostatic testing
- Flow rate verification
- Baseline performance log
15-25%
Energy Efficiency Gain
< 12 Mos
Typical Payback
Measurable Performance Recovery
Restoring a chiller's tubes and water boxes costs a fraction of a re-tube or replacement and immediately lowers electrical demand.
Frequently Asked Questions
How often should commercial chiller tubes be cleaned?
Annual tube brushing is the industry standard for water-cooled chillers. Even a thin layer of scale increases energy consumption by 15–20% and elevates head pressure. BAM recommends pre-season cleaning before peak cooling load to restore design approach temperatures and prevent compressor trips.
Does chiller restoration require a full system shutdown?
Yes, the individual chiller must be isolated and drained for tube brushing and tube sheet work. However, BAM schedules restoration during swing seasons or sequences work across multiple machines so your facility retains cooling capacity throughout the project.
Can you coat chiller tube sheets without blocking the tubes?
Yes. BAM uses precision-machined plugs to mask every tube opening during epoxy application, ensuring zero flow restriction after reassembly. We verify each plug placement before coating and perform holiday testing post-cure to confirm a continuous, pinhole-free barrier against galvanic corrosion.
What is the ROI on chiller tube cleaning and refurbishment?
Most facilities recover the cost within the first cooling season through reduced kW/ton consumption. A chiller operating with fouled tubes can waste 20–30% more electricity. BAM's restoration—tube brushing, tube sheet resurfacing, and epoxy cladding—costs a fraction of a re-tube and delivers measurable efficiency gains immediately.
Do you service both centrifugal and screw chiller condensers?
Yes. BAM's protocols cover water-cooled condensers and evaporators on all major OEM platforms including Trane, York, Carrier, and Daikin. Our technicians carry brush sizes and tooling for standard and enhanced-surface tubes, and we perform borescope inspection to verify cleaning effectiveness.
What happens if chiller tube scale cannot be removed by brushing alone?
BAM implements a chemical descaling circulation prior to mechanical brushing for hardite or calcium carbonate deposits. We use inhibited acid solutions sized to the tube metallurgy—copper, cupronickel, or stainless—to dissolve scale without damaging the substrate. This two-stage approach recovers tubes that brushing alone cannot.
Ready to Restore Performance?
Our restoration engineers are ready to evaluate your facility and provide a documented assessment.
Request a Site Visit