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Five reasons a new hydronic system does not perform, none of them the chiller

When a brand-new chilled water plant will not hold temperature, the chiller is almost never the problem. The piping usually is.

Carol Whitfield, President · June 9, 2025 · 5 min read

Owners call six months after a plant is built: the building is warm, the chiller is new, something is wrong. The chiller is fine. Here is what we find instead.

1. Air in the system

Automatic air vents installed where the drawing showed them instead of at the actual high points. Air collects, pumps cavitate, flow drops. The fix is vents where the air actually goes.

2. Strainers never cleaned

Construction debris in the strainers after flushing. Flow drops at every coil. We clean strainers after flushing and again after the first week of operation.

3. A flush that was a rinse

A real flush runs for hours at velocity with the chemicals the spec calls for. A rinse is a hose. If the balancer could not hit design flows, this is usually why.

4. Hangers that let the pipe sag

Sagging mains trap air and water in the wrong places. Hangers at code spacing for the pipe size, not where the installer could reach.

5. Balancing done before the system was finished

A balance report taken with half the coils isolated is fiction. The balancer should be the last trade in, after flush, treatment and strainer cleaning.

All five are piping-contractor problems, and all five are cheaper to prevent than to find.

Next step

Send the drawings or describe the building.

A project manager or Carol replies the same business day. Contract clients on the 24-hour line get a plumber, not a service.

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