50684234 Centrifugal Water Chillers

A Trane Air Conditioning Clinic

Centrifugal Water Chillers

Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999

ChilledWaterSystem

absorption centrifugal

helical-rotary

period one

Components

condencondenserser

compressorcompressor

controlcontrolpanelpanel

evaporatorevaporator

components of a

Centrifugal Water Chiller

starterstarter

motormotor

Compressor

Impeller

bladesblades

volutevolute

diffuserdiffuserpassagepassage

impeller impeller passagepassagess

Centrifugal Compressor

centrifugal compressor

Energy Conversionrefrigerarefrigerant enters nt enters diffuserdiffuser

path through path through compressorcompressor

refrigerantrefrigerant enters enters impellerimpeller

refrigeranrefrigerant enters t enters volutevolute

Multistage Compressor

Condenser

bafflebaffle

tubetubebundlebundle

liquid liquid refrigerarefrigerantnt

refrigerant refrigerant vaporvapor

coolincooling g

tower tower waterwater

totoevaporatorevaporator

orifice platesorifice plates

expansion device

Orifice Plates

expansion device

Orifice Plates

totoevaporatorevaporator

orifice platesorifice plates

2-stage chiller

Economizer

refrigerant refrigerant vapor to vapor to second stagesecond stageof of compressioncompression

liquid liquid refrigerant refrigerant to to evaporatorevaporator

orificeorificeliquid liquid refrigerant refrigerant from from condensercondenser

3-stage chiller

Economizer

liquid liquid refrigerant refrigerant to to evaporatorevaporator

orificeorifice

refrigerant refrigerant vapor to vapor to second stagesecond stageof of compressioncompression

refrigerant refrigerant vapor to third vapor to third stagestageof of compressioncompression

liquid liquid refrigerant refrigerant from from condensercondenser

Evaporator

eliminatoeliminatorr

liquidliquiddistributdistributoror

orifice orifice systemsystem

liquid liquid refrigerantrefrigerant

tube bundletube bundle

chilled chilled water water returnreturn

impellersimpellers

impellerimpeller

motormotor

motormotorgear-drive

direct-drive

gearsgears

Hermetic Motor Cooling

statorstator

rotorrotor

draindrainliquidliquidrefrigerarefrigera

Controls and Starter

starterstarter

Starters

remote-mounted

starterstarter

line line powerpower

control control power wiringpower wiring

unit-mounted

line line powerpower

control control power wiringpower wiring

period two

Refrigeration Cycle

2-stage centrifugal chiller

Refrigeration Cycle

condenscondenserer

evaporatevaporatoror

expansion expansion devicesdevices

economieconomizerzer

2-stage2-stagecomprescompres

sorsor

Pressure-Enthalpy (p-h) Chart

enthalpyenthalpy

subcooledsubcooledliquidliquid mixture mixture

of liquid of liquid and and vaporvapor

15.5 15.5 Btu/lbBtu/lb[201.0 [201.0 kJ/kg]kJ/kg]

superheatedsuperheatedvaporvapor

BA5 psia5 psia[0.034 [0.034

MPa]MPa]

92.4 92.4 Btu/lbBtu/lb[380.4 [380.4 kJ/kg]kJ/kg]

Refrigeration Cycle

enthalpyenthalpy

evaporaevaporatortor

condenscondenserer

2-stage 2-stage compresscompressoror

expansiexpansion on devicesdevices88

99PPee

55economizeconomizerer

Refrigeration Cycle

enthalpyenthalpy

condenscondenserer

economizeconomizerer

44expansiexpansion on devicesdevices

temperaturetemperature

HCFC-HCFC-2222

HCFC-HCFC-123123atmospheatmosphe

ricricpressurepressure

Refrigerant Operating Pressures

HFC-HFC-134a134a

Low-Pressure Chillers

compressorcompressorsuction suction

elbowelbow

Purge System

Purge Operation

filtratiofiltration n canistercanister

refrigerrefrigerant ant

vapor vapor from from

condencondenserser

to to condensecondenserr

filter filter drierdrier

purge purge evaporaevapora

tor coiltor coil

purge purge tanktank to to

chiller chiller vent vent lineline

period three

Compressor Capacity Control

Inlet Vanes

inlet inlet vanesvanes impellerimpeller

Multistage Compressor

inlet vanes inlet vanes

impellers impellers

VVrrRR

Impeller

Impeller Dynamics

diametediameterr

VVrr ∝ refrigerant flow refrigerant flow

raterate

VVt t ∝ rotational speed × rotational speed ×

diameterdiameter

rotatiorotational nal speedspeed

VVrrRR

refrigerrefrigerant flow ant flow raterate

Compressor Unloading

VVrrRR

rrVVtt

full load part load

VVr r < static < static

pressurepressure

Compressor Map

1010 1414

cediffe

refrigerant flow refrigerant flow raterate

surgesurge

vane vane positionposition

(degrees)(degrees)

Operating Pointpre

cediffe

operatioperatingngpointpoint

compressor map for a 2-Stage Compressor

1010 1414

cediffe

surgesurge 9090

operatioperatingngpointpoint

(degrees)(degrees)

compressor map for a 2-Stage Compressor

1010 1414

cediffe

surgesurge 9090

unloading unloading lineline

Adjustable-Frequency Drivespow

loadload

inlet vanes inlet vanes onlyonly

AFD + inlet AFD + inlet vanesvanes

period four

Maintenance Considerations

▲ Operating log

▲ Mechanical components

▲ Heat-transfer surfaces

▲ Fluid analysis

operating log

ASHRAE Guideline 3▲ Chilled water inlet and outlet

temperatures and pressures

▲ Chilled water flow

▲ Evaporator refrigerant temperature and pressures

▲ Evaporator approach temperature

▲ Condenser water inlet and outlet temperatures and pressures

▲ Condenser water flow

▲ Condenser refrigerant temperature and pressures

▲ Condenser approach temperature

▲ Oil pressures, temperature, and levels

▲ Addition of refrigerant

▲ Addition of oil

▲ Vibration levels

maintenance considerations

Mechanical Components

▲ Required maintenance◆ Compressor and motor: no maintenance required

◆ Controls: no maintenance or calibration required

▲ Recommended maintenance◆ Visually inspect overall unit

◆ Inspect safety controls and electrical components

◆ Tighten electrical connections

◆ Check for leaks

▲ Other design-specific requirements◆ Change oil when oil analysis dictates

◆ Replace oil filter periodically

◆ Replace filter drier periodically

◆ Clean oil strainers annually

◆ Check shaft alignment annually

◆ Check coupling annually

◆ Replace shaft seal every 2 to 4 years

◆ Compressor teardown inspection every 5 to 10 years

Mechanical Components

Heat Transfer Surfaces

▲ Recommended maintenance◆ Use a qualified water treatment

specialist

◆ Clean condenser tubes as needed

◆ Clean water-side strainers

◆ Test tubes every 3 years

Fluid Analysis

▲ Oil analysis◆ Conduct annual analysis to verify

system integrity

◆ Measure oil pressure drop to determine if filter needs changing

◆ Measure charge

▲ Refrigerant charge◆ Conduct analysis of refrigerant

◆ Inspect purge system

Oil Analysis

▲ Why perform regular oil analysis?◆ Helps reduce maintenance costs

◆ Detects problems without compressor disassembly

◆ Extends service life of oil charge

◆ Reduces environmental problems related to oil disposal

◆ Helps maintain compressor efficiency and reliability

◆ Helps lower refrigerant emissions

period five

Application Considerations

Condensing Temperature Control

1010 1414

cediffe

surgesurge 9090

(degrees)(degrees)unloading unloading lineline

condensing temperature control

Cooling Tower Bypass

condensercondenser

bypassbypass

cooling towercooling tower

55°F55°F[13°[13°

40°40°FF

[4°[4°C]C]

65°F65°F[18°C[18°C]]

divertindivertinggvalvevalve

evaporator water flow

Constant or Variable Flow

variablvariable- e- speed speed drivedrive

chilledchilledwater water pumppump

evaporatevaporatoror

variable evaporator water flow

Limitations

▲ Maintain minimum and maximum water flow rates through the chiller evaporator

▲ Rate at which the evaporator water flow changes must be kept below the corresponding limit to:◆ Maintain the chilled water set point control

◆ Keep the chiller on line

◆ Protect the chiller from damage

Short Evaporator-Water Loops

loadload

Short Evaporator-Water Loops

loadload

tanktank

Heat Recovery

heat-heat-recovery recovery

condensercondenser

coolincooling g

tower tower waterwater

standarstandard d

condenscondenserer

heat-recovery(dual) condenser

auxiliarycondenser

◆ No extra condenser

◆ Large base heating loads or continuous operation

◆ High hot water temperatures

◆ Controlled

◆ Chiller efficiency preserved

◆ Second, full-size condenser

◆ Large heating loads

◆ High hot water temperatures

◆ Controlled

◆ Degrades chiller efficiency

◆ Second, smaller size condenser

◆ Preheating loads

◆ Moderate hot water temperatures

◆ Uncontrolled

◆ Improves chiller efficiency

heat pump

Heat-Recovery Chiller Options

air-sideeconomizer

strainercycle

◆ Potential fouling limited to heat exchanger

◆ Requires additional heat exchanger, piping, valves, and controls

◆ Can operate simultaneously with chiller

◆ Most efficient

◆ Requires larger outdoor air, return, and exhaust duct systems

◆ Coldest water temperatures

◆ Potential fouling in chilled water loop

◆ Requires additional piping, valves, and controls

plate-and-frame heat exchanger

Free Cooling

free cooling

Refrigerant Migration

from from comprescompres

sorsor

to to comprescompres

sorsorevaporatevaporatoror

condenscondenserer

equipment certification standards

ARI Standard 550/590

▲ Purpose◆ Establish definitions, testing,

and rating requirements

▲ Scope◆ Factory designed and

prefabricated water chillers

◆ Vapor-compression refrigeration

◆ Air-cooled and water-cooled condensing

equipment certification standards

ARI Standard 550/590

▲ Standard rating conditions◆ Common system conditions for published ratings

◆ Fouling factor

▲ Integrated Part Load Value (IPLV)◆ Part-load efficiency rating

◆ Based on an “average” single-chiller installation

◆ Standard operating conditions

period six

Review

Review—Period 1

condencondenserser

compressorcompressor

starterstarter

motormotor

Review—Period 2

enthalpyenthalpy

condenscondenserer

expansiexpansion on devicesdevices88

99PPee

55economizeconomizerer

Review—Period 3

inlet vanes inlet vanes

impellers impellers

Review—Period 4

▲ Maintenance considerations◆ Operating log

◆ Mechanical components

◆ Heat-transfer surfaces

◆ Fluid analysis

Review—Period 5

▲ Application considerations ◆ Condensing temperature control

◆ Constant or variable evaporator-water flow

◆ Short evaporator-water loops

◆ Heat recovery

◆ Free cooling

◆ Equipment certification standards

50684234 Centrifugal Water Chillers

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