Centrifugal Water Chillers

A Trane Air Conditioning Clinic

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

ChilledWaterSystem

absorption centrifugal

helical-rotary

period one

Components

condensercondenser

compressorcompressor

controlcontrolpanelpanel

evaporatorevaporator

components of a

Centrifugal Water Chiller

starterstarter

motormotor

Compressor

Impeller

bladesblades

volutevolute

diffuserdiffuserpassagepassage

impeller impeller passagespassages

Centrifugal Compressor

centrifugal compressor

Energy Conversionrefrigerant refrigerant enters enters diffuserdiffuser

path through compressorpath through compressor

refrigerantrefrigerant enters impellerenters impeller

refrigerant refrigerant enters voluteenters volute

Multistage Compressor

Condenser

bafflebaffle

tubetubebundlebundle

liquid liquid refrigerantrefrigerant

refrigerant vaporrefrigerant vapor

cooling cooling tower tower waterwater

totoevaporatorevaporator

orifice platesorifice plates

expansion device

Orifice Plates

expansion device

Orifice Plates

totoevaporatorevaporator

orifice platesorifice plates

2-stage chiller

Economizer

refrigerant vapor refrigerant vapor to second stageto second stageof compressionof compression

liquid refrigerant liquid refrigerant to evaporatorto evaporatororificeorifice

liquid refrigerant liquid refrigerant from condenserfrom condenser

3-stage chiller

Economizer

liquid refrigerant liquid refrigerant to evaporatorto evaporatororificeorifice

orificeorifice

refrigerant vapor refrigerant vapor to second stageto second stageof compressionof compression

refrigerant vapor refrigerant vapor to third stageto third stageof compressionof compression

liquid refrigerant liquid refrigerant from condenserfrom condenser

Evaporator

eliminatoreliminatorliquidliquiddistributordistributor orifice systemorifice system

liquid liquid refrigerantrefrigerant

tube bundletube bundle

chilled chilled water water returnreturn

impellersimpellers

impellerimpeller

motormotor

motormotorgear-drive

direct-drive

gearsgears

Hermetic Motor Cooling

statorstator

rotorrotor

draindrainliquidliquidrefrigerantrefrigerant

Controls and Starter

starterstarter

Starters

remote-mounted

starterstarter

line powerline power

control power control power wiringwiring

unit-mounted

line powerline power control power control power wiringwiring

period two

Refrigeration Cycle

2-stage centrifugal chiller

Refrigeration Cycle

condensercondenserevaporatorevaporator

expansion devicesexpansion devices

economizereconomizer

2-stage2-stagecompressorcompressor

Pressure-Enthalpy (p-h) Chart

enthalpyenthalpy

subcooledsubcooledliquidliquid

mixture of mixture of liquid and liquid and vaporvapor

15.5 Btu/lb15.5 Btu/lb[201.0 kJ/kg][201.0 kJ/kg]

superheatedsuperheatedvaporvapor

BA5 psia5 psia[0.034 MPa][0.034 MPa]

92.4 Btu/lb92.4 Btu/lb[380.4 kJ/kg][380.4 kJ/kg]

Refrigeration Cycle

enthalpyenthalpy

condensercondenser

2-stage 2-stage compressorcompressor

expansion expansion devicesdevices

99PPee

55economizereconomizer

Refrigeration Cycle

22pres

enthalpyenthalpy

condensercondenser

economizereconomizer

44expansion expansion devicesdevices

temperaturetemperature

HCFC-22HCFC-22

HCFC-123HCFC-123

atmosphericatmosphericpressurepressure

Refrigerant Operating Pressures

HFC-134aHFC-134a

Low-Pressure Chillers

compressorcompressorsuction elbowsuction elbow

Purge System

Purge Operation

filtration filtration canistercanister

refrigerant refrigerant vapor from vapor from condensercondenser

to condenserto condenserfilter drierfilter drier

purge purge evaporator evaporator

coilcoil

purge tankpurge tankto chiller to chiller vent linevent line

period three

Compressor Capacity Control

Inlet Vanes

inlet vanesinlet vanes

impellerimpeller

Multistage Compressor

inlet vanes inlet vanes

impellers impellers

VVrrRR

Impeller

Impeller Dynamics

diameterdiameter

VVrr refrigerant flow rate refrigerant flow rate

VVt t rotational speed × diameter rotational speed × diameter

rotational rotational speedspeed

VVrrRR

refrigerant refrigerant flow rateflow rate

Compressor Unloading

VVrrRR

full load part load

VVr r < static pressure< static pressureRR

Compressor Map

1010 1414

refrigerant flow raterefrigerant flow rate

surgesurge

vane positionvane position(degrees)(degrees)

Operating Pointpr

operatingoperatingpointpoint

compressor map for a 2-Stage Compressor

1010 1414

surgesurge 9090

operatingoperatingpointpoint

compressor map for a 2-Stage Compressor

1010 1414

surgesurge 9090

unloading lineunloading line

Adjustable-Frequency Drivespo

loadload

inlet vanes onlyinlet vanes only

AFD + inlet vanesAFD + inlet vanes

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

surgesurge 9090

unloading lineunloading line

condensing temperature control

Cooling Tower Bypass

condensercondenser

bypassbypass

cooling towercooling tower

55°F55°F[13°C][13°C]

40°F40°F[4°C][4°C]

65°F65°F[18°C][18°C]

divertingdivertingvalvevalve

evaporator water flow

Constant or Variable Flow

variable- variable- speed speed drivedrive

chilledchilledwater water pumppump

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-recovery heat-recovery condensercondenser

cooling cooling tower tower waterwater

standard standard condensercondenser

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 compressorcompressor

to to compressorcompressor

condensercondenser

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

condensercondenser

compressorcompressor

starterstarter

motormotor

Review—Period 2

enthalpyenthalpy

condensercondenser

expansion expansion devicesdevices

99PPee

55economizereconomizer

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

Centrifugal Water Chillers

Documents

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