YK - Centrifugal Chiller
YK - Centrifugal Chiller
JCI M.E2
Refer to Training Agenda on a Separate Sheets
Topics :
YK - Centrifugal Chiller
JCI M.E3
Centrifugal Chiller
YK chillers are designed and built within an EN ISO 9001 accredited design and manufacturing organization and, within the limits specified in conformity with the essential health and safety requirements of the
Moving & Installation Pressurized System A.C & D.C Electrical Voltage
Be careful when working on:Safety
JCI M.E4
health and safety requirements of the following European Union Directives:
Machinery Directive (89/392/EEC)
Low Voltage Directive (73/23/EEC, EN 60204)
EMC Directive (89/336/EEC)
A.C & D.C Electrical Voltage and Charges. Earth connection. Rotating Parts Sharp Edges parts High Temperature parts Refrigerant. Refrigerant Oil. etc.
Were All at Different Levels
YK - Centrifugal Chiller
Let Me Tell You About Myself
Three Laws from Science Class
Matter
Can Not be Created or Destroyed
YK - Centrifugal Chiller
Matter being (Heat Energy)
Warm Place to a Cool Place
Vapor Density
Changes with Pressure
Heat Flows Down Hill
YK - Centrifugal Chiller
From a Warm Place to a Cold Place
Vapor Pressure
1 lb 1 lb
100 psig
50 psig
1 lb
R-22
1 lb
R-22
The pressure that a gas exerts on the walls of its container is determined by the momentum of the atoms and molecules of the gas, which in turn is determined by the temperature. As the temperature increases the atoms and molecules move faster, and so exert a greater pressure on the walls.
Charlies Law
the walls.
If the volume of a container is increased, the pressure decreases.
If the volume of a container is decreased, the pressure increases.
Why?
Suppose the volume is increased. This means gas
Boyles Law
Suppose the volume is increased. This means gas molecules have farther to go and they will impact the container walls less often per unit time. This means the gas pressure will be less because there are less molecule impacts per unit time.
If the volume is decreased, the gas molecules have a shorter distance to go, thus striking the walls more often per unit time. This results in pressure being increased because there are more molecule impacts per unit time.
What is Refrigeration ?
Refrigeration is....
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Cooling by the Removal of HEAT.
Unfortunately We Must Learn
Some
TERMSConduction
Specific Heat
BTUs
Change of StateConduction
Convection
Radiation
Change of State
Sensible Heat
Latent Heat
Heat Flows 3 Ways
1. Conduction
2. Convection
3. RadiationALL Three Take Place Within A Cooling System
Conduction:
Is the transfer of heat between the closely between the closely packed molecules of a SOLID substance
Convection:
Is the transfer of heat by motion of the heated motion of the heated material itself and is limited to a LIQUID or GAS
Radiation:
Is the transfer of heat by waves similar to light or waves similar to light or sound; Traveling in a straight path without heating the intervening matter of air.
The Ice Tea Absorbs the HeatThe Ice Tea Absorbs the Heat
Heat Flows Down Hill
From a Warm Place to a Cold Place
The Same Theory Applies
55 entering air absorbs the the 75the the 75room air.
Specific Heat:
Is the quantity of heat (in BTUs) required to change BTUs) required to change the temperature of 1lb of a substance 1 F .
BTU: (British Thermal Unit)
Is the amount of heat necessary to change the necessary to change the temperature of 1lb of water 1 F .
Therefore making the SPECIFIC HEAT of WATER equal t o 1
Sensible Heat:
The heat that can be felt or measured. The heat that measured. The heat that causes a change in temperature, but NOT a change in STATE.
Latent Heat: (Hidden Heat)
The heat required to change a substance change a substance STATE (solid to liquid; liquid to vapor) without changing its temperature.
Specific Heat:
Ice = 0.50
Water = 1.00 Water = 1.00
Steam = 0.48
Water Boils @ 212
1 BTU for every 1 Increase in Temperature
Only a 1 To 1 Ratio
Change in State
Over a 900 to 1 Over a 900 to 1 RatioRatio
Never Increased Never Increased the Temperaturethe Temperature
R-22Boils @ -44 degrees
Thats COLD ! ! !
We would like to see something around
R 134a Boils @ -15 degrees
We would like to see something around
45-50 degrees
Solution ??????
The Pressure Cooker
Boiling Pointsfor
BOILING TEMPERATURE OF WATER AT VARIOUS COMPARATIV E PRESSURES
TEMPERATURE 0F INCHES/MERCURY MICRONS
212 0 759,990205 3.921 660,400200 6.451 596,140195 8.771 537,210190 10.904 483,030185 12.851 433,580180 14.626 388,490175 16.245 347,370170 17.718 309,960165 19.054 276,020160 20.265 245,250155 21.36 217,440150 22.348 192,350145 22.238 169,750140 24.037 149,460
forWater
60 29.399 13,25055 29.485 11,07050 29.599 9,20045 29.621 7,63040 29.673 6,29035 29.718 5,17030 29.757 4,18025 29.791 3,31020 29.818 2,61015 29.848 2,05010 29.858 1,6005 29.872 1,2400 29.883 960-5 29.892 730-15 29.904 420-25 29.912 240-35 29.916 127-60 29.920 25.4-70 29.9705 12.7-90 29.9209 2.54
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Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Heat Content(BTU / lb.)
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Liquid - VaporMix
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
100% Liquid
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
100% Vapor
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
20% Liquid 80% Vapor
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Evaporator
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Evaporator
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Evaporator
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Evaporator
Refrigerant absorbs heat from load
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Evaporator
Refrigerant absorbs heat from load
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Evaporator
Net Refrigeration Effect
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Compressor
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Compressor
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
CompressorHead Pressure
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Refrigerant rejects heat to atmosphere
Enthalpy
Condenser
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Metering Device
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
- Thermal expansionvalve
- Orifice
Metering Device
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Condenser
Enthalpy
Evaporator
CompressorMetering Device
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Condenser
Refrigerant rejects heat to atmosphere
Enthalpy
Evaporator
CompressorMetering Device
Refrigerant absorbs heat from load
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
85
Enthalpy
95
54
4444
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
85
Enthalpy
95
44
54
44
54
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
85
Enthalpy
95
44
54
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
85
Enthalpy
44
54
95
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
85
Cooling Tower
Enthalpy
44
54
95
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
85
Cooling Tower
Enthalpy
95
44
54
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Adding a subcooler
Refrigeration
Effect
Enthalpy
Adding a subcooler
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Adding a subcooler
Refrigeration
Effect
Enthalpy
Adding a subcooler
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Adding a subcooler
Refrigeration
Effect
Enthalpy
Adding a subcooler
Increases refrigeration effect
Pressure
Pressure - Enthalpy ChartPressure - Enthalpy Chart
Adding a subcooler
Refrigeration
Effect
Enthalpy
Adding a subcooler
Increases refrigeration effect
Increases energy efficiency
Head PressureHead Pressure
Pressure
Enthalpy
Condenser
Pressure
Head PressureHead Pressure
Evaporator
Compressor
Enthalpy
Condenser
Pressure
Head PressureHead Pressure
Head Pressure
Evaporator
Compressor
Enthalpy
Lowering condenser Lowering condenser water temperaturewater temperature
Condenser
Pressure
Head PressureHead Pressure
Evaporator
Compressor
Enthalpy
Head Pressure
Lowering condenser Lowering condenser water temperaturewater temperature
Condenser
Pressure
Head PressureHead Pressure
Lowers head Lowers head pressurepressure
Evaporator
Compressor
Enthalpy
Head Pressure
Lowering condenser Lowering condenser water temperaturewater temperaturePressure
Head PressureHead Pressure
Lowers head Lowers head pressurepressure
Head Pressure
Evaporator
Compressor
Condenser
Enthalpy
Lowering condenser Lowering condenser water temperaturewater temperaturePressure
Head PressureHead Pressure
Lowers head Lowers head pressurepressure
Evaporator
Compressor
Condenser
Enthalpy
Head Pressure
Lowering condenser water Lowering condenser water temperaturetemperature
Lowers head pressureLowers head pressure
Pressure
Head PressureHead Pressure
Reduces compressorReduces compressorworkwork
Reduces energyReduces energyconsumptionconsumption
Evaporator
Compressor
Condenser
Enthalpy
Head Pressure
SAT DISCH = 100FPRE
138.8
Operation Theory -Lift
LIFT = 60F
SAT SUCT = 40F4038F
ESSURE
PSIA ENTHALPY Btu/lb
49.7
SAT DISCH = 100FPRE
138.8
Operation Theory -Lift
LIFT = 60F
SAT SUCT = 40F4038F
ESSURE
PSIA ENTHALPY Btu/lb
49.7
Intersection of Discharge Temp and Condenser Pressure
Intersection of Discharge Temp and Condenser Pressure
Net Refrigeration
Effect
Flashgas
Reduced Flash Gas with lower Condenser Temps
Net Refrigeration
Effect Extra BTUs Absorbed
Two Stages with Intercooling
Single Stage Cycle
SUBCOOLING
PR SAT
ENTHALPY
RESSURE
SATLIQUID
SATVAPOR
Refrigeration Effect
Two Stage Cycle
SUBCOOLING
PR SAT
ENTHALPY
RESSURE
SATLIQUID
SATVAPOR
Refrigeration Effect
Why Do We Need Chillers ?
To Remove unwanted Heat From a Certain Area to
an Area where we do not care if its heated . i.e. the an Area where we do not care if its heated . i.e. the
outside of the building
Centrifugal Chiller
Why do we need Centrifugal chiller?
o Reciprocating compressors use in high and medium pressure ( High LIFT )with low and medium current flow.
o Centrifugal compressors use in low and medium pressure ( Low LIFT ) and
JCI M.E99
high current flow.
o In a place which we need high refrigerant flow ( High capacity ) with medium pressure ( Low LIFT ) we should use centrifugal compressor.
o Centrifugal compressors (non-positive displacement) have a fixed amount of lift for a given set of operating conditions.
Centrifugal Chiller
Compressor Types :
Positive Displacement ( Recip , screw )
Non Positive Displacement , Centrifugal (Dynamic)
Positive displacement compressors use a piston or other device to reduce the
volume of refrigerant vapor in a compressor chamber. PROCESS:
Power is applied
Chamber volume is reduced
JCI M.E100
Chamber volume is reduced
Refrigerant pressure is increased
Centrifugal Chiller
Positive Displacement Operating Characteristics
Lift
JCI M.E101
Capacity
It means : By increase the LIFT the Capacity will decrease.
Centrifugal Chiller
In Positive Displacement compressors ,Compression chamber reduces in volume to compress gas ( LIFT up )
Unlimited lift
Limited Capacity
ScrewReciprocatingScroll
JCI M.E102
ScrewReciprocatingScroll
Compressor Designs
Reciprocating Screw Centrifugal
Head Variable Variable Fixed
Volume Fixed Fixed Variable
Volume Capacity Low Medium High
Volume flow up to 1000 m3/hr up to 600 CFM
120 7,000 m 3/hr 70 4,000 CFM
700 42,000 m 3/hr 400 25,000 CFM
to 250 kW 40 1,500 kW 200 11,000 kW
JCI M.E103
Driver power to 250 kW to 350 HP
40 1,500 kW 50 2,000 HP
200 11,000 kW 300 15,000 HP
Pumping action
Reciprocating Rotary Rotary
Pressure Ratio 10:1 depends on
refrigerant 20:1 3.5:1 per stage
Min suction temperature
-76F -60C
-76F -60C
-240F -150C
Max discharge pressure
350 psig 24 barg
350 psig 24 barg
600 psig 41 barg
Capacity Control Step Control Variable Variable
Compressor Designs
Centrifugal Rotary Screw Reciprocating
Head Fixed Variable Variable
Volume Variable Fixed Fixed
Volume Capacity High Medium Low
JCI M.E104
Range (CFM) 1,000-25,000 70 4,000 25 600
Power (HP) 300 10,000 50 2,000 30 - 350
Motion Rotary Rotary Reciprocating
Control InfinitelyVariable
Variable Step Control
What the chiller codes tell us (Nomenclature)?
YK CB CB G4 5 CM E S
YK Model ( centrifugal)
CB Cooler code
CB Condenser code
G4 Compressor code
JCI M.E105
5 Frequency
CM Motor code
E Design level
S Special Code
system component
JCI M.E106
system component (Front side)
JCI M.E107
system component (Rear side)
JCI M.E108
Location
YK -- chiller
600 mm Rear view
4900 OR 4275 mm 4900 OR 4275 mm
Minimum Requirement area, with room temperatures range from 4.4C to 43.3C.
JCI M.E109
YK -- chiller
900 mm - Font view
Installation, Piping
Cooler connections
Condenser connections
Refrigerant Relief Valve connection
Oil return pips ( only for Dismantled unites)
Water stop valve ( condenser, cooler)
JCI M.E110
Water Flow switches OR Pressure differential controller
Drain & vent Valve on ( condenser, cooler) water connections
Air vent
Water Box ( will discuss in Evaporator Slides)
Motor cooler
Piping
Schematic of a typical Piping connection
JCI M.E111
CondenserCondenser
Cooling Tower
JCI M.E112
EvaporatorEvaporator
CoilCoil
CondenserCondenser
Cooling Tower
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EvaporatorEvaporator
CoilCoil
44
CondenserCondenser
Cooling Tower
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EvaporatorEvaporator
CoilCoil
44
7255
CondenserCondenser
Cooling Tower
JCI M.E115
EvaporatorEvaporator
CoilCoil
4454
7255
CondenserCondenser
Cooling Tower
4137
JCI M.E116
EvaporatorEvaporator
CoilCoil
4454
7255
4137
CondenserCondenser
Cooling Tower 95
JCI M.E117
EvaporatorEvaporator
CoilCoil
4454
7255
4137
CondenserCondenser
Cooling Tower
9585
4137
JCI M.E118
EvaporatorEvaporator
CoilCoil
4454
7255
4137
CondenserCondenser
Cooling Tower
9585
37
12486
JCI M.E119
EvaporatorEvaporator
CoilCoil
4454
7255
4137
CondenserCondenser
Cooling Tower
9585
37
12486Refrigerant Loop
JCI M.E120
EvaporatorEvaporator
CoilCoil
4454
7255
4137Loop
Centrifugal ChillerCentrifugal Chiller
How does it Work!
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