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A Trane Air Conditioning Clinic
Centrifugal Water Chillers
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
ChilledWaterSystem
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
absorption centrifugal
helical-rotary
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
period one
Components
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
condensercondenser
compressorcompressor
controlcontrolpanelpanel
evaporatorevaporator
components of a
Centrifugal Water Chiller
starterstarter
motormotor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Compressor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Impeller
bladesblades
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
volutevolute
diffuserdiffuserpassagepassage
impeller impeller passagespassages
Centrifugal Compressor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
centrifugal compressor
Energy Conversionrefrigerant refrigerant enters enters diffuserdiffuser
path through compressorpath through compressor
velo
city
velo
city
stat
ic pr
essu
rest
atic
pres
sure
refrigerantrefrigerant enters impellerenters impeller
refrigerant refrigerant enters voluteenters volute
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Multistage Compressor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Condenser
bafflebaffle
tubetubebundlebundle
liquid liquid refrigerantrefrigerant
refrigerant vaporrefrigerant vapor
cooling cooling tower tower waterwater
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
totoevaporatorevaporator
orifice platesorifice plates
HH11
expansion device
Orifice Plates
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
expansion device
Orifice Plates
HH22
totoevaporatorevaporator
orifice platesorifice plates
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Evaporator
eliminatoreliminatorliquidliquiddistributordistributor orifice systemorifice system
liquid liquid refrigerantrefrigerant
tube bundletube bundle
chilled chilled water water returnreturn
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Motor
impellersimpellers
impellerimpeller
motormotor
motormotorgear-drive
direct-drive
gearsgears
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Hermetic Motor Cooling
statorstator
rotorrotor
draindrainliquidliquidrefrigerantrefrigerant
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Controls and Starter
controlcontrolpanelpanel
starterstarter
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Starters
remote-mounted
starterstarter
line powerline power
control power control power wiringwiring
unit-mounted
line powerline power control power control power wiringwiring
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
period two
Refrigeration Cycle
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
2-stage centrifugal chiller
Refrigeration Cycle
condensercondenserevaporatorevaporator
expansion devicesexpansion devices
economizereconomizer
2-stage2-stagecompressorcompressor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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]
pres
sure
pres
sure
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]
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
2-stage centrifugal chiller
Refrigeration Cycle
11
2233
4466
77
pres
sure
pres
sure
enthalpyenthalpy
evaporatorevaporator
condensercondenser
2-stage 2-stage compressorcompressor
expansion expansion devicesdevices
88
99PPee
PPcc
PP11
55economizereconomizer
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
2-stage centrifugal chiller
Refrigeration Cycle
11
22pres
sure
pres
sure
enthalpyenthalpy
evaporatorevaporator
condensercondenser
PPee
PPcc
PP11
C B A
66
77
99
55
2-stage 2-stage compressorcompressor
economizereconomizer
33
44expansion expansion devicesdevices
1010
88
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
pres
sure
pres
sure
temperaturetemperature
HCFC-22HCFC-22
HCFC-123HCFC-123
atmosphericatmosphericpressurepressure
Refrigerant Operating Pressures
HFC-134aHFC-134a
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Low-Pressure Chillers
compressorcompressorsuction elbowsuction elbow
evaporatorevaporator
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Purge System
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
period three
Compressor Capacity Control
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Inlet Vanes
inlet vanesinlet vanes
impellerimpeller
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Multistage Compressor
inlet vanes inlet vanes
impellers impellers
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
VVrrRR
VVtt
Impeller
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Impeller Dynamics
diameterdiameter
VVrr refrigerant flow rate refrigerant flow rate
VVt t rotational speed × diameter rotational speed × diameter
rotational rotational speedspeed
VVrrRR
VVtt
refrigerant refrigerant flow rateflow rate
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Compressor Unloading
VVrrRR
VVtt
VVrr
VVtt
full load part load
RR
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
VVrr
VVtt
Surge
VVr r < static pressure< static pressureRR
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Compressor Map
2525
7575
1010 1414
6363
pres
sure
diff
eren
cepr
essu
re d
iffer
ence
refrigerant flow raterefrigerant flow rate
surgesurge
vane positionvane position(degrees)(degrees)
9090
3636
5151
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Operating Pointpr
essu
re d
iffer
ence
pres
sure
diff
eren
ce
refrigerant flow raterefrigerant flow rate
operatingoperatingpointpoint
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
compressor map for a 2-Stage Compressor
2525
7575
1010 1414
6363
pres
sure
diff
eren
cepr
essu
re d
iffer
ence
refrigerant flow raterefrigerant flow rate
surgesurge 9090
3636
5151
operatingoperatingpointpoint
vane positionvane position(degrees)(degrees)
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
compressor map for a 2-Stage Compressor
2525
7575
1010 1414
6363
pres
sure
diff
eren
cepr
essu
re d
iffer
ence
refrigerant flow raterefrigerant flow rate
surgesurge 9090
3636
5151
C B
A
unloading lineunloading line
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Adjustable-Frequency Drivespo
wer c
onsu
mpt
ion
powe
r con
sum
ptio
n
loadload
inlet vanes onlyinlet vanes only
AFD + inlet vanesAFD + inlet vanes
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
period four
Maintenance Considerations
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Maintenance Considerations
Operating log Mechanical components Heat-transfer surfaces Fluid analysis
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
maintenance considerations
Mechanical Components
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
maintenance considerations
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
period five
Application Considerations
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Condensing Temperature Control
2525
7575
1010 1414
6363
pres
sure
diff
eren
cepr
essu
re d
iffer
ence
refrigerant flow raterefrigerant flow rate
surgesurge 9090
3636
5151
B
AC
vane positionvane position(degrees)(degrees)
unloading lineunloading line
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
evaporator water flow
Constant or Variable Flow
variable- variable- speed speed drivedrive
chilledchilledwater water pumppump
evaporatorevaporator
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Short Evaporator-Water Loops
loadload
chilledchilledwater water pumppump
evaporatorevaporator
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Short Evaporator-Water Loops
loadload
chilledchilledwater water pumppump
evaporatorevaporator
tanktank
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Heat Recovery
heat-recovery heat-recovery condensercondenser
cooling cooling tower tower waterwater
standard standard condensercondenser
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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 Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
free cooling
Refrigerant Migration
from from compressorcompressor
to to compressorcompressor
evaporatorevaporator
condensercondenser
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
period six
Review
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Review—Period 1
condensercondenser
compressorcompressor
controlcontrolpanelpanel
evaporatorevaporator
starterstarter
motormotor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Review—Period 2
11
2233
4466
77
pres
sure
pres
sure
enthalpyenthalpy
evaporatorevaporator
condensercondenser
2-stage 2-stage compressorcompressor
expansion expansion devicesdevices
88
99PPee
PPcc
PP11
55economizereconomizer
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Review—Period 3
inlet vanes inlet vanes
impellers impellers
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Review—Period 4
Maintenance considerations Operating log Mechanical components Heat-transfer surfaces Fluid analysis
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999