Chiller Types and Applications

8/20/2019 Chiller Types and Applications

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A Trane Air Conditioning Clinic

Chiller Types & Applications

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

K Y Yow

23 Jan 2015

ACES Training


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Chiller Types

Water-Cooled Air- Cooled

Centrifugal

Screw

Scroll

By Compressor Type & Heat Rejection Mode

Heat Rejection

C o m p r e s s o r T y p e

W/C Centrifugal A/C Centrifugal

W/C Screw A/C Screw

A/C Scroll

Reciprocating

150-4000rt

50-500rt 50-400rt

5-200rt

W/C Scroll

15-70rt


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absorption

A/C Screw & Scroll

W/C Screw

W/C Centrifugal

Vapour Compression NON-Vapour Compression


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Centrifugal Water Chillers


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condenser

compressor

controlpanel

evaporator

components of a

Centrifugal Water Chiller

starter

motor


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Impeller

blades


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centrifugal compressor

Energy Conversionrefrigerantentersdiffuser

path through compressor

v

e l o c i t y

s t a t i c

p r e s

s u r e refrigerant

enters impeller

refrigerantenters volute


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Multistage Compressor


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Condenser

baffle

tube

bundle

liquid

refrigerant

refrigerant vapor

cooling

towerwater


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toevaporator

orifice plates

H1

expansion device

Orifice Plates


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Evaporator

eliminator

liquiddistributor orifice system

liquidrefrigerant

tube bundle

chilledwaterreturn


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Motor

impellers

impeller

motor

motor

gear-drive

direct-drive

gears


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Hermetic Motor Cooling

stator

rotor

drainliquid

refrigerant


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Controls and Starter

controlpanel

starter


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Starters

remote-mounted

starter

line power

control power

wiring

unit-mounted

line power control powerwiring


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Comparison of LV Starters


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2-stage centrifugal chiller

Refrigeration Cycle

condenserevaporator

expansion devices

economizer

2-stagecompressor


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2-stage centrifugal chiller

Refrigeration Cycle

1

2 p r e s s u r e

enthalpy

evaporator

condenser

Pe

Pc

P1

C B A

6

7

9

5

2-stagecompressor

economizer

3

4 expansiondevices

10

8


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p r e s s u r e

temperature

HCFC-22

HCFC-123

atmosphericpressure

Refrigerant Operating Pressures

HFC-134a ( High Pressure 40/140 psig)

( Low Pressure vac/8 psig


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Compressor Capacity Control


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Inlet Vanes

inlet vanes

impeller


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Multistage Compressor

inlet vanes

impellers


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Impeller Dynamics

diameter

Vr refrigerant flow rate

Vt rotational speed × diameter

rotational

speed

Vr R

Vt

refrigerant

flow rate


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Compressor Unloading

Vr R

Vt

Vr

Vt

full load part load

R


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Vr

Vt

Surge

Vr < static pressureR


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Compressor Map

25

75

1014

63

p r

e s s u r e

d i f f e r e n

c e

refrigerant flow rate

vane position(degrees)

90

36

51


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compressor map for a 2-Stage Compressor

25

75

1014

63

p r

e s s u r e

d i f f e r e n

c e

refrigerant flow rate

90

36

51

C B

A

unloading line


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period five

Application Considerations


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Adjustable-Frequency Drives

Kw/rt

load

inlet vanes only

AFD + inlet vanes

3-4% Losses

AFD Centrifugal Chiller Requires LIFT Reduction to Save Energy

AHRI Temp Relief


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guidance

VSD or High Efficiency?

High efficiency

Significant demandcharges

Humid climates

Multiple chillers in the plant

Economizer(airside or freecooling) that reduces lowload/low lift operatinghours

VSD

Many hours at lowcondenser watertemperature—and low load

Perhaps only on one chiller

Factor in replacement ofVSD when performing lifecycle assessment

Guidance Factors


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SAME Price Option

(700 RT Chiller)

Full Load(kW/ton)

IPLV(kW/ton)

a) VSD 0.572 0.357

b) High Efficiency (Fixed

Drive)0.501 0.430

VSD Chiller or Hi-E Chiller ( Fixed Drive)

VSD Option typically cost around 30% more.Alternatively, this same investment $ can be used to

Upgrade efficiency with larger heat exchangers

FL vs PL efficiency


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VSD Application on Chillers

Understand its Applications… Benefits vs Cost

LIFT Reduction (Min for Trop ics) for VSD Centrifugal chiller Capacity Reduction for VSD Screw

ROI - Efficiency gain vs Higher $Investment &

potential higher service cost


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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


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ASHRAE STD 90.1 ( 2013)

Most Building Codes,

Guides & STDs

Draw Referenceto ASHRAE 90.1 STD

Current 2013 version

(first published 1975)


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Mandatory: Chiller Efficiency as of2015 (Centrifugal chillers)

Chillertype/size

Path A Path B

WC centrif. <150 tons

0.610 kW/ton & 0.550IPLV

0.695 kW/ton & 0.440IPLV

WC centrif. 150< 300 tons

0.610 kW/ton & 0.550IPLV

0.635 kW/ton & 0.400IPLV

WC centrif. 300< 400 tons

0.560 kW/ton & 0.520IPLV

0.595 kW/ton & 0.390IPLV

WC centrif. >=400 tons

0.560 kW/ton & 0.500IPLV

0.585 kW/ton & 0.380IPLV

• Table is for

standard rating

temperatures

• Non-standard

temperatures

and flows use

equation tomodify the

requirements

* Likely to be adopted by SS530


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Chiller Performance Improvements

8.0

ASHRAE Standard 90

c h

i l l e r e f f i c i e n c y , C

O P

6.0

4.0

2.0

0.0

“best” available90-75

(1977)90-75(1980)

90.1-89 90.1-99

centrifugal>600 tonsscrew150-300 tonsscroll


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Air Conditioning Clinic TRG-TRC010-EN © American Standard Inc. 1999IPLV does NOT represent Real Efficiency

AHRI Definition of Integrated Part Load Value (IPLV/NPLV)

Temp eratures: Expected Enter ing Tower Water

AHRI Condit io ns: Chil led Water: 54 ° /44°F (12°/7°C)

Condens er Water: 3 GPM/Ton (0.054 L/S/kW)

A = kW/Ton @ 85°F(30°C) @ 100% Load

B = kW/Ton @ 75°F(24°C) @ 75% Load

C = kW/Ton @ 65°F(18°C) @ 50% Load

D = kW/Ton @ 65°F(18°C) @ 25% Load

1IPLV = 1%

A

42%

B

12%

D+ ++

45%

C

Index Rating

42%

75° (24°C)

1% 85°F(30°C)57%

65° (18°C)

MOR

INFO

U f IPLV NPLV

http://localhost/var/www/apps/conversion/tmp/scratch_3/JumpOffLinks.ppshttp://localhost/var/www/apps/conversion/tmp/scratch_3/JumpOffLinks.ppshttp://localhost/var/www/apps/conversion/tmp/scratch_3/JumpOffLinks.ppshttp://localhost/var/www/apps/conversion/tmp/scratch_3/JumpOffLinks.pps


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Use of IPLV or NPLV

This appendix is for equipment covered by this standard.The IPLV equations and procedure are intended to provide a

consistent method for calculating a single number part load

performance number for water chilling products. The equation

was derived to provide a representation of the average part load

efficiency for a sing le ch i l ler only . However, it is best to use acomprehensive analys is that reflects the actual weather data,

building load characteristics, operational hours, economizer

capabilities and energy drawn by auxiliaries such as pumps

and cooling towers, when calculating the chi l ler and s ystem

eff ic iency . This becomes increasingly important with multiplechiller systems because indiv idual chi l lers operat ing within

mult ip le chi l ler systems are more heavi ly loaded than sin gle

chi l lers within single chiller systems.

(AHRI 550/590 Appendix D, D2.1 Scope)

Superior IPLV does not represent Superior Energy Savings


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AHRI Standard 550/590

Purpose

Establish definitions, testing,and rating requirements

Scope

Factory designed andprefabricated water chillers

Vapor-compression

refrigeration

Air-cooled and water-cooledcondensing


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Selection Printout


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Factory Test to AHRI 550/590


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A Trane Air ConditioningClinic

Helical-Rotary Water Chillers



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air-cooled

water-cooled



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liquid/vaporseparator

motor

oil separator

condenser

oil supplysystem

compressor

controlpanel

evaporator

components of a

Helical-Rotary Water Chiller

starter


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compressor...

Helical Rotors


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compressor...

Helical Rotors

male rotor

female rotor

housing

slide valve


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Oil Separator

refrigerant vaporand oil mixture

oil return to sump

refrigerant vaporto condenser


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water-cooled

Condenser

subcooler

liquidrefrigerant

baffle

tube bundle

refrigerant vapor

coolingtowerwater


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air-cooled

Condenser

subcooler

outdoor air

condensercoil

propeller fan


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expansion device… ( Air -cooled )

Electronic Expansion Valve


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expansion device… ( Water -Cooled )

Orifice Plates

toevaporator

orifice plates

H


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chilledwaterreturn

liquid levelsensor

tube bundle

refrigerantvapor

Flooded Evaporator ( Water-cooled )

liquidrefrigerant

chilledwatersupply


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Direct Expansion Evaporator (air-cooled)

refrigerantvapor

liquidrefrigerant

chilledwater

return

chilledwatersupply

tube bundle

baffles


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Controls and Starter

controlpanel

starter


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helical-rotary water chiller

Refrigeration Cycle

6

p r e s s u r e

enthalpy

evaporator 1

2 5

7

condenser

compressorexpansiondevice

liquid/vaporseparator

4 3


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helical-rotary water chillers…

Refrigerants

HFC-134a ( Currently most commonly applied)

HF0 – XXX ( Next generation )… Low GWP


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Air Conditioning Clinic TRG-TRC010-EN © American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN © American Standard Inc. 1999


per iod f ive

Application Considerations


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RTHD AFD Water cooled Screw Chillerwith Adaptive Frequency™ Driver

CONFIDENTIAL AND PROPRIETARY INFORMATION OF TRANE

Application for Variable Speed Screw Chiller


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Efficiency Improvement : 5-10%

Application for Variable Speed Screw Chiller

AFD Type typically improves overall

efficiency by 5-10% vs STD.

0

20

40

60

80

100120

140

160

180

200

20 30 40 50 60 70 80 90 100

AFD Type

STD

Constant Condenser Temperature 30C

Illustration Only

Investment $ : +30-40%


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VSD Application on Screw Chillers

Understand its Applications… Benefits vs Cost

LIFT Reduction

(Min for Trop ics)

for VSD Centrifugal chiller Capacity Reduction for VSD Screw

ROI - Efficiency gain vs Higher $Investment &

potential higher service cost


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condenser types…

Air-Cooled or Water-Cooled


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water-cooled Greater energy efficiency

Longer equipment life

air-cooled or water-cooled

Comparison

air-cooled Lower maintenance

Packaged system

Better low ambientoperation

ASHRAE STD 90 1 ( 2013)


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ASHRAE STD 90.1 ( 2013)

Most Building Codes,

Guides & STDs

Draw Referenceto ASHRAE 90.1 STD

Current 2013 version

(first published 1975)

Addendum CH


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Mandatory: Chiller Efficiency as of2015

Chiller type/size Path A Path B

Air cooled < 150 tons 10.1 EER and 13.7 IPLV 9.7 EER and 15.9 IPLV

Air cooled >= 150 tons 10.1 EER and 14.0 IPLV 9.7 EER and 16.1 IPLV

WC pos. disp. < 75 tons 0.750 kW/ton & 0.600 IPLV 0.780 kW/ton & 0.500 IPLV

WC pos. disp. 75 < 150 tons 0.720 kW/ton & 0.560 IPLV 0.750 kW/ton & 0.490 IPLV



WC pos. disp. >= 600 tons 0.560 kW/ton & 0.500 IPLV 0.585 kW/ton & 0.380 IPLV

(SCREW Chiller)



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AHRI Standard 550/590

Purpose

Establish definitions, testing,and rating requirements

ScopeFactory designed and

prefabricated water chillers

Vapor-compression

refrigeration

Air-cooled and water-cooledcondensing


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Summary

Types of chillers – Overview

Centrifugal chiller - components, controls and application

Screw chiller – Components, controls and applications

VSD application considerations & Benefits vs cost

ASHRAE 90.1 Min EFF Standard

AHRI 550 Rating Standard for chillers


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Q & A

Chiller Types and Applications

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