TDP 623B - Water Cooled - Chillers Omar Rojas PDF

Technical Development Program
COMMERCIAL HVAC
CHILLER EQUIPMENT
Water-Cooled Chillers
PRESENTED BY:
Omar Rojas
Sales Engineer
© 2013 Carrier Corporation

Menu
Section 1 Introduction
Section 2 Basic Refrigeration Cycle
Section 3 Chiller Components
Section 4 Chiller Controls
Section 5 Screw Compressor Operational Details
Section 6 Centrifugal Compressor Operational Details
Section 7 Capacity Control Methods
Section 8 Refrigerant Related Topics
Section 9 Heat Transfer
Section 10 Codes and Standards
Section 11 Selection Criteria
Section 12 Summary

SECTION 1
WATER-COOLED CHILLERS
Introduction

Objectives
• Compare the advantages of water-cooled
versus air-cooled chillers
• Identify and diagram the different components
of a basic refrigeration cycle as it applies to a
water-cooled chiller
• Compare and describe the differences among
scroll, reciprocating, centrifugal, and screw
water-cooled chillers and their applications
• Discuss the differences in construction of
water-cooled chillers of various sizes
• Identify the codes and standards
that apply to water-cooled chillers
• Understand the typical inputs required
to select a water-cooled chiller
Section 1 – Introduction
Dr. Willis H. Carrier
In the early 1900’s, centrifugal air compressors

were adopted for use in the air conditioning
industry.
Early Centrifugal Chiller
Smithsonian Institute
Carrier Centrifugal Chiller on Display
Evolution of Centrifugal Chillers
Water-Cooled vs. Air-Cooled Chillers
Typical Water-Cooled Chiller System
Water-cooled packaged chillers are available
up to about 3000 tons of capacity.
Water-Cooled
Condenser
Chiller
Condenser
Water Pump
Cooling Tower
SECTION 2
Basic Refrigeration Cycle

Condenser
95° F
85° F
Water
Nozzles
Pressure
Reducing Compressor Hot Gas
Device
Discharge Line
Liquid Suction Line

Line
44° F
54° F
Evaporator
Section 2 – Basic Refrigeration Cycle


Pressure-Enthalpy Diagram
Refrigeration Cycle
Pc Saturated Condensing
PRESSURE
LIFT
Ps Saturated Suction
RE
ENTHALPY

Refrigeration Cycle with Subcooling
SUBCOOLING
tc
Pc
PRESSURE
Vgs
Ps
ts
RE
hfc ENTHALPY hgs

Water-Cooled Condenser Subcooler
Condenser tubes
Orifices in
subcooler
Condenser Float valve

shell Subcooler “box” metering device
at the bottom of
the condenser

Refrigeration Cycle with Economizer
2-Stage Centrifugal Shown
Pc
PRESSURE
Pe
P2
Ps
RE
hfe hfc hgs hge h3

ENTHALPY

SECTION 3
Chiller Components

Brazed-Plate Evaporator
Note: Brazed-plate heat exchangers
are also used as condensers
Return water in
54º F
Refrigerant out
Chilled water out

44º F
Refrigerant in
Section 3 – Chiller Components

Direct Expansion Evaporator
Water Out
Water In
• Refrigerant is in the tubes

• Water is in the shell

Flooded Shell-and-Tube Evaporator
Tubes penetrating Refrigerant Suction Flange
end of tube sheet
Waterbox Ring
End Tube Sheet

Flooded Shell-and-Tube Evaporator
Refrigerant Suction Outlet
Water in tubes
Tube Support Sheets

Liquid refrigerant
“floods” the shell
Water Nozzles around the tubes.

Evaporator Refrigerant Path
Refrigerant Suction Gas to
Distribution System Compressor
Waterbox
Nozzles
Gaseous Refrigerant
Liquid Refrigerant
Liquid Refrigerant from Condenser

Space Elimination
Free space
for gaseous
refrigerant Tube
Support
Sheets
Liquid refrigerant rises
to top-most tube level.
Liquid Refrigerant
Distribution Box
End Tube Support Sheet
Double Grooves

Parallel and Series Evaporators

Large Chiller Shell-and-Tube Condenser
Subcooler
Hot Gas Inlet Circuit
Float Valve
Chamber Waterbox Ring
End Tube Support Sheet

Large Chiller Condenser Cutaway
Hot Gas Inlet
Orifice
Float Valve
Tube
Chamber Liquid
Outlet Support Sheets
Tubes
Subcooler

Condenser Refrigerant Path
Hot Refrigerant Vapor Inlet
Return to
Cooling Tower Water
From
Cooling Tower
Liquid Refrigerant Outlet

Compressors
Two Categories:
- Positive Displacement
- Dynamic Compression
(Centrifugal)

Reciprocating Compressor
Multi-Compressor
Cylinder Head Terminal Box Reciprocating Chiller
Motor
Semi-Hermetic
Compressor
Reciprocating Compressor

Scroll Compressor
Hot Gas
Discharge
Electrical Terminal Orbiting

Connection Scrolls
Hermetic
Shell
Pressure Relief
Suction
Inlet
Hermetic
Motor

Scroll Compressor

Screw Compressor
2-Circuit Screw Chiller
Evaporator
Condenser
Screw Compressor

Double Rotor Screw Compressor

Centrifugal Compressor
Motor
Transmission Rotor
Refrigerant Motor
Cooling Line
Guide Vane
Motor
Hermetic Drive
Inlet Guide
Vanes Impeller
Open Drive

Centrifugal Compressor Need Avi
file

Hermetic Centrifugal Compressor
Refrigerant Cooling Transmission High Speed
Shaft
Impeller
Inlet
Hermetic Guide
Housing Vanes
Low Speed
Shaft
Electric Motor
Rotor
Oil Filter
Oil Pump

Open Drive Centrifugal Compressor
Drive Shaft

Refrigerant Metering – Large Chiller
Hot Gas Inlet
Condenser
Condenser
Tubes
Liquid
Refrigerant
Float Valve Open

Liquid Outlet
Nozzle-in-Head Waterboxes
Waterbox “Dished”
Assembly Head Design
Nozzles

Marine Waterboxes
Outlet Nozzles
1 or 3-Pass
Marine
Waterbox
Outlet
2-Pass
Marine
Waterbox
CONDENSER
Inlet
Hinged Water Box Covers EVAPORATOR

Purge Unit
Purge Unit
Negative Pressure
Centrifugal Chiller

Positive Pressure Chiller/Transfer Compressor

Storage Tank and Transfer Unit
This assembly is required Tank-Mounted
when using a chiller design Transfer
Compressor
where in-chiller storage of
refrigerant is not available.
Refrigerant Storage Tank

Relief Valves
Reseating Type Relief Valves on

Positive Pressure Centrifugal Chiller
Rupture Disk Relief on

Negative Pressure Centrifugal Chiller

SECTION 4
Chiller Controls

Centrifugal Chiller Control Panel
Unit-Mounted Control Panel RUNNING TEMP CONTROL

LEAVING CHILLED WATER
06-07-04 11:48
214 HOURS
CHW IN CHW OUT EVAP REF

55.1 44.1 40.7
CDW IN CDW OUT COND REF
85.0 95.0 98.1
OIL PRESS OIL TEMP MTR AMPS
21.8 132.9 93
CCN LOCAL RESET MENU
• Includes visual display/user interface

• Monitors and controls the chiller and
auxiliary devices such as pumps
• Provides BAS communication functions
Section 4 – Chiller Controls

Chiller Starting Methods
• Across-the-Line
• Auto Transformer*
• Primary Reactor*
• Part-Winding*
• Wye-Delta*
• Solid State*
• Variable Frequency Drive†
* Soft Start
† Softest Start

Unit-Mounted Solid State Starter

VFD Starter for Unit-Mounting

Motor Starting Current Information
Motor Starting Current as a % of

Starting Method
Locked Rotor Current Full Load Current
Across-the-Line 100 600
Auto Transformer & Primary Reactor
80% 80 480
65% 65 390
50% 50 300
Part Winding 65 390

Wye-Delta 33 200
Solid-State 0 - 100 0 - 600
VFD 16.6 100

SECTION 5
Screw Compressor
Operational Details

Screw Chiller Technology
Rotors
Transmission
Large Screw Chiller Compressor

Section 5 – Screw Compressor
Operational Details
SECTION 6
Centrifugal Compressor
Operational Details

Centrifugal Compressor Theory
• Heavier the ball (molecular weight) = MORE FORCE
• Longer the string (diameter) = MORE FORCE
• Faster the ball rotates (rpm) = MORE FORCE
FORCE FORCE
GAS
BALL
MOLECULE
LENGTH
DIAMETER
STRING
Section 6 – Centrifugal Compressor

Operational Details
Centrifugal Compressor Theory

Operational Details
Centrifugal Principle

Operational Details
Centrifugal Principle

Operational Details
Centrifugal Head
PS
Suction
(inlet) pressure
Head can be pictured

as the height of a column
HEAD – FEET
of refrigerant vapor which,
VAPOR
due to its weight, produces

the same pressure as that
developed across the
compressor.
PD
Discharge (outlet)
pressure
Operational Details
Lift
Lift = SCT less SST Saturated temperatures are
surrogates for pressures
95F
85F To condense, refrigerant
must be warmer than the
leaving condenser water.
SCT = 95F + 2F approach
= 97F
To boil, refrigerant must be

44F colder than the leaving
54F 44F chilled water.
SST = 44F – 2F approach
= 42F
Lift is Based On Leaving …

Lift
Sat. Condensing = 97° F

PRESSURE
Lift 55°F
Sat. Suction = 42° F
ENTHALPY

Operational Details
Lift
Like pumps, chiller energy consumption is a function of mass flow and
differential pressure.
Mass Flow X Lift

Compressor Input kW ~
Compressor/Cycle
Efficiency
Cooling
Chiller Tower
CHILLER ENERGY (KW) ~ TONS X LIFT

Lift Reduction

PRESSURE
Lift 55°F
Lift = 35° F
Sat. Suction = 42° F
ENTHALPY

Operational Details
Centrifugal Compressor Map
100%
75%
50%
25%
Head Factor
Stone Wall
Load line
plotted on
compressor map
Flow Factor

Operational Details
Centrifugal Compressor Stages
Single-Stage Design
(one impeller)
Earlier
Multi-Stage
Design

Operational Details
SECTION 7
Capacity Control Methods

Centrifugal Chiller Capacity Control - IGV
Guide Inlet
Vane Guide
Motor Vanes
Inlet
Shroud
Impeller
Section 7 – Capacity Control Methods

Capacity Control - IGV
Inlet
Guide
Vanes
Closed

Centrifugal Compressor Efficiency Characteristics
Constant Speed Centrifugal
90%
Efficiency 80%
70%
60%
Lift
Open Vanes
50% Vanes
25% Vanes
10% Vanes
Capacity (Tons)

Screw Capacity Control Methods
SLIDE VALVE METHOD PORT VALVE METHOD

Infinite Capacity Control Stepped Capacity Control
Slide Valve Step Valves

Affinity Laws for Centrifugal Loads
Flow ~ Speed Lift ~ Speed2 Power ~ Speed3
% Pressure/Head
% Input Power
% Flow
% rpm % rpm % rpm

VFD Saves Energy
Constant Speed kW/ton VFD kW/ton
0.880
0.830
0.780
0.730
0.680
0.630
kW / ton
0.580
0.530
0.480
0.430
0.380
0.330
0.280
20% 30% 40% 50% 60% 70% 80% 90% 100%
Percent Full Load Tons

Typical 500-Ton Centrifugal Chiller

Centrifugal Compressor Efficiency Characteristics
Variable Speed Centrifugal
New operating
characteristics
created by
speed reduction
Lift 100%
90% 100%
90 %
80% 70%
Efficiency 60% Speed
Capacity (Tons)

SECTION 8
Refrigerant Related Topics

HCFC Phase Outs
65% (1 Jan 2004)

Production Cap
Current
Montreal
Protocol
35 % ( 2010)
10 % (2015)
0.5% (2020)
1990 1995 2000 2005 2010 2015 2020 2025 2030
No New R-22 No New R-123
123
Equipment Equipment
Section 8 – Refrigerant Related Topics

Chiller Construction
Large R-134a chillers

are constructed in accordance with
ASME Section VIII, Division I

Chiller Size Refrigerant Impact
Chiller size is affected by
refrigerant molecular size.
HFC HCFC HFC HCFC

410A 22 134a 123

Allowable Exposure Limits
HFC-134a
Exposure Limits
1000 ppm
50 ppm
25 ppm
HCFC 123
Ammonia
Safety

Refrigerant Safety Groups
High A3 B3
Flammability Propane
Low A2 B2
Flammability R-142b, 152a Ammonia
No Flame A1 B1
Propagation R-11, R-12, R-22, R-123, SO2
R-114, R-500, R-134a
Lower Toxicity Higher Toxicity
ASHRAE Standard 34
SECTION 9
Heat Transfer

Heat Transfer - Condenser
Refrigerant Temperature
Temperature “t"
tR tR
Dt Lvg
t2
Dt
Ent
The refrigerant is changing
from a gas to a liquid and is
t1 releasing its latent heat of
condensation
Section 9 – Heat Transfer

Heat Transfer - Evaporator
Temperature “t"
t1
The refrigerant is changing
from a liquid to a
gas while absorbing its
Dt latent heat of vaporization
Ent
t2
tR Refrigerant Temperature Dt
t
Lvg R

Chiller Equation for Tons
gpm * DtF
tons =
24
gpm = Flow rate for evaporator or condenser
DtF = Difference in fluid entering and leaving
24 = Conversion to tons for fresh water

Heat Transfer
Overall Heat Transfer Exchanged
q = U * A * LMTD
Log Mean Temperature Difference
D tF
LMTD =
æ D t Ent ö
Log ç ÷
è D t Lvg ø
e
Heat Transfer Coefficient
1 /U = R W + R F + R M + R R

Overall Heat Transfer
Saturated Condensing Temperature (tR)
HEAT OF Dt
Dt CONDENSATION Lvg
Ent
t2
t1
t1
Dt t2
Ent HEAT OF
VAPORIZATION Dt
Lvg
Saturated Suction Temperature (tR)

Typical Resistances to Heat Transfer - Baseline
HEAT TRANSFER RESISTANCES BETWEEN
FLUID IN THE TUBES AND THE REFRIGERANT
RW 0.000469 46% Fluid Film
RF 0.000250 24% Fouling
RM 0.000029 3% Tube Material
RR 0.000277 27% Refrigerant Film
RT 0.001025 100% Total

Resistances with Increase in Fouling
RW 0.000469 26% Fluid Film
RF 0.001000 56% Fouling
RR 0.000277 16% Refrigerant Film
RT 0.001775 100% Total

Fouling (Scaling Resistance) RF
Fouling is the build-up of deposits on tube surfaces and
depends on the quality of water (i.e., dirty river, etc.)
• Expressed as a number
(0.00025 or 0.0005 or 0.002) Resistant Layers
• Minimal in evaporators
Water Water in Tube
– Closed piping circuit
• Greater in condensers
Water Film RW
Heat Flow
• ARI 0.00025 fouling factor Scale
– Basis of chiller ratings (Fouling) RF
for condensers Metal RM
– For evaporators 0.0001
Refrigerant
• Lower water velocities Film RR
result in higher Refrigerant
fouling rates

Resistances With Lower Water Velocity in Tubes
Fluid Film
RW 0.000985 64% (4 fps velocity)
RF 0.000250 16%
RM 0.000029 2%
RR 0.000277 18%
RT 0.001541 100%
Resistances With Tube Material Change
RW 0.000469 35%
RF 0.000250 18%
70 – 30 CuNi
RR 0.000277 21%
RT 0.001346 100%
Evaporator Tubing Materials Chart
Tubing Materials Chart

Approximate Cost Multiplier
Application Tube Material vs. Copper Tubes
Fresh Water Copper 1.0
Glycols Copper 1.0
Corrosive Water Cupro-Nickel 1.3
Special Process Stainless Steel 2 to 3
Sea Water Titanium or Cupro-Nickel 3 to 4

Shell-and-Tube Heat Exchanger Tubing
INTERNALLY AND
EXTERNALLY ENHANCED
Evaporator Tubing Condenser Tubing

Pass Arrangements
Low Pressure Drop,

One-Pass AREA = A Low Rise
AREA = A/2 Medium Pressure Drop,

Two-Pass Medium Rise
AREA = A/3 High Pressure Drop,

Three-Pass High Rise

SECTION 10
Codes and Standards

ARI Weighting Factors
FOR IPLV CALCULATION
Percent Entering
Percent
Chiller Condenser
Weighting
Load Temp
100 85 1
75 75 42
50 65 45
25 65 12
Section 10 – Codes and Standards

ASHRAE 90.1 and T24 Standard
WATER CHILLING PACKAGES-MINIMUM EFFICIENCY REQUIREMENTS
*kW/TON =
3.516/COP

ASHRAE 90.1 and T24 Standard
Adjustment Formula for Minimum Efficiency Standards
0.660
0.640
/TonRequired
0.620
0.600
IKW
0.580
0.560
0.540
9 10 11 12 13 14 15
Conde ns e r De lta T

ASHRAE Standard 15
Terminate discharge lines
Provide a mechanical room if the away from air intakes Eliminate any passages
amount of refrigerant used allowing refrigerant to
exceeds ASHRAE 15 table values escape into the building
Install dedicated mechanical

Run piping from room ventilation fan
purge and rupture Size relief lines
disk to outside per ASHRAE 15 Use a tight fitting
mechanical room door
Install refrigerant
leak detector
interlocked to
ventilation fan
and alarm
Store refrigerant in
approved storage
vessels only
Restrict mechanical
room access to
authorized personnel

SECTION 11
Selection Criteria

Centrifugal Chiller Input Screen 1
Section 11 – Selection Criteria

Centrifugal Chiller Input Screen 2
Section 11 – Selection Criteria

SECTION 12
Summary

Summary
• Compared the advantages of water-cooled
versus air-cooled chillers
• Identified and diagrammed the different
components of a basic refrigeration cycle
as it applies to a water-cooled chiller
• Compared and described the differences among
scroll, reciprocating, centrifugal, and screw
water-cooled chillers and their applications
• Discussed the differences in construction
of water-cooled chillers of various sizes
• Identified the codes and standards
that apply to water-cooled chillers
• Reviewed the typical inputs required
to select a water-cooled chiller
Section 12 – Summary
Technical Development Program
Thank You
This completes the presentation.

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Technical Development Program

© 2013 Carrier Corporation

© 2013 Carrier Corporation

© 2013 Carrier Corporation

In the early 1900’s, centrifugal air compressors

Carrier Centrifugal Chiller on Display

Basic Refrigeration Cycle

© 2013 Carrier Corporation

Liquid Suction Line

Section 2 – Basic Refrigeration Cycle

Section 2 – Basic Refrigeration Cycle

Section 2 – Basic Refrigeration Cycle

Section 2 – Basic Refrigeration Cycle

Condenser Float valve

Section 2 – Basic Refrigeration Cycle

hfe hfc hgs hge h3

Section 2 – Basic Refrigeration Cycle

© 2013 Carrier Corporation

Chilled water out

Section 3 – Chiller Components

• Refrigerant is in the tubes

Section 3 – Chiller Components

End Tube Sheet

Section 3 – Chiller Components

Tube Support Sheets

Section 3 – Chiller Components

Liquid Refrigerant from Condenser

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

End Tube Support Sheet

Section 3 – Chiller Components

Section 3 – Chiller Components

Hot Refrigerant Vapor Inlet

Liquid Refrigerant Outlet

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

Electrical Terminal Orbiting

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

Float Valve Open

Section 3 – Chiller Components

Hinged Water Box Covers EVAPORATOR

Section 3 – Chiller Components

Section 3 – Chiller Components

Section 3 – Chiller Components

Refrigerant Storage Tank

Section 3 – Chiller Components

Reseating Type Relief Valves on

Rupture Disk Relief on

Section 3 – Chiller Components

© 2013 Carrier Corporation

Unit-Mounted Control Panel RUNNING TEMP CONTROL

CHW IN CHW OUT EVAP REF

• Includes visual display/user interface

Section 4 – Chiller Controls