YK Centrifugal Chillers

YK - Centrifugal Chiller
JCI M.E 2
Refer to Training Agenda on a Separate Sheets
Topics :
JCI M.E 3
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.E 4
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
Let Me Tell You
About Myself
Three Laws from Science Class
Matter
Can Not be Created or Destroyed
Matter being (Heat Energy)
Warm Place to a Cool Place
Vapor Density
Changes with Pressure
Heat Flows Down Hill
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.
Jacques Charles
Charlie's 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
Robert Boyle
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....
Johnson Controls 11
Cooling by the Removal of HEAT.
Unfortunately We Must Learn
Some
TERMS
Conduction
Specific Heat
BTUs
Change of State
Conduction
Convection
Radiation
Change of State
Sensible Heat
Latent Heat
Heat Flows 3
Ways
1. Conduction
2. Convection
3. Radiation
ALL 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 Heat The 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 75 the the 75
room 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 to 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
Ratio Ratio
Never Increased Never Increased
the Temperature the Temperature
R-22
Boils @ -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
Points
for
BOILING TEMPERATURE OF WATER AT VARIOUS COMPARATIVE PRESSURES
TEMPERATURE
0
F INCHES/MERCURY MICRONS
212 0 759,990
205 3.921 660,400
200 6.451 596,140
195 8.771 537,210
190 10.904 483,030
185 12.851 433,580
180 14.626 388,490
175 16.245 347,370
170 17.718 309,960
165 19.054 276,020
160 20.265 245,250
155 21.36 217,440
150 22.348 192,350
145 22.238 169,750
140 24.037 149,460
for
Water
60 29.399 13,250
55 29.485 11,070
50 29.599 9,200
45 29.621 7,630
40 29.673 6,290
35 29.718 5,170
30 29.757 4,180
25 29.791 3,310
20 29.818 2,610
15 29.848 2,050
10 29.858 1,600
5 29.872 1,240
0 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
Johnson Controls 30
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Heat Content
(BTU / lb.)
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Liquid - Vapor
Mix
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
100% Liquid
Pressure
Pressure - Enthalpy Chart Pressure - Enthalpy Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
100% Vapor
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
20% Liquid 80% Vapor
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Evaporator
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Evaporator
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Evaporator
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Evaporator
Refrigerant absorbs heat from
load
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Evaporator
load
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Evaporator
Net Refrigeration Effect
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Compressor
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Compressor
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Compressor
Head Pressure
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Refrigerant rejects heat to
atmosphere
Enthalpy
Condenser
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Metering Device
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
- Thermal expansion
valve
- Orifice
Metering Device
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Condenser
Enthalpy
Evaporator
Compressor
Metering
Device
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Condenser
Refrigerant rejects heat to
atmosphere
Enthalpy
Evaporator
Compressor
Metering
Device
load
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
85
Enthalpy
95
54
44 44
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
85
Enthalpy
95
44
54
44
54
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
85
Enthalpy
95
44
54
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
85
Enthalpy
44
54
95
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
85
Cooling
Tower
Enthalpy
44
54
95
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
85
Cooling
Tower
Enthalpy
95
44
54
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Enthalpy
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Adding a subcooler
Refrigeration
Effect
Enthalpy
Adding a subcooler
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Adding a subcooler
Refrigeration
Effect
Enthalpy
Adding a subcooler
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Adding a subcooler
Refrigeration
Effect
Enthalpy
Adding a subcooler
Increases refrigeration effect
Pressure
Pressure - Enthalpy
Chart
Pressure - Enthalpy
Chart
Adding a subcooler
Refrigeration
Effect
Enthalpy
Adding a subcooler
Increases refrigeration effect
Increases energy efficiency
Head Pressure Head Pressure
Pressure
Enthalpy
Condenser
Pressure
Evaporator
Compressor
Enthalpy
Condenser
Pressure
Head
Pressure
Evaporator
Compressor
Enthalpy
Lowering condenser Lowering condenser
water temperature water temperature
Condenser
Pressure
Evaporator
Compressor
Enthalpy
Head
Pressure
Condenser
Pressure
Lowers head Lowers head
pressure pressure
Evaporator
Compressor
Enthalpy
Head
Pressure
Pressure
pressure pressure
Head
Pressure
Evaporator
Compressor
Condenser
Enthalpy
Pressure
pressure pressure
Evaporator
Compressor
Condenser
Enthalpy
Head
Pressure
Lowering condenser water Lowering condenser water
temperature temperature
Lowers head pressure Lowers head pressure
Pressure
Reduces compressor Reduces compressor
work work
Reduces energy Reduces energy
consumption consumption
Evaporator
Compressor
Condenser
Enthalpy
Head
Pressure
SAT DISCH = 100F
P
R
E
138.8
Operation Theory -
Lift
W/134a DeltaP = 138.8-49.7 =89.1 PSID
LIFT = 60F
SAT SUCT = 40F
4038F
E
S
S
U
R
E
P
S
I
A
ENTHALPY Btu/lb
49.7
SAT DISCH = 100F
P
R
E
138.8
Operation Theory -
Lift
W/134a DeltaP = 138.8-49.7 =89.1 PSID
LIFT = 60F
SAT SUCT = 40F
4038F
E
S
S
U
R
E
P
S
I
A
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
P
R
SAT
ENTHALPY
R
E
S
S
U
R
E
SAT
LIQUID
SAT
VAPOR
Refrigeration
Effect
Two Stage Cycle
SUBCOOLING
P
R
SAT
ENTHALPY
R
E
S
S
U
R
E
SAT
LIQUID
SAT
VAPOR
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.E 99
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.E 100
Chamber volume is reduced
Refrigerant pressure is increased
Centrifugal Chiller
Positive Displacement Operating Characteristics
Lift
JCI M.E 101
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
Screw Reciprocating
Scroll
JCI M.E 102
Screw Reciprocating
Scroll
Compressor Designs
Reciprocating Screw Centrifugal
Head Variable Variable Fixed
Volume Fixed Fixed Variable
Volume
Capacity
Low Medium High
Volume flow
up to 1000 m
3
/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.E 103
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.E 104
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 Infinitely
Variable
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.E 105
5 Frequency
CM Motor code
E Design level
S Special Code
system component
JCI M.E 106
system component (Front side)
JCI M.E 107
system component (Rear side)
JCI M.E 108
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.E 109
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.E 110
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.E 111
Condenser Condenser
Cooling
Tower
JCI M.E 112
Evaporator Evaporator
Coil Coil
Condenser Condenser
Cooling
Tower
JCI M.E 113
Coil Coil
44
Condenser Condenser
Cooling
Tower
JCI M.E 114
Coil Coil
44
72
55
Condenser Condenser
Cooling
Tower
JCI M.E 115
Coil Coil
44
54
72 55
Condenser Condenser
Cooling
Tower
41 37
JCI M.E 116
Coil Coil
44
54
72
55
41 37
Condenser Condenser
Cooling
Tower
95
JCI M.E 117
Coil Coil
44
54
72 55
41 37
Condenser Condenser
Cooling
Tower
95 85
41
37
JCI M.E 118
Coil Coil
44 54
72
55
41
37
Condenser Condenser
Cooling
Tower
95 85
37
124 86
JCI M.E 119
Coil Coil
44 54
72
55
41
37
Condenser Condenser
Cooling
Tower
95 85
37
124 86
Refrigerant
Loop
JCI M.E 120
Coil Coil
44 54
72
55
41
37
Loop
Centrifugal Chiller Centrifugal Chiller
How does it Work!
JCI M.E 121
YK CENTRIFUGAL CHILLERS
Johnson Controls 122
Show animation
CYK CENTRIFUGAL CHILLERS
Show Animation
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YK Centrifugal Chillers

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