CHILLERS

Refrigeration
Refrigeration may be defined as the process of achieving and maintaining a temperature below that of the surroundings, the aim being to cool some product or space to the required temperature. Chiller is a machine or device that may be classified as: Three Different Mechanisms of Chiller a. Water Cooled Chillers b. Air Cooled Chillers c. Evaporative Cooled Chillers Gas Refrigeration Cycle

Evaporative Chillers Air in contact with water to cool it close to wet bulb temperature Advantage: efficient cooling at low cost Disadvantage: air is rich in moisture

Types of Refrigeration Process Vapor Compression Cycle Vapor Absorption Cycle

Type of Refrigeration
Vapors Compression Refrigeration Refrigeration cycle

Water and Air Cooled Chillers Components of Water and Air Cooled Chillers - Evaporator - Condenser - Compressor - Expansion Valve

1|P a ge

Advantages and Disadvantages ADVANTAGES: 1. Smaller in size 2. Low running cost 3. High C.O.P. 4. Temperature change by just control valve DISADVANTAGES: 1. Requires greater safety and prevention of leaks due to the use of inflammable and toxic vaports of refrigerants 2. Initial cost is high

Vapour Absorption Refrigeration

Advantages and Disadvantages ADVANTAGES: 1. Method of compression of the refrigerant 2. Power consumption devices 3. The amount of power required 4. Type of energy required 5. Low running cost 6. Type of Refrigerant Used DISADVANTAGES: 1. Initial cost is high 2. Corrosive nature of lithium bromide 3. Low working pressures 4. Higher heat rejection

2|P a ge

FUNCTION OF REFRIGERATION COMPONENTS

EVAPORATOR

METERING DEVICE

meters the flow of the refrigerant

Absorb heat from the medium being cooled. Allow heat to boil off the liquid refrigerant to a vapor in its tubing bundle. Allow the heat to superheat the refrigerant vapor in its tubing bundle.

COMPRESSOR
Common Compressors Used in Refrigeration: Reciprocating Compressor Rotary Screw Compressor Scroll Compressor CONDENSER

Two primary systems used to control evaporator pressure and temperature: TXV systems (thermal or thermostatic expansion valve) OT systems (orifice tube) TXV System A TXV controls the refrigerant flow from the high pressure side to the evaporator. A receiver dryer is mounted in the liquid line of all TXV systems.

Desuperheat the refrigerant vapor. Condensed the refrigerant from vapor to liquid

3|P a ge

OT System An OT controls the refrigerant flow from the high pressure side to the evaporator. An accumulator is mounted in the suction line of all OT systems.

The expansion device separates the high side from the low side and provides a restriction for the compressor to pump against.

Refrigerants that can no longer be manufactured/have phase-out dates R-12 - Used primarily in medium and high temperature refrigeration applications. R-22 Used primarily in residential, commercial and industrial air conditioner and refrigeration applications . R-500 - used primarily in older air conditioner applications and some commercial refrigeration. R-502 - Used primarily in lower temperature refrigeration applications. Replacements R-134a - Properties same as R-12. Used primarily in medium and high temperature refrigeration applications, refrigerators, freezers and automobile air conditioners. R-404A - Replaced R-502. Used in low and medium temperature refrigeration applications. R-407C - Similar properties as R-22 used in residential and commercial airconditioning. R-410A - Replace R-22 used in high operating pressures. R-507 - Replace R-502 used in low and medium refrigeration applications and has higher pressure capacity than R-404A.

TWO TYPES OF REFRIGERATION OPERATION LOW SIDE OPERATION Expansion device Evaporator Accumulator (if equipped)

HIGH SIDE OPERATION Compressor Condenser Receiver-drier (if equipped)

Refrigerants - defined as any body or substance that acts as a cooling medium by extracting heat from another body or substance. A chlorofluorocarbon (CFC) is an organic compound that contains carbon, chlorine, and fluorine, produced as a volatile derivative of methane and ethane.

4|P a ge

Mechanical Compression Chillers

CHILLERS SYSTEM Key Components of Chiller: EVAPORATOR Component in which liquid refrigerant flows over a tube bundle and evaporates, absorbing heat from the chilled water circulating through the tube bundle. COMPRESSOR The refrigerant vapor to the condenser by raising the refrigerant pressure (and thus, the temperature). CONDENSER Component in which refrigerant condenses on a set of cooling water coils giving up its heat to the cooling water.

PROCESS CHILLERS
EXPANSION VALVE The high-pressure liquid refrigerant coming from the condenser passes through this expansion device, reducing the refrigerants pressure (and temperature) to that of the evaporator. CONTROLS It allows adjustment to some chiller operating parameters. To better monitor chiller performance, the chiller control system should communicate with the facilitys direct digital control. A refrigeration system using halocarbon or ammonia refrigerants that provide cooling for process or industrial application. Who uses Process Chillers: Plastic Industry Baking Industry Food Industry Pharmaceutical Industry Printing Industry

How Process Chiller Works?

It may use an air or water condenser in its cooling process. A sub cooled liquid refrigerant passes from the condenser to evaporator, a thermostatic expansion valve causes the pressure and temperature to drop. The refrigerant then picks up the heat from the fluid flowing through the evaporator, changing from a liquid to a vapor.

TYPES OF CHILLERS Compression chillers Absorption chillers

5|P a ge

Absorption chillers

Types of Compression Chillers

Reciprocating Compression Chiller Scroll Compression Chiller Rotary Screw Compression Chiller Centrifugal Compression Chiller

Industrial Chiller Technology

Industrial Chillers consist of: Chiller Unit Condenser Pump Station with Recirculating Pump Expansion Valve No-flow shut down Internal Cold water tank Temperature control

Industrial Chiller Selection

Specifications to consider Power Source Chiller IP Rating Chiller Cooling Capacity Evaporative Capacity Evaporator Type Condenser Material Condenser Capacity Ambient Temperature Motor Fan Type Noise Level

Process Pump Specifications

Specifications to consider Process flow Process Pressure Pump Material Elastomer Mechanical Shaft Seal Material Motor Voltage Motor Electrical Class Motor IP Rating Pump Rating Internal Water Tank Size

6|P a ge

Control Panel Features

Local Control Panel Remote Control Panel Fault Indicators Temperature Indicators Pressure Indicators

Additional feature includes Emergency Alarms Hot gas bypass City water Switch over Casters

Applications of Chillers
Air-Conditioning Industry printing industry plastics industry Food industry MRI

7|P a ge