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COMMERCIALREFRIGERATION
UNIT22
CONDENSERS
UNITOBJECTIVES
Afterstudyingthisunit,thereadershouldbeableto
Explainthepurposeofcondensersinrefrigerationsystems
Describewatercooledandaircooledcondensers
Listthreetypesofwatercooledcondensers
Describetheoperatingdifferencesbetweenwastewaterand
recirculatingwatersystems
Describetheoperationandfunctionofacoolingtower
Listmethodsthatfacilitatelowambientsystemoperation
THECONDENSER
Heatexchangesurfacethatrejectssystemheat
Rejectssensibleheat
Desuperheatingvaporrefrigerantfromthecompressor
Subcoolsrefrigerantattheoutletofthecondenser
Rejectslatentheatduringthecondensingprocess
Thegreatestamountofheatistransferredduringthe
changeofstate
Condenserisonthehighpressuresideofthesystem
WATERCOOLEDCONDENSERS
Moreefficientthanaircooledcondensers
Watertemperaturecanbemaintained
Watertemperaturedirectlyaffectssystempressures
Threetypesofwatercooledcondensers
Tubewithinatubecondenser
Shellandcoilcondenser
Shellandtubecondenser
TUBEWITHINATUBECONDENSER
Heatexchangetakesplacebetweenthefluidsin
theinnerandoutertubes
Refrigerantflowsintheoutertube
Waterflowsintheinnertube
Refrigerantandwaterflowinopposite
directionstomaximizetheheattransferrate
Dependingontheconstruction,thecondenser
canbecleanedmechanicallyorchemically
Watertotower(95F)
Coolwater
fromthe
cooling
tower
85FWater
Hotdischargegasfromthe
compressor
Subcooledliquidto
thereceiver
CrossSectionofatubewithinatubecondenser
Surroundingair
Waterfromtower
(innertube)
Hotdischargegasfrom
compressor(outertube)
Dischargegastransfers
heattoboththe
surroundingairandthe
waterintheinnertube
MINERALDEPOSITS
Heatfromthedischargegascausesmineralsinthe
watertocomeoutofsolution
Thesemineralsformscalethatadheredtothepipes
Thescaleactsasaninsulatorandreducestherateof
heattransferbetweentherefrigerantandthewater
Waterischemicallytreatedtoreducetherateof
scaleformationontheinteriorpipesurfaces
Dirtycondensersleadtohighheadpressures
CrossSectionofatubewithinatubecondenser
Surroundingair
Hotdischargegasfrom
compressor(outertube)
MINERAL
DEPOSITS
Heattransferbetween
therefrigerantandthe
waterisreduced
becauseofthe
insulatingeffectofthe
mineraldeposits
Waterfromtower
(innertube)
110Fliquidrefrigeranttoreceiver
85F
WATERTUBESARECLEAN
95F
Discharge
gas200F
145Fliquidrefrigeranttoreceiver
85F
90F
Discharge
gas200F
Scale
MECHANICALLYCLEANABLE
CONDENSERS
Tubewithinatubecondenserhasendflanges
Flangesareremovedtoaccessthewatercircuit
Therefrigerantcircuitremainssealedwhilethe
watercircuitisopen
Themechanicallycleanabletubeintube
condenserismorecostlythanthechemically
cleanableversionofthecondenser
MECHANICALLYCLEANABLE
TUBEWITHINATUBE
CONDENSER
Waterand
refrigerant
connections
MECHANICALLYCLEANABLETUBE
WITHINATUBECONDENSER
Flange
Gasket
Accesstointerior
ofwatertubes
SHELLANDCOILCONDENSERS
Coiloftubingenclosedinaweldedshell
Waterflowsthroughthecoil
Refrigerantfromthecompressorisdischargedinto
theshell
Theshellalsoactsasthereceiver
Whenrefrigerantcomesincontactwiththecool
coil,itcondensesandfallstothebottom
Thiscondensermustbecleanedchemically
ShellandCoilCondenser
Shell
Hotdischargegasfrom
compressor
Watercoil
Dropletsofcondensed
refrigerant
Warmwaterout
Bottomofshellacts
asareceiver
Coolwaterin
Subcooledliquidfromcondenser
SHELANDTUBECONDENSERS
Canbecleanedmechanically
Compressordischargegasispipedintotheshell
Waterflowsthroughthetubesinthecondenser
Theendsoftheshellareremovedforcleaning
Theshellactsasareceiver
Refrigerantcircuitisnotdisturbedwhentheendsof
theshell(waterboxes)areopened
Mostexpensivetypeofcondenser
Shell
WaterTubes
Hotdischargegasfrom
compressor
Warm
waterout
Coolwater
in
Bottomofthecondenser
actsasthereceiver
Subcooledliquidfromcondenser
Hotdischargegasfrom
compressor
Waterout
Waterin
Subcooledliquidfromcondenser
Directswater
throughthe
tubes
Hotdischargegasfrom
compressor
Accesstotubes
forcleaning
Waterbox
Subcooledliquidfromcondenser
WASTEWATERSYSTEMS
Waterusedonceandthenwasteddownthedrain
Economicalifwaterisfreeorifthesystemissmall
Themaindrawbackisthatthewatertemperature
canvaryagreatdeal
Typicalwatertemperatureisabout75F
75Fwastewaterrequiresaflowofabout1.5gpm
pertonofrefrigerationtoabsorbtheheatrejectedby
thecondenser
Watertypicallyleavesthecondenserat95F
WastewaterSystem
Hotdischargegasfrom
compressor
Warmwater
outtodrain
(95F)
Subcooledliquidfromcondenser
Waterregulatingvalve
Coolwaterin
(75F)
Tocompressorhead
REFRIGERANTTOWATERTEMPERATURE
RELATIONSHIPFORWASTEWATERSYSTEMS
Waterflowiscontrolledbyawaterregulatingvalve
Twopressurescontrolthewaterregulatingvalve
Theheadpressurepushestoopenthevalve
Thespringpressurepushestoclosethevalve
Thevalveopenswhentheheadpressurerises
Watertemperatureishigherinthewarmermonths
Watertemperatureislowerinthecoolermonths
RECIRCULATEDWATERSYSTEMS
Thewaterflowingthroughthecondenseris
pumpedtoaremotelocation,cooledandreused
Designwatertemperatureis85F
Awaterflowrateof3.0gpmpertonof
refrigerationisrequiredtoabsorbtheheatrejected
bythesystemcondenser
Thewaterleavingthecondenserisabout95F
Thereisa10degreesplitacrossthewatercircuit
RecirculatedWaterSystem
Hotdischargegasfrom
compressor
Warmwater
outtodrain
(95F)
Coolwaterin
(85F)
Subcooledliquidfromcondenser
COOLINGTOWERS
Deviceusedtoremoveheatfromthewaterused
inrecirculatedwatersystems
Towerscancoolthewatertoatemperature
within7Fofthewetbulbtemperatureoftheair
surroundingthetower
Ifthewetbulbtemperatureis90degrees,water
canbecooledtoatemperatureaslowas83F
Naturaldraft,forceddraft,orevaporative
Hotwaterin(95F)
Fanmotor
Airin95Fdry
bulb,78Fwet
bulb
Airout
Cooledwaterout(85F)
NATURALDRAFTCOOLINGTOWERS
Redwood,fiberglassorgalvanizedsheetmetal
Therearenoblowerstomoveairthroughthetower
Naturalbreezesmoveairthroughthetower
Waterentersthetowerfromthetopandiscooledas
thewaterfallstothebottom
Somewaterevaporatesintheprocess,helpingto
cooltheremainingwaterinthetower
Additionalwaterisaddedthroughafloatvalve
FORCEDORINDUCEDDRAFTTOWERS
Useafanorblowertomoveairthroughthetower
Asthewaterfallsthroughthetower,airismoved
acrossittoaidinthecoolingprocess
Canbelocatedalmostanywhere
Thefaniscycledonandofftomaintainthedesired
watertemperature
ForceddraftAirispushedthroughthetower
InduceddraftAirispulledthroughthetower
EVAPORATIVECONDENSERS
Designedtooperatefullofliquid
Alatentheattransfertakesplacethroughoutthecoil
Coilefficiencyismaximized
Otherdevicesmustbeusedtopreventliquidfrom
enteringthecompressor
Normallyuseafloattypemeteringdevicetokeep
theliquidlevelinthecoilhigh
AIRCOOLEDCONDENSERS
Usesairtoabsorbheatrejectedbythesystem
Usedinlocationswherewaterisdifficulttouse
Horizontal,vertical,orsideintakeandtopdischarge
Hotgasentersthecondenserfromthetop
Forstandardefficiencysystems,therefrigerantwill
condenseatatemperatureabout30Fhigherthan
theoutsideambienttemperature
AIRCOOLEDCONDENSEREXAMPLE
R134amediumtemperaturerefrigerationsystem
Outsideairtemperature95F
Condensingtemperature125F(95F+30F)
FromP/Tchart,highsidepressureis184psig
Dischargerefrigerantfromthecompressorat200F
Refrigerantmustdesuperheatfrom200Fto125F
Refrigerantwillbegintocondenseat125F
Liquidrefrigerantsubcoolsbelow125F
CALCULATINGSUBCOOLING
Refrigerant R-134a
HIGHEFFICIENCYCONDENSERS
Havelargersurfaceareasthanstandard
condensers
Allowsystemstooperateatlowerpressures
Allowsystemstooperatemoreefficiently
Canoperatewithheadpressuresaslowas10F
higherthantheoutsideambienttemperature
THECONDENSERANDLOWAMBIENT
CONTROLS
Condensingtemperaturesdropwhentheoutside
ambienttemperaturedrops
Thecondensingpressuremustbeatleast75psig
higherthantheevaporatorpressureinorderforthe
meteringdevicetooperateproperly
Lowambientcontrols
Designedtomaintainthedesiredheadpressure
Neededonsystemsthatoperateyearround
HEADPRESSURECONTROL
FANCYCLINGDEVICES
Usedonaircooledcondensers
Astheheadpressuredrops,thefancyclesoff
Astheheadpressurerises,thefancycleson
Somecondensershavemorethanonefan
Somefansremainonallthetime
Otherscycleonandofftomaintainproperpressure
Canbecontrolledbypressureortemperature
HEADPRESSURECONTROL
VARIABLESPEEDMOTORS
Motorspeedchangestomaintainheadpressure
Astheheadpressuredrops,thefanslowsdown
Astheheadpressurerises,thefanspeedsup
Canutilizevariablefrequencydrives(VFD)
Maintainsamoreconstantheadpressure
Canbecontrolledbypressureortemperature
HEADPRESSURECONTROL
AIRSHUTTERSORDAMPERS
Locatedattheinletoroutletofthecondenser
Opensandclosesbyapressurecontrolledpiston
Controlsairflowthroughthecondensercoil
Asambienttemperaturedrops,thedamperscloseto
reducetheamountofairflowthroughthecoil
Asambienttemperaturerises,thedampersopento
increasetheamountofairflowthroughthecoil
HEADPRESSURECONTROL
CONDENSERFLOODING
Valveinstalledinparallelwiththecondenser
Valveclosedwhentheambienttemperatureishigh
Valveopensastheambienttemperaturedrops
Asthevalveopens,refrigerantbacksupinthe
condenser,reducingtheheattransfersurfacearea
Duringverycoldweather,thecondenserwillbe
almostcompletelyfilledwithliquidrefrigerant
Systemsmusthaveanoversizedreceiver
FLOATINGHEADPRESSURES
Termusedforattainingthelowestpossible
condensingtemperatureinthesystem
Allowstheheadpressuretofollowtheambient
temperaturewithoutusingheadpressurecontrols
Newerexpansiondevicescanoperateproperlywith
pressuredifferencesaslowas30psig
Systemsbecomemoreefficientsincetheyoperateat
lowerpressures
UNITSUMMARY1
Thecondenseristhesystemcomponentresponsible
forrejectingsystemheat
Condensersrejectbothlatentandsensibleheat
Watercooledcondensersaremoreefficientthanair
cooledcondensers
Threetypesofwatercooledcondensersarethetube
withinatube,shellandcoil,andtheshellandtube
Mineraldepositsinthewatercircuitreducetheheat
transferratebetweenthewaterandtherefrigerant
UNITSUMMARY2
Somecondenserscanbemechanicallycleaned
whileothersmustbecleanedchemically
Wastewatersystemsusewateronceandthenwaste
itdownthedrain
Wastewatersystemstypicallysupply75degree
watertothecondenserandrequire1.5gpm/ton
Recirculatingwatersystemstypicallysupply85
degreewaterandrequire3.0gpm/ton
UNITSUMMARY3
Wastewatersystemsutilizeawaterregulatingvalve
whilerecirculatedwatersystemsdonot
Evaporativecondensersuseacombinationofwater
andairtoachievethecondensingprocess
Highefficiencycondensersoperatewithlowerhead
pressuresthanstandardefficiencycondensers
Lowambientcontrolsallowsystemstooperate
properlywhentheambienttemperatureislow