Ibrahim Fibres Limited (Polyester Plant)

Production Department
Utilities Process
Date: 21.12.2002
Chillers ( CVGF)
Two-stage, hermetic centrifugal liquid chillers, water cooled
!hiller is a de"ice #hich is used to cool li$uids at desired temperatures.
%#o&sta'e( hermetic centri)u'al li$uid chillers( #ater cooled installed in IFL has the
)ollo#in' characteristics.
*ptimi+ed )or the alternati"e re)ri'erant ,F! 1-.a.
!oolin' capacities )rom /-0 to .000 01.
,ermetic t#o&sta'e centri)u'al compressor #ith economi+er cycle.
2icroprocessor based control and protection system.
Description :
In !hiller re)ri'eration cycle is used to cool #ater.
It consist o) a shell and tube e"aporator desi'n #ith re)ri'erant e"aporatin' on
shell side and #ater )lo#in' inside tubes that ha"e enhanced heat trans)er sur)aces.
%he compressor is a t#o&sta'e centri)u'al compressor. %he motor is a li$uid
re)ri'erant cooled motor that operates at economi+er temperature under continuous
)ull and part load operatin' conditions. n oil mana'ement system pro"ides oil )ree
re)ri'erant to the shells to ma3imi+e heat trans)er per)ormance( #hile pro"idin'
lubrication to 'ears and bearin's. %he lubrication system ensures lon' compressor li)e
. !alibrated ori)ice de"ices maintain pressure di))erential( and meter re)ri'erant )lo#
)rom the condenser to the e"aporator.
unit mounted control panel on chiller pro"ides accurate chilled
#ater control as #ell as monitorin'( protection( and adapti"e limit )unctions.
Cycle Description :
%he re)ri'eration cycle o) the !45F chiller can be described usin' the
pressure enthalpy dia'ram sho#n belo#.
schematic o) the system( illustratin' re)ri'erant )lo#( is 'i"en in )i'ure.
Evaporator:
li$uid "apor re)ri'erant mi3tures enters the e"aporator at state point 1. Li$uid
re)ri'erant is "apori+ed to state point 2 as it absorbs heat )rom the system coolin'
load. %he "apori+e re)ri'erant )lo#s into the compressor )irst sta'e.
Compressor first stage:
6e)ri'erant "apor is dra#n )rom the e"aporator into the )irst sta'e compressor. %he
)irst sta'e impeller accelerates the "apor increasin' its temperature and pressure to
state point -.
Compressor second stage:
6e)ri'erant "apor lea"in' the )irst sta'e compressor is mi3ed #ith cooler re)ri'erant
"apor )rom the economi+er. %his mi3in' lo#ers the enthalpy o) the "apor enterin' the
second sta'e. %he second sta'e impeller accelerates the "apor( )urther increasin' its
temperature and pressure to state point ..
Condenser:
6e)ri'erant "apor enters the condenser #here the system coolin' load and heat o)
compression are re7ected to the condenser #ater circuit. %his heat re7ection cools and
condenses the re)ri'erant "apor to a li$uid at state point 8.
Economizer and refrigerant orifice system:
Li$uid re)ri'erant lea"in' the condenser at state point 8 )lo#s throu'h the )irst ori)ice
and enters the economi+er( )lashin' a small amount o) re)ri'erant at an intermediate
pressure labeled P1. Flashin' some li$uid re)ri'erant cools the remainin' li$uid to
state point 9.
nother bene)it o) )lashin' re)ri'erant is to increase the total e"aporator
re)ri'eration e))ect )rom 6:
;
to 6:. %he economi+er pro"ides around . < ener'y
sa"in's compared to chillers #ith no economi+er.
%o complete the operatin' cycle( li$uid re)ri'erant lea"in' the economi+er at
state point 9 )lo#s throu'h a second ori)ice. ,ere( re)ri'erant pressure and
temperature are reduced to e"aporator conditions at state point 1.
In desi'n )eature o) the !45F chiller is ma3imi+in' the e"aporator
heat trans)er per)ormance #hile minimi+in' re)ri'erant char'e re$uirements. %his is
accomplished by the %rane patented )allin' )ilm e"aporator desi'n. %he amount o)
re)ri'erant char'e re$uired in !45F is less than that in comparably si+ed chillers o)
)looded e"aporator desi'n.
Compressor Description:
%he !45F compressor consist o) three distinct sections: the t#o sta'e
centri)u'al compressor( the motor( and the 'ear bo3 #ith inte'ral oil sump.
Compressor:
%he centri)u'al compressor is t#o sta'e( #ith hi'h stren'th aluminum alloy )ully
shrouded impellers. %he impellers are tested at 28 < o"er desi'n operatin' speed. %he
rotatin' assembly is dynamically balanced )or "ibration o) less than 8.1 mm ; second
at nominal operatin' speeds. %he control system a))ords 100 = 20 percent capacity
modulation usin' electrically actuated 'uide "ane upstream o) each impeller.
Driven Train:
%he dri"e train consist o) helical bull and pinion 'ears. 5ear tooth sur)aces are case
hardened and precision 'round. %he one piece impeller sha)t is supported by
hydrodynamic thrust and radial bearin's.
Motor:
%he motor is hermetic( li$uid re)ri'erant cooled( t#o pole( lo# slip s$uirrel ca'e
induction motor. radial hydrodynamic bearin' and duple3 an'ular contact ball
bearin' support the rotor assembly. 1indin' embedded sensors pro"ide positi"e
thermal protection.
High Lift nloading Valve ( HLV ) :
hi'h li)t unloadin' "al"e is standard e$uipment on the .00 > 800 ton !45F units.
this is a solenoid "al"e located bet#een the condenser and the economi+er( #hich(
#hen ener'i+ed( allo#s re)ri'erant 'as to )lo# )rom the condenser to the economi+er.
%he "al"e is either open or closed #ith no modulation capability. %his "al"e allo#s
smooth operation #hile unloadin' do#n to a minimum load #ithout re$uirin'
condenser relie).