Chiller Types & Applications

A Trane Air Conditioning Clinic

ACES Training
K Y Yow
23 Jan 2015

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Chiller Types
By Compressor Type & Heat Rejection Mode

W/C Centrifugal A/C Centrifugal

Centrifugal
150-4000rt
Compressor Type

W/C Screw A/C Screw

Screw
50-500rt 50-400rt

W/C Scroll A/C Scroll

Scroll
15-70rt 5-200rt

Reciprocating
Heat Rejection

Water-Cooled Air- Cooled

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Vapour Compression NON-Vapour Compression

W/C Centrifugal

absorption
W/C Screw

A/C Screw & Scroll

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Centrifugal Water Chillers

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

components of a
Centrifugal Water Chiller
compressor
motor

condenser

starter
control
panel
evaporator
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Impeller

blades

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

centrifugal compressor
Energy Conversion
refrigerant
enters
diffuser
velocity

refrigerant
refrigerant enters volute
static pressure

enters impeller

path through compressor

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Multistage Compressor

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Condenser
refrigerant vapor

baffle

cooling
tower
water

tube liquid
© American Standard Inc. 1999 bundle refrigerant Air Conditioning Clinic TRG-TRC010-EN
expansion device
Orifice Plates

orifice plates
to
evaporator
H1

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Evaporator
tube bundle

liquid
refrigerant

chilled
water
return
liquid
distributor eliminator orifice system
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Motor

motor
gear-drive
impeller
motor

impellers

direct-drive
gears
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Hermetic Motor Cooling
stator

rotor

liquid drain
© American Standard Inc. 1999
refrigerant Air Conditioning Clinic TRG-TRC010-EN
Controls and Starter

starter
control
panel

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Starters
line power line power control power
wiring

starter

unit-mounted
control power
wiring

remote-mounted
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Comparison of LV Starters

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 2-stage centrifugal chiller
Refrigeration Cycle
2-stage
compressor

economizer

evaporator condenser

expansion devices
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
2-stage centrifugal chiller
Refrigeration Cycle

6 condenser
Pc 4
expansion 5
pressure

economizer
devices
8 2-stage
P1
7 3 2
compressor
10
Pe 1
9 evaporator

C B enthalpy A
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
 Refrigerant Operating Pressures

HCFC-22

HFC-134a ( High Pressure 40/140 psig)

pressure

HCFC-123
atmospheric ( Low Pressure vac/8 psig

pressure

© American Standard Inc. 1999

temperature Air Conditioning Clinic TRG-TRC010-EN
Centrifugal Water Chillers

Compressor Capacity Control

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Inlet Vanes

inlet vanes
impeller

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Multistage Compressor
impellers

inlet vanes
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Impeller Dynamics
Vr  refrigerant flow rate
Vr
R Vt  rotational speed × diameter
Vt
diameter
refrigerant
rotational flow rate
speed

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

Compressor Unloading

Vr
R Vr
R
Vt Vt

full load part load

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Surge
Vr
R
Vr < static pressure
Vt

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

Compressor Map

90
pressure difference

75

51 63

36
10 14 25 vane position
(degrees)

© American Standard Inc. 1999 refrigerant flow rate Air Conditioning Clinic TRG-TRC010-EN
compressor map for a
2-Stage Compressor

A
90
pressure difference

C B 75

51 63
36
10 14 25

unloading line

© American Standard Inc. 1999 refrigerant flow rate Air Conditioning Clinic TRG-TRC010-EN
Centrifugal Water Chillers
period five
Application Considerations

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Adjustable-Frequency Drives

3-4% Losses

inlet vanes only

Kw/rt

AFD + inlet vanes

AHRI Temp Relief

load
AFD Centrifugal Chiller Requires LIFT Reduction to Save Energy
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
guidance
VSD or High Efficiency?
Guidance Factors
 High efficiency  VSD
 Significant demand  Many hours at low
charges condenser water
 Humid climates temperature—and low load

 Multiple chillers in the plant  Perhaps only on one chiller

 Economizer(airside or free  Factor in replacement of

cooling) that reduces low VSD when performing life
load/low lift operating cycle assessment
hours

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 FL vs PL efficiency
VSD Chiller or Hi-E Chiller ( Fixed Drive)

SAME Price Option Full Load IPLV

(700 RT Chiller) (kW/ton) (kW/ton)

a) VSD 0.572 0.357

b) High Efficiency (Fixed

0.501 0.430
Drive)

VSD Option typically cost around 30% more.

Alternatively, this same investment $ can be used to
Upgrade efficiency with larger heat exchangers

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 VSD Application on Chillers

Understand its Applications… Benefits vs Cost

 LIFT Reduction (Min for Tropics) for VSD Centrifugal chiller

 Capacity Reduction for VSD Screw
 ROI - Efficiency gain vs Higher $Investment &
potential higher service cost

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

equipment certification standards
ARI Standard 550/590
 Standard rating conditions
 Common system conditions for published ratings
 Fouling factor
 Integrated Part Load Value (IPLV)
 Part-load efficiency rating
 Based on an “average” single-chiller installation
 Standard operating conditions

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 ASHRAE STD 90.1 ( 2013)
Current 2013 version
(first published 1975)

Most Building Codes,

Guides & STDs
Draw Reference
to ASHRAE 90.1 STD

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Mandatory: Chiller Efficiency as of
2015 (Centrifugal chillers)
Chiller Path A Path B • Table is for
type/size
standard rating
WC centrif. < 0.610 kW/ton & 0.550 0.695 kW/ton & 0.440
150 tons IPLV IPLV temperatures
WC centrif. 150
< 300 tons
0.610 kW/ton & 0.550 0.635 kW/ton & 0.400
IPLV IPLV
• Non-standard
temperatures
WC centrif. 300 0.560 kW/ton & 0.520 0.595 kW/ton & 0.390 and flows use
< 400 tons IPLV IPLV
equation to
WC centrif. >= 0.560 kW/ton & 0.500 0.585 kW/ton & 0.380 modify the
400 tons IPLV IPLV
requirements
© American Standard Inc. 1999 * Likely to be adopted by SS530 Air Conditioning Clinic TRG-TRC010-EN
 Chiller Performance Improvements
Centrifugals & Screws: 62%
Smaller scrolls & recips: 41% ( 7.3 COP)
8.0
centrifugal
6.2 COP >600 tons
screw
6.0
150-300 tons
chiller efficiency, COP

scroll
<75 tons
4.0
reciprocating
<125 tons

2.0
Go for the Best
0.0
ASHRAE Standard 90 “best”
90-75 90-75 90.1-89 90.1-99 90.1-2010 available
(1977) (1980)

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Efficiency Comparison:
MORE
Index Rating INFO

AHRI Definition of Integrated Part Load Value (IPLV/NPLV)

1 A = kW/Ton @ 85°F(30°C) @ 100% Load

IPLV = 1% +
42% + 45% +
12% B = kW/Ton @ 75°F(24°C) @ 75% Load
A B C D C = kW/Ton @ 65°F(18°C) @ 50% Load
D = kW/Ton @ 65°F(18°C) @ 25% Load
Temperatures: Expected Entering Tower Water
AHRI Conditions: Chilled Water: 54°/44°F (12°/7°C)
Condenser Water: 3 GPM/Ton (0.054 L/S/kW)

1% 85°F (30°C)

57% 42%
75° (24°C)
65° (18°C)

IPLV does NOT represent Real Efficiency

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
 Use of IPLV or NPLV
(AHRI 550/590 Appendix D, D2.1 Scope)

 This appendix is for equipment covered by this standard.

The IPLV equations and procedure are intended to provide a
consistent method for calculating a single number part load
performance number for water chilling products. The equation
was derived to provide a representation of the average part load
efficiency for a single chiller only. However, it is best to use a
comprehensive analysis that reflects the actual weather data,
building load characteristics, operational hours, economizer
capabilities and energy drawn by auxiliaries such as pumps
and cooling towers, when calculating the chiller and system
efficiency. This becomes increasingly important with multiple
chiller systems because individual chillers operating within
multiple chiller systems are more heavily loaded than single
chillers within single chiller systems.
Superior IPLV does not represent Superior Energy Savings
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
equipment certification standards
AHRI Standard 550/590

 Purpose
 Establish definitions, testing,
and rating requirements
 Scope
 Factory designed and
prefabricated water chillers
 Vapor-compression
refrigeration
 Air-cooled and water-cooled
condensing

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Selection Printout

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Factory Test to AHRI 550/590

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

Helical-Rotary Water Chillers
A Trane Air Conditioning
Clinic

© American
American Standard
StandardInc.
Inc.1999
1999 Air Conditioning Clinic TRG-TRC012-EN
TRG-TRC010-EN
Helical-Rotary Water Chillers

water-cooled

air-cooled

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

components of a
Helical-Rotary Water Chiller
oil supply compressor motor
system

oil separator liquid/vapor

separator

condense
r
control
panel

starter
evaporator

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

compressor...
Helical Rotors

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compressor...
Helical Rotors
female rotor

male rotor

housing

slide valve
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Oil Separator

refrigerant vapor
to condenser

refrigerant vapor
and oil mixture

oil return to sump

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
 water-cooled
Condenser
refrigerant vapor
baffle

cooling
tower subcooler
water
liquid
refrigerant
tube bundle
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
air-cooled
Condenser

propeller fan
condenser
coil

outdoor air

subcooler
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
expansion device… ( Air-cooled )
Electronic Expansion Valve

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

expansion device… ( Water-Cooled )
Orifice Plates

orifice plates to
evaporator

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Flooded Evaporator ( Water-cooled )
refrigerant chilled
vapor water
liquid
refrigerant supply
tube bundle

chilled
water
return
liquid level
sensor
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Direct Expansion Evaporator (air-
cooled)
chilled
water
supply chilled
baffles water
return

refrigerant
vapor
liquid
refrigerant
tube bundle
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
Controls and Starter

control
panel

starter

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

helical-rotary water chiller
Refrigeration Cycle

5 condenser
2
4 3
pressure

expansion liquid/vapor
device compressor
separator
7
1
6 evaporator

© American Standard Inc. 1999

enthalpy Air Conditioning Clinic TRG-TRC010-EN
 helical-rotary water chillers…
Refrigerants

 HFC-134a ( Currently most commonly applied)

 HF0 – XXX ( Next generation )… Low GWP

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

Helical-Rotary Water Chillers
period five
Application Considerations

© American
American Standard
StandardInc.
Inc.1999
1999 Air Conditioning Clinic TRG-TRC012-EN
TRG-TRC010-EN
RTHD AFD Water cooled Screw Chiller
with Adaptive Frequency™ Driver

CONFIDENTIAL AND PROPRIETARY INFORMATION OF TRANE

Application for Variable Speed Screw Chiller
Efficiency Improvement : 5-10% Investment $ : +30-40%

Constant Condenser Temperature 30C

200
180
Illustration Only
160
140
120
100 STD

80
60 AFD Type

40
20
0
20 30 40 50 60 70 80 90 100

AFD Type typically improves overall

efficiency by 5-10% vs STD.
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN
 VSD Application on Screw Chillers

Understand its Applications… Benefits vs Cost

 LIFT Reduction (Min for Tropics) for VSD Centrifugal chiller

 Capacity Reduction for VSD Screw
 ROI - Efficiency gain vs Higher $Investment &
potential higher service cost

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

condenser types…
Air-Cooled or Water-Cooled

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

air-cooled or water-cooled
Comparison

air-cooled
 Lower maintenance
 Packaged system
 Better low ambient
operation
© American Standard Inc. 1999
water-cooled
 Greater energy efficiency
 Longer equipment life
Air Conditioning Clinic TRG-TRC010-EN
 ASHRAE STD 90.1 ( 2013)
Current 2013 version
(first published 1975)

Most Building Codes,

Guides & STDs
Draw Reference
to ASHRAE 90.1 STD

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Addendum CH
Mandatory: Chiller Efficiency as of
2015 (SCREW Chiller)
Chiller type/size Path A Path B
Air cooled < 150 tons 10.1 EER and 13.7 IPLV 9.7 EER and 15.9 IPLV

Air cooled >= 150 tons 10.1 EER and 14.0 IPLV 9.7 EER and 16.1 IPLV

WC pos. disp. < 75 tons 0.750 kW/ton & 0.600 IPLV 0.780 kW/ton & 0.500 IPLV

WC pos. disp. 75 < 150 tons 0.720 kW/ton & 0.560 IPLV 0.750 kW/ton & 0.490 IPLV

WC pos. disp. 150 < 300 tons 0.660 kW/ton & 0.540 IPLV 0.680 kW/ton & 0.440 IPLV

WC pos. disp. 300 < 600 tons 0.610 kW/ton & 0.520 IPLV 0.625 kW/ton & 0.410 IPLV

WC pos. disp. >= 600 tons 0.560 kW/ton & 0.500 IPLV 0.585 kW/ton & 0.380 IPLV

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

equipment certification standards
AHRI Standard 550/590

 Purpose
 Establish definitions, testing,
and rating requirements
 Scope
 Factory designed and
prefabricated water chillers
 Vapor-compression
refrigeration
 Air-cooled and water-cooled
condensing

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Summary

 Types of chillers – Overview

 Centrifugal chiller - components, controls and applications
 Screw chiller – Components, controls and applications
 VSD application considerations & Benefits vs cost
 ASHRAE 90.1 Min EFF Standard
 AHRI 550 Rating Standard for chillers

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN

 Q&A

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC010-EN