Helical-Rotary Water Chillers

A Trane Air Conditioning Clinic

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Chilled
Water
System

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

absorption centrifugal

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

water-cooled

air-cooled

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Helical-Rotary Water Chillers
period one
Components

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

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

oil separator liquid/vapor

separator

condenser
control
panel

starter
evaporator

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

compressor...
Helical Rotors

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

compressor...
Helical Rotors
female rotor

male rotor

housing

slide valve
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
compressor...
Helical Rotors
intake
port

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

compressor...
Helical Rotors

intake
port
pocket of refrigerant vapor
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
compressor...
Helical Rotors
intake port

discharge port

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

compressor...
Helical Rotors

discharge port

© American Standard Inc. 1999

meshing point Air Conditioning Clinic TRG-TRC012-EN
compressor...
Helical Rotors

discharge port

© American Standard Inc. 1999

meshing point Air Conditioning Clinic TRG-TRC012-EN
compressor...
Helical Rotors

discharge port

meshing point
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
Oil Separator

refrigerant vapor
to condenser

refrigerant vapor
and oil mixture

oil return to sump

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
 Oil Supply System
oil rotor bearings
separator

refrigerant rotor
vapor to
condenser

oil tank compressor

sump master
solenoid 2 1
valve

© American Standard Inc. 1999

oil filter Air Conditioning Clinic TRG-TRC012-EN
 water-cooled
Condenser
refrigerant vapor
baffle

cooling
tower subcooler
water
liquid
refrigerant
tube bundle
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
air-cooled
Condenser

propeller fan
condenser
coil

outdoor air

subcooler
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
expansion device…
Electronic Expansion Valve

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

expansion device…
Orifice Plates

orifice plates to
evaporator

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Liquid/Vapor Separator
refrigerant vapor
to compressor

from liquid refrigerant

expansion to evaporator
© American Standard Inc. 1999
device Air Conditioning Clinic TRG-TRC012-EN
Flooded Evaporator
refrigerant vapor chilled
liquid water
refrigerant supply
tube bundle

chilled
water
return
liquid level
sensor
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
Direct Expansion Evaporator
chilled
water
supply chilled
baffles water
return

refrigerant
vapor
liquid
refrigerant
tube bundle
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
Controls and Starter

control
panel

starter

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Helical-Rotary Water Chillers
period two
Refrigeration Cycle

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

helical-rotary water chiller
Refrigeration Cycle
liquid/vapor
separator
compressor

expansion
device
evaporator

oil separator

condenser
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
Pressure–Enthalpy (p-h) Chart

subcooled
pressure

liquid
mixture of
liquid and
vapor
147.5 psia A B superheated
[1.02 MPa] vapor

46.4 Btu/lb 116.6 Btu/lb

[256.4 kJ/kg] [419.6 kJ/kg]
© American Standard Inc. 1999 enthalpy Air Conditioning Clinic TRG-TRC012-EN
helical-rotary water chiller
Refrigeration Cycle

5 condenser
2
4 3
pressure

expansion
liquid/vapor
device separator compressor
7
1
6 evaporator

© American Standard Inc. 1999

enthalpy Air Conditioning Clinic TRG-TRC012-EN
helical-rotary water chillers…
Refrigerants
 HCFC-22
 HFC-134a
 HFC-404a
 HFC-407c
 HFC-410a

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

 refrigerants…
Thermodynamic Characteristics
efficiency capacity pressure
160
140
120
100
percent

80
60
40
20
0
HCFC-22 HFC-134a HFC-404a HFC-407c HFC-410a
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
Helical-Rotary Water Chillers
period three
Compressor Capacity Control

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Slide Valve

axial
discharge
port
radial
discharge
port
slide valve
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
slide valve position...
Full Load

compressor
discharge
slide valve axial port
(closed)
radial port

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

slide valve position...
Part Load

compressor
discharge
slide valve
to suction axial port
open
radial port

valve
opening
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
compressor capacity control...
Unloading

compressor
discharge
slide valve
to suction
open
radial port

valve
opening
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
Slide Valve Operation
high-pressure
refrigerant vapor load unload
valve valve

to low-
pressure
compressor
slide valve housing
operator
shaft
spring piston cylinder
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
Helical-Rotary Water Chillers
period four
Maintenance Considerations

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

helical-rotary water chillers
Maintenance Considerations
 Operating log
 Mechanical
components
 Heat transfer
surfaces
 Fluid analysis

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

operating log
ASHRAE Guideline 3
 Chilled water inlet and outlet  Compressor refrigerant suction
temperatures and pressures and discharge temperatures
 Chilled water flow  Refrigerant level
 Evaporator refrigerant  Oil pressures, temperature, and
temperature and pressures
levels
 Evaporator approach
temperature
 Addition of refrigerant
 Condenser water inlet and  Addition of oil
outlet temperatures and
pressures
 Vibration levels
 Condenser water flow
 Condenser refrigerant
temperature and pressures
 Condenser approach
temperature
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
maintenance considerations
Mechanical Components
 Required maintenance
 Compressor and motor: no maintenance required
 Controls: no maintenance or calibration required
 Recommended maintenance
 Visually inspect overall unit
 Inspect safety controls and electrical components
 Tighten electrical connections
 Check for leaks
 Test vent piping

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

maintenance considerations
Mechanical Components
 Other design-specific requirements:
 Change oil when oil analysis dictates
 Replace oil filter periodically
 Replace filter drier periodically
 Clean oil strainers annually
 Check shaft alignment annually
 Check coupling annually
 Replace shaft seal every 2 to 4 years
 Compressor teardown inspection every 5 to 10 years

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

maintenance considerations
Heat Transfer Surfaces
 Recommended maintenance
 Use a qualified water treatment
specialist
 Clean condenser tubes as
needed (water-cooled)
 Clean water-side strainers
 Test tubes every 3 years
 Clean condenser coils as
needed (air-cooled)

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

maintenance considerations
Fluid Analysis
 Oil analysis
 Conduct annual analysis to verify
system integrity
 Measure oil pressure drop to
determine if filter needs changing
 Measure charge
 Refrigerant charge
 Measure charge and trim as
necessary
 Measure superheat and subcooling

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

maintenance considerations
Fluid Analysis
 Why perform regular oil analyses?
 Helps reduce maintenance costs
 Detects problems without
compressor disassembly
 Extends service life of oil charge
 Reduces environmental problems
related to oil disposal
 Helps maintain compressor
efficiency and reliability
 Helps lower refrigerant emissions

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Helical-Rotary Water Chillers
period five
Application Considerations

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

condenser types…
Air-Cooled or Water-Cooled

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-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-TRC012-EN
Condensing Temperature Control

cooling tower

condenser
water
pump
condenser

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

condensing temperature control
Cooling Tower Bypass

40°F
[4°C]
cooling tower
diverting
valve
bypass
65°F
55°F [18°C]
[13°C]
condenser

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

evaporator water flow…
Constant or Variable Flow

chilled
water
pump
evaporator

variable
speed
drive

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

variable evaporator water flow
Limitations
 Maintain minimum and maximum water flow
rates through the chiller evaporator
 Rate at which evaporator water flow changes
must be kept below the corresponding limit to:
 Maintain the chilled water set point control
 Keep the chiller on line
 Protect the chiller from damage

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Short Evaporator Water Loops

load

chilled
water
pump
evaporator

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Short Evaporator Water Loops

load

tank

chilled
water
pump
evaporator

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

equipment certification standards
ARI Standard 550/590
 Purpose
 Establish definitions and
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-TRC012-EN
equipment certification standards
ARI Standard 550/590
 Standard rating conditions
 Common system conditions for published ratings
 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-TRC012-EN

Helical-Rotary Water Chillers
period six
Review

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Review—Period 1
oil supply compressor motor
system

oil separator liquid/vapor

separator

condenser
control
panel

starter
evaporator

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Review—Period 2

5 condenser
2
4 3
pressure

expansion
liquid/vapor
device separator compressor
7
1
6 evaporator

© American Standard Inc. 1999

enthalpy Air Conditioning Clinic TRG-TRC012-EN
Review—Period 3

axial
discharge
port
radial
discharge
port
slide valve
© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN
Review—Period 4
 Maintenance considerations
 Operating log
 Mechanical components
 Heat transfer surfaces
 Fluid analysis

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN

Review—Period 5
 Application considerations
 Air-cooled or water-cooled
 Condensing temperature control
 Constant or variable evaporator water flow
 Short evaporator water loops
 Equipment certification standards

© American Standard Inc. 1999 Air Conditioning Clinic TRG-TRC012-EN