centrifugal water chillers - life cycle engineering · pdf filemaintenance considerations...
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Centrifugal Water ChillersScott MeyerkordTrane Account ManagerTrane Account Manager
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
ChilledWaterSystemy
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
absorption centrifugalabsorption g
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
helical-rotary
Centrifugal Water Chillers
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
Components
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
components of a
compressorcompressor
Centrifugal Water Chillermotormotor
condensercondenser
pp motormotor
controlcontrolpanelpanel
starterstarter
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999 6
panelpanel
evaporatorevaporator
Compressor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Impeller
bladesblades
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Multistage Compressor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Multistage Compressori lli llimpellers impellers
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
inlet vanes inlet vanes
Centrifugal Compressor
volutevolute
diffuserdiffuserpassagepassage
impeller impeller passagespassages
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
centrifugal compressorEnergy Conversion
refrigerant refrigerant ggenters enters diffuserdiffuser
ocity
ocity
velo
velo
f i t f i t
essu
rees
sure
refrigerantrefrigerantenters impellerenters impeller
refrigerant refrigerant enters voluteenters volute
static
pre
static
pre
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
path through compressorpath through compressor
ss
Condenserrefrigerant vaporrefrigerant vapor
bafflebaffle
refrigerant vaporrefrigerant vapor
cooling cooling tower tower tower tower waterwater
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
tubetubebundlebundle
liquid liquid refrigerantrefrigerant
expansion deviceOrifice Plates
totoorifice platesorifice plates totoevaporatorevaporator
HH11
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
expansion deviceOrifice Plates
totoorifice platesorifice plates totoevaporatorevaporator
HH22
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
2-stage chillerEconomizer
refrigerant vapor refrigerant vapor refrigerant vapor refrigerant vapor to second stageto second stageof compressionof compression
liquid refrigerant liquid refrigerant liquid refrigerant liquid refrigerant to evaporatorto evaporatororificeorifice
liquid refrigerant liquid refrigerant from condenserfrom condenser
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
from condenserfrom condenser
3-stage chillerEconomizer
refrigerant vapor refrigerant vapor refrigerant vapor refrigerant vapor refrigerant vapor refrigerant vapor to second stageto second stageof compressionof compression
refrigerant vapor refrigerant vapor to third stageto third stageof compressionof compression
liquid refrigerant liquid refrigerant q gq gto evaporatorto evaporatororificeorifice
liquid refrigerant liquid refrigerant from condenserfrom condenser
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
orificeorificefrom condenserfrom condenser
Evaporator
tube bundletube bundle
liquid liquid refrigerantrefrigerant
chilled chilled
liquidliquiddi t ib tdi t ib t
water water returnreturn
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
eliminatoreliminatordistributordistributor orifice systemorifice system
Motor
motormotorgear-drive
impellerimpellermotormotor
impellersimpellersimpellersimpellers
direct-drive
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
gearsgears
Hermetic Motor Coolingt tt tstatorstator
rotorrotorrotorrotor
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
draindrainliquidliquidrefrigerantrefrigerant
Controls and Starter
controlcontrolpanelpanel
starterstarter
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
panelpanel
Centrifugal Water Chillers
Refrigeration Cycle
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
2-stage centrifugal chillerRefrigeration Cycle
22 stagestage22--stagestagecompressorcompressor
economizereconomizer
condensercondenserevaporatorevaporator
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
expansion devicesexpansion devices
Refrigerant Operating Pressures
HCFCHCFC--2222
ssur
ess
ure
HFCHFC--134a134a
pres
pres
HCFCHCFC 123123HCFCHCFC--123123
atmosphericatmosphericpressurepressure
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999temperaturetemperature
pressurepressure
Low-Pressure Chillers
compressorcompressorsuction elbowsuction elbow
evaporatorevaporator
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Purge System
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Centrifugal Water Chillers
Maintenance Considerations
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Maintenance Considerations
Operating logMechanical componentsHeat-transfer surfaces Fluid analysis
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
operating logASHRAE Guideline 3
Chilled water inlet and outlet Oil pressures temperatureChilled water inlet and outlet temperatures and pressuresChilled water flowEvaporator refrigerant
Oil pressures, temperature, and levels
Record refrigerant activity,p g
temperature and pressuresEvaporator approach temperatureC d t i l t d
Motor voltage and amperage
Purge activity
Condenser water inlet and outlet temperatures and pressuresCondenser water flowCondenser refrigerant temperature and pressuresCondenser approach t t
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
temperature
maintenance considerationsMechanical Components
R d d M i tRecommended MaintenanceHermetic Compressor and motor: no routine maintenance required. Compressor teardown / overhaul inspection every 8 to 10 years or 25 000 tooverhaul inspection every 8 to 10 years or 25,000 to 30,000 operating hoursTemperature Controls: no routine maintenance calibration requiredcalibration required Visually inspect overall unit Inspect safety controls and electrical componentsS i t t t Ti ht l t i l tiService motor starters: Tighten electrical connections, service contractors, megger test motor, visual inspection of transition resistors.Pressurize and leak test annually or as indicated by the
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Pressurize and leak test annually or as indicated by the purge rate
maintenance considerationsMechanical Components
Other design-specific requirementsRemove oil sample for Lab Analysis: Change oil when oil analysis dictateswhen oil analysis dictatesReplace oil filter annually or as requiredReplace purge filter drier annuallyep ace pu ge te d e a ua yVisual Inspection of Condenser Tubes AnnuallyCheck operation of oil sump heater
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
maintenance considerationsHeat Transfer Surfaces
Recommended maintenanceUse a qualified water treatment specialistspecialistClean condenser tubes as needed, mechanical brush l i llcleaning annually
Clean water-side pump strainersTest tubes every 3 years
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
maintenance considerationsTube Analysis
Eddy Current TestingTest evaporator tubes every 4-5 yearsevery 4-5 yearsTest condenser tubes every 2-3 years
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Fluid Analysis
Oil analysisConduct annual analysis to verify system integritysystem integrity
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Oil Analysis
Why perform regular oil analysis?Helps reduce maintenance costsD bl i hDetects problems without
compressor disassemblyExtends service life of oil chargete ds se ce e o o c a geReduces environmental problems related to oil disposalHelps maintain compressorefficiency and reliability
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Oil AnalysisA l ti l D tAnalytical Data
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Oil Analysis
Written Recommendations
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Oil Analysis
Graphical Representation of Data
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
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