Agenda
Chiller Components
Chiller Refrigerant Cycle
lowers pressure in the
1. Compressor
evaporator, allowing refrigerant to
boil and absorb heat from water.
Chiller Refrigerant Cycle
2.
Compressor
raises pressure
of refrigerant gas
and discharges
into condenser
lowers pressure in the
1. Compressor
evaporator, allowing refrigerant to
boil and absorb heat from water.
Chiller Refrigerant Cycle
3.
2.
Cooling water in condenser removes heat from
refrigerant gas allowing it to condense back into liquid.
Compressor
raises pressure
of refrigerant gas
and discharges
into condenser
lowers pressure in the
1. Compressor
evaporator, allowing refrigerant to
boil and absorb heat from water.
Chiller Refrigerant Cycle
3.
Cooling water in condenser removes heat from
refrigerant gas allowing it to condense back into liquid.
device
4. Metering
maintains seal
2.
between condenser
and evaporator.
Compressor
raises pressure
of refrigerant gas
and discharges
into condenser
lowers pressure in the
1. Compressor
evaporator, allowing refrigerant to
boil and absorb heat from water.
Chiller Efficiency
" !
" " What Influences
Chiller Efficiency ?
Importance of
Maintaining Chiller Efficiency
""
"
Cost of
Inefficiency
Condenser Problems
Evaporator Problems
Reality of
Chiller Plant Operation
• • Typical Chiller
Maintenance Program
Log Readings Alone
Are Not Efficient
Log Readings Alone
Are Not Efficient
Chiller Logging
Chiller Instrumentation
Orange Research
Fair
Weiss Instruments
Better
For R-11 & R-123
Low Pressure Refrigerant Chillers
Condenser Liquid
Refrigerant Temperature
Take temperature at liquid line
leaving condenser. Recommend
Raytek Model ST 60 or better.
Condenser Saturated
Refrigerant Temperature
On a Low-Pressure
Refrigerant Chiller
R-11 & R-123
Non-Condensables
Non-Condensables
Sat Temp
Sat Pres
91
5.3
92
5.6
93
6.0
94
6.4
95
6.8
96
7.2
97
7.6
98
8.0
99
8.4
Non-Condensables
Non-Condensables
Condenser Approach
!"
Pressure
Temperature
Condenser
Pressure
Condenser Water Out
Pressure
Temperature
Condenser Water In
Liquid
Refrigerant
Temperature
Causes of
High Condenser Approach
Condenser Approach:
Clean Versus Dirty
Condenser Tubes
When Tubes Are Clean
High Condenser Approach:
When Condenser Tubes Get Dirty...
Tube Fouling:
When Condenser Tubes Get Dirty
High Condenser Approach
High Condenser Approach
High Condenser Approach
Water Flow Problems
Pressure
Temperature
Condenser
Pressure
Pressure Drop = P in – P out
Pressure
Temperature
Liquid Refrigerant
Temperature
Low Condenser Water Flow
!$
!$
$
Calculate Flow
Actual Versus Design
$,
,-
,$"""!#"
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High Inlet Condenser
Water Temperature
! ! $! Evaporator Instrumentation
Pressure
Temperature
Evaporator
Pressure
Evaporator Water Out
Pressure
Temperature
Evaporator Water In
Liquid
Refrigerant
Temperature
Evaporator Approach Problems
Pressure
Temperature
Evaporator
Pressure
Evaporator Water Out
Pressure
Temperature
Evaporator Water In
Liquid
Refrigerant
Temperature
High Evaporator Approach
Can be Caused by:
Low Evaporator Set Point
!$
Compressor
Instrumentation
This log sheet was taken at a chiller plant with over 40,000 tons of chiller
capacity. During your site survey you obtain the following log sheet.
Chiller Capacity - 1,500 tons
ChillerMax:
The High-Tech Solution
Easy and
effective.
Operator visits all operating chillers
and collects data on a daily basis
Operator hot syncs with the website for chiller report
or using Autolog, log data can be entered directly
from a BAS system
Problems are identified and quantified by source
Corrective actions are given and scheduled
Efficiency is restored or maintained
ChillerMax Identifies Problems
Using the
ChillerMax
Website
Logon to ChillerMax Website using
Username and Password Provided
Using the ChillerMax Website
Chiller Dashboard
Solutions
Logsheet View
Readings in
yellow indicate a
run time error
View Charts
Chart Trends
Logging Chillers
Using ChillerMax
Add Log Record
Enter Required Data
Digital Control Panels
Condenser and Evaporator Readings
Water
temperatures
Water pressure
drops
Refrigerant
pressures
Condenser refrigerant
temperature
For R-11 & R-123
Low Pressure Refrigerant Chillers
Compressor and Electrical Readings
Oil pressure
Oil level &
temperature
Amps & volts
Using ChillerMax to
Track Maintenance Tasks
Condition Based Maintenance
Example: Emory University
#%
!$" #%" $
"
#
Internally Enhanced Tubes
Dirty Tube
Two-Direction Versus Single-Direction Tube Brushing
Two-Direction Brushing
Single-Direction Brushing
Single Direction
ChillerMax Identifies Problems
Single Direction
ChillerMax Restores Efficiency
Lessons Learned with Internally Enhanced Tubes
Use a brush designed
for internally enhanced tubes
Brush with a cleaning machine
using dual rotation action
Change brushes as required, use a bore scope to inspect tubes
Use Borescope to Inspect Tubes
Questions
& Answers
For additional information contact:
Don Tomovich
302-753-7940
[email protected]