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Topics: Introduction Types of Chillers Key Components of Mechanical Compression Chillers Safety Issues Best Practices for Efficient Operation Sample Operating Log for Chillers Best Practices for Maintenance Maintenance Schedule for Chillers References
Introduction
Chillers are a key component of air conditioning systems for large buildings. They produce cold water to remove heat from the air in the building. They also provide cooling for process loads such as file-server rooms and large medical imaging equipment. As with other types of air conditioning systems, most chillers extract heat from water by mechanically compressing a refrigerant. Chillers are complex machines that are expensive to purchase and operate. A preventive and predictive maintenance program is the best protection for this valuable asset. Learn more about establishing a Best Practice O&M Program. Chillers commonly use more energy than any other piece of equipment in large buildings. Maintaining them well and operating them smartly can yield significant energy savings.
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Types of Chillers
Mechanical Compression
During the compression cycle, the refrigerant passes through four major components within the chiller: the evaporator, the compressor, the condenser, and a flow-metering device such as an expansion valve. The evaporator is the low-temperature (cooling) side of the system and the condenser is the hightemperature (heat-rejection) side of the system.
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Reciprocating compressor Rotary Screw: The screw or helical compressor has two mating helically grooved rotors in a stationary housing. As the helical rotors rotate, the gas is compressed by direct volume reduction between the two rotors. Capacity is controlled by a sliding inlet valve or variable-speed drive (VSD) on the motor. Capacities range from 20 to 450 tons.
Screw compressor Centrifugal: The centrifugal compressor operates much like a centrifugal water pump, with an impeller compressing the refrigerant. Centrifugal chillers provide high cooling capacity with a compact design. They can be equipped with both inlet vanes and variable-speed drives to regulate control chilled water capacity control. Capacities are 150 tons and up.
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Centrifugal compressor Frictionless Centrifugal: This highly energy-efficient design employs magnetic bearing technology. The compressor requires no lubricant and has a variable-speed DC motor with direct-drive for the centrifugal compressor. Capacities range from 60 to 300 tons.
Absorption Chillers
Absorption chillers use a heat source such as natural gas or district steam to create a refrigeration cycle that does not use mechanical compression. Because there are few absorption machines in the Northwest U.S., this document covers only mechanical-compression chillers. You can learn more about absorption chillers at the Energy Solutions Center.
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Learn more about Operation and Maintenance of Air Distribution Systems. The chilled water passes through coils in the air-handler to remove heat from the air used to condition spaces throughout the building. The warm water (warmed by the heat transferred from the building ventilation air) returns to the evaporator and the cycle starts over.
Compressor
Vaporized refrigerant leaves the evaporator and travels to the compressor where it is mechanically compressed, and changed into a high-pressure, high-temperature vapor. Upon leaving the compressor, the refrigerant enters the condenser side of the chiller.
Condenser
Inside the water-cooled condenser, hot refrigerant flows around the tubes containing the condenser-loop water. The heat transfers to the water, causing the refrigerant to condense into liquid form. The condenser water is pumped from the condenser bundle to the cooling tower where heat is transferred from the water to the atmosphere. The liquid refrigerant then travels to the expansion valve. Learn more about Operation and Maintenance of Cooling Towers.
Expansion valve
The refrigerant flows into the evaporator through the expansion valve or metering device. This valve controls the rate of cooling. Once through the valve, the refrigerant expands to a lower pressure and a much lower temperature. It flows around the evaporator tubes, absorbing the heat of the chilled water thats been returned from the air handlers, completing the refrigeration cycle.
Controls
Newer chillers are controlled by sophisticated, on-board microprocessors. Chiller control systems include safety and operating controls. If the equipment malfunctions, the safety control shuts the chiller down to prevent serious damage to the machine. Operating controls allow adjustments to some chiller operating parameters. To better monitor chiller performance, the chiller control system should communicate with the facilitys direct digital control (DDC).
Safety Issues
Chillers are typically located in a mechanical equipment rooms. Each type of refrigerant used in a chiller compressor has specific safety requirements for leak detection and emergency ventilation. Consult your local mechanical code or the International Mechanical Code for details. The EPA has enacted regulations regarding the use and handling of refrigerants to comply with the Clean Air Act of 1990. All personnel working with refrigerants covered by this act must be appropriately licensed.
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setpoint for the water leaving the cooling tower should be as low as the chiller manufacturer will allow for water entering the condenser. The actual leaving tower water temperature may be limited by the ambient wet bulb temperature. Purge air from refrigerant: Air trapped in the refrigerant loop increases pressure at the compressor discharge. This increases the work required from the compressor. Newer chillers have automatic air purgers that have run-time meters. Daily or weekly tracking of run time will show if a leak has developed that permits air to enter the system. Optimize free cooling: If your system has a chiller bypass and heat exchanger, known as a water-side economizer, it should be used to serve process loads during the winter season. The water-side economizer produces chilled water without running the chiller. Condenser water circulates through the cooling tower to reject heat, and then goes to a heat exchanger (bypassing the chiller) where the water is cooled sufficiently to meet the cooling loads. Verify Performance of hot-gas bypass and unloader: These are most commonly found on reciprocating compressors to control capacity. Make sure they operate properly. Maintain refrigerant level: To maintain a chiller's efficiency, check the refrigerant sight-glass and the superheat and subcooling temperature readings, and compare them to the manufacturers requirements. Both low-level and high-level refrigerant conditions can be detected this way. Either condition reduces a chillers capacity and efficiency. Maintain a daily log: Chiller O&M best practices begin with maintaining a daily log of temperatures, fluid levels, pressures, flow rates, and motor amperage. Taken together, these readings serve as a valuable baseline reference for operating the system and troubleshooting problems. Many newer chillers automatically save logs of these measurements in their on-board control system, which may be able to communicate directly with the DDC system. Below is an example of a daily log that can be adapted for use with your chiller.
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Chiller use/sequencing Check chilled water reset settings and function Check chiller lockout setpoint Clean evaporator and condenser tubes
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Description Verify motor amperage load limit Compressor motor and assembly Compressor oil system
Comments Motor amperage should not exceed manufacturer's specification Conduct vibration analysis: Check all alignments to specifications. Check all seals. Lubricate where necessary. Perform analysis on oil and filter. Change if necessary. Check oil pump and seals Check oil heater and thermostat Check all strainers, valves, etc. Check all electrical connections and terminals for full contact and tightness Add refrigerant if low. Record amounts and address leakage problems. Indications include: poor water quality, excessive fouling, and age of chiller. Eddy current testing may be done to assess tube condition.
Annually
Electrical connections Check refrigerant condition Check for condenser and evaporator tube corrosion and clean as needed.
References
FEMP 2004. O&M Best Practices Guide 2.0. FEMP 2002. Continuous Commissioning Guidebook for Federal Energy Managers.
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