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Principles of
and medical imaging. These applications are
collectively referred to as the process, hence
the name Process Chiller.
Fluid Chillers Fluid chillers remove heat based on the
immutable principle that heat will move
Design Criteria for Reliable from a hotter source to a colder source
Operation from the process to a conditioned fluid. They
comprise two main parts called circuits a
refrigeration and a fluid circuit. The two
Designing a high reliability process chiller circuits work in concert to transfer heat
requires an in depth understanding of away from the process and maintain a
chiller system dynamics and associated reasonably constant process temperature.
components, their limitations in specific
There are several types of chillers they are
cooling applications, and how they affect
categorized based on the heat transfer
overall chiller performance. Described here
medium used (air, gas, fluid) and their use
is a tutorial of a single-stage recirculating
depends on the application. A fluid chiller,
fluid (or liquid) chiller with emphasis on the
the most common, is a closed-loop system
factors that determine reliable operation.
that recirculates its fluid.
Refer to Figure 1 below while reading about
chiller component types and functionality. A fluid chiller works by generating low
temperatures in a refrigeration circuit.
The basics: A process chiller removes heat
A heat transfer fluid flows between the
from a heat source where temperature must
refrigeration circuit and the process where
be maintained within a narrow region, on a
it carries heat away from the process. The
continuous basis. Examples of environ-
warmer fluid absorbed from the process is
ments that need continuous cooling include
pumped through a heat exchanger,
semiconductor fabrication, industrial
transferring heat back to the refrigeration
machinery, chemical processing,
circuit and, finally, expelled by a condenser:
Heat Exchanger (Evaporator): The Heat line. This counter-flow configuration ensures
Exchanger (also referred to as an maximum heat transfer from the fluid as it
Evaporator) moves heat away from the exits the Heat Exchanger.
process similar to the condenser. It absorbs
heat from the fluid circuit. The Thermal Fully brazed heat exchangers are the most
Expansion Valve on the inlet of the Heat reliable and efficient design; providing the
Exchanger creates a pressure drop for best heat transfer and leak proof protection.
expansion of the liquefied refrigerant as the
Thermal Expansion Valve: The Thermal
refrigerant enters the Heat Exchanger. This
Expansion Valve (TXV) acts as a metering
pressure drop forces the refrigerant to
device that regulates the amount of
evaporate (i.e. changes from liquid to a
refrigerant allowed into the Heat Exchanger
mixture of boiling liquid and gas).
(HTX). A bulb in the valve is filled with gas
that expands and contracts based on the
temperature it monitors at the outlet of the
HTX. This action opens and closes the TXV
as needed.
Fluid Circuit
Table 1. Common heat transfer fluids for various heat removal temperatures.
Pump: The pump is the heart of a fluid the Fluid Return port to begin the heat
circuit; it circulates fluid through the fluid extraction (cooling) process again.
lines. Pumping power must be sufficient to
create the desired flow at the outlet of the Flow Regulation Components: Filters and
heat exchanger. Positive Displacement Gear valves keep the fluid clean and control fluid
Pumps and Velocity Turbine pumps are flow. Filters are installed at the inlet and
typically the most reliable and best outlet of the pump to filter contaminates.
performing pumps. Choosing between Flow control valves, typically solenoid
them depends on the application. valves, control the flow of fluid through the
fluid circuit. They are directed by the logic in
Typically, Gear Pumps are used when fluids the controller to open and close as needed to
are extremely viscous and exhibit a high regulate fluid flow to the process and
level of lubricity. Gear Pumps need to be maintain the required temperature.
lubricated; they are capable of moving
viscous liquids at high pressure. Turbine Process Material: A liquid chiller
pumps are used when high flow rates or low accomplishes heat removal using a variety
noise levels are required. Turbine pumps of fluids and materials. However, their
have fewer moving mechanical parts than selection must be chemically compatible
gear pumps; they are quieter and require with the process material they will contact.
less lubrication. For example, copper lines passing through
the pump, heat exchanger and reservoir
Fluid Reservoir: The Fluid Reservoir holds
would be corrosive to cooling an aluminum-
fluid that is not circulating through the fluid
based process. Considerations for selection
circuit. The purpose of a reservoir is
of wetted materials used in components
threefold: 1) to fill the lines initially; 2) to
making up the fluid circuit:
ensure a flooded return line for the pump;
and 3) to serve as an expansion tank with
fluid expansion and contraction.
3. For stainless applications, steel welds range; e.g. fluid temperature or reservoir
and finishes require a passivation level too high, or fluid flow too low.
process to restore its chromium oxide
surface, preventing iron from leaching Providing diagnostic information is another
into the system. important function of a controller. With
moving parts under continuous operation
Control System compressors, pumps, and valves process
chiller components need to be monitored.
The controller is the traffic cop that directs Storing data on valve counts and component
chiller operations controlling temperature, run times, for example, provides records
monitoring sensors, and communicating necessary for maintaining chiller health.
data and events. Actual control is driven by
software algorithms, which use data from
sensors to maintain programmed set points.
For example, in the refrigeration circuit the
controller monitors temperature at various
inlet and outlet points of the compressor,
condenser and heat exchanger. The
processed data results in opening and
closing valves for appropriate durations.