Familiarization and Basic Operation of CVHF Chiller

Date

TOPICS

Overview Typical View Major Components of CVHF Chiller Refrigeration System Operating Principle L brication & Motor Cooling S Lubrication System stem Purge System Chiller Control System M i t Maintenance Questions

2 Insert Footer

Overview
CVHF Feature > Single compressor, CENTRIFUGAL type water cooled liquid chillers > Uses R-123 as refrigerant and Trane Oil 0022 Model Number Coding System CVH F 049 D A 2 P 0 L C N 2 7 1 8 W B E 8 R B C00 12 3 4 567 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Digits 1,2 3 4 5,6.7 8 CV H F 049 D A 2P 0 L Unit type Centravac Hermetic Drive Type, Direct Driv Design Sequence, Sequence fifth Nominal Tonnage,770Ton Design tons 751.75 Voltage, 460/60/3 Unit type, Cooling Condenser Design Sequence Hotgas bypass, without Purge Purifier 14 C Control Interface, UCP3 15 N Comp KW, CPKW 16 17 18 271 16,17,18 Comp Impeller Cutback 1st 2nd 27.6 27.6 19 20 8 Evap Shell Size, 080 long shel W Evap tube bundle size,800 Nom

9
10,11 12 13

3 Insert Footer

Typical View of a CVHF Chiller

4 Insert Footer

Major Components of the Chiller

Compressor

It is the heart of the vapor compression system. It provides the pressure increase necessary to facilitate the transfer of heat. It receives superheated refrigerant from the compressor and removes the superheat and liquefy the refrigerant (sub cooling). It reduce the pressure of the refrigerant and regulate the flow of refrigerant to the evaporator. It transfer heat from a substance being cooled to a boiling refrigerant. g

Condenser Metering Device Evaporator

Economizer Purge

It is a devices intended to reduce energy consumption, or to perform another useful function like p p preheating g a fluid. The purgeis designed to remove non-condensable gases and water from the refrigeration system.

5 Insert Footer

Refrigeration g System y
It provides cooling to equipment equipment, processes processes, and
personnel spaces. The systems do this with refrigerants that remove heat from the heat source and discharge it to a heat sink.

6 Insert Footer

Basic Refrigeration Cycle

Cooling Tower Sub-cooled liquid Superheated vapor

3
HP Liquid line

CONDENSER

Metering Device
LP Vapor line

COMPRESSOR

4
Mixture

EVAPORATOR

1
Saturated vapor

AHU HEAT COOL

7 Insert Footer

OPERATING PRINCIPLES

Evaporator Components
tube bundle

liquid refrigerant

chilled water return liquid distributor

8 Insert Footer

eliminator

orifice system 8

CENTRIFUGAL COMPRESSOR COMPONENTS

Inlet Guide Vanes

Impellers

Pre-spins Refrigerant Vapor

9 Insert Footer

Inlet Guide Vanes

10 Insert Footer

1 0

Condenser

Condenser Water Out

95

85
Condenser Water In

De De-superheats superheats and Condenses Refrigerant

Vapor
11 Insert Footer

1 1

Metering Orifice

The Metering Orifice Meters

Refrigerant Flow

12 Insert Footer

CVHF Refrigeration Cycle with Economizer

2-Stage Refrigerant Flow

13 Insert Footer

ECONOMIZER

T 2 To ndS t ta g e

Eli mi na to r To Ev a po ra Fro m Co nd en ser Orifice

14 Insert Footer

CVHF Refrigeration Cycle

2-Stage P-H Diagram

Efficiency
15 Insert Footer

General Assembly Oil/Refrigeration System Schematic

16 Insert Footer

Purge System

17 Insert Footer

Refrigerant Report Purge Operating Modes

(Stop, On, Auto, Adaptive) p The p purge g condensing g unit will not 1. Stop
run. The purge condensing unit runs continuously regardless of the chiller operational status.

2. On -

3. Auto - the purge condensing unit runs when

the chillers main compressor is in operation

4. Adaptive The purge condensing unit

operation is totally dependent on past purge activity. Purge monitors its 1.) daily pumpout time with the chiller ON or OFF, over the last 24 hours and 2.) average daily pumpout time with the chiller ON or OFF, over the last 7days.

18 Insert Footer

Advantages of Adaptive Mode

Objectives of operating the unit in the Adaptive mode are:
Operating the purge refrigeration circuit to effectively accumulate non-condensables with or without the chiller hill running. i Provide information to the operator as to whether leakage is on the high-pressure or low-pressure side of the chiller chiller. Decrease energy usage by running the purge refrigeration circuit only when needed to remove noncondensables rather than running continuously. condensables, continuously

19 Insert Footer

Purge System R-404a Condensing Unit

20 Insert Footer

System Contamination

Results From:
Equipment Leaks Poor Evacuation Introducing Contaminated Refrigerant

21 Insert Footer

Earthwise Purge System

Condensing Unit

Condenser C Compressor
Carbon Tank Temp Sensor

Pressure Relief Device

Expansion Device
Restrictor

Exhaust Solenoid Valve

To Chiller Vent Line

Pumpout Solenoid Valve

Compressor p Suction Temp Sensor Pump-out Compressor Purge Tank Vapor V Pick-up Line Filter/Drier

To Chiller Evaporator

Regeneration Solenoid Valve

Isolation V l Valve

Float Switch Liquid Drain Line

Heater Finned Heater Well

Carbon Tank

Chiller Condenser

Isolation Valves

22 Insert Footer

Purge Condenser RR-404a Circuit

150F Vapor

CO CONDENSER S

R-404a EVAP COMPRESSOR 85 F LIQUID

TEMP SENSOR > 60 F Vapor R-123 R 123 INLET

-16 F LIQUID

AEV R-123 OUTLET 75 F LIQUID

23 Insert Footer

No Air in purge tank

R-404a R 404a Liquid/Vapor Mixture from EXV (-16 o F)

Purge coil area available for superheating

R404a Gas to condensing unit Compressor suction (90 F) 24 Insert Footer

Chiller refrigerant vapor (100 F)

Air of Purge Tank

R404a Liquid/Vapor Mixture from EXV (-16F)

Purge coil area available for superheating

Air

Chiller refrigerant vapor (100F)

R404a Gas to Condensing Unit compressor Suction (70F) 25 Insert Footer

Air fills Purge Tank

R404a Liquid/Vapor Mixture from EXV (-16F)

No coil area available for superheating

Air R404a Gas to condensing unit compressor Suction (-16F)

26 Insert Footer

N -Condensable NonNon C d bl Removal R l

When sufficient non-condensable have accumulated in the purge tank to decrease the compressor suction temperature below the pump out initiate set point a pump out cycle has begun. The cycle will be terminated when the compressor suction temperature sensor increases above the pump out terminate set-point.

27 Insert Footer

Control System

28 Insert Footer

Maintenance

29 Insert Footer

Maintenance

Change Oil and Oil Analysis

After the first 6 months or 1000 hours operation, whichever comes first, it is recommended to change the oil and filter. After this oil change, recommendations are to subscribe to an annual oil analysis program rather than automatically change the oil as part of scheduled maintenance.

Proper Water Treatment

The use of untreated or improperly treated water in a CenTraVac may result in scaling, erosion, corrosion, algae or slime. It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment, if any, is required. Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

30 Insert Footer

Basic Maintenance Items

Daily Monitoring g of Chiller Required q Parameters Oil Level visual check (using sight glass) Quarterly Cleaning of water strainers (Piping) Semi-Annually Lubrication of Vane Control System (bearings, ball joints,...) Annually Calibration C lib ti of f Controls C t l (relays, ( l sensors, ) ) Measure Compressor Motor Winding resistance Oil Change and Oil Analysis Replacement of Oil Filter Other Maintenance Requirements Inspect and clean condenser tubes if necessary Evaporator Tubes cleaning interval shall be 3-years 3 years
31 Insert Footer

Compressor Motor Problem Voltage And Current Unbalance

100 X the Sum of the Deviation of the Voltages, (Currents), Di id d by Divided b 2 X the th Average A The Unbalance Should Not Exceed 2% Voltage or 10 % Current

Example:
Measured Voltages : 480 Volts 470 Volts 460 Volts Average: = 470 Volts Sum of the Deviation: 480 - 470 = 10 470 - 470 = 0 2 000 : 2 X 470 = 2 2,000 2.13 13 % 470 - 460 = 10 20 X 100 = 2,000

32 Insert Footer

Other Important Items CAUSES OF SURGE

Too high g condensing g temperature p Too much incondensable in a low pressure unit : don't operate unit at full load if purge unit is not stabilized ( pay attention to leaks of refrigerant through purge unit ) Cooling tower temperature too high : too much refrigerant dirty tubes too low water flow rate Lack of refrigerant too long part load operation unit it might i ht surge d during i al long ti time at t part tl load d ( 15 t to 20% ) ), it i is th then recommended to reduce condenser inlet water temperature of 1F per 10% load reduction

33 Insert Footer

Other Important Items

CAUSES OF SURGE
Liquid refrigerant carry over
too much refrigerant too high evaporator water temperature Oil carry y over noisy compressor amperage fluctuations

SURGE CONSEQUENCES Q

Loss of performance Pressure instability Amperage peaks Vibrations and noise Bearing wears

34 Insert Footer

Normal Parameters
Normal Operating Conditions Description Condition E Evaporator t Pressure P 15 t to 20 H Hg (V (Vacuum) ) Condenser Pressure 0 to 10 psig Oil Sump Temperature Unit U t Not ot Running u g 140 0 to 145F 5 Unit Running 62 to 162F Differential Oil Pressure 18 to 22 psid Discharge Oil Pressure 7 to 15 psig Oil Tank Pressure 12 to 18Hg Condenser Approach Temp = Sat Cond Temp - Lvg Cond Water Temp Evaporator Approach Temp = Lvg CHW Temp - Sat Evap Temp Notes: 1. ARI Conditions are: cond water - 85F & 3 gp gpm/xxx tons Evaporator Water: 54 to 44F 2. Condenser pressure is dependent on condenser water temp and should equal the saturation pressure of HCFC-123 at a temp above that of leaving condenser water at full load load. 3. Std. Cond App Temp: 0 to 5F ; Std Evap App Temp: 0 to 4F
35 Insert Footer

Questions

36 Insert Footer

Th k you !!! Thank

37 Insert Footer