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http://www.ishrae.in/journals/2003oct/article01.html 07-06-2013
Air-Cooled Chillers : Myths & Facts - Issue Oct-Dec 2003 Page 2 of 15
Further, detailed analysis which was carried out on some installations has thrown up
some interesting facts and has established their overall efficiency and suitability, regardless
of climate conditions. It is also a fact that the use of these chillers, results in conserving water
resources, which are becoming scarce in many places, and which does not have the required
quality, hence, requiring extensive treatment.
The operation of these chillers is simple, because there are fewer parts to operate.
Maintenance costs are also lower due to fewer components and saving in the water treatment
plant.
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[top]
In an office application, the air conditioning system operates for 250 to 300 days in a
year, depending on the location of the city. Thus, the annual operating hours for offices
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working 10 hours a day, are between 2,500 to 3,000 out of a total of 8,760 hours in a
year. An hourly chart in Table 1 indicates the number of hours for which a system operates
annually at different ambient temperatures in north India.
What emerges is that, the hours of operation in excess of 35C ambient are only between
500 to 600 or 20% of the total operating time. The system, therefore, operates between 27C
to 35C for 80% of the time and the power consumption at these points is quite favorable.
The average power consumption thus varies between 1.0 to 1.1 ikW/ton and not 1.3 to 1.5 as
it would appear at first glance.
In cases where a system operates for 12 or 24 hours per day, the percentage of hours
above 35C will be much less than 20%. This will result in an even lower average ikW/ ton.
This is quite favourable as compared to the water-cooled system as can be seen later in this
article.
As the demand reduces the ikW of the chiller compressor reduces and also the power
used by condenser fans, reduces proportionally because some of the fans shut down on
reduced demand and also at lower ambient temperatures. Thus, the ikW remains nearly
constant even at part loads conditions.
Added benefit
There is another advantage of aircooled chillers in night application. During night, while
the building load falls by 20 to 30%, the output of the chiller increases by 20 to 25%. Thus,
while one air-cooled unit may meet the night requirement, it may be necessary to run 1
water-cooled units for the same load.
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The water required for 500 to 600 hours on the pads, is approximately 10% of the water
required for a water-cooled system. The increase in generator capacity will only be 5%
instead of 20% and this can make the air-cooled systems more attractive than water-cooled
systems in certain cases.
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Air-Cooled Chillers : Myths & Facts - Issue Oct-Dec 2003 Page 6 of 15
out for the Delhi climate to arrive at the Mean annual ikW per ton. Similar calculations
can be carried out for any other city using the weather data and daily variation chart.
It will be seen that the maximum and minimum temperatures have been worked out for
each month based on ISHRAE weather data for monthly variations and the daily range each
month, based on the Carrier Handbook.
The daily range is then used in conjunction with the Carrier Handbook chart to arrive at
the number of hours for which the system is likely to operate upto a given ambient
temperature which represents the air entering temperature to the chillers. A copy of Carrier
Chart is given in Table 2.
Table 2 : Daily temperature variation Ref.: Handbook of Air Conditioning System Design by
Carrier Air Conditioning Corp., USA.
Daily Range of Dry or Wet- SUN TIME
Temperature Bulb AM+ PM
(F)*
8 10 12 2 3 4 6 8 10 12
10 Dry-Bulb -9 -7 -5 -1 0 -1 -2 -5 -8 -9
Wet-Bulb -2 -2 -1 0 0 0 -1 -1 -2 -2
15 Dry-Bulb -12 -9 -5 -1 0 -1 -2 -6 -10 -14
Wet-Bulb -3 -2 -1 0 0 0 -1 -1 -3 -4
20 Dry-Bulb -14 -10 -5 -1 0 -1 -3 -7 -11 -16
Wet-Bulb -4 -3 -1 0 0 0 -1 -2 -3 -4
25 Dry-Bulb -16 -10 -5 -1 0 -1 -3 -8 -13 -18
Wet-Bulb -4 -3 -1 0 0 0 -1 -2 -3 -5
30 Dry-Bulb -18 -12 -6 -1 0 -1 -4 -10 -15 -21
Wet-Bulb -5 -3 -1 0 0 0 -1 -3 -4 -6
35 Dry-Bulb -21 -14 -7 -1 0 -1 -6 -12 -18 -24
Wet-Bulb -4 -4 -2 0 0 0 -1 -3 -5 -7
40 Dry-Bulb -24 -16 -8 -1 0 -1 -7 -14 -21 -28
Wet-Bulb -7 -4 -2 0 0 0 -2 -4 -6 -9
45 Dry-Bulb -26 -17 -8 -2 0 -2 -8 -16 -24 -31
Wet-Bulb -7 -5 -2 0 0 0 -2 -4 -8 -10
* The daily range of dry-bulb temperature is the difference between the highest and
lowest dry-bulb temperature during a 24 hour period on a typical design day.
Equation : Outside Design temperature at any time = Standard Outside Design
temperature + correction from above table.
The power consumption and output at different air entering temperatures are available
from chiller manufacturers. The ikW/ton and hours at each condition have been multiplied
to arrive at the total ikW/hours at each temperature. This data has been used to work out the
Mean ikW/ton for the whole year.
http://www.ishrae.in/journals/2003oct/article01.html 07-06-2013
Air-Cooled Chillers : Myths & Facts - Issue Oct-Dec 2003 Page 7 of 15
It will thus be seen that the average ikW/ton is only 1.09 which is not very high. In the
case of a water- cooled system, the net ikW/ ton even at full load works out to 0.95 for
reciprocating, scroll and small size screw compressor and at part load this figure increases to
1.0 ikW.
http://www.ishrae.in/journals/2003oct/article01.html 07-06-2013
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[top]
Heat pumps
The use of air cooled chillers offers another advantage in places where both cooling and
heating are required. These units can efficiently provide both cooling in extreme hot weather
and heating in extreme cold weather, when the machines are configured in a "Heat Pump"
mode.
In winter, the air-cooled condenser becomes the evaporator to extract heat from the
atmosphere. The unit chiller then acts as a shelland- tube condenser, to produce hot water,
which can be used for providing heating in the premises. The outlet temperature of the hot
water can be as high as 55C, but is usually designed for 50C to achieve a reasonable balance
between cooling efficiency and heating demand.
The advantage of the heat pump is that it produces the same amount of hot water as an
electric boiler by using less then approximately 40% of electricity as compared to an electric
boiler. This can reduce the overall cost of winter heating by 50% as compared to an electric
hot water system.
A further provision in the aircooled chiller or heat pump is that of a superheat (or
auxiliary) condenser to generate hot water. This auxiliary condenser removes the excess
superheat from the discharge gas, before it goes to the condenser without affecting the
performance of the refrigeration cycle. This heat from the discharge gas is available both in
cooling cycle and the heating cycle. The bonus hot water thus becomes available both in
summer and winter or for nearly 10 months in a whole year.
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The hot water produced by this extra condenser can be used to meet the hot water
requirements of the kitchen and toilets without any additional operating cost. This bonus
heat improves the overall performance of the air-cooled system.
Several comparative analysis have found that the cost of an air-cooled system varies
between 95% to 105% of a similar water-cooled system. The variation in the cost of the two
types of system depends on the size of the plant and whether indigenous or imported chillers
are selected.
There is however, an additional cost due to a bigger D.G. set capacity, but this is not
significant in the overall context.
Comparative chart
A chart showing the advantages and disadvantages of an air-cooled and water-cooled
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Water saving
The water-cooled system requires approximately 12 litres of water per hour per ton
capacity. This water has to be of a reasonably good quality as per factors given below:
http://www.ishrae.in/journals/2003oct/article01.html 07-06-2013
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Since most available water has impurities and high hardness level, the water has to be
filtered and softened, with a water softener for the make-up water system. If the water is not
softened, it will cause deposition of salts on the tubes of the water-cooled condenser, which
reduces heat transfer and raises the ikW of the chiller.
As the air-cooled system does not use water, all the above processes of descaling etc.
become unnecessary and irrelevant. In addition, there is a saving of water of nearly 120 litres
per day per ton or 12,000 litres per day for a small 100 ton system.
It is obvious that the additional equipment requires more steps to put the plant in
operation. It also requires greater effort to make sure that there is adequate quantity of
suitable quality of water in the cooling tower at all times and that the water treatment system
is always functional.
If there is a shortage of water, the system may stop in mid-operation, and poor water
quality will lead to scaling in the pipes, condenser etc.
It is clear that to operate the aircooled system, no such care is required. The system can
simply be put in operation in just two steps of starting the water pumps and the chiller at any
time. The conclusion of simplicity of operation is obvious.
Ease of maintenance
Air-cooled systems are also simple to maintain, as there are fewer components, in view of
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the fact, that the condenser water pumps and cooling towers are not required.
The cooling towers require periodic cleaning to remove the sludge which accumulates in
the sump. It is necessary to make sure that there is sufficient quantity of water in the cooling
tower at all times to ensure proper functioning of the system.
The water treatment plant requires constant attention, so that the makeup water is
always below the required hardness. There is also a need for regular descaling of the
condenser tubes, so that the condenser efficiency is maintained near its peak.
In comparison, the air-cooled condenser does not scale and therefore, it only requires
annual cleaning with hot water to function properly. It is quite clear that there are very few
components or functions which need to be checked in an aircooled system.
Therefore, fewer number of staff are required for the operation and maintenance of the
air-cooled system.
Space saving
The air-cooled chiller has to be installed in an open space without any roof cover on top.
Therefore, these units are installed either on the roof of a building or in an open space,
outside the building. The space required for them is 50% to 80% more than the space
normally required for installing cooling towers of the water-cooled systems.
This means that these plants do not require a covered plant room either within the
building or adjacent to the building, thereby saving usable space and the cost of constructing
such spaces. A small pump room is however required for the air-cooled system, which is built
near the place where the air-cooled chillers are installed. The size of pump room requires
approximately 10 to 15% of the size of a regular plant room.
Thus, the total space required is much less and usually does not represent prime usable
space.
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Case studies
A few case studies are given to illustrate various applications. These are :
1. Videocon Plaza, New Delhi. The largest air-cooled installation in north India.(950
tons)
2. Apartment Building, Laburnum, Gurgaon. A system providing summer cooling,
winter heating and hot water throughout the year. (120 tons)
3. Tala Hydel Authorities Gedu, Bhutan. Winter heating only for offices and club
house building. (6,75,000 Kcal/hr.)
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The requirements called for central heating of an office complex measuring 7,000 m2 and
club house and auditorium facility measuring 3,000 m2 i.e. a total of 10,000 m2. Electricity
was the referred medium since these offices were meant for a new 1,000 mW hydel project
and Bhutan is surplus in electricity.
The requirement was assessed at 6,75,000 kcal/hr requiring electric hot water boilers of
750 kW or 780 kW including pumps, AHUs etc. The use of heat pumps was suggested as an
alternative, even through the initial cost increase was nearly 50% over a conventional system.
The advantage of the above system was that it reduced the electric demand from 780 kW
to 280 kW which meant a release of 0.5 mW electricity for better use else where.
The system is operated with five, air-cooled heat pumps each of 150 kW heat output
totaling 750 kW. All the units together require input electricity of 250 kW. The heat pumps
will give the design output of 50C at 5C ambient and are equipped with a defrost
arrangement for the evaporator.
The system is in its first year of operation and is functioning satisfactorily. This is the
first installation in this region, where pure heating is being done using heat pumps resulting
in considerable saving of electricity.
Conclusion
It will be seen that the air-cooled chillers represent a fairly efficient and cost effective
alternative to the watercooled system. These chillers can be used very effectively for
installations upto 1,000 tons.
In the milder climate of south India, there is no practical limit to the overall plant
capacity.
They are very useful for heating /cooling applications as well as pure heating
applications.
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http://www.ishrae.in/journals/2003oct/article01.html 07-06-2013