centrifugal water chillers - life cycle engineering · pdf filemaintenance considerations...
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Centrifugal Water ChillersScott MeyerkordTrane Account ManagerTrane Account Manager
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ChilledWaterSystemy
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absorption centrifugalabsorption g
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helical-rotary
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Centrifugal Water Chillers
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Centrifugal Water Chillers
Components
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components of a
compressorcompressor
Centrifugal Water Chillermotormotor
condensercondenser
pp motormotor
controlcontrolpanelpanel
starterstarter
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panelpanel
evaporatorevaporator
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Compressor
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Impeller
bladesblades
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Multistage Compressor
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Multistage Compressori lli llimpellers impellers
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inlet vanes inlet vanes
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Centrifugal Compressor
volutevolute
diffuserdiffuserpassagepassage
impeller impeller passagespassages
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centrifugal compressorEnergy Conversion
refrigerant refrigerant ggenters enters diffuserdiffuser
ocity
ocity
velo
velo
f i t f i t
essu
rees
sure
refrigerantrefrigerantenters impellerenters impeller
refrigerant refrigerant enters voluteenters volute
static
pre
static
pre
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path through compressorpath through compressor
ss
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Condenserrefrigerant vaporrefrigerant vapor
bafflebaffle
refrigerant vaporrefrigerant vapor
cooling cooling tower tower tower tower waterwater
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tubetubebundlebundle
liquid liquid refrigerantrefrigerant
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expansion deviceOrifice Plates
totoorifice platesorifice plates totoevaporatorevaporator
HH11
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expansion deviceOrifice Plates
totoorifice platesorifice plates totoevaporatorevaporator
HH22
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2-stage chillerEconomizer
refrigerant vapor refrigerant vapor refrigerant vapor refrigerant vapor to second stageto second stageof compressionof compression
liquid refrigerant liquid refrigerant liquid refrigerant liquid refrigerant to evaporatorto evaporatororificeorifice
liquid refrigerant liquid refrigerant from condenserfrom condenser
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from condenserfrom condenser
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3-stage chillerEconomizer
refrigerant vapor refrigerant vapor refrigerant vapor refrigerant vapor refrigerant vapor refrigerant vapor to second stageto second stageof compressionof compression
refrigerant vapor refrigerant vapor to third stageto third stageof compressionof compression
liquid refrigerant liquid refrigerant q gq gto evaporatorto evaporatororificeorifice
liquid refrigerant liquid refrigerant from condenserfrom condenser
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orificeorificefrom condenserfrom condenser
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Evaporator
tube bundletube bundle
liquid liquid refrigerantrefrigerant
chilled chilled
liquidliquiddi t ib tdi t ib t
water water returnreturn
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eliminatoreliminatordistributordistributor orifice systemorifice system
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Motor
motormotorgear-drive
impellerimpellermotormotor
impellersimpellersimpellersimpellers
direct-drive
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gearsgears
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Hermetic Motor Coolingt tt tstatorstator
rotorrotorrotorrotor
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draindrainliquidliquidrefrigerantrefrigerant
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Controls and Starter
controlcontrolpanelpanel
starterstarter
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panelpanel
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Centrifugal Water Chillers
Refrigeration Cycle
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2-stage centrifugal chillerRefrigeration Cycle
22 stagestage22--stagestagecompressorcompressor
economizereconomizer
condensercondenserevaporatorevaporator
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expansion devicesexpansion devices
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Refrigerant Operating Pressures
HCFCHCFC--2222
ssur
ess
ure
HFCHFC--134a134a
pres
pres
HCFCHCFC 123123HCFCHCFC--123123
atmosphericatmosphericpressurepressure
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999temperaturetemperature
pressurepressure
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Low-Pressure Chillers
compressorcompressorsuction elbowsuction elbow
evaporatorevaporator
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Purge System
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Centrifugal Water Chillers
Maintenance Considerations
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Maintenance Considerations
Operating logMechanical componentsHeat-transfer surfaces Fluid analysis
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operating logASHRAE Guideline 3
Chilled water inlet and outlet Oil pressures temperatureChilled water inlet and outlet temperatures and pressuresChilled water flowEvaporator refrigerant
Oil pressures, temperature, and levels
Record refrigerant activity,p g
temperature and pressuresEvaporator approach temperatureC d t i l t d
Motor voltage and amperage
Purge activity
Condenser water inlet and outlet temperatures and pressuresCondenser water flowCondenser refrigerant temperature and pressuresCondenser approach t t
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temperature
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maintenance considerationsMechanical Components
R d d M i tRecommended MaintenanceHermetic Compressor and motor: no routine maintenance required. Compressor teardown / overhaul inspection every 8 to 10 years or 25 000 tooverhaul inspection every 8 to 10 years or 25,000 to 30,000 operating hoursTemperature Controls: no routine maintenance calibration requiredcalibration required Visually inspect overall unit Inspect safety controls and electrical componentsS i t t t Ti ht l t i l tiService motor starters: Tighten electrical connections, service contractors, megger test motor, visual inspection of transition resistors.Pressurize and leak test annually or as indicated by the
Air Conditioning Clinic TRG-TRC010-ENAir Conditioning Clinic TRG-TRC010-EN© American Standard Inc. 1999
Pressurize and leak test annually or as indicated by the purge rate
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maintenance considerationsMechanical Components
Other design-specific requirementsRemove oil sample for Lab Analysis: Change oil when oil analysis dictateswhen oil analysis dictatesReplace oil filter annually or as requiredReplace purge filter drier annuallyep ace pu ge te d e a ua yVisual Inspection of Condenser Tubes AnnuallyCheck operation of oil sump heater
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maintenance considerationsHeat Transfer Surfaces
Recommended maintenanceUse a qualified water treatment specialistspecialistClean condenser tubes as needed, mechanical brush l i llcleaning annually
Clean water-side pump strainersTest tubes every 3 years
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maintenance considerationsTube Analysis
Eddy Current TestingTest evaporator tubes every 4-5 yearsevery 4-5 yearsTest condenser tubes every 2-3 years
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Fluid Analysis
Oil analysisConduct annual analysis to verify system integritysystem integrity
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Oil Analysis
Why perform regular oil analysis?Helps reduce maintenance costsD bl i hDetects problems without
compressor disassemblyExtends service life of oil chargete ds se ce e o o c a geReduces environmental problems related to oil disposalHelps maintain compressorefficiency and reliability
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Oil AnalysisA l ti l D tAnalytical Data
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Oil Analysis
Written Recommendations
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Oil Analysis
Graphical Representation of Data
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