F O R A I R C O N D I T I O N I N G A N D I N D U S T R I A L C O O L I N G

T h e e c o - f r i e n d l y s o l u t i o n . . . .

The Latest Advanced TechnologyHigh Efficiency Series

H O T W A T E R D R I V E N A B S O R P T I O N C H I L L E R S

Cogenie

10 NTR - 80 NTR

Cogenie theawardedEnvironmental Productof the Year 2001ACR News, U.K.

2

hot water driven absorption chillers

Conserving Energy and

Preserving the Environment.

At Thermax, not only are the

products eco-friendly, but also the

manufacturing processes. They

even conform to the Kyoto

Protocol and are in absolute

tandem with Clean Development

Mechanisms Code (CDM) which

is becoming the order of times

worldwide.

t ab l e o f conten t s

Introduction 3

Manufacturing and Testing 4

CHPC 5

Features 6-7

Controls 7

Technical Specifications and

GA Drawing

Cycle Diagram 12

Performance Curves 8

Safeties 8

Testing Procedure 8

Operating Principle 9

10

P & I Diagram and Foundation Drawing 11

Hotels Hospitals

Multiplexes

Auditoriums

Retail Stores

Office Complexes Schools

Residential Blocks Museums

Shopping Malls

Restaurants

Fast Food Parlours

Cogenie

A P P L I C A T I O N S

Cogenie theawardedEnvironmental Productof the Year 2001ACR News, U.K.

VA

PO

UR

ABSORPTIO

NC

HIL

LE

RS

CFC

FREE

a company with engineering excellence ...

Thermax, a technology driven company has been in the core sectors of

for more than 25 years and has

defined its business as -

Electricity is scarce and expensive. It should be used

only where it is irreplaceable. Keeping this in mind, Thermax took up

the challenge of finding an alternative for traditional electrically

operated compression chillers. About a decade ago, Thermax

introduced the revolutionary concept of

for air-conditioning and process cooling requirements, in India.

Considering the growing demand for Vapour Absorption Chillers,

Thermax set up its state-of-the-art manufacturing plant in 1988, in

India at Pune which has been awarded the ISO 9001 and the ISO 14001

certificates. Needless to mention, these chillers conform to

international standards. To maintain these high standards, a team of

workers and engineers is specially trained and exposed to global work

and quality culture. With this positive and innovative attitude, Thermax

has carved a niche in the global market where competition is stiff and

performance is the only criteria.

Thermax sales and after-sales service is efficient, responsive and

responsible. Our Engineers understand customer requirements, design

the most optimal solutions and ensure quality at every stage, to achieve

customer delight.

Energy, Environment and Exports

Conserving Energy and Preserving the

Environment.

Vapour Absorption Chillers

3

hot water driven absorption chillers

Thermax manufactures the environment friendly and

energy efficient Vapour Absorption Chillers at its plant

in Pune, India. Its state-of-the-art manufacturing facility

is awarded with ISO 9001 and ISO 14001 certificates.

Stringent quality control procedures alongwith a skilled

workforce ensure that a highly reliable product leaves

the factory. The equipment and manufacturing processes

conform to most of the International standards.

Thermax’s manufacturing capabilities are confirmed by

thefactthatovertheyearsit hasinstalledmanychillers in

countries like USA, Germany, UK, Spain, Italy, Middle

East, South East Asia with the product conforming to the

respective country standards like ETL, CE, TUV, DNV,

ISPESL, ASME, etc.

The chillers can be performance tested under the

simulated site conditions before it leaves the factory. The

factory assembled and tested unit considerably reduces

the time needed for installation and commissioning at

site.

CNC drilling machine with high speed and direct feed technology

ensures fine tube hole finish and accuracy, which is important for

leak tight expansion and effective heat transfer.

CNC Gas cutting machine for plate cutting ensures precision

cutting of shell plates and profile cut tube plates.

A Helium leak detection test ensures there is no leakage at

the welding joints.

M A N U F A C T U R I N G & T E S T I N G

4

Cogenie

100%

Coolant Losswithout heat recovery

24.5%

Radiation Loss3.3%

Hotwater

driven chiller

Stackloss afterheat recovery

13.6%

Stackloss withoutheat recovery

33.6%

Mechanicaloutput38.6%

Alternatorloss

3.6%

Steamgenerated

20%

Net useful outputpower + heat + chillingfrom steam driven chiller

55%

Electricaloutput35%

Sankey Diagram

GensetCapacity

6 MW

4 MW

2.5 MW

1.5 MW

225

150

100

70

Indicative ChillingCapacity (TR)

Indicative Table

Jacket water Inlet / OutletTemperature : 90.6 / 85 Co

hot water driven absorption chillersCogenie

Chilled Water

NaturalGas

Gas Turbine

Air

Air

Exhaust toAtmosphere

Alternator

Hot TurbineGases

After FiringBurner

Hot Water

To Cooling Tower

Hot Water

Electricity

HotWaterChiller

HeatRecoveryUnit

NaturalGas

Air

HeatRecoveredfrom Engine 85 C

o

85 Co

90.6 Co

90.6 Co

HotWater

6.7 Co

6.7 Co

29.4 Co

29.4 Co

To Cooling Tower

Chilled Water

Alternator

JacketWater

Electricity

12.2 Co

12.2 Co

HotWaterChiller

Gas Engine

M I C R O T U R B I N E C H PG A S E N G I N E C H PExhaust toAtmosphere

The concept of co-generation by means of Genset is becoming

increasingly popular worldwide for reducing overall energy

costs.

Sankey Diagram :

The Sankey diagram shows the heat energy distribution per unit

quantity of fuel to a Genset. The portion indicated in blue

represents the net useful output which is raised from 35% to 65%

by recovering the waste heat from exhaust gases and jacket water,

to enhance the utilization of fuel.

Around 25% of the input energy of the Genset is wasted in a

cooling tower to cool the jacket water coming out of the engine,

which is at a high temperature. The same heat can be used as an

energy heat source for the Hot water driven chiller to produce

chilling at a negligible cost.

The benefits of CHPC systems were confined to large scale

projects only. With the launch of Cogenie series (10 NTR - 80

NTR) Thermax is now extending these benefits to small scale

projects too! This reiterates Thermax's commitment to provide

the most economical and "Best in Class" solutions for Combined

Heat, Power and Cooling systems.

Cogenie can work on following CHPC schemes :

1. Gas Engine CHP

2. Microturbine CHP

The typical system schematic given below explains the

connectivity between the Genset and Cogenie.

CHPC with Cogenie :

C O M B I N E D H E A T , P O W E R & C O O L I N G S Y S T E M

5

f ea tures

Capacity :

Operating Hot Water Temperatures:

Compact Design :

High efficiency :

10-100% Stepless modulation :

Auto De-crystallization :

On-line purging :

Gravity feed system :

PLC based control panel :

Cogenie is available in models ranging from 10 NTR - 80 NTR and can achieve chilled water

temperature upto 4.5 C.

Cogenie can operate on Hot water temperatures ranging from : 70 C - 110 C

Cogenie are designed to be extremely compact. This ensures minimum foot print area and provides ease

of transportation and installation.

Special tube material and other innovations help to increase the COP considerably.

For cooling loads ranging from 10% to 100% of the designed capacity, a 3-way diverting valve

automatically varies hot water flow in order to maintain the temperature of chilled water leaving the

chiller. This ensures better part load performance.

These chillers are installed with a unique auto de-crystallization circuit to eliminate any chances of

crystallization.

The factory mounted and tested purging unit consists of an electric motor driven purge pump, palladium

cell, storage tank, necessary piping and valves. Any non-condensable gas generated in the chiller

during operation, is purged continuously into the storage tank, thereby maintaining low vacuum in the

shell. The gases stored in the tank can be purged periodically. Palladium cell purges Hydrogen from the

storage tank continuously thus reducing the requirement of running the purge pump.

The Thermax chillers use gravity feed, non-pressurized super-spraying system, for spraying refrigerant

and absorbent. This avoids the use of nozzles, which have the problem of clogging and wear & tear.

These chillers are provided with state-of-art PLC based control panel with unique display, user friendly

interface and data-logging system.

o

o o

hot water driven absorption chillers

hot water driven absorption chillers

Cogenie

Cogenie

6

Cross-over piping :

Generator Tubes:

Corrosion Inhibitors:

The cross-over piping from absorber to condenser is a standard feature in Thermax Absorption Chillers. It reduces the

piping work, welding, at site.

Cogenie uses Low fin Copper tubes in its generator for better performance.

Thermax uses new generation corrosion inhibitor, Lithium Molybdate which is more effective than conventionally

used Lithium Nitrate and Lithium Chromate. Lithium Nitrate can generate Ammonium Nitrate (NH NO ) which is

harmful to Copper.4 3

Electrical / Pneumatic Control Valve :

Factory Performance test :

As an option Cogenie can be provided with Electrical/ Pneumatic Control Valve.

After assembly, the chillers can be performance tested under simulated site conditions before it leaves the

factory. The factory assembled and tested units considerably reduce the time needed for installation and

commissioning at site.

hot water driven absorption chillers

Cogenie

CogenieP LC co ntro l s

op t ion a l f e a t u res

Improved Reliability :

Elaborate Diagnostics :

Easier Operation & Maintenance :

Data Acquisition and Logging :

Holiday Schedule :

Cogenie incorporates a state-of-the-art programmable logic controller, which

incredibly enhances the flexibility and reliability of the chiller. It brings along

all the advantages of a solid state control system. Elimination of rigid electro-

mechanical control components promises enhanced reliability and fail safe

operation, which reduces maintenance and ensures minimum downtime of the

chiller.

chiller

Control system allows the user to log parameters noted in the last one week, at

a sampling time of one hour. During a chiller trip condition, the data is logged

at a faster, adjustable sampling time. Also a log of last six alarms with date and

time stamp is maintained.

Client can program chiller operating schedule as per his convenience so that

the chiller is switched on or switched off as per the programmed schedule. It

can be set by the customer anytime.

Thermax Control system provides a host of diagnostic information such as

hardware related faults, chiller trip causes, sensor errors, pump errors and

data history regarding previously occurred faults and alarms. This equips the

operator with an overview of the chiller and adequate data for faster and easier

troubleshooting and routine maintenance.

Unique 2 line display, keypad and the software constitute a user-friendly

operator interface. The operator can easily control the functions, with

the aid of self-explanatory messages appropriately displayed on the screen.

The status screen provides audio-visual alarms and displays warnings about

the abnormal conditions in the chiller function. This alerts the operator,

specifying the abnormality, to initiate the necessary action.

7

CogenieT E S T I N G P R O C E D U R E

As the Vapour Absorption Chillers work under vacuum conditions, the manufacturing of these chillers is very critical with

respect to leak tightness. Hence it is necessary to follow stringent quality control procedures and also perform leak

detection tests. Understanding the importance, Thermax carries out the leak detection test in the following sequence :

Nitrogen is charged into the shell side of the chiller upto 1.3 to 1.4 kg/cm g pressure and soap solution is sprayed on all the

joints and expanded tube ends. In case of leakage, Nitrogen leaks out, forming soap bubbles, indicating the leak points.

The chiller is kept under pressurized condition for 24 hours, by charging it with Nitrogen upto 1.3 kg/cm g pressure on the

shell side. In case of leakage, Nitrogen escapes out, resulting in drop in Nitrogen pressure inside the chiller, indicating

leakage.

Helium, the next smallest molecule after Hydrogen, can leak through very minute holes. In this test Helium is sprayed on

all the joints of the chiller. As the chiller is under vacuum conditions, leakages, if any, will result in Helium entering into the

chiller and thus will be displayed on the screen of Helium leak detector. The joints are marked for repairs.

In this test, the chiller is fully covered by a polythene sheet and Helium is passed from below, to observe the cumulative

leak rate of the entire chiller.

After the chiller passes all the above tests, it is tested for hydraulic test, at 1.5 times the design pressure on the tube side.

2

2

1. Nitrogen or Soap Test :

2. Decay Test :

3. Helium Spray Test :

4. Helium Shroud Test :

5. Hydraulic Test :

CH/W : Chilled Water

C/W : Cooling Water

H/W : Hot Water* Above graphs are for indicative purpose only.

CAPACITY V/S C/W INLET TEMPERATURE

At constant CH/W & H/W inlet / outlet temperatures,& C/W flow

COOLING WATER INLET TEMPERATURE ( C)o

CAPACITY

%28 29 30 31 32

120

110

100

90

80

70

CAPACITY V/S H/W INLET TEMPERATURE

At constant CH/W temperatures,C/W inlet temperature & flows

HOT WATER INLET TEMPERATURE ( C)o

CAPACITY

% 90.6 89.6 88.6 87.6 86.6 85.6

100

90

80

70

P E R F O R M A N C E C U R V E S

L-cut - refrigerant pump

Antifreeze thermostat

Chilled water pump interlock

Chilled water flow switch

Generator temperature high cutout

Cooling water low temperature cutout

Antifreeze Protection :

Crystallization Protection :

Alarm Cycle :

Motor Protection :

Chiller routine fault alarm

Total shutdown alarm

Absorbent pump overload relay

Refrigerant pump overload relay

Purge pump overload relay

S A F E T I E S Cogenie

8

29.4

Absorption process

Cooling water

LiBr solutionConcentrated

Water (refrigerant) Closed vessel

Vacuum

Chilled water

Water circulatingheat exchangertubes

ConcentratedLiBr solution

Water (refrigerant)

Refrigerant vapour

Driving heat source

Diluted solution

Absorption pump

Chilled water

Absorber

Cooling water

Concentratedsolution

Liquidrefrigerant

Refrigerant vapour

GeneratorCondenser

Absorbent Pump

Driving heatsource

Coolingwater

Coolingwater

AbsorbentPump

Chilled water

CONDENSER GENERATOR

EVAPORATOR ABSORBER

5

O P E R A T I N G P R I N C I P L E

Vapourized refrigerant

Refrigerant

Chilled water

Chilled water

Evaporator

4

1

2

3

Drivingheatsource

When maintained at high vacuum, water will boil and flashcool itself.

Concentrated Lithium Bromide solution has affinity towardswater. The solution absorbs vapourised refrigerant water.

As Lithium Bromide becomes dilute it loses its capacity to absorbwater vapour. It thus needs to be reconcentrated using a heat source.

The basic operation cycle of the single effect vapour absorption

chiller.

This heat causes the solution to release the absorbed refrigerant in the form ofvapour. This vapour is cooled in a separate chamber to become liquid refrigerant.

hot water driven absorption chillersCogenie

Opera t ing Pr inc iple :

The vapour absorption chiller produces chilled water upto

C, utilizing hot water as the driving source. The

chiller utilizes the latent heat absorbed by the refrigerant

(water) as it evaporates (in a closed pressure vessel,) for

cooling. Unlike a compression chiller which uses a

compressor to pressurize the vapourized refrigerant

(Freon) and condenses it by using cooling water, the

absorption chiller uses an absorbent (LiBr) to absorb the

vapourized refrigerant (water). The refrigerant is then

released from the absorbent when heated by an external

source.

4.5o

Basic Pr inc iple :

Boiling point of water is a function of pressure. At

atmospheric pressure, water boils at 100 C. At lower

pressure it boils at lower temperature. The boiling point of

water at 6 mm of mercury absolute, is only 3.7 C.

o

o

Lithium Bromide (LiBr) salt has the property to absorb

water due to its chemical affinity. It is soluble in water. As

the concentration of LiBr increases, its affinity towards

water increases. Also as the temperature of LiBr increases

the affinity decreases.

There is a large difference between vapour pressure of

LiBr and water.

9

UNIT LT - 1 LT - 2 LT - 3 LT - 5 LT - 6 LT - 8

NTR 10 20 30 50 65 80

Length (L) mm 1600 1800 2300 2400 2500

Width (W) mm 1600 1400 1400 1500 1800

Height (H) mm 2100 2200 2100 2500 2800

Operating weight x 10 kg 2 2.5 3 4 5.5 5.8

Maximum Shipping weight x 10 kg 1.75 2.2 2.5 3.5 4.2 4.5

Clearance for tube removal mm 1500 2200

3

3

MODEL NUMBERS

NOMINAL REFRIGERATION CAPACITY

DIMENSIONS

T E C H N I C A L S P E C I F I C A T I O N S

T Y P I C A L G E N E R A L A R R A N G E M E N T

EARTH TERMINAL / ELECTRICAL WIRING OPENING

ACCESS DOOR FOR CONTROL PANEL

DESCRIPTION

B

MAINTENANCE SPACE (DOOR SPACE)

ANCHOR BOLT LOCATION

TUBE CLEANING SPACE

H

G

F

C

DIRECT SPACE

SR.

A

LEGEND :NOZZLE SCHEDULE

HOT WATER OUTLET

COOLING WATER INLET

N6

N5

N3

N4

N1

N2

SR. DESCRIPTION

CHILLED WATER INLET

CHILLED WATER OUTLET

COOLING WATER OUTLET

HOT WATER INLET

10

Minimum operating cooling water inlet temperature = 20°CMinimum chilled water outlet temperature = 4.5°C

Fouling Factor in water circuits is 0.0001 metricMaximum working pressure in chilled / cooling / hot water lines = 5 kg/cm gVoltage available on request : 380 / 440 / 460 V, 50 / 60 Hz

Ambient condition should be between 5 to 45°C

Performance based on JIS B8622

2

FOR CONDITIONS OTHER THAN ABOVE

PLEASE CONTACT THE NEAREST

THERMAX OFFICE / DISTRIBUTOR

CHILLED WATER

CIRCUIT

HOT WATER

COOLING WATER

CIRCUIT

CIRCUIT

ELECTRICAL

DATA

MODEL NUMBERS

NOMINAL REFRIGERATION CAPACITY

UNIT LT - 1 LT - 2 LT - 3 LT - 5 LT - 6 LT - 8

NTR 10 20 30 50 65 80

kW 35 70 106 176 229 282

Flow Rate m /hr 5.5 11 16.5 27.5 35.7 44

Friction Loss m.w.c. 6.8 5.9 3.2 4.4 3.2 4.1

Connection Diameter mmNB 40 65 80 100

Flow Rate m /hr 10 20 30 50 67 85

Inlet Temperature

Friction Loss m.w.c. 1.2 3.0 4.0 4.1 5.1 5.5

Connection Diameter mmNB 50 80 125

Flow Rate m /hr 7.8 15.7 23.2 39.8 51.3 63.1

Friction Loss m.w.c. 1.2 2.0 3.2 3.2 3.1 3.0

Connection Diameter mmNB 40 65 80 100

Absorbent Pump kW (A) 0.3 (1.1) 0.55 (1.7) 1.5 (5.0)

Refrigerant Pump kW (A) 0.3 (1.1) 0.3 (1.4)

Purge Pump kW (A) 0.25 (1.3)

Total power consumption kVA 2.2 2.83 5.2

3

3

3

Inlet / Outlet Temperature °C 12.2 / 6.7

No of passes (Evaporator) nos. 8 4

°C 29.4

Outlet Temperature °C 36.8 36.7 36.6 36.7 36.4 36.3

No of passes (Absorber) nos. 4

No of passes (Condenser) .nos. 2

Inlet / Outlet Temperature °C 90.6 / 85

No of passes (Generator) nos. 4

Power Supply 415 V(± 10%), 50 Hz( ± 5%), 3 Phase+N

TS

TUBE CLEANING SPACE

ON ANY ONE SIDE

A

ON

AN

YO

NE

SID

E

TU

BE

CLE

AN

ING

SP

AC

E

C

F

G

B

N2

N1

N6

N3

N5

N4

L

46

W

H

H

Cogenie

F O R R E F E R E N C E O N LY

11

T Y P I C A L S Y S T E M P & I D I A G R A Mhot water driven absorption chillers

HOT WATER OUTLET

HOT WATER INLET

E/P

AIR HEADER

CH

ILLE

DW

AT

ER

INLE

T

(1 WORKING + 1 STD. BY)

CHILLED WATER PUMPS

INSULATION

THERMOCOL

2" THICK.

CHILLED WATER OUTLET

2" THICK

THERMOCOL

INSULATION

COOLING WATER OUTLET

CO

OLI

NG

WA

TE

RIN

LET

COOLING WATER PUMPS

(1 WORKING + 1 STD. BY)

DOWN

COOLING TOWER

BLOW

REFER NOTE-1

S

AIR

SU

PP

LYF

RO

M

CO

MM

ON

HE

AD

ER

.

PIPI

M

M

PIPI

PI TI

PI TI

PI

PI TIPI TI

PI TI

PI TI

TI

PI

M

PI

PI

M

PI

FM

CONTROL VALVE

PNEUMATIC CONVERTERE/P

THERMOSTAT

BALANCE VALVE

MOTOR

PUMP

GLOBE VALVE (CLOSE)

GATE VALVE (CLOSE)

BUTTERFLY VALVE (CLOSE)

PNEUMATIC LINE

THERMODYNAMIC STEAM TRAP

INVERTED BUCKET STEAM TRAP

S - SWITCH

R - RECORDER

L - LOW

I - INDICATOR

M - METER

F - FLOW

L - LEVEL

T - TEMPERATURE

P - PRESSURE

BUTTERFLY VALVE (OPEN)

AIR FILTER REGULATOR

COCK

``Y'' STRAINER

NON RETURN VALVE

GLOBE VALVE (OPEN)

GATE VALVE (OPEN)

M

F O R R E F E R E N C E O N LY

1. AUTOMATIC ARRANGEMENTS SHOULD BE PROVIDED TO STOP

COOLING WATER FLOW IF THE CHILLED WATER FLOW STOPS.

NOTES:

2. THERMAX SCOPE IS UP TO THE NOZZLES OF ALL WATER CIRCUITS

Cogenie

Cogenie

NOTES :

1. There should be a drain ditch around the foundation.

2. Anchor bolts should be fixed in the foundation prior to the chiller installation.

3. Anchor bolts (anchor bolts, nuts & washers) are supplied with the chiller.

4. Be sure to weld the washer as shown in above detail.

5. The floor surface should be made water proof, for ease of maintenance work

F O U N D A T I O N D R A W I N G

A

F

DB

E

J

M

G

K

C

ON

AN

YO

NE

TU

BE

CLE

AN

ING

SP

AC

ES

IDE

G

UNIT mm

MODEL A B C D E F G J K M

LT-1 1250 1140 1100 635 1125 3450 850 275 1050 600

1250 1140 1100 635 1125 3450 850 275 1050 600

1872 940 1120 620 1220 4112 626 210 1120 680

1982 1047 1126 621 1300 4235 695 250 1350 700

2170 1341 1100 600 1282 4364 880 280 1398 969

2170 1295 1100 600 1282 4364 880 278 1398 969

LT-2

LT-3

LT-5

LT-6

LT-8

In view of our constant endeavour to improve the quality of products,we reserve the rights to alter or change design specifications and contents ofthis literature without prior notice and without incurring any obligations.

Visit us at : www.thermaxindia.com/acd

Distributor / Agent

THERMAX LTD.ABSORPTION COOLING DIVISION

ACD/Cogenie/08/01

Thermax world-wide network

REGISTERED OFFICE / WORKSD-13 MIDC Industrial Area,Chinchwad, Pune 411 019. INDIATel : 00-91-20- 7475941-49 / 7470436Fax : 00-91-20- 7475907

Thermax Inc.

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Tel : 00-941-325997 /329566 / Fax No : 00-941-447060Email : lalanengg@eureka.lk

th

C Y C L E D I A G R A Mhot water driven absorption chillers

Heat Exchanger

Valve open

Valve close

Refrigerant

Dilute Solution

Chilled Water

Hot Water

Concentrated Solution

Cooling Water

Chilled WaterOutlet

CoolingWaterOutlet

CoolingWaterInlet

Chilled WaterInlet

Absorber

Hot WaterInlet

3 Way Valve

Hot WaterOutlet

PurgePump

PurgeUnit

RefrigerantPump

AbsorbentPump

Condenser

Overflow Pipe