Chiller Types & Applications

A Trane Air Conditioning Clinic

ACES Training
K Y Yow
23 Jan 2015

American Standard Inc. 1999

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Chiller Types
By Compressor Type & Heat Rejection Mode

W/C Centrifugal

Centrifugal

Scroll

150-4000rt
Compressor Type

Screw

A/C Centrifugal

W/C Screw

A/C Screw

50-500rt

50-400rt

W/C Scroll

A/C Scroll

15-70rt

5-200rt

Reciprocating
Heat
Water-Cooled
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Rejection
Air- Cooled
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Vapour Compression

NON-Vapour Compression

W/C Centrifugal

absorption
W/C Screw

A/C Screw & Scroll

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Centrifugal Water Chillers

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components of a

Centrifugal Water Chiller

compressor

motor

condenser

control
panel

starter

evaporator
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Impeller

blades

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centrifugal compressor

Energy Conversion

static pressure

velocity

refrigerant
enters
diffuser

refrigerant
enters impeller

refrigerant
enters volute

path through compressor

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Multistage Compressor

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Condenser
refrigerant vapor
baffle

cooling
tower
water

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tube
bundle

liquid
refrigerant

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expansion device

Orifice Plates

orifice plates

to
evaporator

H1

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Evaporator
tube bundle
liquid
refrigerant

chilled
water
return

liquid
distributor

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eliminator

orifice system
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Motor
motor

gear-drive
impeller
motor
impellers

direct-drive
gears
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Hermetic Motor Cooling

stator

rotor

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liquid
refrigerant

drain
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Controls and Starter

control
panel
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starter

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Starters
line power

line power

control power
wiring

starter

control power
wiring

unit-mounted

remote-mounted
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Comparison of LV Starters

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2-stage centrifugal chiller

Refrigeration Cycle
2-stage
compressor

economizer

condenser

evaporator
expansion devices
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2-stage centrifugal chiller

pressure

Refrigeration Cycle

Pc
P1
Pe

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condenser

6
expansion
devices
8

economizer
7

2-stage
compressor

10
9

evaporator
C B enthalpy

A
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Refrigerant Operating Pressures

HCFC-22
( High Pressure 40/140 psig)

pressure

HFC-134a

HCFC-123
atmospheric
pressure
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( Low Pressure vac/8 psig

temperature

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Centrifugal Water Chillers

Compressor Capacity Control

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Inlet Vanes

inlet vanes
impeller

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Multistage Compressor
impellers

inlet vanes
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Impeller Dynamics
Vr refrigerant flow rate
R

Vr

Vt rotational speed diameter

Vt
diameter
rotational
speed

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refrigerant
flow rate

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Compressor Unloading
R
Vt

full load
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Vr
R

Vr

Vt

part load
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Surge
Vr
R
Vt

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Vr < static pressure

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Compressor Map

pressure difference

90

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75

51

10

14

25

36

refrigerant flow rate

63

vane position
(degrees)

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compressor map for a

2-Stage Compressor
A
pressure difference

90

75

51

10

14

25

63

36

unloading line

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refrigerant flow rate

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Centrifugal Water Chillers

period five

Application Considerations

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Adjustable-Frequency Drives

3-4% Losses

Kw/rt

inlet vanes only

AFD + inlet vanes
AHRI Temp Relief

load
AFD Centrifugal Chiller Requires LIFT Reduction to Save Energy
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guidance

VSD or High Efficiency?

Guidance Factors

High efficiency

Significant demand
charges

Humid climates

Multiple chillers in the plant

Economizer(airside or free
cooling) that reduces low
load/low lift operating
hours

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VSD

Many hours at low

condenser water
temperatureand low load

Perhaps only on one chiller

Factor in replacement of
VSD when performing life
cycle assessment

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FL vs PL efficiency
VSD Chiller or Hi-E Chiller ( Fixed Drive)
SAME Price Option

Full Load
(kW/ton)

IPLV
(kW/ton)

a) VSD

0.572

0.357

b) High Efficiency (Fixed

Drive)

0.501

0.430

(700 RT Chiller)

VSD Option typically cost around 30% more.

Alternatively, this same investment $ can be used to
Upgrade efficiency with larger heat exchangers
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VSD Application on Chillers

Understand its Applications Benefits vs Cost
LIFT Reduction (Min for Tropics) for VSD Centrifugal chiller
Capacity Reduction for VSD Screw
ROI - Efficiency gain vs Higher $Investment &
potential higher service cost

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equipment certification standards

ARI Standard 550/590

Standard rating conditions

Common

Fouling

system conditions for published ratings

factor

Integrated Part Load Value (IPLV)

Part-load

Based

on an average single-chiller installation

Standard

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efficiency rating
operating conditions

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ASHRAE STD 90.1 ( 2013)

Current 2013 version
(first published 1975)
Most Building Codes,
Guides & STDs
Draw Reference
to ASHRAE 90.1 STD

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Mandatory: Chiller Efficiency as of

2015 (Centrifugal chillers)
Chiller
type/size

Path A

Path B

WC centrif. <
150 tons

0.610 kW/ton & 0.550 0.695 kW/ton & 0.440

IPLV
IPLV

WC centrif. 150
< 300 tons

0.610 kW/ton & 0.550 0.635 kW/ton & 0.400

IPLV
IPLV

WC centrif. 300
< 400 tons

0.560 kW/ton & 0.520 0.595 kW/ton & 0.390

IPLV
IPLV

WC centrif. >=
400 tons

0.560 kW/ton & 0.500 0.585 kW/ton & 0.380

IPLV
IPLV

American Standard Inc. 1999

* Likely to be adopted by SS530

Table is for
standard rating
temperatures

Non-standard
temperatures
and flows use
equation to
modify the
requirements
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Chiller Performance Improvements

8.0

Centrifugals & Screws: 62%

Smaller scrolls & recips: 41%

chiller efficiency, COP

6.2 COP

6.0

4.0

( 7.3 COP)
centrifugal
>600 tons
screw
150-300 tons
scroll
<75 tons

reciprocating
<125 tons

2.0

Go for the Best

0.0
ASHRAE Standard 90
90-75
(1977)

American Standard Inc. 1999

90-75
(1980)

90.1-89

90.1-99

90.1-2010

best
available

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Efficiency Comparison:

MORE
INFO

Index Rating
AHRI Definition of Integrated Part Load Value (IPLV/NPLV)

1
IPLV =

1%
A

42%
B

A = kW/Ton @ 85F(30C) @ 100% Load

45%
C

12%
D

B = kW/Ton @ 75F(24C) @ 75% Load

C = kW/Ton @ 65F(18C) @ 50% Load

D = kW/Ton @ 65F(18C) @ 25% Load

Temperatures: Expected Entering Tower Water

AHRI Conditions: Chilled Water: 54/44F (12/7C)
Condenser Water: 3 GPM/Ton (0.054 L/S/kW)

1%

85F

(30C)

42%

57%

75 (24C)

65 (18C)

IPLV does NOT represent Real Efficiency

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Use of IPLV or NPLV

(AHRI 550/590 Appendix D, D2.1 Scope)

This appendix is for equipment covered by this standard.

The IPLV equations and procedure are intended to provide a
consistent method for calculating a single number part load
performance number for water chilling products. The equation
was derived to provide a representation of the average part load
efficiency for a single chiller only. However, it is best to use a
comprehensive analysis that reflects the actual weather data,
building load characteristics, operational hours, economizer
capabilities and energy drawn by auxiliaries such as pumps
and cooling towers, when calculating the chiller and system
efficiency. This becomes increasingly important with multiple
chiller systems because individual chillers operating within
multiple chiller systems are more heavily loaded than single
chillers within single chiller systems.

Superior IPLV does not represent Superior Energy Savings

American Standard Inc. 1999

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 American Standard Inc. 1999

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equipment certification standards

AHRI Standard 550/590

Purpose
Establish

definitions, testing,
and rating requirements

Scope
Factory

designed and
prefabricated water chillers

Vapor-compression

refrigeration
Air-cooled

and water-cooled
condensing

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Selection Printout

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Factory Test to AHRI 550/590

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Helical-Rotary Water Chillers

A Trane Air Conditioning
Clinic

American
American Standard
StandardInc.
Inc.1999
1999

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Helical-Rotary Water Chillers

water-cooled

air-cooled

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components of a

Helical-Rotary Water Chiller

oil supply
system

compressor motor
liquid/vapor
separator

oil separator
condense
r

control
panel

starter
evaporator
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compressor...

Helical Rotors

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compressor...

Helical Rotors
female rotor

male rotor
housing

slide valve
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Oil Separator
refrigerant vapor
to condenser

refrigerant vapor
and oil mixture

oil return to sump

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water-cooled

Condenser
refrigerant vapor
baffle

cooling
tower
water

subcooler

liquid
refrigerant
tube bundle

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air-cooled

Condenser
propeller fan

condenser
coil

outdoor air

subcooler
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expansion device ( Air-cooled )

Electronic Expansion Valve

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expansion device ( Water-Cooled )

Orifice Plates

orifice plates

to
evaporator

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Flooded Evaporator ( Water-cooled )

liquid
refrigerant

refrigerant
vapor

chilled
water
supply

tube bundle

chilled
water
return

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liquid level
sensor
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Direct Expansion Evaporator (aircooled)

chilled
water
supply
baffles

chilled
water
return

refrigerant
vapor
tube bundle
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liquid
refrigerant
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Controls and Starter

control
panel

starter

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helical-rotary water chiller

Refrigeration Cycle

condenser

pressure

expansion
device

liquid/vapor
separator

7
6

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evaporator

enthalpy

compressor
1

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helical-rotary water chillers

Refrigerants

HFC-134a ( Currently most commonly applied)

HF0 XXX ( Next generation ) Low GWP

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Helical-Rotary Water Chillers

period five

Application Considerations

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RTHD AFD Water cooled Screw Chiller

with Adaptive Frequency Driver

CONFIDENTIAL AND PROPRIETARY INFORMATION OF TRANE

Application for Variable Speed Screw Chiller

Investment $ : +30-40%

Efficiency Improvement : 5-10%

Constant Condenser Temperature 30C

200
180
160
140
120
100
80
60
40
20
0

Illustration Only

STD

AFD Type

20

30

40

50

60

70

80

90

100

AFD Type typically improves overall

efficiency by 5-10% vs STD.
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VSD Application on Screw Chillers

Understand its Applications Benefits vs Cost
LIFT Reduction (Min for Tropics) for VSD Centrifugal chiller
Capacity Reduction for VSD Screw
ROI - Efficiency gain vs Higher $Investment &
potential higher service cost

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condenser types

Air-Cooled or Water-Cooled

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air-cooled or water-cooled

Comparison

air-cooled

water-cooled

Lower maintenance

Greater energy efficiency

Packaged system

Longer equipment life

Better low ambient

operation

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ASHRAE STD 90.1 ( 2013)

Current 2013 version
(first published 1975)
Most Building Codes,
Guides & STDs
Draw Reference
to ASHRAE 90.1 STD

American Standard Inc. 1999

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Addendum CH

Mandatory: Chiller Efficiency as of

2015 (SCREW Chiller)
Chiller type/size

Path A

Path B

Air cooled < 150 tons

10.1 EER and 13.7 IPLV

9.7 EER and 15.9 IPLV

Air cooled >= 150 tons

10.1 EER and 14.0 IPLV

9.7 EER and 16.1 IPLV

WC pos. disp. < 75 tons

0.750 kW/ton & 0.600 IPLV

0.780 kW/ton & 0.500 IPLV

WC pos. disp. 75 < 150 tons

0.720 kW/ton & 0.560 IPLV

0.750 kW/ton & 0.490 IPLV

WC pos. disp. 150 < 300 tons

0.660 kW/ton & 0.540 IPLV

0.680 kW/ton & 0.440 IPLV

WC pos. disp. 300 < 600 tons

0.610 kW/ton & 0.520 IPLV

0.625 kW/ton & 0.410 IPLV

WC pos. disp. >= 600 tons

0.560 kW/ton & 0.500 IPLV

0.585 kW/ton & 0.380 IPLV

American Standard Inc. 1999

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equipment certification standards

AHRI Standard 550/590

Purpose
Establish

definitions, testing,
and rating requirements

Scope
Factory

designed and
prefabricated water chillers

Vapor-compression

refrigeration
Air-cooled

and water-cooled
condensing

American Standard Inc. 1999

Air Conditioning Clinic TRG-TRC010-EN

Summary

Types of chillers Overview

Centrifugal chiller - components, controls and applications
Screw chiller Components, controls and applications
VSD application considerations & Benefits vs cost
ASHRAE 90.1 Min EFF Standard
AHRI 550 Rating Standard for chillers

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Q&A

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