Agenda



  











 



Chiller Components

Chiller Refrigerant Cycle

1. Compressor lowers pressure in the

evaporator, allowing refrigerant to
boil and absorb heat from water.
 Chiller Refrigerant Cycle

2. Compressor
raises pressure
of refrigerant gas
and discharges
into condenser

1. Compressor lowers pressure in the

evaporator, allowing refrigerant to
boil and absorb heat from water.
 Chiller Refrigerant Cycle

3. Cooling water in condenser removes heat from
refrigerant gas allowing it to condense back into liquid.

2. Compressor
raises pressure
of refrigerant gas
and discharges
into condenser

1. Compressor lowers pressure in the

evaporator, allowing refrigerant to
boil and absorb heat from water.
 Chiller Refrigerant Cycle

3. Cooling water in condenser removes heat from
refrigerant gas allowing it to condense back into liquid.

4. Metering device
maintains seal
between condenser
2. Compressor
raises pressure
and evaporator.

of refrigerant gas
and discharges
into condenser

1. Compressor lowers pressure in the

evaporator, allowing refrigerant to
boil and absorb heat from water.
Chiller Efficiency

"
 
 








 !






  
  




 


  
 

"

  

 
  




 



 


"

 

 
  




 

 
  

What Influences
Chiller Efficiency ?
Importance of
Maintaining Chiller Efficiency




 





"

"


 









 





"

 







 

Cost of
Inefficiency


 
 



 











  









 

 







 
 



Condenser Problems






 




 





 






































 

Evaporator Problems





 





 











 


















 






 

Reality of
Chiller Plant Operation



















 









































 











Typical Chiller
Maintenance Program






 







 























Log Readings Alone
Are Not Efficient













 



  








Log Readings Alone
Are Not Efficient


 



 





 


 

Chiller Logging

Chiller Instrumentation


 















 
 









Orange Research Weiss Instruments

Fair Better
For R-11 & R-123
Low Pressure Refrigerant Chillers

Condenser Liquid Take temperature at liquid line

Refrigerant Temperature leaving condenser. Recommend
Raytek Model ST 60 or better.

Condenser Saturated
Refrigerant Temperature


On a Low-Pressure
Refrigerant Chiller


R-11 & R-123

Non-Condensables




 
 










Non-Condensables




 


Sat Temp Sat Pres

91 5.3
92 5.6

93 6.0

94 6.4
95 6.8

96 7.2

97 7.6
98 8.0

99 8.4
Non-Condensables






 

Non-Condensables








Condenser Approach



















 









!

"



 







 Pressure

Temperature Condenser
Pressure

Condenser Water Out

Pressure

Temperature

Liquid
Condenser Water In Refrigerant
Temperature
Causes of
High Condenser Approach













 









 
















 

 

 
 

  



  

 

  





 Condenser Approach:
Clean Versus Dirty
Condenser Tubes
When Tubes Are Clean

High Condenser Approach:

When Condenser Tubes Get Dirty...


 




 





 








 

 

Tube Fouling:

When Condenser Tubes Get Dirty

High Condenser Approach































 


 






 





 



 

High Condenser Approach



 




High Condenser Approach



 
  

 
 




 







 




  


 





 Water Flow Problems

Pressure
Temperature Condenser
Pressure

Pressure Drop = P in P out

Pressure

Temperature

Liquid Refrigerant
Temperature
Low Condenser Water Flow



  
 

   

  





  
  






   

!$

  



  

!$


 
 
   



$


 



 


 
  
 
  

Calculate Flow
Actual Versus Design


  $
,



,-



 


 

,$"""
!
#"








,
'

,
-'#"

$"""
,
("(

$"""
,
#&#&


#&#&

,
%"+





%"+










 


High Inlet Condenser
Water Temperature

  

  




  


 
 
  


!
  







 
  
 
  
 
!


  

 



  

  






$
 
 

!
  

 Evaporator Instrumentation

Pressure
Temperature Evaporator
Pressure

Evaporator Water Out

Pressure

Temperature

Liquid
Evaporator Water In Refrigerant
Temperature
 Evaporator Approach Problems

Pressure 












 


Temperature

Evaporator
Evaporator Water Out
Pressure

Pressure

Temperature

Liquid
Evaporator Water In Refrigerant
Temperature









High Evaporator Approach
Can be Caused by:


 





 









 



 





 

Low Evaporator Set Point














 




























 




!$












Compressor
Instrumentation




 




 













 


This log sheet was taken at a chiller plant with over 40,000 tons of chiller
capacity. During your site survey you obtain the following log sheet.

Chiller Capacity - 1,500 tons

ChillerMax:
The High-Tech Solution

Easy and
effective.


Operator visits all operating chillers

and collects data on a daily basis

Operator hot syncs with the website for chiller report
or using Autolog, log data can be entered directly
from a BAS system

Problems are identified and quantified by source

Corrective actions are given and scheduled

Efficiency is restored or maintained
ChillerMax Identifies Problems







 




 






 




 



 






















 Using the
ChillerMax
Website
Logon to ChillerMax Website using
Username and Password Provided



 
  

Using the ChillerMax Website

 Chiller Dashboard





 







Solutions









 












 







 Logsheet View

 


  



  


 
  


  
  

 


 
 

 





 



Readings in
yellow indicate a
  

 
run time error
 


 



View Charts

Chart Trends

Logging Chillers
Using ChillerMax
Add Log Record










Enter Required Data

Digital Control Panels

Condenser and Evaporator Readings

Water
temperatures

Water pressure
drops

Refrigerant
pressures Condenser refrigerant
temperature
 For R-11 & R-123
Low Pressure Refrigerant Chillers
  


 
  


  




 
  

Compressor and Electrical Readings

Oil pressure

Oil level &

temperature
Amps & volts
Using ChillerMax to
Track Maintenance Tasks
Condition Based Maintenance


 

 











 

 












 





  

 




 


Example: Emory University








 


 













#%





!$


" #

%


" $








" #

Internally Enhanced Tubes







 


 

Dirty Tube

Two-Direction Versus

Single-Direction Tube Brushing

Two-Direction Brushing Single-Direction Brushing

Single Direction
ChillerMax Identifies Problems




  







  
 
 










 


 
 

Single Direction
ChillerMax Restores Efficiency

 

 


   
 


 




 







 
 


Lessons Learned with

Internally Enhanced Tubes

Use a brush designed

for internally enhanced tubes

Brush with a cleaning machine

using dual rotation action

Change brushes as required, use a bore scope to inspect tubes

 Use Borescope to Inspect Tubes

 
 
 
 




 
 



  
  


 

Questions

& Answers

For additional information contact:

Don Tomovich
302-753-7940
dtomovich@kroff.com