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Training Objective
1. Participants are able to know the history and development of chiller. 2. Participants are able to explain type of major component use. 3. Participants are able to explain type of chiller control use. 4. Participants are able to Calculate Energy in absorption cycle. 5. Participants are able to use the knowledge to operate chiller safely and efficiently. 6. Participants are able to use the knowledge for maintaining chiller.
7. Participants are able to use the knowledge to carry out initial troubleshooting or mis-operation.
Topics to cover
1. History Refrigeration start with ice harvesting First refrigeration system The development 2. Unit of Refrigeration 3. Absorption Principles Absorption Chiller in GDC. Major Component Absorption cycle. Lithium Bromide & Refrigerant Characteristic Crystallization Curve
4. Chiller safety General / common safety in absorption chillers Crystallization protection Freeze protection Safety devices 5. Maintenance, Inspection and Trouble Shooting Preventive Maintenance Trouble Shooting Chiller/HTG, Gas & Oil Burner Overhaul & Inspection
6. Chiller Performance Energy Calculation C.O.P 7. Auxiliary Equipment Common auxiliary system in absorption chillers Refrigerant pump Solution pump Purging system
8. Chiller Piping Water system (CHW, CW) Steam system Fuel system Exhaust system
1.0 History
Ice Harvesting.
Refrigeration start by the use of ice to refrigerate and preserve
food during prehistoric times. Chinese, Hebrews, Greek, Roman, Persian ice and snow were stored in caves or dugouts lined with straw or other insulating materials. In the 16th century, the discovery of chemical refrigerant was one of the first steps toward artificial means of refrigeration. Sodium nitrate or potassium nitrate, when added to water, lowered the water temperature and created a sort of refrigeration bath for cooling substances. In Italy, such a solution was used to chill wine and cakes. During the first half of the 19th century, ice harvesting became big business in America.
demonstrated by William Cullen at the University of Glasgow in Scotland. Cullen used a pump to create a partial vacuum over a container of diethyl ether, which then boiled, absorbing heat from the surrounding air. The experiment even created a small amount of ice, but had no practical application at that time.
1758 Benjamin Franklin & John Hadley, Chemistry professor at
Cambridge University conducted an experiment to explore the principle of evaporation as a means to rapidly cool an object. They confirmed that evaporation of highly volatile liquids such as alcohol and ether could be used to drive down the temperature of an object past the freezing point of water.
First Refrigeration System1805 American inventor Oliver Evans designed vapor compression refrigeration cycle rather than chemical solutions or volatile liquids such as ethyl ether but never built a refrigeration system
1820 British scientist, Michael Faraday liquefied ammonia and other
gases by using high pressures and low temperatures. 1834 Jacob Perkins, an American living in Great Britain obtained the first patent for a vapor-compression refrigeration system. Built a prototype system and actually work although it did not succeed commercially. 1842 American physician, John Gorrie designed the first system for refrigerating water to produce ice. It can cooled the air to a temperature low enough to freeze water and produce ice but the system is a commercial failure.
The Development
1848 Alexander Twining began experimenting vaporcompression refrigeration and obtain patents in 1850 and 1853. Successful and credited with having initial commercial refrigeration in US 1856. 1851 In Australia, James Harrison began operation of a mechanical ice-making machine in 1851. His first commercial ice making machine followed in 1854 and patent for an ether liquidvapor compression refrigeration system was granted in 1855. Introduce commercial vapor compression refrigerant to breweries and meat packing housing. 1861 dozen of this system in operation. 1882 The first commercial success on refrigerated shipping when William Soltau Davidson fitted a compression refrigeration unit to the New Zealand vessel/ship Dunedin leading to a meat and dairy boom industry in Australasia & South America.
1859 The first gas absorption refrigeration system using gaseous ammonia dissolved in water (referred to as aqua ammonia) developed by Ferdinand Carre and patented in 1860. Due to the toxicity of Ammonia, such systems were not developed for use in homes but were used to manufacture ice for sale. 1895 German engineer Carl von Linde set up a large scale for the production of liquid air and eventually liquid oxygen for use in safe household refrigerators. 1920s Refrigerant Freon is a trademark of the DuPont Corporation and refers to CFC(chlorofluorocarbon) and later HCFC and HFC is developed.
absorption cycle lost much of its importance because of its low COP (about one fifth of that of the vapor compression cycle).
The absorption cycle is similar to the compression cycle, except for
absorber which dissolves the refrigerant in a suitable liquid, a liquid pump which raises the pressure and a generator which, on heat addition, drives off the refrigerant vapor form the high pressure liquid.
Some work is required by the liquid pump but, for a given quantity of
refrigerant, it is much smaller than needed by the compressor in the vapor compression cycle.
In an absorption refrigerator, a suitable combination of refrigerant
and absorbent is used. The most common combinations are ammonia (refrigerant) and water (absorbent), and water (refrigerant) and lithium bromide (absorbent)
1950s and 1960s, both centrifugal chillers driven by electric motors &
SAC to provide summer cooling were widely used in central refrigeration plants.
Steam widely used because excess steam was available in summer
in many central plant (used steam to provide winter heating) and because energy cost were of little concern.
1973 energy crisis; the price of NG and oil used to fuel steam boiler
drastically increased.
0.7. they required more energy and could not compete with ECC.
Many absorption chillers were replaced by ECC in the late 1970s
and 1980s
High investment required to build new power plants, electric utility
company added high demand charges and raised cost-per-unit charges during peak usage period.
In recent years, double effect, direct fired absorption chillers have
been developed in both Japan and the US with a COP approximately equal to 1.
America are rated in Tons of Refrigeration (TR). Historically, one Ton of Refrigeration was defined as the rate of heat (energy) removal that will freeze one short ton of water at 0 C (32 F) in one day
It was also defined as cooling capacity of an air conditioner or
refrigerator equal to 12,000 British Thermal Unit (Btu) per hour 200 Btu per minute and denotes; the amount of heat required to melt one ton of ice in 24 hours
were in ice houses. The simple unit allowed owners of these refrigeration systems measure a days output of ice against energy consumption and compare their plant to one down the street.
While ice houses make up a much smaller part of the refrigeration
industry than they once did the unit of Tons of Refrigeration has remained in North America. The unit's value as historically defined is approximately 11,958 BTU/hr (3.505 kW) has been redefined to be exactly 12,000 BTU/hr (3.517 kW).
The Formula
One short Ton = 2,000 lb Latent heat of ice (i.e., heat of fusion) 144 Btu / lb
(or 334.5 kJ/kg) Therefore, One Ton of Refrigeration = 2,000 * 144 = 288,000 Btu / 24 hr = 12,000 Btu/hr = 200 Btu / Minute = 3.517 kJ/s = 3.517 kW
Absorption Chiller in GDC. Major Component Absorption cycle. Lithium Bromide & Refrigerant
9
2 DFC SANYO 2 4 6 KAWASAKI 3 45
KLIA
UTP PLANT 2 PICC PJ1-ANNEX WP
2500
1250 1500 830 1000 700 86,920
a. Evaporator
Chilled water outlet
Chilled water enters at 12oC-13oC Refrigerant flow to evaporator from condenser by gravity flow and refrigerant pump sprays the liquid refrigerant through the spray nozzles over the outer surface of the CHW tube bundles Refrigerant water is sprayed at 5oC. However, for 2 modules SAC like HITACHI, the 1st module ~7-8C Refrigerant evaporates & absorbs heat from CHW Return. Heat is transferred from the CHW to the vaporized refrigerant at an amount equal to the latent heat of vaporization. Chilled water temp goes down to 6oC-7oC Refrigerant vapor enters Absorber. Pressure: 5.6 6.5 mmHg (0.7kPa 0.9kPa). For Hitachi 1st module, P= ~8mmHg(1.05kPa)
Refrigerant spray
RERIGERANT PUMP TYPE OF CHILLER HITACHI EBARA SPECIFICATION 415V x 3 x 50Hz x 0.4kW X 4P 415V x 3 x 50Hz x 1.5kW x 4P QTY 2 2 REMARK 1 UNIT EACH / MODULE
SANYO / KAWASAKI
b. Absorber
LiBr 64%
LiBr 57%
When its absorbs water vapor, temp goes up and becomes diluted 57%. Cooling water takes away heat of absorption Diluted solution is pumped into generator to be heated & concentrated Pressure = 6mmHg In the absorber, concentrated solution is supplied and sprayed at about 40-49C with a concentration of 62-64% Vaporized refrigerant is absorbed by the concentrated LiBr solution because of its lower vapor pressure It is cooled by the CDW flowing inside the tube bundle at an entering temperature of 29-30C. As the water vapor from the evaporator is absorbed, the solution is diluted to a concentration of about 57% & its temp drops to 35C The vapor pressure of the solution is then about 5mmHg abs, which is lower than the evaporator pressure of 5.6 6.5 mmHg The heat of absorption is removed by the CDW. Diluted solution is then pumped to the LTG & HTG by the solution pump. However for Hitachi chiller one solution pump is used to circulate diluted LiBr back to the absorber
Detail Process
evaporator diffuses into the LiBr solution that is sprayed down over the tubes in the absorber. Diffusion is a term that is used when a substance tends to move( spread of particles) from an area of greater concentration to an area of lesser concentration. The diffusion of refrigerant vapor into liquid LiBr solution is almost the same. It happens because the vapor pressure of the LiBr solution is lower than that the vapor pressure of the refrigerant.
How it happen?
When the solution has only small amounts of refrigerant in it (higher
concentration of LiBr) and its temperature is reasonably low, its vapor pressure is also low and the refrigerant vapor has great desire to diffuse or dissolve into the solution. The greater the difference in vapor pressure between solution mixture and the refrigerant vapor, the greater the desire to merge and so on. Two simple rules govern the rate of absorption. 1) The lower the solution mixture temperature, the lower the vapor pressure of the solution 2) The higher the concentration, the lower the vapor pressure of the solution. Therefore, the lower the solution temperature & the higher the concentration, the greater the rate of absorption Reference; Durhing Diagram.
In our example, LiBr solution entering the absorber is 62% LiBr while
the temperature is approximately 48.9C. Figure 1 (Durhing Diagram) which shows the vapor pressure verses solution temperature for 62% LiBr, reveals that at 48.9C, the solution has a vapor pressure of slightly less than 7 mmHg absolute.
Since the refrigerant vapor is at pressure of 5.6mmHg absolute,
diffusion of the refrigerant vapor into the solution cannot take place. In order for the solution to absorb refrigerant vapor, its vapor pressure must be lower than the refrigerant vapor pressure.
As the solution from the spray nozzles hits the top layer of tubes, its
temperature is lowered by the Cooling Water passing through the tubes. Our typical droplet lands on one of the tubes in the top row and spreads nicely around the tubes outer surface.
The Cooling Water flowing through the inside of the absorber tubes
at approx. 29-30C begins to cool our droplet of solution. When the droplet temperature falls below approx. 43C, its vapor pressure is lowered (~5 mmHg) below that of refrigerant vapor.
effect of the absorber tubes, the refrigerant vapor with a higher pressure than the solution, is able to diffuse into the solution and absorption takes place.
This is actually only the beginning of the absorption process or mass
transfer. Mass transfer simply means that the solution is gaining mass or weight if you prefer. The mass that it is gaining is refrigerant.
Hitachi Chiller :
1.Solution Pump 1 unit for each module (7.5kW) To pump out diluted solution (57%) to LTG via LT Hex To pump out diluted solution (57%) to HTG via LT hex, HT hex & drain cooler 2. Solution spray pump #1- 1 unit for each module (5.5kW) To circulate diluted LiBr back to absorber to maintain good cooling process for LiBr so that vapor pressure is always low and absorption rate is efficient.
3. Solution spray pump #2 1 unit for each module (5.5kW) To pump concentrated LiBr (64%) from LTG & HTG via LT Hex & HT Hex back to absorber
Ebara Chiller
1.
Solution pump 4 units To pump out diluted LiBr to LTG & HTG via LT Hex, Drain Hex1#. After drain Hex #1, the LiBr flow is split to LTG and HTG (via HT Hex and drain Hex #2)
c. HTG
Water vapor
There is a different between Hitachi & Ebara chiller before the solution entering HTG due to some component arrangement. It can be explained as below; For HITACHI chiller -The diluted solution (57%) from absorber is separated into two ; i) Flowing through LT Hex (in 35C-out 70C) & partly to HT Hex (in 70C- out 120C). Another part from LT Hex will flow to LTG (70C) ii) Flowing through Drain Hex (in 35C-out 70C) - The solution leaving from the above section which is partly concentrated (~60%) will join again before entering HTG For EBARA chiller - The diluted solution (57%) from absorber is flowing through LT Hex (in 35C- out 68C max.) and LT Drain Hex (in 68C-out 80C max.) and after that is separated into two; i) Flowing through HT Hex (in 70C out ~115C) and HT Drain Hex (in 115C out 122C) to HTG ii) Flowing directly to LTG (70C)
Burner/Steam
Concentrated LiBr
Diluted LiBr
i.e steam for SAC (up to 160C) and ~1,400C flame for DFC. The water vapor boils off at a pressure of about 390 mmHg abs. (52 kPa abs). For DFC the pressure is at maximum 690mmHg abs (91kPa abs) The solution release the absorbed refrigerant (vaporized) and also reconcentrates to 66% Refrigerant vapor (~149C) flows via the tubes submerged in the diluted solution in the LTG and condenses to liquid there. The LiBr solution;66% and 130C in temperature returns to the HT Hex and cools to about 90C.
It will then flow via LT Hex, leaves at ~45C before entering absorber
with 63-64% concentration For SAC Hitachi, a pump (solution spray #2) is used to pump LiBr from HT Hex & LTG via LT Hex back to absorber while for EBARA, LiBr flow to absorber by gravitational force Steam source that has been utilized will flow via drain Hex before turns to steam condensate at ~80C back to Hot Well Tank while for DFC the combustion exhaust is release to the atmosphere
and a low temp generator (LTG) The refrigerant vapor produced by HTG is used to heat LiBr solution in the LTG in which the pressure (hence the boiling point) is lower. Thus the heat of condensation is effectively utilized. In the single effect type, the refrigerant vapor produced by the (LTG) generator is send to the condenser to become liquid refrigerant In the double effect, the refrigerant vapor produced by the HTG turns to water in LTG HEX tubes as it releases heat to the LiBr solution. In this step, the diluted solution is heated by driving heat source (HTG) and by the latent heat in the refrigerant vapor (LTG) which otherwise would be released into the cooling water.
refrigerant liquid and mixes in the condenser before returning to the evaporator.
This combination means a lower energy consumption of driving heat
source.
Moreover, less heat being discarded into the Cooling Water translates
1.2
double effect is as follows. The amount of evaporated refrigerant per one (1) USRT in the evaporator is;
Heat amount of 1 USRT = 3,024 kcal/h = 5 kg/h Latent heat of evaporated refrigerant 594.3 kcal/kg
Namely, in order to get 1 USRT, 5 kg/h of refrigerant is needed
is produced by the LTG. In other word, only driving energy to produce 3 kg/h of refrigerant is required.
Accordingly, the double effect type can save 2kg/h of driving energy
as compared with the single effect type and still more as a heat released to the air by cooling water; cooling tower can be sized down.
d. LTG
Condenser
Refrigerant Vapor
Diluted Solution
The diluted LiBr from LT Hex (Hitachi) and LT DHex (EBARA) enters the LTG at 65-70C. The water vapor from HTG (149C) flows through the tube bundle submerged in the diluted LiBr and condenses to liquid form at ~90C The liquid refrigerant then enters the trench in the condenser The latent heat of condensation released from the liquid refrigerant heats the diluted solution from 65C to 82C & boils off the water vapor from the diluted solution at pressure of about 50mmHg abs (6.7 kPa abs). The vapor goes to condenser As the water vapor is boiled off, the LiBr solution becomes partly concentrated with a concentration of 60.2%. At the outlet of the LTG, partly concentrated LiBr combines with the concentrated LiBr from the HT Hex at 95C & the mixture enters the LT Hex at ~89C and a concentration of 63-64%. After it flows through the LT Hex, the temperature of the solution drops to about 45C. The solution then enters the absorber, spray over the CDW tube bundle & absorbs the water vapor from the evaporator.
e. Condenser
Condenser
The liquid refrigerant from LTG tubes enters the trench in the condenser at ~90C Condensed liquid refrigerant from the tubes is cooled to a temperature 37C & combined with the liquid refrigerant condensed in the condenser Refrigerant vapor boiled off in the LTG is extracted by the condensers low saturated pressure of 46.2 mmHg abs. (6.2 kPa abs.) through the top passage & condenses to liquid as the Cooling Water removes the latent heat of condensation at a temperature of about 37C Liquid refrigerant is forced through an orifice, throttled to a pressure of about 6.8mmHg abs. (906 Pa abs.) and returned to the evaporator
Absorbent: Lithium Bromide Stable. Solid state. Similar to salt, high boiling point. Very stable but corrosive to the metal Very High Absorption Ability, Dissolve up to 60% at normal temperature. Non Toxic, Odorless Component: Li = 8%, Br = 92%. Specific Gravity = 3.46 (at 25oC)
LiBr Solution
Refrigerant: Pure Water LiBr Solution: Pure Water + LiBr LiBr solution charged in composition: - LiBr = 53 56%, Water = 46 43 % Strong LiBr Solution: - % of LiBr Concentration > 64% Weak LiBr Solution - % of LiBr Concentration < 64%
LiBr Solution
Inhibitor -To protect chiller internal materials such as steel, copper etc. from corrosion attack. -Chemical used: Lithium Molybdate, Lithium Chromate, Lithium Nitrite.
Surfactant -To maintain solution surface tension. Increase solution absorption rate hence will increase heat transfer efficiency and chiller performance. -Chemical used: Alcohol based e.g. Octyle Alcohol, Iso-Octanol. pH Adjuster -To maintain pH at certain range (xx-xx) due solution Alkalinity increase after internal chemical reaction. -Chemical used: Hydrogen Bromide (HBr).
Additional Substance
A chemical compound of Lithium (from lithium ore) & Bromine (from seawater) Prepared by treatment of lithium carbonate with Hydrobromic acid. The salts forms several crystalline hydrates. The anhydrous salt forms cubic crystals similar to common salt A white, deliquescent, granular powder with a bitter taste, melting at 547C, soluble in alcohol & glycol A desiccant material which has hygroscopic character Hygroscopic is the ability of a substance to attract and hold water molecules from the surrounding environment with the absorbing material becoming physically changed somewhat by an increase in volume, stickness or other physical characteristics of the materials Water molecules become suspended between the materials molecules in the process Same characteristics as salt (Sodium Chloride) but absorption power is stronger than salt LiBr has strong corrosive action to a metal under existing oxygen
Inhibitor Characteristics
Lithium Chromate/Molybdate
-
Lithium Chromate and Lithium Molybdate protect steel without the formation of ammonia or iron oxide They don't scavenge hydrogen gas formed when the iron corrodes. They stop iron from corroding in the first place Effective corrosion inhibitors in brine systems such as lithium bromide Chromates are pollutants, their usage has been highly reduces over the years. However it is still quite reasonable to apply chromate systems since nothing is being discharge into the environment Molybdate is not as effective as chromate Lithium Nitrate
Nitrate has the ability to scavenge the hydrogen gas generated by corrosion thus maintain good vacuum condition Nitrate works by increasing the formation of iron oxide commonly found in all absorbers Idea is that the oxide will coat the steel surface and prevent additional corrosive attack A good concept except that the oxide layer becomes too thick (accumulate), ultimately falling off the steel into the solution. Debris the fouls all of the internal orifices causing significant problems The disadvantage is nitrate can reacts directly with hydrogen, reducing it to ammonia Ammonia is very harmful to cuprous (copper) material and increase the overall corrosion rate of copper-based metal Can be a component of more exotic corrosion failures such as stress corrosion cracking. Therefore, the nitrate must not be overused
Ph Adjuster Characteristics
-
Hydrobromic acid and lithium hydroxide modify the solutions pH and alkalinity The acid lowers these values while the hydroxide increases them The cuprous (copper) metals are naturally protected at low pH and low solution alkalinities It is the ferrous metal (iron/steel) that is affected under these condition If low pH and alkalinity are maintained in the lithium bromide brine, an inhibitor is needed to protect the steel
Octyl Alcohol
-
As an accelerating agent of absorption power Without alcohol, the solution surrounding the absorber tube tends to stratify or develop layers As refrigerant is absorbed into the outer surface of the solution surrounding the absorber tube, the solution reaches equilibrium due to lack of heat transfer. Equilibrium is a scientific way of saying things that have stopped happening In other words, the heat build up in LiBr on the outer-layer causes absorption to cease due to solution temperature rising. Vapor pressure goes up and when it gets as high as the refrigerant vapor pressure, no more absorption can take place. Some stirring up of the solution is needed to mix the layer and get the heat from the outer layers to the inner area of the tube where the heat can be carried away. Alcohol will stir up the layers by convection at the correct quantity therefore a small quantity should be added and observed the performance It will maintain solution surface tension and increase heat transfer efficiency and chiller performance
Issues
-
Lithium Bromide corrosion control in absorption refrigeration is a very complex scheme of proper mechanical operation and the balance of added chemical. What complicates the situation still further is that there arent a large number of highly skilled personnel available to service absorption systems. These conditions lead to many absorption machines suffering from severe corrosion. They are performing very poorly at best and many are ready to be scrapped prematurely Therefore, attention should be paid to handle the solution and it is necessary to keep inhibitor concentration/limit within the maintenance standard (OEM) by performing chemical analysis of the solution as well as any air leakages from outside that can affected vacuum side of the chiller
Refrigerant Characteristic
Refrigerant Characteristic
oRefrigerant (Pure water) boiling point will depend on surrounding pressure. oWater boiling point is relatively low at low surrounding pressure. oAbsorption Cycle chiller evaporator & absorber shall be maintained at pressure below 6 mmHg in order to achieve chilled water temperature at 6oC. oIf evaporator & absorber pressure slightly high chiller will not be able to produce lower chilled water temperature hence chiller capacity will be reduced.
Example: Refer to Water Saturated Temperature Curve, determine water boiling point temperature at 5 mmHg absolute pressure.
Common Safety
o Crystallization prevention/protection function
High concentration alarm Combustion or steam will be stopped when high concentration detected o High Stage Generator temperature high alarm Fuel or steam flowrate will be reduced when high temperature generator reached high temperature setting. o Cooling water temperature low Setting temperature of cooling water can be controlled automatically depending on inlet CW temperature.
o
o Freeze protection function To prevent chilled water freezing The chiller will cut-off when the chilled water outlet temperature fall below than the setting temperature.
HTG
CW inlet pipe CHW outlet pipe HTG Refrigerant chamber in evaporator Control Cabinet Control Cabinet
* Typical safety devices may be different for other Manufacturers. Separate list will be provided.
Preventive Maintenance
ACTIVITY WEEKLY Recording Of Operation Data x DURATION MONTHLY ANNUALLY
x
x x Every 3 months x x
x
x x
ACTIVITY
DURATION
WEEKLY
Capacity Of Purging Unit Leakage Check for Purging Solenoid Valve Air Tightness Check Analysis Of Quality for CHW, CW and steam drain Analysis Of Solution & Refrigerant
MONTHLY
x
ANNUALLY
x
Troubleshooting: Chiller/HTG
FAULTS NO . 1 Poor vacuum condition a. Leakage caused during transportation and leakage detection not performed at initial start, or new leakage occurred during operation. b. Leakage at welding seam caused by serious outside corruption. c. Improper purging. d. Performance of vacuum pump decreased. e. Aging sealing element or improper installation. f. Vacuum valve does not close tightly. g. HTG temp. high than 165OC during operation which generates Hydrogen. h. Leaking at Solution & Refrigerant Pump. a. Carry out overall leakage detection and eliminate the leakage. b. Clean the rust and eliminate the leakage then repaint it or all chiller (the chiller should be in vacuum during painting); maintain good ventilation, humidity (<85%) and drainage condition of the machine room. c. Refer to Vacuum Management. d. Detect vacuum pump purge capacity with vacuum pump, detect the air tightness of the purging pipe connection, check the type and charging volume of vacuum pump oil and replace the badly emulsified oil. e. Replace or reinstall f. Close tightly g. Readjust the temp. setting of HTG to avoid operating at high temp. h. Conduct leak check during inspection and overhaul. CAUSES KEYS
CAUSES a. Poor vacuum condition b. Insufficient cooling water flowrate c. High cooling water inlet temperature (higher than the rated) d. Too high solution cycling e. Low temperature of HTG f. Soot with combustion chamber and fire tubes g. Crystallization h. Refrigerant polluted i. Insufficient solution j. Copper tubes in condenser and absorber blocked or scaled k. Hot water overloaded l. Non or insufficient octanol charging
KEYS a. Refers to No 1 b. Vent air in water system air and make up water fully; check water system to see if valves are completely opened and filters are blocked. Check if the water pump can meet the chillers requirement, or it will be replaced c. Check if the cooling tower fan belt is loose or fallen off; adjust the cooling tower fan blade angle; check if the angle & speed of the water distributor in he cooling tower is correct; check if the cooling tower can meet the chillers requirement d. Regulate the HTG solution concentration to 63% +- 0.5%, Regulate the LTG solution concentration to 62% +- 0.5% Warning: lock the screw after regulating the concentration regulation valve. e. Readjust the burner and increases combustion f. Clean the soot and readjust the burner with shell-Bacharach meter
FAULTS NO. 2
CAUSES
KEYS g. Refers to No.4 and 5. h. Refers to No.6. i. Charge enough solution and readjust the concentration j. De-scale. k. Adjust per actual condition l. Charge per the rate of 0.3%
a. Overloaded of the chiller b. Cooling load lower than the rated c. Deviation of the sensor d. Improper data setting
a.Load does not match the chiller capacity; equip more chillers or lower load requirement b.Refers to no 2 c.Calibrate with precise thermometer ; replace the temp. sensor when tolerance >2oC; readjust the water temp. compensating parameter when tolerance <2oC d.Modify the data setting
FAULTS
CAUSES a. Air leaks into the HTG resulting in pressure rise and solution cycling decrease b. Poor vacuum condition in main shell causes more refrigerant at condenser or evaporator that increases the solution concentration. c. Solution angle valve does not open enough d. HTG solution level or inverter out of control causes solution cycling decreased e. Combustion too great f. Too small opening of HTG concentration regulating valve g. Cooling water inlet temp too low: 2425oC.
KEYS Auto judge temp. difference between HTG and THG concentrated solution outlet and auto start decrystallization program, then take the following procedures; HTG leakage detection, eliminate leakage to make the solution cycling normal main shell leakage detection and eliminate leakage to make refrigerant level normal Increase the solution angle valve to largest angle Check solution control or regulate the inverter Regulate the combustion Increase HTG concentration regulating valve opening Check the cooling water temp. setting to keep cooling water inlet temp. normal or make it inverter-controlled
NO.
4 HTHE crystallization
NO. 5
CAUSES a. HTG solution level control or inverter out of control b. Poor vacuum condition in main shell causes more refrigerant at condenser or evaporator that increases the solution concentration. c. Solution angle valve does not open enough d. HTG solution level or inverter out of control causes solution cycling decreased e. Combustion too great f. Cooling water inlet temp too low 24 25 oC.
KEYS Auto judge temp. difference between HTG and THG concentrated solution outlet and auto start decrystallization program, then take the following procedures; HTG leakage detection, eliminate leakage to make the solution cycling normal. Main shell leakage detection and eliminate leakage to make refrigerant level normal. Increase the solution angle valve to largest angle. Check solution control or regulate the inverter. Regulate the combustion. Increase HTG concentration regulating valve opening. Check the cooling water temp. setting to keep cooling water inlet temp. normal or make it invertercontrolled.
NO. 6
CAUSES a.cooling water inlet temp. too low b.combustion too great c.too much cycling causes HTG or LTG solution level too high and concentration too weak. d.concentration of mixed solution too dilute
KEYS a. Increase the cooling water inlet temp. properly. b. Regulate the burner decreasing the combustion. c. Discharge some refrigerant per the sampling result. d. Discharge some refrigerant per the sampling result. By-pass refrigerant completely after above procedures. a.Long time observe and set frequency parameter accurately. b.Overhaul. c.Overhaul or replace. d.Replace. e.Check the grounding. b,c, d and e items also applicable to refrigerant control abnormal.
a.Solution level does not stabilize at zone C with wide fluctuation, sometimes fluctuates to Zone A or E: keeps at Zone D or B for a long time. b.Solution level probes are not wellconnected or disconnected. c.Something wrong with solution level control or PLC. d.UKD aging. e.Solution level control is poor grounded.
NO. 8
CAUSES a.Tube frozen. - Some valve plate in CHW system falls suddenly. - CHW pump fault. - Filter at CHW system blocked. b.CHW temp. outlet too low. c. Water system improper cleaning. d. Additional anti-freeze while machine room <0oC. e. Broken copper tube due to vibration. f. Corrosive gas leaks due to copper tube eroded.
KEYS a. CHW pump stop immediately. b. Close inlet/outlet valve immediately. c. Shut off chiller immediately. d. Close 3 angle valve (vapor, diluted solution and concentrated solution angle valve). e. Measure specific gravity. If <1.1, take CHW sample at inlet & outlet valves for regeneration. f. Inform service engineer immediately.
DURATION
MONTHLY ANNUALLY
Analysis Of Solution & Refrigerant Inspection Inside Steam Chamber Of HTG Disassembly, Inspection and Cleaning of Solution & Refrigerant Pump Replacement Of Gasket of Air Tight Parts Inspection Of CHW Chamber & Replace Packing
Every 2 Years
x
x Every 5 Years x
Every 4 Years
Every 2 Years Every 4 Years
Every 6 Years
Energy calculation
Refrigerant capacity Heat consumption Power Consumption Coefficient of performance (COP)
POWER CONSUMPTION Electrical power consumed by other auxiliary equipment. Example of auxiliary equipment: Refrigerant pump. Solution pump. Chiller Control panel.
Solution pump (hermetic type) The pump is used to transfer absorbent solution to high temperature and low temperature generators. Motor stator and rotor are enclosed in an extremely stainless steel can thin
Discharge liquid refrigerant or solution is circulated and used for cooling the motor, for lubricating the radial and thrust bearing. Precaution: 1. Never run pump without liquid in machine (check side glass)
Purging system During the internal passivation and heating process, non condensable gasses (such as N2, O2, H2, etc) were produced through chemical reaction. When this happened, internal main shell pressure will no longer in vacuum condition and this can be observed through U loop manometer or Pressure Gauge at absorber side.
The purging system is used to pool and remove the non condensable gasses inside shell and hence keep maintaining high vacuum condition in the shell.
The system normally consist vacuum pump, purge valves, and purge hose. Purging mode: Auto & Manual Mode.
Purging Diagram
The piping system for absorption chiller normally inclusive the following : Water system (cooling water & chilled water) Steam system Fuel system ( gas and oil ) Exhaust system
Chiller
MOV blowdown
Closed loop
Make-up through head tank
make-up
User (AHU or Hex) MOV Flowmeter
Tubes are made of copper for better heat transfer. Chilled water enters evaporator and heat exchanged with the refrigerant.
Steam System
Needle valve
Strainer
Condensate Boiler Hot Feedwater Well Water Purification Plant Steam Boiler MOV Raw Water
Flowmeter
Chiller
Chemical Treatment
Blowdown
Tubes are made of copper for better heat transfer. Steam at 8.0 barg enters HTSG and condensate return back to Hot Well Tank.
Gas System A gas leakage alarm must be installed in machine room and the room should be well ventilated. Pressure release device must be installed if gas pressure is higher than normal. Drain valve should be installed at the lowest point of gas pipes. Buffer tube must be installed on the main pipe to avoid flame out due to gas low pressure caused by simultaneous start
Oil System Piping system includes oil storage tank, oil pump, daily oil tank, oil filter and measuring instruments. Oil tank must be equipped with oil check nozzle, oil vent, oil refill valve, oil level sensor and drain valve.
Exhaust System
Independent stack is recommended but if not possible, the main stack must be bigger and higher to avoid interference from one to another If furnace pressure is too low to get over the stack resistance, a high temperature draft fan shall be equipped in the exhaust stacks.
Fouling collector installed at the flue duct inlet to a chiller to prevent condensate flowing back to chiller.
Normally chiller rate exhaust temperature is 170 o C and insulation material can withstand 300 o C.