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DEPARTMENT OF MECHANICAL ENGINEERING

SAINT LOUIS UNIVERSITY


BAGUIO CITY

DESIGN OF ICE PLANT AND COLD STORAGE


PLANT WITH AN AIR CONDITIONING SYSTEM

Progress Report No. 3

GROUP NO. 8
MEMBERS:
Aben, Christian Louie B.
Aromin, Christian Froi C.
Onia, Christian Arvin L.
Palos, Joshua D.
DESIGN OF ICE PLANT AND COLD STORAGE
PLANT WITH AN AIR CONDITIONING SYSTEM

IV. CENTRALIZE REFRIGERATION SYSTEM

A single refrigeration system that will serve the whole plant:


A. Schematic diagram of the whole system
B. Evaporator system: parallel / series
C. P-H diagrams of the processes
D. Each building should be labeled with their respective
temperature requirements and the product/s stored.
E. The amount of refrigeration, mass flow, volume flow in the
piping system. Indicate the directional flows.
F. Mass and flow of air in the air conditioned ducting system.

V. DESIGN OF THE EVAPORATOR FOR EACH SECTION

VI. SELECTION OF CONDENSER

VII. SELECTION OF COMPRESSOR (SIZE, CAPACITY, ETC.)

VIII. DESIGN/SELECTION OF OTHER AUXILIARY EQUIPMENT


(COOLING TOWER, PUMPS, FANS, BLOWERS, DUCTING SYSTEM,
ETC.)
a) P-H diagrams of the processes
V. DESIGN OF THE EVAPORATOR FOR EACH SECTION

TLP - Low Profile Evaporators

Overview:

The LP Low Profile Unit Cooler line offers a compact flush to ceiling design featuring internally
enhanced tube technology. Storage space is optimized by a compact, slim profile, which
provides uniform air distribution through the coil for maximum heat transfer performance. Many
models also available as value-priced pre-assembled units.

Ample electrical and header


compartments
Certification:
Lower heater wattage

PSC Motors
Features:
Proven motor/fan/motor mount design
Streamlined cabinet style
Liquid line solenoid valve wire harness
High efficiency and high strength fan factory installed
guard
Schrader valve on suction header
Front access
Positive slope, hinged drain pan
Higher capacity
Central drain connections (approximate)
Compact
Universal drain fitting
Internally enhanced tubing
Large 3/4 ID (3/4 MPT) drain hole
More uniform air flow
Factory installqed distributor nozzle
Reverse cycle & 3 pipe hot gas available
460/1/60 PSC motor only
Convenient mounting brackets
Options: -30F and above room temperatures

Optional Features (Factory Mounted): Air, electric and hot gas defrost (reverse
cycle or 3 pipe) models
EC motors with SmartSpeed Technology
(Patent Pending)
R404A, R22, R407C
Compatible with SmartVap Capacity:
Electronically Controlled System
Medium Temp. models from 4,300 to
Heat exchanger - shipped loose
39,000 BTUH @10F TD, R404A
Heresite Coating
Low Temp. models from 3,070 to 34,400
Copper or GW Aluminum Gold Coat Fins BTUH @10F TD, R404A
Wire fan guard Electrical:

Painted Cabinet 115/1/60

208-230/1/60
SPECIFICATIONS:
Application: 208-230/3/60

Medium and Low Temperature Applications

VI. SELECTION OF CONDENSER

TrilliumSeries Condenser
The TrilliumSeries Condenser uses a patented Dry-Coil Adiabatic Design that saves energy,
reduces refrigerant charge, and lowers operating costs. With the use of proprietary logic and
EcoFlex controls, the On-Demand Adiabatic Pre-Cooler uses water only on the hottest days to
maintain condensing temperatures that typical air cooled technology cannot achieve. Because of
this, the TrilliumSeries Condenser is the lowest total cost of ownership product for supermarket
refrigeration systems.

Installation Advantages
Ownership Benefits
o 60% lower refrigerant charge may
In a variety of climate conditions, the
help meet EPAs Greenchill Certification
TrilliumSeries Condenser provides the
lowest total cost of ownership compared to o Compact and lighter in weight
air
o Single point electrical connection
cooled units.
o Direct drive VSEC motors and System Energy Savings Reduce Monthly
Whisper Quiet Fans are standard Energy Bills

o For new stores, reduces overall Reduced condensing temperature


system size by operating at lower condensing
Less compressor work
temperatures
Direct drive VSEC motors minimize
o Exempt from Title 24 legislation
fan energy required
o For refrigeration upgrades, increases
system capacity without changing out
expensive racks

Economic Advantages

o Attractive payback timeframes

o Lower total cost of ownership

Annual 37.2% System Energy Reduction for El


Paso, Texas

Peak Energy Savings


Up to 43.5% peak energy reduction
compared to air cooled units by operating
compressors at significantly lower
condensing temperatures
Average Payback Period by Region
o Peak energy is more expensive than
Notes for the Average Payback by Region
off peak energy
Graph:
o Reduces peak demand charges
1. Average payback periods based on current
analyses performed. Specific payback periods o Potential for substantial state and
vary. Utility prices (electricity, water, etc) local energy rebates
vary by state and system details vary by job.

2. Northeast region includes MA, MD, CT, DC,


NJ, NY, PA, RI.

3. Midwest region includes MN, MO.

4. Southwest region includes LA, TX,


Southern CA.

5. Northwest region includes Northern CA,


OR, and UT.
Average Peak Energy Reduction %kW by

State

Rebates
Most states offer utility incentives and
rebates which further decrease the initial
investment of the TrilliumSeries Condenser.

Type of Rebate Example based on www.dsireusa.org

Custom Measures and Retro-commissioning:


Custom $0.11/kWh saved up to 75% of incremental cost

Refrigeration Equipment: $35-$1000/unit


Refrigeration Air Conditioning and Refrigeration: $0.09 $0.15/kWh saved

Variable Frequency Drives: $80/HP


VFDs on Fan Motors or Other Controls Refrigeration Controls: $75-$100/Controller

Optional energy monitoring


maintains efficient operation over the life of
Dsireusa.org is a website with information on
the product
state, local, utility, and federal incentives and
policies that promote renewable energy and
energy efficiency. Established in 1995 and
On-Demand Adiabatic Pre-
funded by the U.S. Department of Energy, Cooler
DSIRE is an ongoing project of the N.C. Solar Water is used ONLY when the
Center and the Interstate Renewable Energy ambient temperatures require it
Council.
o Water spray saturates and cleans the
For custom rebates, an analysis of the overall On-Demand Adiabatic Pre-Cooler media of
system energy savings from air cooled to the any dust and debris
TrilliumSeries Condenser may be necessary
and is available from Baltimore Aircoil No water treatment is required
Company. Free draining prevents stagnant
water
Optional Built-in Energy
LEED Points available for water
Tracking / Alarms efficient landscaping (WE credit 1) based on
Optional alarms for the fans, pumps 2009 LEED for Retail and Commercial Interior
and valves reduce high head pressure rating system
instances
o Water from the drain and overflow
can be used for irrigation or other non-
potable uses

Controls Options

o Water Quality Sensor (Option)


Flushes the sump based on a factory preset
conductivity level to minimize water use.

o Water Monitoring (Option) This


option monitors the amount of purged water
and maintains efficient operation over the
Sound Levels
life of the product.

Easy Maintenance
Requires the same time to maintain
as an air cooled condenser

Water treatment is not required

o Water is turned on only when


ambient temperature requires it

o Water spray saturates and cleans the


On-Demand Adiabatic Pre-Cooler media of
any dust and debris

On-Demand Adiabatic Pre-Cooler


media acts as a filter to prevent debris from
Average Annual Water Use Compared to reaching the microchannel
Evaporative Condensers
o Can be removed without tools for
Low Sound easy coil inspection
Whisper Quiet Fans are standard Clean-out ports on both ends of
Direct drive VSEC fan motors vary the water distribution header facilitate easy
fan speed eliminating sudden starts and cleaning
stops The EcoFlex Controls maintain a
clean sump

Pump and strainer are easily


accessible from the access hatch
Adiabatic Pre-Cooler, and daily automatic
sump clean out

Critical components are stocked and


ship within 24-hours

Manual discrete spray system (water


bypass) standard

Easy Access to Pumps and Valves

Charge Reduction
60% less charge than comparable air
cooled condensers

Reduced charge could help meet


EPAs Greenchill commitments

Lowers greenhouse gas emissions of Discrete Spray System


the supermarket refrigeration system
Durable materials of construction
extend the life of the unit

Sump and drain pans drain freely

Ability to switch fans from automatic


to manual fan override in case of control
signal loss

Access hatch sensor shuts off the fan


when the hatch is opened

UL Approved unit

Coated microchannel independently


tested per G85-A4 for 3,000+ hours
Unit Refrigerant Charge Reduction The TrilliumSeries Condenser program
allows you to select the optimum
Peace of Mind TrilliumSeries Condenser based on ASHRAE
All units are equipped with state of design conditions and weather profile by bin
the art EcoFlex controls, On-Demand data that are pre-populated by city and state.
VII. SELECTION OF COMPRESSOR (SIZE, CAPACITY, ETC.)

Copeland Scroll Compressors for


Refrigeration
Because of their unmatched reliability, Copeland Scroll compressors are being used more and
more in commercial refrigeration as contractors and original equipment manufacturers (OEMs)
seek new ways to utilize the technology in supermarket, foodservice and healthcare applications.
Copeland Scroll K5 Compressor

7.515 horsepower for supermarket,


walk-in, and industrial applications
Approved for low, medium, & high
temperature applications
R-404A, R-407A, R-407C, R-134a ready
Enhanced Vapor Injection (EVI)
available for best total store efficiency
Improvements in low condensing
performance for better real world
benefit (AEER)
Equipped with CoreSense Diagnostics
for advanced reliability

Copeland Scroll CO2 Compressor

Leverages reliability of proven


Copeland Scroll technology
Designed For CO2 pressure and
lubrication requirements
Hermetic design to reduce potential
for leaks
Digital modulation available from 10
100%

Copeland Scroll ZS*KA Compressor

1-4 horsepower applications


Evaporating temperatures from -25F
to 45F
R-404A, R507, R-134a, R-407A/C, & R-
22
Recommended for walk-in
refrigerators and freezers, soft serve
machines, frozen beverage machines
Copeland Scroll ZFKV Compressor

415 horsepower low temp optimized


compressor
R-404A, R-407A, & R-407C ready
Designed for Enhanced Vapor
Injection (EVI) performance gains
Improved system capacity (~50%) and
efficiency (~20%)
Digital modulation available from 10-
100%

Copeland Scroll ZBKC Compressor

2-15 horsepower compressors


optimized for medium & high
temperature applications
R-404A, R-407C & R-134a ready
Improved efficiency from 10-15%
annually
Digital modulation available from 10-
100%

Copeland Scroll Transport Compressors

Best in class energy efficiency and


pull-down
Precision temperature control through
digital modulation
Corrosion protection and superior
reliability for demanding
environments
Copeland Scroll Outdoor Condensing Unit - XJ
Series

Scroll compressor unit with


CoreSense Diagnostics provides
superior reliability
High efficiency compressor, fan and
coil result in energy savings of 20% or
more over standard systems
Slim profile, lightweight and quiet
operation offer flexible installation
options

http://www.emersonclimate.com/en-
us/Products/Compressors/Scroll_Compressors/copeland_scroll_refrigeration/Pages/copeland_scroll_for_refrige
ration_applications.aspx#sthash.e6MyeYPG.dpuf

Table 27.1: COMPRESSOR POWER


Power Efficiency Brake Standard
(hp) (%) (hp) (hp)
Wk1 = 0.4609 40 1.15225 2
brake power = power/efficiency = 0.4609 hp / 0.4 = 1.15225 hp 2 hp
Wk2 = 39.9672 40 99.918 100
Wk3 = 4.6003 40 11.5 12
Wk4 = 1.4437 40 3.6093 4
Wk5 = 0.4813 40 1.2033 2
Wk6 = 0.4337 40 1.0843 2
Wk7 = 0.1663 40 .4158 1
Wk10 = 0.152 40 .38 1
Wk11 = 0.1739 40 .4348 1
WkA = 106.1355 40 265.3388 266

VIII. DESIGN/SELECTION OF OTHER AUXILIARY EQUIPMENT


(COOLING TOWER, PUMPS, FANS, BLOWERS, DUCTING
SYSTEM, ETC.)
A. COOLING TOWER
Paragon Induced Draft Towers

Deltas Paragon Induced Draft, counter flow design is available in single module capacities from 55
to 250 cooling tons.

Manufactured since 1981, the Paragon tower has been very well received in both commercial and
industrial applications.

Paragons unique design provides unlimited flexibility of modular operation, future upgrade
capability and location convenience.

Standard Features:
Seamless Engineered Plastic (HDPE) Shell

Corrosion Proof Construction

Direct Drive Fan System

Totally Enclosed VFD Rated Motors

Factory Assembled for Simple Installation

20 Year Shell Warranty


Low Pressure Drop Self Propelled PVC Water Distribution System

High Efficiency PVC Fill

Made in the USA

Basic Specs
A self-propelled PVC distribution system
Detailed Features incorporating a rotating sprinkler head and
lateral distribution arms with integral drift
eliminators. An inspection port is provided in
the cooling tower shell at the lateral arm
elevation for adjustment. (Non-rotating
water distribution system is also available).

Wet Decking:

A continuous wrapped spiral configuration of


lightweight PVC, bonded and packed for
maximum film cooling efficiency.

Fan Assembly:

The fan assembly consists of a fan ring,


propeller, motor and guard. The fan ring is
coated with premium plasite coating ideal for
the harshest corrosive environments. An
adjustable pitch propeller fan, fiberglass
reinforced polypropylene with a silica alloy
hub, is directly driven by a totally enclosed
All Delta Cooling Towers are factory VFD Premium rated motor designed for
assembled to the fullest extent possible for cooling tower duty. A fan guard is included
ease of installation and shipment. The that allows protection from the propeller and
following features are standard on our access to the motor.
Paragon Series Induced Draft Cooling Motor:
Towers:
Totally enclosed air over (TEAO) VFD rated
Shell: motor with 1.15 service factor, designed for
A seamless engineered polyethylene 208 or 230/460V 3 phase 60 cycle operation
cylindrical (HDPE) molded shell, with conical and suitable for outdoor service. Motor is
transition for motor/fan assembly, louvered provided with a 5-year motor manufacturers
inlets and fitting orientation. Louvered inlets warranty.
are designed for 360 air distribution. There Fitting Connections:
are no joints, seams, panels, gaskets, bolts,
fasteners or caulking like conventional PVC fittings are provided for inlet, outlet,
towers. overflow, drain and make-up connections at
standard orientation locations. Orientation
Sump: for special requirements is available for new
Sump is integral with cooling tower shell, and replacement installations.
creating a one-piece seamless structure. Hardware:
Water Distribution System: All fasteners are 304 stainless steel. Anchor
and lifting lugs are aluminum.
Cutaway View 2 - Lightweight And Heavy Duty: Plastic is
lighter than conventional cooling towers and
average wall thickness is 5-10 times sheet
metal towers.

3 - Leak Proof Sump: Molded as Unitary (One-


Piece) Structure that has no joints to leak or
require recaulking and sealing

4 - Water Distribution System: Self-propelled


multiple PVC rotating arm system evenly
distributes the water

5 - Drift Eliminator: Polyethylene drift


eliminators prevent water droplets from
leaving the tower

6 - Fill Material: high efficiency spiral wound


PVC cellular design for maximum cooling
1 - Corrosion-Proof Shell: HDPE Plastic 7 - Direct Drive Air Moving System: Totally
Construction can not corrode and is backed enclosed PVC rated cooling tower motor
by 15 Year Warranty powers fiber-reinforced polypropylene axial
propeller fan.
http://www.deltacooling.com/paragon-induced-draft-towers/#sthash.5u6znWyb.dpuf

B. PUMP
Refrigeration Circulation Pump

Product Description
Specifically designed for refrigeration cold plate circulation, this pump allows you to adjust water flow
accordingly to your system. This 8050 features a positive displacement, three chamber diaphragm,
self-priming to 4 feet verticaland EPDM valves for proven ability and longer life.

Model Numbers
Model # 8050-261-105 Aftermarket
Model # 8050-261-105 OEM
Features & Benefits
Continuous Duty Motor
Cold Plate Circulation
Self-Priming up to 4
Run Dry Capability
12 VDC Motor
Seamless Motor Shell-Waterproof
30 PSI Pressure

Specifications / Replacement Parts


Name : Refrigeration Circulation Pump
Model # OEM/Aftermarket : 8050-261-105 OEM, 8050-261-105 Aftermarket
Description: 12 VDC-CE Version, No switch, Continuous Duty Motor, Cold
Plate,
Refrigeration Pump.
Dimensions : 7.25" x 4.25" x 4.40" [184x108x112mm]
Flow Rate GPM/LPM : 0.5 GPM [1.9 LPM]
Amps (Max) : 1.5
Max Pressure : 30 PSI [2.1 BAR]
Refrigeration Circulation Pump

Product Description
Specifically designed for refrigeration cold plate circulation, this pump allows you to adjust water flow
accordingly to your system. This 2095 features a positive displacement, three chamber diaphragm,
self-priming to 4 feet verticaland EPDM valves for proven ability and longer life.

Model Numbers

Model # 2095-273-200 Aftermarket

Model # 2095-273-200 OEM

Features & Benefits


Continuous Duty Motor
Cold plate circulation
Self-Priming up to 4
Run Dry Capability
12 VDC Motor
Seamless Motor Shell-Waterproof
70 PSI

Specifications / Replacement Parts


Name : Refrigeration Circulation Pump
Model # OEM/Aftermarket : 2095-273-200 OEM, 2095-272-200
Aftermarket Description: 12 VDC-CE Version, No switch, Continuous Duty
Motor, Cold Plate,
Refrigeration Pump.
Dimensions : 6.25" x 6" x 4.6" [159x152x117mm]
Flow Rate GPM/LPM : 1.5 GPM [5.7 LPM]
Amps (Max) : 3.5
Max Pressure : 70 PSI [4.9 BAR]
C. FANS

Haiku / S3150-A2

Model Name/#
Cocoa
Haiku / S3150-A2 Number of Airfoils

Fan Diameter 3

60 in. (1524 mm) Motor Type


Motor & Assembly Finish EC motor with a digital inverter drive

Controller Included
Black
Yes, remote
White
Airfoil Material Controller Features

Bamboo On/Off
Sleep Mode
Airfoil Finish
Off Timer
Whoosh Mode
Caramel
Reverse
Mount and Drop Tube Watts (min/max)

Standard length, included (10.2 in. / 260 2/30 W (fan only)


mm) Ambient Operational
Hanging Weight Temperature Change

13.2 lb (6 kg) 32120 F (049 C)

Number of Fan Speeds Environment

7 For indoor use only

Operating Voltage Fan Mode Indicator

100240 VAC, 1 LED display

Operating Frequency Warranty*

5060 Hz Limited lifetime

RPM (min/max) Energy Information at High Speed**

35/175 RPM Airflow: 5,365 CFM


Electricity Use: 11W (w/out light)
Amps (min/max)
Airflow Efficiency: 485 CFM/watt
0.05 - 0.363 A

View DOE Label

** Many standard ceiling fans feature only three speeds, so ENERGY STAR tests CFM at high,
medium and low speeds. Haiku's measured "high speed" is actually just the fifth of its
six/seven speeds.
* Limited Lifetime Warranty applies to U.S. and Canada purchases only. Outside U.S. and
Canada; 1 year warranty.
D. BLOWERS
InLine-Series Fan Centrifugal Exhaust Blower

The KCH Inline Series exhaust blower is completely weatherproof and fully
corrosion resistant. This tubular centrifugal inline blower offers straight airflow design
for duct installations requiring minimal space, low noise characteristics, and high
efficiency.

These blowers can be fabricated from a wide variety of materials such as:

PVC
FRP
Polypropylene
Stainless Steel
Epoxy coated carbon steel

Each unit is complete with TEFC motor with cover, formed inlet cone, backward
inclined wheel, and V-belt drive.

Fan Specs for CI & NH


Fan Ratings:
The fans shall be tested and rated according to AMCA Standard 210. They shall be
certified by the Air Movement and Control Association (AMCA) and shall be licensed to
bear the AMCA seal. Fans shall be model CI or NH as manufactured by KCH Services,
Inc.

Fan Units:
Provide factory-assembled and tested fan units consisting of housing, wheel, fan shaft,
bearings, access door, corrosion resistant support structure, drive, motor, drain, and
OSHA approved belt guard and shaft cover.
Fan Corrosion Resistance:
All fan parts in contact with the airstream shall be resistant to corrosion by chemicals in
the air stream. Fan housings shall be PVC, Polypropylene, or FRP Material.

Fan Wheels:
Wheels to be keyed to shafts. Steel wheels to be minimum Class II construction and
coated with FRP. Solid FRP, Stainless Steel, or Hastelloy wheels can be offered as an
alternative. Wheels to be statically and dynamically balanced after assembly and
before shipment.

Fan Bearings:
Provide heavy-duty grease lubricated, precision anti-friction ball or roller, self-aligning,
pillow block type bearings selected for minimum average life (AFBMA L 50) of 100,000
hours.

Fan Drive:
Provide V-belt drive, selected for 1.5 services factor. Belts shall be provided in matched
sets.

Fan Arrangement:
Fans to be arrangement 9 for motors of less than 40 H.P. and Arrangement 1 for
motors 40 H.P. and above.

Fan Base:
Provide slide rail motor base.

Fan Motors:
Provide totally enclosed fan cooled motors, 230/460 volt, 3 phase, 60 hertz. 1800 RPM
or 3600 RPM.

Fan Access Doors:


Provide bolted access door in housing scroll. Provide stainless steel bolts with bolt
surface inside housing capped and sealed.

Fan Drain Connection:


Provide 1" - 1 1/2" dia. coupling drain connection at lowest point of housing.

Fan Connections:
Provide flanged or flexible type inlet and flanged outlet connections.

HARTZELL TURBO PRESSURE BLOWER


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Features:
Sizes 14" to 26" wheel diameters, available in Arrg. 1, 4, 8, 9, and 10
CFM from 100 to 5,250 with SP up to 60"
Designed for applications with high static pressure and low flow requirements and features a
compact design, easy installation, and low maintenance
Housings are continuously welded heavy gauge steel
Type PB turbo blower wheel is fabricated high strength aluminum and steel using a spun front
plate and formed blades and is available in AMCA Type A or B spark resistant construction
Type SB turbo blower wheel is fabricated steel or stainless steel with a spun front plate and
formed blades
Available in clockwise or counter clockwise rotation with six standard discharge positions and
rotatable housing
Options and accessories are available
REFERENCES:
Kents Mechanical Engineering Handbook
Wikipedia.org
HVAC Handouts
Mechanical Engineering Handbooks and Manuals
World Wide Web