J.

ILANGUMARAN
 Liquid Chilling System

A liquid chilling system cools water, brine,
or other secondary coolant for air
conditioning or refrigeration.

The system may be either factory assembled
and wired or shipped in sections for
erection in the field
Components of chillers (vapor compression
system)
 Chilled Water System

Air Handling unit Circulating Pumps

Chilled Water Headers

Condenser
Chiller
Chiller - Pump Evaporator
Components of vapor compression system
 Chilled Water System

Chiller Yard Pump

Room

HT
To Hotel Tower 450Dia
OT
To Office Tower 400Dia
To Podium 250Dia

PD
Chiller Yard
 Multiple Chiller System

Parallel chilled water flow
arrangement

Series water flow arrangement
Parallel chilled water flow arrangement
Series water flow arrangement
 Type Of Chillers

Based On Based on
Condensing Media Compressor

Air cooled
Reciprocating

Water cooled Compressor

Screw Compressor

Centrifugal
Compressor
 Chiller package

Hermetically sealed Compressor & Motor,

Condenser, Expansion device & Evaporator, inter-
connected to form refrigeration cycle with
Fully charged refrigerant.
Safety & operational controls.
Lubrication system.
Operation monitoring devices.
Control panel duly wired.
Starter with Disconnect switch duly wired
 Chillers
Air-cooled Reciprocating Chiller OR
Water cooled Reciprocating Chiller
Air-cooled Screw Chiller OR Water
cooled Screw Chiller
Air-cooled Centrifugal Chiller OR
Water cooled Centrifugal Chiller
Chiller with Reciprocating Compressor

1. Semi Hermetic Reciprocating compressor

2. Muffler
3. Fan & condenser coil
4. Filter drier
5. Liquid Line sight glass
6. Moisture indicator
7. Expansion valve
8. Dx-Evaporator
9. Control Panel
10. Starter
11. Controls
 Chiller with Centrifugal
Compressor
Semi Hermetic Centrifugal compressor
Fan & condenser coil
Liq. Line sight glass
Moisture indicator
Fixed orifice assembly
Flooded Evaporator
External Lubrication system
External Capacity control system
Motor cooling system
Control Panel
Starter
 Controls
 Chiller with Screw
Compressors
Semi Hermetic Screw compressor
Oil Separator
Fan & condenser coil
Receiver/Sub-cooling coils
Filter drier
Liq. Line sight glass
Moisture indicator
Expansion valve
Dx-Evaporator
Lubrication system
Control Panel
Starter
Controls
 Basis of Design

The Chilled Water System has been

designed to produce the chilled water
at following so as to achieve the
comfort conditions by Air conditioning
system at floors.

Entering Chilled Water Temp. : 55ºF

Leaving Chilled Water Temp. : 45ºF
 Variable Speed Drive

All the chilled water pumps are

provided with a microprocessor based,
pulse width modulated, adjustable
frequency AC drive.

The drive controls AC motor.
 Chilled Water system
Operation- Logic

The whole system is automatic thru
Building Management System to achieve
the specified conditions at floors.

Once temperature is achieved in condition
space the motorized 2-way valve closes
which in turn increases the difference in
pressure between supply & Return pipes.

Reduction in speed reduces the chilled
water flow in the system and save the
energy.
 Chilled Water system Operation-
Logic

Once load in condition space increases,

two way valves opens thus reduces the
pressure difference between supply &
return pipes.

Increase in speed, increases the Chilled
flow to meet the requirement of condition
space.
Pumps- Automatic Shutdown

The VFD shuts down the pump should

any of the following happens:
– Over Temperature
– Motor Overload
– High Motor Current
– Motor Ground
Chiller principle
Reciprocating Chillers
Refrigeration cycle
Refrigeration cycle
 T0 Conditioned Space
RefrigerationCycle

Return air
Motor Compressor

Metering
Device

Condenser
Reciprocating compressors
Reciprocating Compressor
Semihermetic reciprocating compressors
Semihermetic reciprocating compressors
Thermostatic expansion valve
Thermostatic expansion valve
Returning discharge to suction
 Capacity control

Controlling suction pressure by throttling;

Controlling discharge pressure;

Returning discharge gas to suction;

Adding reexpansion volume;

Changing the stroke;

Opening a cylinder discharge port to suction while
closing the port to discharge manifold;

Changing compressor speed;

Closing off cylinder inlet, and

Holding the suction valve open
Factors Affecting the performance of
Refrigeration unit

Discharge pressure
Lubrication system
– Out door air temperature – Low oil pressure
– Air circulation thru – Oil filter choke
condenser
Quality & Accuracy of
– Condenser fins & tube controls and Sensors
condition
– Calibration & setting
– Space between chillers
– Proper installation
– Condenser fans
– Excess refrigerant
Routine & preventive
maintenance

Evaporator pressure
– Timely
– Lack of refrigerant
– Properly
– Less water flow
– Erratic operation of
metering device
 Factors Affecting the
performance of
Air & water side system

Quality,Accuracy and

Air balancing setting of Thermostats,
– Supply air flow Humidistat and Sensors
– Return air flow
Chilled water distribution
– Grills and damper
– Strainers
adjustment
– Flow control Valves

Fresh air flow

Pump performance
– Dampers adjustment

Chiller performance

AHU performance

Routine & preventive
– Filters condition
maintenance
– Cooling coil
– Belts & pulleys
– Dampers
Air Cooled Condenser
Dx Evaporator -Coil & Fins
Type
 DX Evaporator-Shell &Tube
type
Water flow thru the shell.
Refrigerant is in tubes.
 DX Evaporator- Shell &Tube
type
Water flow thru the shell
Refrigerant is in tubes
 Critical Factors
Shell & Tube Evaporators
 Quality of waters
 Cleaned
 Chemically treated
 Velocity of water should not be higher
than recommended
 Proper setting of Expansion valve
 Adequate water flow
 Proper installation of Sensors /Thermistor
 Flooded Evaporators
In flooded type evaporator a
constant Refrigerant liquid level is
maintained.
A float valve / Level switches are
used as metering device to maintain
the constant level.
Types
Coil & Fins type
Shell & Tube type
Flooded Evaporator
Coil & Fins type
 Flooded Evaporator
Shell & Tube Type

To Compressor
From Condenser

Tubes
Orifice Assembly

Distributor
Metering Devices
 Capillary tube
 Fixed orifice type
 Float valve
 Automatic expansion valve
 Thermostatic expansion valve
 Electronic expansion valve
Automatic expansion valve
 It allows the flow of
refrigerant to
maintain the constant
pressure in
evaporator.
 It does not allow the
refrigerant flow to
maintain the Suction
superheat.
Thermostatic Expansion
valve
Thermostatic Expansion valve
Electronic Expansion Valve
Sensing Bulb Fixing

 Smaller diameter 1
Inch and below
suction line
 Sensing bulb should
be on top
 Above 1 Inch dia,
 4 O’ Clock Position.
 Sensing Bulb should
be fully covered by
insulating material.
 Protective devices
A high-pressure cutout.
High-temperature control devices to protect against
overheating and oil breakdown.

Motor over temperature protective devices

Low-pressure protection may be provided for
Suction gas and compressor

Time delay, or lockouts with manual resets,
prevents damage to both compressor motor and
contactors from repetitive rapid-starting cycles

Low voltage and phase loss or reversal protection
is used on some systems. Phase reversal
protection is used with multi-phase devices to
ensure the proper direction of rotation.

Suction line strainer.
Testing of Positive Displacement Refrigerant Compressors.

Compressor tests are of two types: the first

determines capacity, efficiency, sound level, motor
temperatures, etc.; the second predicts the
reliability of the machine.

Standard rating conditions, which are usually
specified by compressor manufacturers, include
the maximum possible compression ratio, the
maximum operating pressure differential, the
maximum permissible discharge pressure, and the
maximum inlet and discharge temperature

Lubrication requirements

Power requirements for compressor starting
 Reciprocating Chillers “Controls”

Discharge Pressure Control (High Pressure Control)

 Its function is to switch off the compressor, Once discharge
pressure exceeds the pre-determined set pressure.
 Set Point
 Cut out - 425 (+ or – 6 ) Psig with R-22 Refrigerant
 Cut In - 320 (+ or – 20) Psig
Low Pressure Control (Depends upon Manufacturer)
 Its function is to unload the compressor, once Suction /
Evaporator pressure decreases to pre set pressure. Some time
used to switch off the compressor.
 Set Point
 Cut out 30 (+ or - 5) Psig with R-22 refrigerant.
 Cut In 45 (+ or – 5) Psig.
 Reciprocating Chillers “Controls”
Low Water Temperature Control
 Its function is to stop the refrigeration by stopping the compressor, once
evaporator water temperature goes down below Set point so as to avoid
freezing of water in the evaporator of chiller. Some time, it is called as
Anti-Freeze.
 Set Point 34 to 36 o F
Low Refrigerant Temperature Control
 It is used for not allowing the refrigerant temperature to go below Set
point, so as to avoid freezing of water and as well as loosing the
efficiency of chiller.
 Flow Control
 Its function is to ensure the adequate water flow through evaporator.
Once flow decreases below set point, The switch will actuate and give
alarm / stop signal to control panel, to avoid lower water temperature or
freezing of water in evaporator
 Reciprocating Chillers “Controls”

Oil pressure differential switch

It is used to ensure proper lubrication of bearings
and other moving parts of compressor. To ensure
proper lubrication, a pressure difference is to be
maintained between oil pump pressure and crank
case pressure. Once Differential pressure is lower
than the preset differential pressure, It will actuate
and alarm /stop the compressor operation.
 Set point – 6 to 10 Psig- Differential

Ground Current Safety

It opens on sensing a current to ground in
compressor winding exceeds the 2.5 Amps.
 Reciprocating Chillers “Controls”

In Adequate air flow thru condenser

 Condensing Pressure will increase.
 Load on compressor increases.
 Power consumption will increase.
 Cooling capacity will reduce.
 Leaving chilled water temperature will remain high.

Inadequate chilled water flow through evaporator
 Low suction pressure & Low evaporating temperature.
 Liquid flood-back to compressor and may damage
compressor discharge reeds (In Reciprocating compressor).
May damage the Helical of screw compressor.
 Ice formation may occur and burst the evaporator.
 Cut out 30 (+ or - 5) Psig with R-22 refrigerant.
 Cut In 45 (+ or – 5) Psig.
 Reciprocating Chillers “Controls”

Non- Condensable gases in the system

 Condensing Pressure will be high.
Load on compressor increases and compressor
will be very hot.
 Power consumption will be high.
 Cooling capacity will reduce.
 Leaving chilled water temperature will remain
high.
 Poor cooling in conditioned space.
 Refrigerant Charge

Less charge
 Compressor suction pressure will be low.
 Evaporator pressure and temperature will be low.
 Heavy flashing and ice formation will occur at expansion
valve, as a result lesser liquid refrigerant shall be available
for actual refrigeration.
Being low evaporator pressure & temperature, Any moisture
present in refrigerant will freeze expansion valve orifice and
restrict the refrigerant flow.
 Lower cooling capacity.

Over charge
 Higher head pressure and higher suction pressure.
 Load on compressor, will draw more current and
unnecessary High power consumption.
 Liquid flood back to compressor and can damage discharge
reeds.
Centrifugal Chillers
Centrifugal Chillers
Working Of centrifugal Chiller
 Refrigeration cycle
(With Centrifugal Compressor)
Centrifugal Chiller
(Water Cooled)

Centrifugal Compressor

Condenser -Shell & Tube

Orifice Assembly-1

Economizer

Orifice Assembly-2

Flooded Evaporator

Lubrication System

Motor Cooling System

Control Panel

Starter

Controls
Centrifugal Chiller
(Air-Cooled)

Centrifugal Compressor with motor

Air cooled Condenser

Orifice plate assembly

Flooded Evaporator

Lubrication system

Motor cooling system

Electrical System
– Starter
– Control panel

Controls
 Compressor

Compressor &
Journal bearings

Motor casing.
High speed gears

Ist stage impeller assembly Inner oil

IInd stage impeller guards

Volute casings
Gear spray nozzles

Thrust bearing
Motor stator & rotor

Suction inlet guide
vane & actuator
 Orifice Assembly

 It is a assembly of two
plates having nos. of
orifices Orifice
 Liquid refrigerant
pressure reduces while
passing thru it.
 Refrigerant flow
controlled based on
differential pressure.
From Condenser To Evaporator
 Economizer
 This is a intermediate pressure chamber in which
a intermediate pressure (Second stage suction
pressure) is maintained.
 The high pressure liquid refrigerant enters into
economizer through orifice plate assembly.While
liquid passing thru orifice assembly,a portion of it
evaporates (flashes) by absorbing heat from
remaining liquid refrigerant and thus remaining
liquid gets cooled.
 Evaporated refrigerant goes directly to 2nd stage
impeller for recycling.
 Evaporators

Flooded Evaporator
 Water in tubes
 Refrigerant in shell.
 Distributor &Eliminator
Liquid refrigerant enters the evaporator
through orifices assembly causing some of the
liquid to flash, thus chilling it to evaporator
temperature. This chilled flashed gas and
refrigerant mixture is then spread through out
the evaporator with the help of distributor
passage. Distributor openings discharge liquid &
flash gas against deflectors and produces
spray effects on evaporator tubes bundle.This
evaporative process chills water circulating
thru tubes.
 Lubrication System

 Oil Sump  Oil cooling coil

 Oil Heater  Oil Filter & Isolating
 Sight glass valve
 Thermometer  Oil by pass valves
 Submersible Oil  Oil piping
Pump  Temperature
 Oil Pressure sensors
regulator
 Motor Cooling System

 The hermetic motor are cooled by liquid

refrigerant.
 Liquid refrigerant enters the motor housing thru
an orifice and flows into a chamber surrounding
the stator.
 The refrigerant flows from this chamber thru the
motor stator,thus cooling the stator and rotor.
 Liquid refrigerant evaporates by absorbing heat
from stator and rotor.
 Finally Liquid & vapor mixture drain back to
evaporator thru bottom pipes.
 Electrical System

Starter panel Control panel

 Switches  Control switch
 Fuses  Control Transformer
 Transformer  Fuses
 Star-Delta starter for  Relays
compressor motor  Microprocessor modules
 DOL / Star-Delta  Unit control modules
starter for fans  Timers
 Anti-Recycle Timer
 Overload relays
 Coast down Timer
 Timers  Safety switches (Outside)
 Contractors
 Flow Switches
It is a combination of Microprocessor and
Flow sensor.
Function is to give alarm or stop signal to
chiller once flow reduces below set point.
Setting in % (Minimum 50 %).
Shall give alarm signal to BMS at alarm
setting.
Shall stop the chiller at stop setting.
Modulate Chiller capacity suit to
temperature outlet.
High Oil Temperature Sensor

It is a combination of microprocessor

and sensor.
Some time it is a Temperature switch.
 The function is to give alarm / stop signal to
compressor once oil temperature increases
above set point.
 Set point 1800 F (82O C).
 Will give alarm signal to BMS on rising oil
temperature above set point.
 May stop compressor if control circuit is made
accordingly.
 Low Pressure cut out Switch

It is a combination of
microprocessor and sensor.
– Some times it is a pressure switch.

The function is to give alarm / stop
signal to compressor once the
evaporator pressure reduces below the
set point.

Set point
– Cut out 2.0 bar (R-12 & R-134a)
– Cut in 2.3 to 2.4 bar
Winding Temperature Sensors

It is a combination of microprocessor and

sensor.

A sensor sense the temperature and give
signal to microprocessor.

Microprocessor compares this signal with
set point and give out put command to
stop the compressor if temperature is
higher than set point.

Set point 265 deg F.

Will Stop Motor once motor temperature
rises to set point and will give alarm signal
to BMS.
 Current Limiter

Its function is to limit the current

drawn by motor within set point.

Set point 85-95 % of full load
amperes.

It will unload the compressor by
closing the suction vane damper and
over ride all inputs / feed back for:
– Opening the vane dampers .
– Increasing the load on compressor
 Critical Factors
(Evaporator)

Soft & Clean water.

Cleaned tubes.
Adequate chilled water flow.
Adequate refrigerant flow.
Sensors are fitted properly.
Application of Silicon grease or
alternative heat transfer paste.
Chilled water temperatures as designed.
 Critical Factors
(Motor Cooling System)

Adequate liquid refrigerant flow

 Strainer (Filter cum drier)
 Adjustment of Service valves
 Design condenser pressure
 Design evaporator pressure
Problem
 Higher motor temperature
 System

a)Compressor- Able Balance
to pump refrigerant at same rate at
which liquid ref. vaporizes in evaporator

b)Condenser- Able to reject heat from ref.at same rate at
which ii picks up heat in evaporator and compressor

c)Throttling device- Able to feed liquid ref.to evaporator at
same rate at which the refrigerant is vaporized in the
evaporator

Interconnecting liquid, suction and suction lines- capable
of handling the same rate of flow of liquid ref, low
pressure vapor and high pressure vapour with a minimum
of pressure drop
 Capacity control

Reciprocating Centrifugal compressor

compressor Guide vanes (inlet of
Variable speed motor impeller )
Compressor cylinder Screw compressor
unloading Slide valve method
Hotgas bypass Lift valve method
 Lubrication

Adequate Oil Charge
 Manufacturer recommended oil should be used.
 Recommended quantity of oil should be charged.
 Lubricating oil container should never be left open.

Excess Charge
 Can cause hydraulic knocking and damage the pistons.
 It will be difficult to monitor the lubrication system.

Under Charge
 Oil pump will not be able to build up the pressure.
 Poor lubrication will damage the moving parts of
compressor.
 Centrifugal Chiller “Controls”

Flow switches / Flow Sensor & Microprocessor Combination
 It is a combination of Microprocessor and Flow sensor.
 Function is to give alarm or stop signal to chiller once flow reduces
below set point.
 Setting in % (Minimum 50 %).
 Shall give alarm signal to BMS at alarm setting.
 Shall stop the chiller at stop setting.
 Modulate Chiller capacity suit to temperature outlet.

Oil Differential Pressure Switch
 Its function is to stop chiller once differential pressure between oil
supply and compressor casing reduces below the differential set point.
 Normally set at 1.0 bar to 1.5 bar differential.
 Shall give Alarm signal to BMS at Alarm setting.
Will stop Chiller if differential pressure below set point
 Centrifugal Chiller “Controls”

High Oil Temperature Sensor

 It is a combination of microprocessor and sensor or some time it is a
Temperature switch.
 The function is to give alarm / stop signal to compressor once oil
temperature increases above set point.
 Set point 1800 F.
 Will give alarm signal to BMS on rising oil temperature above set
point.
 May stop compressor if control circuit is made accordingly.

High Pressure Control
 t is a combination of microprocessor and pressure sensor.
 In some Chillers, it is a Pressure switch.
 The function is to give alarm / stop signal to compressor once the
discharge pressure increases to set point.
 Set point 12.0 to 12.5 (R-12) and 15.0 (R-134a).
 Centrifugal Chiller “Controls”

Low Pressure Control

 It is a combination of microprocessor and Pressure sensor.
 In some chiller, it is a pressure switch.
 The function is to give alarm / stop signal to compressor once the
evaporator pressure reduces below the set point.
 Set point -Cut out 2.1 bar and Cut in 2.5 bar

Low chilled water temperature Sensor
 Its function is to stop chiller once temperature goes below the set point to
avoid freezing of water in evaporator.
 It is inserted in evaporator to sense the temperature.
 Set Point 34o F.
 It will Stop compressor once water temperature inside evaporator reduces
to set point and will give alarm signal to BMS.
 Centrifugal Chiller “Controls”

Chilled Water Temperature Control
 It is a combination of Microprocessor and Temperature Sensor.
 A sensor (installed in the outlet pipe of Evaporator) senses the leaving chilled
water temperature and gives temperature signal to microprocessor.
 The Microprocessor compares this temperature signal with set temperature.
 According to difference, Microprocessor give output command to vane control
modulating motor, either for closing or opening the vane to modulate the flow
of refrigerant. Thus by it controls the capacity of Chiller.
 Set Temperature generally 41 to 46o F

Motor Winding Temperature Sensors
 It is a combination of microprocessor and sensor.
 A sensor sense the temperature and give signal to microprocessor.
 Microprocessor compares this signal with set point and give out put command
to stop the compressor if temperature is higher than set point.
 Set point 265 deg F.

Will Stop Motor once motor temperature rises to set point and will give alarm
signal to BMS
 Centrifugal Chiller “Controls”

Motor Over Load Protection
 Its function is to protect compressor motor against
overloading.
 Set point 95-100 % full load Amperes.
 It will stop compressor motor, once current drawn by
motor increases to set point and remain for more than 30-
40 second.
 Alarm signal will be given to BMS once it actuates.

Current Limiter
 Its function is to limit the current drawn by motor
within set point.
 Set point 80-90 % of full load current.
 It will unload the compressor by closing the suction
vane damper, and over ride all inputs for opening the
vane dampers for increasing the load on compressor.
 Centrifugal Chiller “Controls”

Anti Re-cycle Timer
 Its function is to ensure that chiller re-start is not taking place before the
Set time.
 Once chiller stops either from controls or manually, It should not take re-
start before a time recommended by manufacturer for the safety of
Compressor & Motor.
 Set time generally 15 -20 Minutes.

Coast Down Timer
 Its function is to ensure that the Oil Pump is running for a certain period
even after chiller is given stop command either by controls or Manual
stop.
 As chiller has been given stop command either by controls or manual
stop, The motor & impeller keeps rotating for some time due to inertia.
During this period, it is essential to provide lubrication to bearing and
rotating parts of Compressor & Motor.
 Set time generally 3 minutes (It is the time, Motor / Impeller takes in
coming to idle condition after giving stop command).
Pre-start Checks
 Check oil sump temperature
 Should be 60o - 70o C.
 Check oil level
 Should be visible 1/ 4 to 3/4 in
lower glass.
 Check system pressure
 Should be below 8 Bar.
 Physical check - Condenser
 Check condenser fan and fan
belts.
 Check chilled water flow
 Control panel reading (
Microprocessor & Flow Sensor)
 Pressure drop method

Start up -Chiller
 Place system switch in “OFF”
position.
 Place oil pump switch in “AUTO”
position.
 Close the main disconnect switch
(Make “ON”).
 Operate oil pump and fans on
“Manual” to check operation.
 Set the current limiter “%
Current”.
 Suggest to set 75 to 80 % initially
or Minimum.
 Set the “Control Temperature” at
desired temperature.
 Reset the safety controls or circuit
breaker.
 Place the “Vane Position” switch
in “Auto” position.
Start Chiller by Putting the system
switch in “ON” Position
 Daily Operation Checks (Log Recommended by Manufacturer)

Parameter Normal operation Reading Actual Reading Actual reading

Ambient Condition DB & WB
Chilled water Temperature
 Entering
 Leaving
 Temp Drop
Chilled water pressure
 Entering
 Leaving
 Pressure drop
Condenser Water Temperature
 Entering
 Leaving
 Temp. Rise
Condenser Water Pressure
 Entering
 Leaving
 Pressure drop
Evaporator Pressure

Discharge Pressure

Ooil pressure
 Supply to Bearings
 Return from bearing
Ooil Temperature
 Supply to Bearings
 Return From bearing
Sump oil Temperature

% Vane opening

Amperes

Abnormal Sound or Noise


Maintenance (Weekly)
 Check Sump oil level.
 Oil should be visible in
lower site glass.
 Check liquid line site
glasses.
 Check unit piping and coils
for visible signs of leaks.
 Listen and observe the
operation of the chiller for
usual sounds.
 Check all operating
pressure and temperature
against normal operating
condition.

Maintenance (Monthly)
 Perform weekly checks.
 Check fan belt tension and
wear.
 Check fan and fan motor for
lubrication.
 Check condenser condition,
 If required clean the coil by NU-
coil/ cal-clean.
 Or follow individual
manufacturer recommendation.
 Maintenance (Annual)

Mechanical
 Perform weekly & monthly
inspection checks.
 Clean the condenser coil by
recommended chemical.
 Straighten the fins by Nylon
comb.
 Change oil by approved oil
only.
 Be doubly sure about oil
quality and storage time.
 Change oil filter.
 Check and change the
liquid line filter of motor
cooling system.

Clean the chilled water inlet
strainer

Electrical
 Check physical condition of
the components in starter
panel.
 Check physical condition
of all actuating components.
 Terminal & Lugs condition.
 Clean the contactor by
Commercial carbon tetra
chloride (CCL 100) or
equivalent.
 Check for loose connection.
 Check sensors.
 Fill the conductive liquid in
thermo -well, if required.
 Periodic Checks
 Leak check
 Purge operation
 System dryness
 Lubricant level
 Lubricant filter pressure drop
 Refrigerant quantity or level
System pressures
temperatures
 Water flows
 Expansion valves operation
Regularly Scheduled Maintenance
Condenser and lubricant cooler
cleaning
Evaporator cleaning on open
systems
Calibrating pressure, temperature,
and flow controls
Tightening wires and power
connections
 Inspection of starter contacts and
action
 Safety interlocks
 Dielectric checking of hermetic and
open motors
and  Tightness of hot gas valve
 Lubricant filter and drier change
Analysis of lubricant and refrigerant
 Seal inspection
 Partial or complete valve or bearing
inspection, as per manufacturer’s
recommendations
 Vibration levels
 Extended Maintenance Checks
Compressor guide vanes and linkage
operation and wear
Eddy current inspection of heat
exchanger tubes
Compressor teardown and
inspection of rotating components
 Other components as
recommended by manufacture
 Screw Chillers
Liquid Chilling System

A liquid chilling system cools water, brine,
or other secondary coolant for air
conditioning or refrigeration.

The system may be either factory
assembled and wired or shipped in
sections for erection in the field.
Twin Screw Compressors
 Components of chillers

Compressor (reciprocating, centrifugal or
rotary),

Liquid cooler (evaporator),

Condenser, a compressor drive, a liquid
refrigerant expansion or flow-control
device, and a control center.
Components of Screw chillers
 Components of chillers

The system may also include a receiver, an
economizer, an expansion turbine, and/or
a sub cooler.

In addition, certain auxiliary components
may be used, such a lubricant cooler,
lubricant separator, lubricant-return
device, purge unit, lubricant pump, a
refrigerant transfer unit, refrigerant vents,
and/or additional control valves.
 Economizer
 Economizer is a separate vessel
containing the Electronic Expansion
valve and a float valve
 Purposes
⇒It improves chiller capacity and
efficiency
⇒It provides compressor motor cooling
 Screw Compressors

Screw compressors belong to the
broad class of rotary positive-
displacement compressors.

Screw compressors currently in
production for refrigeration and air-
conditioning applications comprise
two distinct types

single-screw and twin-screw.
 Screw Compressors

Both are conventionally used with fluid
injection where sufficient fluid cools and
seals the compressor.

Screw compressors have the capability to
operate at pressure ratios above 20:1
single stage.

The capacity range currently available is
from 20 to 1300 tons
 Screw Compressors

The single-screw compressor consists
of a single cylindrical main rotor that
works with a pair of gaterotors.

Both the main rotor and gaterotors
can vary widely in terms of form and
mutual geometry.
Single Screw Compressor
 Screw Compressors

The main rotor has six helical grooves,
with a cylindrical periphery and a globoid
(or hourglass shape) root profile.

The two identical gaterotors each have 11
teeth and are located on opposite sides of
the main rotor.

The casing enclosing the main rotor has
two slots, which allow the teeth of the
gaterotors to pass through them
 Sequence of Compression

Suction

Compression

Discharge
 Compressor rotation
Compressor rotation in Screw
compressor is extremely important
Operation in the opposite direction, even
momentarily, can cause serious rotor
damage and must be avoided
 Mechanical Features
Rotors

The screw rotor is normally made of cast
iron and the mating gate rotors are made
from an engineered plastic.

The inherent lubricating quality of the plastic,
as well as its compliant nature, allow the
single-screw compressor to achieve close
clearances with conventional manufacturing
practice.
 Mechanical Features

Rotors

Bearings

Economizers
Economizers
 Hermetic Compressors

Hermetic screw compressors are

commercially available through 200 tons of
refrigeration effect using R-22. The hermetic
motors can operate under discharge, suction,
or intermediate pressure. Motor cooling can
be with gas, oil, and/or liquid refrigerant. Oil
separation for these types of compressors
may be accomplished either with an
integrated oil separator or with a separately
mounted oil separator in the system.
 Capacity Control

All positive-displacement compressors, both
speed modulation and suction throttling can be
used. Ideal capacity modulation for any
compressor includes
 Continuous modulation from 100% to less than
10%,
 Good part-load efficiency
 Unloaded starting

Unchanged reliability
 Twin-screw compressors

Twin screw is the common designation for
double helical rotary screw compressors.

A twin-screw compressor consists of two
mating helically grooved rotors-male
(lobes) and female (flutes or gullies) in a
stationary housing with inlet and outlet
gas ports.

The flow of gas in the rotors is mainly in
an axial direction
 Sequence of Compression Process in
Twin Screw Compressor

Suction

Compression

Discharge
 Lubricant
 Lubricant is cooled by one of the following methods
 Water-cooled using condenser water, evaporative condenser
sump water, chilled water, or a separate water- or glycol-to-
air cooling loop
 Air-cooled using a lubricant-to-air heat exchanger
 Refrigerant-cooled (where lubricant cooling load is low)
 Liquid injection into the compressor
 Condensed refrigerant liquid thermal recirculation
(thermosyphon), where appropriate, compressor head
pressure is available
 Oil separators

Efficient lubricant separators are
required. The types and efficiencies
of these separators vary according to
refrigerant and application. Field
built systems requires better
separation than complete factory-
built systems
 control

Comp Motor

CAPACITY CONTROL

Gauge control
Oil separator
Gauge
oil filters

strainer
oil pump
oil cooler

OIL LUBRICATION SYSTEM

 SCREW.CH.FLOW CYCLE
Control

Comp Motor
Air cooled condenser

Control Oil separator

Strainer
Oil pump
Evaporator Oil cooler

Receiver
Filter core
 control

Comp Motor

CAPACITY CONTROL

Gauge control
Oil separator
Gauge
oil filters

strainer
oil pump
oil cooler

LUBRICATION SYSTEM
 Capacities and Types Available

Screw compressor liquid chillers are available as factory-

packaged units from about 30 to 1250 Tons.
The following types of liquid chillers are generally used for air
conditioning:
 Up to 25 tons —Reciprocating or scroll
 25 to 80 tons —Screw, reciprocating, or scroll
 80 to 450 tons —Screw, reciprocating, or centrifugal
 200 to 1000 tons —Screw or centrifugal
 Above 1000 tons —Centrifugal
 Safety controls

 Lubricant failure switch,

 High discharge pressure cutout,

 Low suction pressure switch,

 Cooler flow switch,

 High lubricant and discharge temperature cutout,

 Hermetic motor inherent protection,

 Lubricant pump and compressor motor overloads,
and

 Low lubricant temperature (flood back/dilution
protection).
 Starting of Screw compressor

The compressor is unloaded

automatically (slide valve driven to
minimum position) before starting.
Once it starts operating, the slide
valve is controlled hydraulically by a
temperature-load controller that
energizes the load and unload
solenoid valves
 Starting of Screw compressor

The current limit relay protects against motor

overload from higher than normal condensing
temperatures or low-voltage and also allows a
demand limit to be set, if desired. An antire cycle
timer is used to prevent overly frequent
recycling. Lubricant sump heaters are energized
during the off cycle. A hot gas capacity control is
optionally available and prevents automatic
recycling at no-load conditions such as is often
required in process liquid chilling. A suction to
discharge starting bypass sometimes aids starting
and allows the use of standard starting torque
motors.
 Starting of Screw compressor

Some units are equipped with electronic

regulators specially developed for the
screw compressor

These regulators include PI control
(Proportional-Integrating) of the leaving
brine temperature and such functions as
automatic/manual control, capacity
indication, time circuits to prevent
frequent recycling and to bypass the
lubricant pressure cutout during startup,
switch for unloaded starting, etc.
 Inspection or change out
timetable

 Shaft seals 1.5 to 4 yr Inspect

Hydraulic cylinder seals 1.5 to 4 yr
Replace
 Thrust bearings 4.0 to 6 yr
 Shaft bearings 7 to 10 yr Inspect
Check preload via shaft end play every 6
months and replace as required
 Capacity Slide Valve

A slide valve for capacity control is a valve

with sliding action parallel to the rotor
bores. They are placed within or close to
the high-pressure cusp region, face one or
both rotor bores, and bypass a variable
portion of the trapped gas charge back to
suction, depending on their position
 Capacity Lift Valve

Capacity lift valves or plug valves are
movable plugs in one or both rotor
bores (with radial or axial lifting
action) that regulate the actual start
of compression. These valves control
capacity in a finite number of steps,
rather than by the infinite control of
a conventional slide valve
 Chiller Number
Nomenclature

Example

0 6 N A 11 2 3 S 6 E A

First three digits are the basic model 06N

Fourth digit “A” for Air-cooled“W” for Water-cooled

Fifth digit Type of Refrigerant “1”for refrigerant 134a

Sixth, Seventh and Eighth digits Compressor displacement

Ninth digit Electrical characteristics

Tenth digit Electrical Frequency

Eleventh digit Type of motor cooling “E” for
economized “N” noneconomized

Twelfth digit Packaging “A” standard packaging “B”
service packaging
 HVAC controls

Automatic HVAC control systems are designed to
maintain temperature, humidity, pressure, flow,
power, lighting levels, and safe levels of indoor
contaminants

Automatic control primarily modulates, stages, or
sequences mechanical and electrical equipment
to meet load requirements and provide safe
operation of the equipment.

It can use digital, pneumatic, mechanical,
electrical, and electric control devises, and
implies that human intervention is limited in
starting and stopping equipment and adjusting
control set points.
 HVAC controls

The sensor measures
A controller can be in

the controlled variable the form of hardware
and transmits values to or software.
the controller Thermostats,

The controller compares humidistat, and
the value of the pressure controls are
controlled variable with examples of hardware
the set point and controllers. Digital
generates a signal to the algorithms are
controlled device for examples of software
corrective action. controllers.
 HVAC controls

The set point is the desired

value of the controlled
The controlled
variable. device may be a

The controller seeks to valve, damper,
maintain this set point.
heating element, or a

The controlled device reacts
motor driving a
to signals received from the
controller to vary the flow of pump or a fan.
the control agent
 Control Components

The first subsection
The third, Controllers
considers the controlled
device or control
element, examples of
which are relays, valves,
and dampers. Actuators,
which are used to drive
the valve or damper
assembly

The second subsection
considers the sensing
element the measures
changes in the controlled
variable
are classified according
to the control action
they cause to maintain
the desired condition
(set point) whether
they are two-position,
floating, proportional,
proportional plus
integral (PI) or
proportional plus
integral plus derivative
(PID) control
 Valves
Valves

A single-seated valve is
A three-way mixing
designed for tight valve has two inlet and
shutoff one outlet connections

A double-sealed or and a double-faced disc
balanced valve is operating between two
designed so that the seats
media pressure acting
against the valve disc is
A three-way diverting
essentially balanced, valve has one inlet and
reducing the operator two outlet connections
force required and two separate discs
and seats
 HVAC controls

A thermistor is a
Preprogrammed control

semiconductor that routines, known as firmware,
changes electrical are typically stored in
resistance with permanent memory such as
EEPROM (electronically
temperature. It has a
erasable programmable read
negative temperature only memory). To prevent
coefficient; i.e., the unauthorized alteration, the
resistance decreases as the operator can modify parameters
temperature increases such as set points, limits, and
minimum off times within the
control routines, but the
program logic cannot be
changed without replacing the
memory chips.
 HVAC controls

Dampers
Indoor Air Quality

Humidity Sensors Sensors

Pressure Transmitters and
Digital Controllers
transducers

Thermostats

Flow Rate Sensors

PI Controllers

Transducers