CHILLER

ASIAN PAINTS KHANDALA PLANT

 WHAT IS CHILLER AND ITS USE

• A chiller is a machine that removes heat from

a liquid via a vapor-compression or
absorption refrigeration cycle.
 SPECIFICATION
• MAKE : Trane India PVT LTD
• MODEL : RTHD C1E1F1
• CAPACITY : 200 TR
• CONNECTED LOAD : 213 KW
• REFRIGERANT : R-134 A
 Chiller Component
• Compressor :
The compressor is the prime mover, it creates
a pressure difference to move the refrigerant
around the system.
Compressor
• Condenser :
The condenser is located after the compressor
and before the expansion valve. The purpose of
the condenser is to remove heat from the
refrigerant which was picked up in the
evaporator.

Condenser
• Expansion Valve :
The expansion valve is located between the
condenser and the evaporator. It’s purpose is to
expand the refrigerant reducing its pressure and
increase it’s volume which will allow it to pick up
the unwanted heat in the evaporator.

Expansion Valve
• Evaporator :
The evaporator is located between the
expansion valve and the compressor, its purpose
is to collect the unwanted heat from the return
water and move this into the refrigerant so that
it can be sent to the cooling tower and rejected.

Evaporator
• Power Unit :
The power unit is mounted directly to the
chiller. The purpose of the power unit is to
control the flow of electrical power to the chiller.
These usually contain a Star Delta starter, circuit
breakers, speed controller and power
monitoring equipment etc.
Power Unit
• Process Flow :

Vapor(High pressure, high temp.)

Compressor Condenser

Vapor(Low Liquid(High
pressure, pressure, low
high temp.) temp.)

Expansion
Evaporator Valve
Liquid + Vapor(Low pressure, low temp.)
To Cold Well From Hot Well
• Hot Well /Cold Well system :

EVAPORATOR

HOT WELL COLD WELL

TO HOT WELL
Evaporato
r Pump

Pump TO PROCESS
• Cooling Tower System :

CT FAN
CONDENSER

Cooling Tower

Condenser
Pump
• ELECTRICAL COMPONENTS :
- Compressor motor (3M1)
- Transformer (Pri-440v ac /sec-115v & 27v ac)
- Power Supply Module (1A2)
- DYNA View Display (1A1)
- Starter Module (1A3)
- Main Contactor(1K1), Run Contactor (1K2),
Shorting Contactor (1K3) & Transition contactor
(1k4)
• Starter Power Diagram :
• Operation Of Starter :
Star state : Firstly Main contactor(1K1) & Star
contactor(1K3) close.
Star Transition State : Motor is connected in star &
resistors are connected across Delta contactor(1K2)
via transition contactor(1K4).
Closed Transition State : Star(1K3) & delta
contactor open, current flows through winding &
transition resistor via transition contactor(1K4).
Delta State : Main contactor(1K1) & delta
contactor(1K2) close. And motor is connected to full
line voltage.
Transition circuit
• Starting interlock :
- NC contact of high pressure cutout switch (4B29).
• Input/output from starter module(1A3) :
- All start, stop, transition command comes from starter power
module.
- High pressure cutout (1A4)
- Load/Unload solenoid valve (1A5)
- Oil return gas pump Drain\Fill solenoid valve (1A6)
- Chilled/Condensed water flow switch (1A7)
- Chilled/ Condensed water pump starter (1A9)
- Auto stop / Emergency stop (1A12)
- Oil loss level (1A11)
- Ice/External base load (1A15)
- Ice building status (1A8)
• Analog input / output :
- Condenser control output & compressor %RLA-o/p (1A13)
- External current limit & External chilled water set point
(1A14)
- Refrigerant monitor i/p & external base load set point(1A17)
From Power Supply Module supply goes to :
- Compressor discharge temp. sensor (4B27)
- Condenser refrigerant pressure transducer (4B26)
- Evaporator refrigerant pressure transducer (4B25)
- Evaporator refrigerant liquid level sensor (4B3)
- Dual port EXV actuator (4Y20)
- Evaporator entering water temp. sensor (4B20)
- Evaporator Leaving water temp. sensor (4B21)
- Condenser entering water temp. sensor (4B22)
- Condenser leaving water temp. sensor (4B23)
- Oil pressure transducer
- Outdoor air temp. sensor (5B28)
• We used the chiller for cooling of :
- WPB/SPB dyno mill, Basket mill, TSD & OHM.
- EB-RB reactor cooling, condenser & tank farm.
- For cooling of whole admin block atmosphere.