Kroff Chillmax Training

Agenda

Chiller Components

Chiller Refrigerant Cycle

Compressor lowers pressure in the

evaporator, allowing refrigerant to

boil and absorb heat from water.

1.

Chiller Refrigerant Cycle

Compressor

raises pressure

of refrigerant gas and discharges

into condenser

Compressor lowers pressure in the

evaporator, allowing refrigerant to

boil and absorb heat from water.

1.

2.

Chiller Refrigerant Cycle

Compressor

raises pressure

of refrigerant gas and discharges

into condenser

Cooling water in condenser removes heat from

refrigerant gas allowing it to condense back into liquid.

Compressor lowers pressure in the

evaporator, allowing refrigerant to

boil and absorb heat from water.

1.

2.

3.

Chiller Refrigerant Cycle

Compressor

raises pressure

of refrigerant gas and discharges

into condenser

Cooling water in condenser removes heat from

refrigerant gas allowing it to condense back into liquid.

Metering device

maintains seal

between condenser and evaporator.

Compressor lowers pressure in the

evaporator, allowing refrigerant to

boil and absorb heat from water.

1.

2.

3.

4.

Chiller Efficiency

" !

"

"

What Influences Chiller Efficiency ?

Importance of Maintaining Chiller Efficiency

""

"

Cost of Inefficiency

Condenser Problems

Evaporator Problems

Reality of Chiller Plant Operation

Typical ChillerMaintenance Program

Log Readings Alone Are Not Efficient

Log Readings Alone Are Not Efficient

Chiller Logging

Chiller Instrumentation

Fair Better

Orange Research Weiss Instruments

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

Condenser Liquid

Refrigerant Temperature

Take temperature at liquid line

leaving condenser. Recommend

Raytek Model ST 60 or better.

Condenser Saturated Refrigerant Temperature

On a Low-Pressure Refrigerant Chiller

R-11 & R-123

Non-Condensables

Non-Condensables

91 5.3

92 5.6

93 6.0

94 6.4

95 6.8

96 7.2

97 7.6

98 8.0

99 8.4

Sat Temp Sat Pres

Non-Condensables

Non-Condensables

Condenser Approach

!"

Condenser Water In

Condenser Water Out

Condenser

Pressure

Liquid

Refrigerant

Temperature

Temperature

Pressure

Temperature

Pressure

Causes of High Condenser Approach

Condenser Approach:

Clean Versus Dirty Condenser Tubes

When Tubes Are Clean

High Condenser Approach:When Condenser Tubes Get Dirty...

Tube Fouling:When Condenser Tubes Get Dirty

High Condenser Approach

High Condenser Approach

High Condenser Approach

Condenser

Pressure

Liquid Refrigerant

Temperature

Temperature

Pressure

Temperature

Pressure

Pressure Drop = P in P out

Water Flow Problems

Low Condenser Water Flow

!$!$

$

Calculate Flow Actual Versus Design $, ,-

,$"""!#",',-'#"$""",("($""",#&,%"+%"+

High Inlet Condenser Water Temperature! ! $!

Evaporator Instrumentation

Evaporator Water In

Evaporator Water Out

Evaporator

Pressure

Liquid

Refrigerant

Temperature

Temperature

Pressure

Temperature

Pressure

Evaporator Approach Problems

Evaporator Water In

Evaporator Water Out Evaporator

Pressure

Liquid

Refrigerant

Temperature

Temperature

Pressure

Temperature

Pressure

High Evaporator Approach Can be Caused by:

Low Evaporator Set Point

!$

Compressor Instrumentation

Chiller Capacity - 1,500 tons

This log sheet was taken at a chiller plant with over 40,000 tons of chiller

capacity. During your site survey you obtain the following log sheet.

Easy and

effective.

ChillerMax:The High-Tech Solution

Operator visits all operating chillers and collects data on a daily basis

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

from a BAS system

Problems are identified and quantified by source Corrective actions are given and scheduled Efficiency is restored or maintained

ChillerMax Identifies Problems

Using the ChillerMax

Website

Logon to ChillerMax Website using Username and Password Provided

Using the ChillerMax Website

Chiller Dashboard

Solutions

Logsheet View

Readings in

yellow indicate a

run time error

View Charts

Chart Trends

Logging ChillersUsing ChillerMax

Add Log Record

Enter Required Data

Digital Control Panels

Condenser and Evaporator Readings

Water

temperatures

Water pressure

drops

Refrigerant

pressures Condenser refrigerant

temperature

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

Compressor and Electrical Readings

Oil level &

temperature

Oil pressure

Amps & volts

Using ChillerMax to Track Maintenance Tasks

Condition Based Maintenance

Example: Emory University

#%!$" #%" $

" #

Internally Enhanced Tubes

Dirty Tube

Single Direction

Two-Direction Versus Single-Direction Tube Brushing

Two-Direction Brushing Single-Direction Brushing

Single Direction

ChillerMax Identifies Problems

ChillerMax Restores Efficiency

Lessons Learned with Internally Enhanced Tubes

Use a brush designed

for internally enhanced tubes

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

Brush with a cleaning machine

using dual rotation action

Use Borescope to Inspect Tubes

Questions& Answers

For additional information contact:

Don Tomovich 302-753-7940

[email protected]