Agenda



  











 



Chiller Components

Chiller Refrigerant Cycle

lowers pressure in the

1. Compressor
evaporator, allowing refrigerant to
boil and absorb heat from water.

Chiller Refrigerant Cycle

2.

Compressor
raises pressure
of refrigerant gas
and discharges
into condenser

lowers pressure in the

1. Compressor
evaporator, allowing refrigerant to
boil and absorb heat from water.

Chiller Refrigerant Cycle

3.

2.

Cooling water in condenser removes heat from

refrigerant gas allowing it to condense back into liquid.

Compressor
raises pressure
of refrigerant gas
and discharges
into condenser

lowers pressure in the

1. Compressor
evaporator, allowing refrigerant to
boil and absorb heat from water.

Chiller Refrigerant Cycle

3.

Cooling water in condenser removes heat from

refrigerant gas allowing it to condense back into liquid.
device
4. Metering
maintains seal

2.

between condenser
and evaporator.

Compressor
raises pressure
of refrigerant gas
and discharges
into condenser

lowers pressure in the

1. Compressor
evaporator, allowing refrigerant to
boil and absorb heat from water.

Chiller Efficiency

"
 
 








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What Influences
Chiller Efficiency ?

Importance of
Maintaining Chiller Efficiency




 





"

"


 









 





"

 







 

Cost of
Inefficiency


 
 



 








  









 

 







 
 



Condenser Problems






 




 





 






































 

Evaporator Problems





 





 











 


















 






 

Reality of
Chiller Plant Operation



















 










































 











Typical Chiller
Maintenance Program






 







 























Log Readings Alone

Are Not Efficient













 



  








Log Readings Alone

Are Not Efficient


 



 





 


 

Chiller Logging

Chiller Instrumentation


 















 
 









Orange Research

Fair

Weiss Instruments

Better

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




 


Sat Temp

Sat Pres

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

Non-Condensables






 

Non-Condensables







Condenser Approach




















 









!

"



 







Pressure
Temperature

Condenser
Pressure

Condenser Water Out

Pressure
Temperature

Condenser Water In

Liquid
Refrigerant
Temperature

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



 
  

 
 




 







 




  


 





Water Flow Problems

Pressure
Temperature

Condenser
Pressure

Pressure Drop = P in P out

Pressure
Temperature

Liquid Refrigerant
Temperature

Low Condenser Water Flow



  
 

   

  





  
  






   

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!$


 
 
   



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Calculate Flow
Actual Versus Design


  $
,



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High Inlet Condenser

Water Temperature

  

  




  


 
 
  


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!
  

Evaporator Instrumentation

Pressure
Temperature

Evaporator
Pressure

Evaporator Water Out

Pressure
Temperature

Evaporator Water In

Liquid
Refrigerant
Temperature

Evaporator Approach Problems














 


Pressure

Temperature
Evaporator
Pressure

Evaporator Water Out

Pressure
Temperature

Evaporator Water In









Liquid
Refrigerant
Temperature

High Evaporator Approach

Can be Caused by:


 





 









 



 





 

Low Evaporator Set Point














 




























 




!$












Compressor
Instrumentation




 




 













 


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.

Chiller Capacity - 1,500 tons

ChillerMax:
The High-Tech Solution
Easy and
effective.


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 Chillers
Using 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 pressure
Oil level &
temperature

Amps & volts

Using ChillerMax to
Track Maintenance Tasks

Condition Based Maintenance


 

 











 

 












 





  

 




 


Example: Emory University








 


 













#%





!$


" #

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" $








"

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Internally Enhanced Tubes







 


 

Dirty Tube

Two-Direction Versus

Single-Direction Tube Brushing

Two-Direction Brushing

Single-Direction Brushing
Single Direction

ChillerMax Identifies Problems




  







  
 
 










 


 
 

Single Direction

ChillerMax Restores Efficiency


 

 


   
 


 




 







 
 


Lessons Learned with

Internally Enhanced Tubes
Use a brush designed
for internally enhanced tubes

Brush with a cleaning machine

using dual rotation action
Change brushes as required, use a bore scope to inspect tubes

Use Borescope to Inspect Tubes

 
 
 
 




 
 



  
  


 

Questions

& Answers

For additional information contact:

Don Tomovich
302-753-7940
dtomovich@kroff.com