TEST ROOM DEVELOPMENT FOR BULK MILK COOLER

By

Solanki Rajkumar D.
(090370721001)

Prof. Avdhoot N. Jejurkar

M.E (Mechanical) Assistant Professor

A Thesis Submitted to Gujarat Technological University in Partial Fulfillment of the Requirements for the Degree of Master of Engineering in Thermal Engineering

June 2011

DEPARTMENT OF MECHANICAL ENGINEERING PARUL INSTITUTE OF ENGINEERING AND TECHNOLOGY VADODARA-391 760

CERTIFICATE
This is to certify that research work embodied in this thesis entitled TEST ROOM DEVELOPMENT FOR BULK MILK COOLER was carried out by Mr. Solanki Rajkumar D. (090370721001) at Parul Institute of Engineering & Technology (21) for partial fulfillment of M.E. degree to be awarded by Gujarat Technological University. This research work has been carried out under my supervision and is to my satisfaction.

Date: Place:

Supervisor Prof. A. N. Jejurkar

Principal Dr. Vilin P. Parekh

Seal of Institute

ii

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COMPLIANCE CERTIFICATE
This is to certify that research work embodied in this thesis entitled TEST ROOM DEVELOPMENT FOR BULK MILK COOLER was carried out by Mr.Solanki Rajkumar D. (090370721001) at Parul Institute of Engineering & Technology (37) for partial fulfillment of M.E. degree to be awarded by Gujarat Technological University. He has complied with the comments given by the Mid Semester Thesis Reviewer to my satisfaction.
Date: Place: Guide Solanki Rajkumar D. Prof. A. N. Jejurkar

PAPER PUBLICATION CERTIFICATE

This is to certify that research work embodied in this thesis entitled TEST ROOM DEVELOPMENT FOR BULK MILK COOLER, out by Mr. Solanki Rajkumar D. (090370721001) at Parul Institute of Engineering & Technology (37) for partial fulfillment of M.E. degree to be awarded by Gujarat Technological University, has been accepted for publication by the Second National Conference on Emerging Vistas of Technology in 21st Century at Parul Institute of Engineering & Technology during 4-5 December 2010. Guide Solanki Rajkumar D. Prof. A. N. Jejurkar

Principal Dr. Vilin P. Parekh

Seal of Institute

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THESIS APPROVAL
This is to certify that research work embodied in this entitled TEST ROOM DEVELOPMENT FOR BULK MILK COOLER was carried out by Mr. Solanki Rajkumar D. (090370721001) at Parul Institute of Engineering & Technology (37) is approved for award of the degree of Thermal Engineering by Gujarat Technological University.

Date: Place: Examiner(s):

DECLARATION OF ORIGINALITY
I hereby certify that I am the sole author of this thesis and that neither any part of this thesis nor the whole of the thesis has been submitted for a degree to any other University or Institution. I certify that, to the best of my knowledge, my thesis does not infringe upon anyones copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or any other material from the work of other people included in my thesis, published or otherwise, are fully acknowledged in accordance with the standard referencing practices. I declare that this is a true copy of my thesis, including any final revisions, as approved by my thesis review committee. Date: Place: Solanki Rajkumar D. (090370721001) Verified Supervisor Prof. A. N. Jejurkar

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ACKNOWLEDGEMENT
First of all, I am indebted to Parul Institute of Engineering and Technology for giving me all the utility that I needs towards the completion of this project. With great pleasure I wish to express my deep gratitude to Prof. K. B. K. Lamba, (Head of Department, Mechanical Engineering, Parul Institute of Engineering & Technology, Vadodara) for his keen interest, constant encouragement and valuable guidance for this work. I would like to express my deepest appreciation and gratitude to my project guide, Prof. A N JEJURKAR, Professor, Mechanical Engineering Department, PIET for his guidance, patience for giving advises and supports throughout the progress of this project. With deep sense of honor and gratitude, we acknowledge our obligation to Mr. J. P. GOPAL, Managing Director IDMCL, Mr. K. U. MANGLANI, General Manager IDMCL and Mr. H. R. Patel, H. R. Manager IDMCL for their immense co-operation, valuable suggestions and encouragement for \this project. We take precious opportunity to express our gratitude and sincere regards to Mr. Ankit Gupta, Mr. Saurabh Vyas, Mr. Devendra Gupta, Mr. Vinay Nayak, Mr. N. H. Patel, Mr. Hemant Kumar, Mr. Kuldeep Sishodhia, Mr. Sourabh Mishra and Mr. Ashok Nangal for their guidance, co-operation, valuable and constant inspiration during entire period of our training. We are highly indebted to them for their constant encouragement and able guidance during our training. We also highly appreciate the co-operation of skilled technical staff of the plant and thank them who all helped out in my project. Not forget to my family members for their support, advises and motivation.

Solanki Rajkumar D.

(090370721001)

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TABLE OF CONTENTS
Sr. No. Contents Title Page Certificate Industrial Certificate Compliance Certificate Paper Publication Certificate Thesis Approval Declaration of Originality Acknowledgement Table of Contents List of Tables List of Figures Abstract 1 Introduction 1.1 Introduction 1.2 Installation Objective Behind Bulk Milk Cooler 1.3 Advantage using Bulk Milk Cooler 1.4 Types of Bulk Milk Cooler 1.4.1 Open Type Bulk Milk Cooler 1.4.2 Closed Type Bulk Milk Cooler 2 Literature Survey 2.1 Bulk Milk Cooler 2.2 Performance of Bulk Milk Cooler 2.3 ISO 5780:1983 Test Set Up for Bulk Milk Cooler 2.3.1 Test Set Up for Bulk Milk Cooler 2.3.2 Specification for Prefabricated Wall 2.4 Heat Load Design 2.5 Variable Chiller Flow Pumping 2.6 Piping Design 2.7 HVAC Control
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Page No. i ii iii iv iv v vi vii viii xiii xiv xvi 1 1 2 3 3 3 4 5 5 6 9 9 10 11 11 12 14

Air Conditioning System 3.1 What is Air Conditioning 3.2 Air Conditioning Systems Classification 3.3 Central Air Conditioning Systems 3.3.1 Central Air Conditioning System Components 3.3.2 Advantage of Central Air Conditioning System 3.3.3 Disadvantage of Central Air Conditioning System 3.4 Decentralized Systems 3.4.1 Advantage of Decentralized Air Conditioning System 3.4.2 Disadvantage of Decentralized Air Conditioning System 3.5 Applied Psychometrics 3.6 Description of Terms, Process and Factors 3.6.1 Sensible Heat Factor 3.6.2 Room Sensible Heat Factor 3.6.3 Effective Sensible Heat Factor (ESHF) 3.6.4 Air Quantities using ESHF, ADP, and BF

15 15 15 15 15 16 16 16 17 17 17 18 18 18 19 20 21 23 23 23 23 23 24 25 26 27 28 28 28 29 29

Heat Load Calculation 4.1 Summer Season 4.1.1 Inside Design Condition 4.1.2 Outside Design Condition 4.2 Sensible Heat 4.2.1 Solar Heat Gain through Glass 4.2.2 Heat Gain through Building Structure 4.2.3 Transmission Heat Gain except Walls 4.2.4 Infiltration and Ventilation Heat 4.2.5 Internal Heat 4.3 Latent Heat 4.3.1 People 4.3.2 Outside Air 4.4 Outside Air Heat 4.5 Apparatus Dew Point and Air Quantity
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4.6 Prediction of Heat Load 5 Chiller Plant Design 5.1 Chiller Basics 5.2 Chiller Arrangement 5.2.1 Parallel Chiller System 5.2.2 Series Chiller System 5.3 Piping Basis 5.3.1 Open Loop Piping System 5.3.2 Closed Loop Piping System 5.3.3 Reverse Return Vs Direct Return Piping 5.4 Types of Piping System 5.4.1 Two pipe system 5.4.2 Three Pipe System 5.4.3 Four Pipe System 5.5 Flow Calculation 5.6 Types of Heat Exchangers 5.6.1 Shell and Tube Heat Exchanger 5.6.2 Plate Type Heat Exchanger 5.7 Selection Criteria of Heat Exchanger 5.8 Types of Chiller Compressors 5.9 Centrifugal Pump 5.10 Flow Control System 5.11 Selected Equipment 6 Test Room Layout 6.1 Cooling Process 6.2 Heating Process 6.3 Bulk Milk Cooler Test 6.4 Bill of Quantities 7 Performance of Chiller Heat Exchanger 7.1 Heat Transfer and Pressure Drop Calculation 7.2 Stepwise Performance Analysis
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30 31 31 31 31 32 33 33 33 33 35 35 35 35 36 39 39 43 43 45 49 52 54 55 55 55 55 57 59 59 61

7.2.1 Required Heat Duties 7.2.2 Sizing of Heat Exchanger 7.2.3 Heat Transfer Analysis 7.2.4 Pressure Drop Analysis 7.3 Data Analysis of Thermal Heat Exchanger for Chiller Flow 7.3.1 Heat Transfer Trend for Chiller Flow 8 Bulk Milk Cooler Test 8.1 10KL Closed Type Bulk Milk Cooler Test 8.1.1 Room Temperature and Chiller Test 8.1.2 Bulk Milk Cooler Test 8.1.3 Calculation for Heat Remove from Condenser 8.1.4 Total Room Heat Load 8.2 5KL Closed Type Bulk Milk Cooler Test 8.2.1 Room Temperature and Chiller Result 8.2.2 Bulk Milk Cooler Test Result 8.2.3 Calculation for Heat Remove from Condenser 8.2.4 Total Room Heat Load 8.3 2KL Closed Type Bulk Milk Cooler Test 8.3.1 Room Temperature and Chiller Result 8.3.2 Bulk Milk Cooler Test Result 8.3.3 Calculation for Heat Remove from Condenser 8.3.4 Total Room Heat Load 9 Result and Discussion 9.1 10KL Bulk Milk Cooler 9.1.1 Compare Actual Chiller Flow and Required Chiller Flow 9.1.2 Average Room Temperature Trend 9.1.3 Predictable and Experimental Chiller Flow Trend 9.2 5KL Bulk Milk Cooler 9.1.1 Compare Actual Chiller Flow and Required Chiller Flow 9.1.2 Average Room Temperature Trend 9.1.3 Predictable and Experimental Chiller Flow Trend
xi

61 61 62 65 67 67 68 68 69 70 70 71 72 73 74 74 75 76 76 77 77 78 79 79 79 80 80 81 81 82 82

9.3 2KL Bulk Milk Cooler 9.3.1 Total Room Load and Chiller Flow Required 9.3.2 Compare Actual Chiller Flow and Required Chiller Flow 9.3.3 Average Room Temperature Trend 10 Conclusion References Appendix A Heat Transfer Correlation for Plate Heat Exchanger

83 83 84 84 85 86 88

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LIST OF TABLES
Sr. No. 2.1 2.2 2.3 4.1 4.2 4.3 4.4 5.1 5.2 6.1 7.1 7.2 7.3 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9.1 9.2 9.3 Contents Page No. Performance of Bulk Milk Cooler 7 Characteristic of Cooling Tank 8 Comparison of Various Refrigerant used in 5000L Bulk Milk 8 Cooler Outside Design Temperature 23 Ventilation Standard 26 Internal Heat from Person for Various Activities 27 Load Prediction for Summer and Winter Data 30 Pipe Size for Required Flow Rate 36 Standard Steel Pipe Data 38 Bill of Quantities 58 Plate Heat Exchanger Data Sheet 59 Construction Data for Plate Heat Exchanger 60 Chiller Heat Transfer Analysis 67 Chiller and Room Temperature Test for 10KL Bulk Milk Cooler 69 10KL Bulk Milk Cooler \Test 70 Total Room Load for 10KL Bulk Milk Cooler 71 Chiller and Room Temperature Test for 5KL Bulk Milk Cooler 73 5KL Bulk Milk Cooler \Test 74 Total Room Load for 5KL Bulk Milk Cooler 75 Chiller and Room Temperature Test for 2KL Bulk Milk Cooler 76 2KL Bulk Milk Cooler \Test 77 Total Room Load for 2KL Bulk Milk Cooler 78 Compare Chiller Flow Rate for 10KL BMC 79 Compare Chiller Flow Rate for 5KL BMC 81 Compare Chiller Flow Rate for 2KL BMC 83

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LIST OF FIGURES
Sr. No. 1.1 1.2 2.1 3.1 4.1 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 6.1 7.1 8.1 8.2 8.3 9.1 9.2 9.3 9.4 9.5 9.6 Contents Page No. Typical Open Type Bulk Milk Cooler 3 Typical Closed Type Bulk Milk Cooler 4 Two Piping System In Chiller Arrangement 12 Sensible Heat Factor Lines 19 Top View of Test Room 22 Parallel Flow Chiller 32 Series Flow Chiller 33 Reversed Return Piping 34 Direct Returns Piping 34 Friction Loss Chart for 40 Schedule Steel Pipe 37 Counter path in shell and tube heat exchanger 40 U- Tube Shell and Tube Heat Exchanger with Removable Bundle 41 Assembly and Cast K Pattern Flanged Head U-Tube Tank Heater with Removable Bundle Assembly and Cast Bonn 41 Head U-Tube Tank Suction Heater with Removable Bundle Assembly and 41 Cast Flanged Head Straight-Tube Floating Tube sheet Shell-and-Tube Heat Exchanger with 42 Removable Bundle Assembly and Fabricated Channel Heads Flow Path of Gasket Plate Heat Exchanger 43 Pump Efficiency Curve 50 Pump Pressure Curve for Parallel Arrangement 51 Pump Pressure Curve for Series Arrangement 51 Three Way Bypass and Mixing Valve 52 Test Room Layout 56 Dimension View of Plate Heat Exchanger 60 10KL Bulk Milk Cooler Set Up 68 Chiller Arrangement 69 5KL Bulk Milk Cooler Set Up 72 Average Room Temperature Trend for 10KL BMC 80 Chiller Flow Trend for 10KL 80 Average Room Temperature Trend for 5KL BMC 82 Chiller Flow Trend for 5KL 82 Average Room Temperature Trend for 2KL BMC 84 Chiller Flow Trend for 2KL 84

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ABSTRACT

Bulk milk cooling tank works as an important tool in maintaining the cold chain of milk between the producers of it at rural area to the processing of it at main dairy plant. It provides the cooling and holding milk at a cold temperature until it can be picked up by a milk hauler. For this reason the bulk milk cooling tanks acts as a boon to the dairy industry. Present work concerned to developed test facility for bulk milk cooler because of variation of ambient condition affect the performance of bulk milk cooler. Test room is suitable for testing bulk milk cooler up to maximum capacity under all condition specified in ISO 1983:5708 as far as cooling test are concerned, the room temperature can be set within the range of 15C to 50C with stability of 0.2C. For this calculation of heat load and choosing cooling system element such as evaporator, compressor, condenser for designing test room. Transmission heat, Infiltration heat, product heat, heat of other sources and unknown and unexpected heat which is component of heat load are calculated and designed chiller water arrangement based on heat load calculation. Based on hot and cold water arrangement for different ambient temperature obtained by controlling three way control valve that install in the system, three way control valve set as per different type of bulk milk cooler equipment load and room load for summer and winter weather data and also include one pipe arrangement for getting water temperature set at 35C in bulk milk cooler and cool to 4C .After installation of system then testing different type of bulk milk cooler for different ambient condition .For testing particular bulk milk cooler set the chiller flow as per calculated design load and compare this chiller flow with required experiment load to achieve uniform temperature of room and dispatch the customer as per the said ambient condition. Thesis includes 10KL, 5KL and 2KL bulk milk cooler test with maintain ambient condition.

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CHAPTER 1: INTRODUCTION
1.1 INTRODUCTION [B5]:

As per the latest Draft Codex International Code of Hygienic Practice for Milk and Milk Products from Codex Secretariat, if the milk is not processed within two hours of milking, it is required to be cooled to a temperature below 4oC. Bulk milk cooling tank works as an important tool in maintaining the cold chain of milk between the producers of it at rural area to the processing of it at main dairy plant. It provides the cooling and holding milk at a cold temperature until it can be picked up by a milk hauler. For this reason the bulk milk cooling tanks acts as a boon to the dairy industry. Thus, the present scenario of collection system of milk is chilling the milk immediately after milking by Bulk Milk Cooling Tanks. The usage of such tanks has become popular in the recent past because it not only has helped in increasing the shelf-life of milk but also provided systematic and simple way of the procurement of milk. Also ensures procurement of more milk by covering untapped rural areas for milk collection, where transportation facilities are scarce by providing only one time transportation in a day and storing the milk of another milking in it. Bulk milk cooling unit is used to cool raw milk at the village level co-operative milk societies from the ambient temperature to 4 degree Celsius in conformity to specified ISO standard. The cooling tank is used for cooling the milk immediately after milking to conserve quality of milk and check growth of micro-organisms. It is intended for daily collection of milk. It is a hygienic container built to sanitary standards, which besides cooling also serves as buffer storage prior to transfer of milk for onward transportation and further processing. The agitator provided in the cooling tank works intermittently and at a very gentle speed to avoid damage to the milk fat globules. The best alternative to present collection system of milk is cooling of milk immediately after milking by bulk cooling tanks. The usage of such tanks has become popular in the recent past because it not only helps in increasing the shelf life of milk but also provides a systematic and simple way, to ensure procurement of more milk by covering untapped areas for milk procurement. Refrigeration plays a very vital role in dairy industry as milk and milk products are highly susceptible to bacteria growth in very short time. Fresh milk does not form any bacteria for
1

the first 40 minutes, after that bacterium multiplies every 20 minutes in unprocessed milk. So the quality of collected milk is preserved by cooling it as quickly as possible to below 4 C at milk collection centers with the help of Milk Coolers before dispatching it daily in insulated tanks to big plant for further processing. Production of milk in India is very widely scattered in the rural areas and at vast distances from the places of high consumption in the urban areas. Dairy Farming as such is not a professional occupation but part of the overall agriculture operation. The hygienic conditions and environment of milk production in the rural area are still not up the desired standards. High ambient temperature throughout the year in a tropical country like India is an additional disadvantage since the bacterial growth is very rapid if the temp of milk is not brought down immediately after the production. It is very essential to cool the milk immediately after milking to maintain the quality of milk as final transporting to processing plant may take 8 hours or more from the time of milking. In fact the chilling of milk at or near the production centers is the most important factor which has influenced the growth of milk industry. The chilling of milk to about 4 C or less is done to check the growth of bacteria and preserve the quality as produced, until it is subjected to pasteurization process. This is done at collection centers using Instant Milk Chilling Units and Bulk Milk Coolers. A milk cooling tank as a bulk tank or milk cooler, consist of an inner and an outer tank, both made of high quality stainless steel. For a direct expansion tank, attach to inner tank is a system of plates and pipes through which refrigerant fluid gas flows. The refrigerant withdrawn heat from the tanks content (milk in this case). Direct expansion milk cooling tank come with set of condensing unit which circulate the refrigerant and convey the withdrawn heat to air. 1.2 1. 2. 3. 4. 5. OBJECTIVE BEHIND BULK MILK COOLER INSTALLATION: Enhance and maintain quality of milk to avoid economic losses to farmers because of spoilage/sour age. To produce quality products for export and domestic requirements. To reduce cost by regulating transportation of the milk on alternative days and also through reduction in expenditure on purchase and maintenance of cans. Flexibility in milk collection time resulting in increase in volume of milk collected at the centers. Farmers to get better returns for quality of milk.
2

6. 1.3 1. 2. 3. 4. 5. 1.4

Energy saving by avoiding chilling at the main dairy ADVANTAGE USING BULK MILK COOLER: Compact package unit simple to operate, Power savings, almost trouble free running just like a large domestic refrigerator Milk gets immediately cooled when poured progressively (Cooling Curve) Only to be run during reception hours' and not a three shift operation Can be easily relocated to other potential areas, being a package unit TYPES OF BULK MILK COOLER: 1.4.1 Open Type Bulk Milk Cooler:

Figure 1.1: Typical Open Type Bulk Milk Cooler [B5] It is available in the capacity ranges of 500L, 1000L, 2000L & 3000L, 5000L. Following are the features of this type of cooler. Features: 1. Available in horizontal rectangular/vertical circular configuration. 2. Designed as per ISO standards 3. Top cover is openable for direct tipping of milk. 4. Available in single phase as well as three phase electric supply. 5. Cleaning done manually with tank cleaning brush. 6. One agitator and one condensing unit up to capacity 1000L and two condensing units
3

for cap: 2000L and above. 7. Best option for small, remote societies 8. Low initial investment and operating cost 1.4.2 Closed Type Bulk Milk Cooler:

Figure 1.2: Typical Closed Type Bulk Milk Cooler [B5] It is available in the capacity ranges of 3000L, 4000L, and 5000L. Following are the features of this type of cooler. Features: 1. Available in horizontal cylindrical configuration. 2. Designed as per ISO standards 3. Pump feed system for milk loading 4. Available in three phase electric supply. 5. Cleaning done using spray ball. 6. One agitator and two condensing units for all capacity. 7. Best option for large societies. 8. High initial investment and low operating cost.

CHAPTER 2: LITERATURE SURVEY

2.1 BULK MILK COOLER [P1]:

When refrigeration first arrived (the 19th century) the equipment was initially used to cool cans of milk, which were filled by hand milking. These cans were placed into a cooled water bath to remove heat and keep them cool until they were able to be transported to a collection facility. As more automated methods were developed for harvesting milk, hand milking was replaced and, as a result, the milk can was replaced by bulk milk cooler. 'Ice banks' were the first type of bulk milk cooler. This was a double wall vessel with evaporator coils and water located between the walls at the bottom and sides of the tank. A small refrigeration compressor was used to remove heat from the evaporator coils. Ice eventually builds up around the coils, until it reaches a thickness of about three inches surrounding each pipe, and the cooling system shuts off. When the milking operation starts, only the milk agitator and the water circulation pump, which flows water across the ice and the steel walls of the tank, are needed to reduce the incoming milk to a temperature below 40 degrees. This cooling method worked well for smaller dairies, however was fairly inefficient and was unable to meet the increasingly higher cooling demand of larger milking parlors. In the mid 1950's direct expansion refrigeration was first applied directly to the bulk milk cooler. This type of cooling utilizes an evaporator built directly into the inner wall of the storage tank to remove heat from the milk. Direct expansion is able to cool milk at a much faster rate than early ice bank type coolers and is still the primary method for bulk tank cooling today on small to medium sized operations. Another device which has contributed significantly to milk quality is the plate heat exchanger (PHE). This device utilizes a number of specially designed stainless steel plates with small spaces between them. Milk is passed between every other set of plates with water being passed between the balances of the plates to remove heat from the milk. This method of cooling can remove large amounts of heat from the milk in a very short time, thus drastically slowing bacteria growth and thereby improving milk quality. Ground water is the most common source of cooling medium for this device. Dairy cows consume approximately 3 gallons of water for every gallon of milk production and prefer to drink slightly warm water as opposed to cold ground water. For this reason, PHE's can result in drastically improved milk quality, reduced operating costs for the dairymen by reducing the refrigeration load on
5

his bulk milk cooler, and increased milk production by supplying the cows with a source of fresh warm water. Plate heat exchangers have also evolved as a result of the increase of dairy farm herd sizes in the US. As a dairyman increases the size of his herd, he must also increase the capacity of his milking parlor in order to harvest the additional milk. This increase in parlor sizes has resulted in tremendous increases in milk throughput and cooling demand. Today's larger farms produce milk at a rate which directs expansion refrigeration systems on bulk milk coolers cannot cool in a timely manner. PHE's are typically utilized in this instance to rapidly cool the milk to the desired temperature (or close to it) before it reaches the bulk milk tank. Typically, ground water is still utilized to provide some initial cooling to bring the milk to between 55 and 70 F (21 C). A second (and sometimes third) section of the PHE is added to remove the remaining heat with a mixture of chilled pure water and propylene glycol. These chiller systems can be made to incorporate large evaporator surface areas and high chilled water flow rates to cool high flow rates of milk. 2.2 PERFORMANCE OF BULK MILK COOLER [P1, P2, B5]:

Direct expansion systems are the most common choice in farm milk cooling systems. In these systems, the evaporator plates are incorporated in the lower portion of the storage tank, in direct contact with the milk. Milk cooling takes place within the tank and one or more agitators move the milk over the evaporator plates for cooling. The refrigerated surface area is limited by the tank geometry and therefore, in many cases, the ability to remove heat from the milk fast enough to meet cooling requirements with high milk loading rates is not possible without reducing evaporator surface temperature to the point where freezing of milk may occur. Agitating warm milk for long periods of time can also be detrimental to milk quality. The milk cooling tank is usually not completely filled at once. A two milking tank is designed to cool 50 % of its capacity at once, a four milking tank is designed to cool 25 % of its capacity at once, etc. Therefore, the cooling performance depends on the number of milking it takes to completely fill the tank, the ambient temperature and the cooling time. In Europe, the EN standard 13732 sets different classes of cooling performance based on these three parameters (number of milking, ambient temperatures and cooling times) as summarized in Table. Similar classifications are given by the international standard ISO 5708 or the American standard 3A 13-10.
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1. No. of Milking Class 2 2-milking tank designed to cool 50% of its capacity at once . 4 6 4- milking tank designed to cool 25% of its capacity once 6- milking tank designed to cool 16.7% of its capacity once 2. Ambient temperature class Class A B C Performance temperature 38C 32C 25C Safe Operating temperature 43C 38C 32C 3.Cooling time class( maximum cooling time cool any milk (35 deg to 4 deg ) Class 0 1 2 3 Time 2 hours 2.5 hours 3 hours 3.5 hours Table 2.1 - Performance of Bulk Milk Cooler [P2] In 2007 F. Illan, A.Viedma analyzed milk cooling tanks in this work are assumed to be class 2 B II (milking tank designed to cool 50 % of its capacity from 35 C to 4 C in 3 hours at an ambient temperature of 32 C). Three different tank capacities of 1.5, 5 and 9 m 3 were studied. Both specific heat and density of milk are influenced by its fat content and temperature. Since the milk directly comes from the cow milking machine, it can be considered whole milk (3.5 % fat). For a temperature range between 4 and 35C, the specific heat cp of whole milk can be considered constant and equal to 3890 KJ/ kg k, where its density around 1032 considered constant 1030 kg/m3 Therefore, the cooling capacity required to cool a n-milking tank of volume V from 35 C to 4 C in 3 hours can be obtained as: Q = (m v cp T)/(n t) =1023 *V*3890*(35-40) /(n*3*3600) (W) Usually milk cooling tanks had its own condensing unit, which only produces the refrigeration effect required to cool the milk stored in one tank. The cooling capacity of any condensing unit depends on tank volume and class and it must be at least equal to (and normally higher than) the value obtained applying equation. In this work it had been assumed that this cooling capacity is strictly equal to the minimum. Summarizes the main characteristics of the cooling tanks (condensing units included) analyzed in this work. Model 1500L Volume 1.5m^3 Class 2B2 Cooling capacity 8.64
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Refrigerant charges 8.16kg

Energy consume 4.39kw

5000L 9000L

5m^3 2B2 28.79 19.94kg 14.64kw 9m^3 2B2 51.82 29.91kg 26.35kw [P2] Table 2.2 - Characteristic of Cooling Tank

In 2009 hazard chilling centre Bhopal installed 5000 L bulk milk cooler It is bulk milk cooler with direct expansion cooling system. The cooling unit of bulk cooler adequate design to cool milk from 35 to 4 according ISO 5708 norms. The compact condensing unit is simple easy to install comprise reliable hermetic compressor operating 0c evaporator and 50condensing temperature (Alfa level) and charged with 14 kg of Freon 22 which is injected by the expansion valve in evaporator. For this calculation bulk milk cooler isentropic efficiency 0.80. Compressor and motor efficiency 1.00 and cooling capacity28.64kw this value taken from Alfa level limited (Replacing harmful refrigerant R22 in bulk milk cooler volume 2 Indian journals of science and technology). Refrigerant M(kg/sec) P(kW) Qk (kW) R.E (kJ/kg) COP R22 .207 10.62 39.25 138.41 2.87 R134a .232 10.77 39.40 123.60 2.66 R152a .135 10.08 38.71 212.24 2.84 R717 .028 9.99 38.52 1009.36 2.87 R143a .288 12.83 41.46 99.43 2.23 R32 135 11.41 40.04 212.08 2.51 R290 .125 11.10 39.76 236.60 2.57 Table 2.3 - Comparison of Various Refrigerants used in 5oooL Bulk Milk Cooler [P1]

2.3

TEST SETUP REQUIRED FOR BULK MILK COOLER AS PER ISO 5708:1983 [B5]:

The test room is suitable for testing the Bulk Milk Coolers up to the maximum capacity of 5000 LPD under 2AII conditions as specified in ISO 5708: 1983, as far as the Cooling Tests are concerned. The room temperature can be set within the range of 15C to 50C with the stability of 0.2C.
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2.3.1
1.

The Setup for Bulk Milk Cooler Consists of:

An Insulated Room made from Sandwich Panels measuring 4.5 M X 4.5 M X 4 M Height. A Semi-hermetic Water Chiller of nominal 35HP rating (with water cooled condenser) or of nominal 40HP rating (if the air cooled condenser is used). The refrigerant used is R22.

2.

3.

Hot & Cold Tank Arrangement for the chiller so that the room temperature is maintained within 0.2C and the temperature gradient around the test piece is within the limits of ISO 5708: 1983 section 15.1.

4.

A Vertical Inline Pump of Grundfos make, for circulating the water from the cold tank to the Refrigerant to Water PHE and back. A Vertical Inline Pump of Grundfos make, for circulating the conditioned water from the hot tank to the water cooling coil located inside the air handling unit and back to the hot tank.

5.

6.

An Air Handling Unit Assembly located at the roof of the room consisting of a blower of adequate capacity and a water cooling coil and the heaters. The air is delivered thru the perforated wall and is sucked from the opposite wall. This ensures uniform air velocity and air temperature across the length, breadth and the height of the room. The arrangement easily satisfies the temperature uniformity and maximum air velocity requirements of ISO 5708: 1983 section 15.1.

7.

PID Control System for the control of the room temperature consisting of Siemens make Three Ways Flow Control Valve, Thyrister for modulating the room air heaters, and a PID controller. The Heat-Cool Control is used so as to keep the running cost to the minimum.

8.

Yokogawa make Data Acquisition System and the sensors like RTD PT100 for mapping of the air temperature around the tank under test and the condensing unit as per ISO 5708: 1993 section 15.1.2 and 15.1.3, pressure and temperature sensor for the measurement of the parameters at the evaporator inlet (ISO 5708:1983 section 19.2).

9.

Sensors (Transducers) for the measurement of the electrical parameters such as the voltage, frequency, power consumption and the integrated power for calculating the power consumption of the bulk milk cooler on per liter basis as per ISO 5708: 1983 section 21.1.1.9. The transducers are connected to Data Acquisition System as
9

explained in h above. Specified starting point such as 35 C or 19 C, consisting of the heaters, pump and a PID Controller.
10.

A Computer consol and the Data Acquisition software based on Instruments, USA LAB View. The setup is designed to work 24 hours a day and 7 days a week.

National

11.

12.
13.

The setup is user friendly and has the provision to make all the operations from the computer terminal. A Milk (Water) Heating System, to raise the temperature of the water to the tripping signals is indicated on the computer monitor whenever a safety device trips or a parameter exceeds the preset limit. ISO 5708: 1983 requirements such as filling the tank under test with the correct milk/water quantity within the prescribed time period, etc. are out of the scope of our supply 2.3.2 Specification of Pre-Fabricated Wall:

The test room is of prefabricated type with tongue and groove joints and silicone sealant at the joints. Given below are the specifications. Size of the room Cladding, Inside Cladding, Outside Flooring : : : : Length 4.5M X Breadth 4.5M X Height 4M 80MM PUF all over, 40 2 kg/m3 Density. Galvanized & pre-coated Steel Sheets, 0.6MM thick Steel Sheets, 0.6MM thick, percolated galvanized 0.6MM thick pre-coated sheets outside, PUF insulation & 12MM Marine plywood with FRP coating. 1.5MM Stainless Steel Sheet above. Door : User to specify the size. Has glass viewing window, one each for indoor and outdoor rooms. Heavy duty hinges, latches and gaskets are provided for proper sealing. Conditioned Air Delivery: From perforated wall. Air Suction Illumination Floor of the room Roof of the room : : : ; From the opposite wall. 40W X 4 tubes with decorative fittings. made from heavy gage SS sheets and can withstand the loading of 800 kg/m3. The conditioning equipment (AHU) is strategically located
10

Insulation thickness :

2.4

HEAT LOAD DESIGN [P2, P6, B3]:

According to carrier air conditioning company primary function of air conditioning is to maintain human comfort or require by product or process within a space. To perform this function equipment must be installed proper capacity. The purpose of calculating heat load is important choosing system component such as chiller, pump, air handling unit carrier (1987) , Aybers (1992) stated that choice of ideal cooling system requires good calculation heat load and all source of heat must be take into consideration. According to Erol (1993) determines all inputs of heat load would not be possible for this reason, there may be some deviation in the heat load and focus point must be minimizing deviation. The capacity of compressor must be enough to suck and pump cooling gas to compressor ( sava 1987). For calculating heat load of the environment detailed construction design information used as a testing room. Anonymous (1998). 2.5 VARIABLE FLOW CHILLER WATER PUMPING [P5, P7]:

The principal objectives of chilled water pumping system selection and design are to provide the required cooling capacity to each load, to promote the efficient use of refrigeration capacity in the plant, and to minimize pump energy consumption subject to whatever budgetary constraints may apply. In the typical design process, such decisions are made on the basis of economic calculations. Accurate energy use prediction is an essential step in the development of the operating cost component of such analyses. Typically, flow is at a constant flow rate or in increments such that flow through active evaporators of chillers is constant while flows vary in proportion to the cooling load to reduce the part load energy consumption of pumps. Primary/secondary systems with constant flow have been converted into variable flow systems by introducing a valve into the bypass line to permit flow only from supply to return (Avery 1998), a practice that have received universal approval from the design community (Rishel 1998). Multiple chillers are generally connected in parallel, although some plants employ series arrangements. 2.6 PIPING DESIGN: ASHARE STANDARD 90.1(2001) STATES [B1, B2]:

6.3.2.2.2: two pipe changes over system that use a common distribution system to supply both heated and chilled water is acceptable provide all the following met system is built. Many designers consider humidity control through reheat In October of 2000 the Trane company is said modern two pipe arrangement is arranged for ease of balancing in almost all
11

area . Modern two pipe system does not vary much changes in load show up as variation in the system delta T . In this two pipe chiller water system divide the flow of two chillers same way two condensing unit required for particular one unit chiller and return from air handling unit suck two unit of chiller, water is recalculated in the system

Figure 2.1 - Two Piping Systems in Chiller Arrangement [B2] Piping materials and design have a large influence on the system pressure drop, which in turn affects the pump work. Many of the decisions made in the piping system design will affect the operating cost of the chiller plant every hour the plant operates for the life of the building. When viewed from this life cycle point of view, any improvements that can lower the operating pressure drop should be considered. Some areas to consider are pipe size, pipe material, valve, direct return vs reverse return. Three pipe systems with a common return for heating and cooling are not allowed. (6.3.2.2.1) Pipe joint: According to division 15, 15060 HVAC pipe 1. Threaded joint: a. Thread pipe with tapered pipe threads in accordance with ANSI B2.1. Ream threaded ends to remove burrs. Apply pipe joint sealant (Rector Seal No. 5) or Teflon tape suitable for the service for which the pipe is intended on the male threads at each joint. Teflon tape shall not be used for oil services. 2. Welded Joints
12

a. b.

Weld pipe joints in accordance with ASME Code for Power Piping, B31.1. Whenever welded piping connects to equipment valves or other units needing maintenance, servicing, or possible removal, flange the connecting joints. Match the pressure rating of the pipe flanges with the pressure rating of the flanges on the equipment to which the piping connects. Provide flanged pipe sections to permit removal of equipment components.

c. d.

Welding Process: Sizes 4 inch and smaller, use either gas welding (oxyacetylene process) or metallic arc process; sizes above 4 inches, use metallic arc process. Beveling and Welding: All pipe 2 inches and larger may be purchased mill beveled or shall be machine beveled on both ends before welding. On odd lengths of pipe, beveling may be accomplished by means of the oxyacetylene cutting torch provided all paint, rust, scale and oxide are carefully removed with hammer, chisel or file and bevel left smooth and clean. Joints shall be prepared and welded to assure thorough fusion of alignment and the production of a joint that shall develop the full strength of the pipe and that shall be leak proof in service.

e.

Welding Rods: The welding rod used for welding steel and wrought iron shall be approved welding rod in accordance with ASTM Spec. A233. Electrodes of Classifications E6012, E6013, E7014 and E7024 shall not be used.

f. 1)

Repair of Welds and Weld Defects A weld is considered defective and shall be repaired if it does not meet the acceptance standard of each applicable non-destructive examination as defined ASME/ANSI B31.9. 2) 3) Repairs shall be made in accordance with ASME/ANSI B31.9. Brazed Joints: For copper tube and fitting joints, braze joints in accordance with the AWS Soldering Manual, the Contractors tested Procedure Qualification Record, ANSI B31.1 Standard Code for Pressure Piping, Power Piping, and ANSI B9.1 Standard Safety Code for Mechanical Refrigeration. 4) Soldered Joints: For copper tube and fitting joints, solder joints in accordance with the AWS Soldering Manual and The Copper Handbook. Thoroughly clean tube surface and inside surface of the cup of the fittings, using very fine emery cloth, and prior to making soldered joints. Wipe tube and fittings clean and apply flux. Flux shall not be used as the sole means for cleaning tube and fitting surfaces.
13

2.7

HVAC CONTROL [B9]:

It was only natural that the first HVAC controllers would be pneumatic, as the engineers probably understood fluid control. Thus mechanical engineer could use their experience with the properties of steam and air to control the flow of heated or cooled air. There are still pneumatic HVAC systems in operation in some buildings, such as schools and offices, which can be a century old. After the control of air flow and temperature was standardized, the use of electromechanical relays in ladder logic to switch dampers became standardized. Eventually, the relays became electronic switches, as transistors eventually could handle greater current loads. By 1985, pneumatic control could no longer compete with this new technology. By the year 2000, computerized controllers were common. Today, some of these controllers can even be accessed by web browsers, which need no longer be in the same building as the HVAC equipment. This allows some economies of scale as single operations center can easily monitor thousands of buildings.

CHAPTER 3: AIR CONDITIONING SYSTEM

3.1 WHAT IS AIR CONDITIONING?

Heating ventilating and air-conditioning HVAC is one of the building mechanical services that include plumbing, fire protection, and escalators. Air-conditioning refers to any form of
14

cooling, heating, ventilation or disinfection that modifies condition of air. the goal of an HVAC system is to provide an energy efficient, cost effective, healthy and comfortable indoor environment with acceptable indoor air quality. 3.2 1. 2. AIR CONDITIONING SYSTEMS CLASSIFICATION: Central systems. Decentralized systems; heating are

Corresponding to their related equipment Air conditioning systems may be classified as:

According to the method by which the final within the space cooling and attained, air conditioning systems are generally divided into four basic types: 1. 2. 3. 4. 3.3

All-air system when energy is transferred only by means of heated or cooled air. All-water system when energy is transferred only by means of hot or chilled water. Air-water system when energy is transferred by a combination of heated/cooled air and hot/chilled water Unitary refrigerant based system when energy is transferred by a refrigerant CENTRAL AIR CONDITIONING SYSTEMS:

A central HVAC system serves one or more thermal zones and has its major components located outside the zone or zones being served in some convenient central location in the building or near it. District systems serving more than one building revert to central systems at the single building level. 3.3.1 1. 2. 3. Central Air Conditioning Systems Components:

Central air conditioning systems basically consist of three major parts: An air system or air handling unit (AHU), air distribution system (air ducts) and terminals. Water system chilled water system, hot water system, condenser water system Central plant refrigeration (chiller) plant, boiler plant 3.3.2 Advantages of Central Air Conditioning Systems:

Allow major equipment components to be isolated in a mechanical room (i.e. Allows maintenance to occur with limited disruption to building functions, reduce noise and aesthetic impacts on building occupants).
15

Offer opportunities for economies of scale. Larger capacity refrigeration equipment is usually more efficient than smaller capacity equipment; larger systems can utilize cooling towers that improve system efficiencies in many climates.

Central systems may permit building-wide load sharing resulting in reduced equipment sizes, costs, and the ability to shift conditioning energy from one part of a building to another.

Central systems are amenable to centralized energy management control schemes; i.e. reduced building energy consumption. A central system may be appropriate for other than climate control perspective; active smoke control is best accomplished by a central all-air HVAC system. 3.3.3 Disadvantages of Central Air Conditioning Systems:

As a non-distributed system, failure of any key equipment component mayaffect the entire building. As system size and sophistication increase, maintenance may become more difficult and may be available from fewer providers if specialists are needed. Large centralized systems tend to be less intuitive making systems analysis and understanding more difficult

3.4 1.

DECENTRALIZED SYSTEMS: Individual Systems using self-contained, factory-made air conditioner to serve one or two rooms. more

Decentralized systems may be divided into:

2. Unitary Systems, which are similar in nature to individual systems but serve rooms or even more than one floor, have an air system consisting of

fans, coils, filters,

ductwork and outlets (e.g. In small restaurants, small shops and small cold storage rooms). The term packaged air-conditioner is sometimes used interchangeably with the unitary air-conditioner. The air-conditioning and refrigeration institute ARI defines unitary air-conditioners one or more factory-made assemblies that normally include an evaporator/cooling coil and a compressor and condenser combination. 3.4.1 Advantages of Decentralized Air Conditioning Systems:
16

1. 2. 3.

Serving only a single zone, decentralized HVAC systems will have only one point of control typically a thermostat for active systems. Each decentralized system generally does its own thing, without regard to the performance or operation of other decentralized systems. Decentralized systems tend to be distributed systems providing greater collective reliability than do centralized systems 3.4.2 Disadvantages of Decentralized Air Conditioning Systems:

1. 2.

Decentralized system units cannot be easily connected together to permit centralized energy management operations. Decentralized systems can usually be centrally controlled with respect to on-off functions through electric circuit control, but more sophisticated central control (such as night-setback or economizer operation) is not possible.

3.5

APPLIED PSYCHOMETRICS:

The practical data to properly evaluated the heating and cooling loads They also recommend outdoor air quantities for ventilation purpose in area where state city, or local code does not exist Description of various terms, process and factor as encounter in normal air conditioning application Dry bulb temperature The temperature of air is as register by an ordinary thermometer Wet bulb Temperature The temperature register by thermometer whose bulb is covered by wetted wick and exposed to a current of rapidly moving air Dew point temperature The temperature at which condensation of moisture begins when air is cooled Relative humidity - Ratio of actual water vapor pressure of air to the saturate water vapor pressure at same temperature Specific humidity or moisture content The weight of water vapor in grains or pound of moisture per pound of dry air Enthalpy a thermal property indicating quantity of heat in the air above arbitrary datum in Btu per pound of dry air. The datum for dry air is 0F and for moisture content, 32F water Enthalpy deviation Enthalpy indication above for any given condition is enthalpy of saturation, it should be corrected by enthalpy deviation due to air not being saturated state.
17

Enthalpy in Btu per pound of dry air, Enthalpy deviation applied where extreme accuracy is required on normal air conditioning system they omitted. Specific volume The cubic feet of the mixture per pound of dry air Sensible heat factor The ratio of sensible heat to total heat Alignment circle Locate 80F dry bulb temperature and 50% relative humidity and used in conjunction with the sensible heat factor to plot various air condition process line Pound of dry air The basic for all psychometrics calculations remains constant during all psychometrics process The dry bulb, wet bulb, dew point temperature and the relative humidity are so related that if two properties are known, all other properties shown may then determined. When the air is saturated dry bulb, wet bulb, and dew point temperature are all equal. 3.6 DESCRIPTION OF TERMS, PROCESS AND FACTORS: 3.6.1 Sensible Heat Factor:

The thermal properties of air separated from latent heat & sensible heat .the term sensible heat factor is the ratio of sensible heat to total heat, where total heat is sum of sensible heat load and latent heat load. This ratio mat be expressed as SHF = SH/ (SH+LH) =SH/TH Where SHF = sensible heat factor SH = sensible heat LH = latent heat TH = total heat 3.6.2 Room Sensible Heat Factor:

The room sensible heat factor is the ratio of room sensible heat the summation of room sensible heat and room latent heat. The ratio is expressed following formula RSHF = RSH/ (RSH+RLH) =RSH/RTH The supply air to a conditioned space must have the capacity to offset simultaneously both room sensible heat and room latent heat .The room and supply air condition to the space may be plotted on the standard psychometrics chart and these point connect straight line ( oc) shown in figure 3.1 . The line represents the psychometrics process of the supply air within condition space and is called sensible heat factor line. The slope of RSHF line illustrates the ratio of sensible to latent load within the space and is illustrating in fig hs (sensible heat)
18

and hl (latent heat)

Figure 3.1: Sensible Heat Factor Lines [B3] 3.6.3 Effective Sensible Heat Factor (ESHF);

To relate bypass factor and apparatus dew point to the load calculation, the sensible heat factor term developed. ESHF is interwoven with BF and ADP and thus greatly simplified the calculation of air quantities and apparatus selection. The effective sensible heat factor is the ratio of effective room sensible heat to effective room sensible and latent heats. Effective room sensible heat is composed of room sensible heat plus the portion of outside air sensible load which is considered as being bypassed unaltered through condition space. The effective room latent heat is composed of room latent heat plus the portion of outside air latent heat load which is considered as being bypassed unaltered through conditioned space. The ratio is expressed in the following formula ESHF = 3.6.4 ERSH / (ERSH+ERLH) = ERSH/ERTH

Air Quantities using ESHF, ADP, and BF:

A simplified approach for determining the required air quantity is to use psychometrics correlation of effective sensible heat factor apparatus dew point and bypass factor .ERSH, BF and ADP with GDHF and RSHF, These two factor need not be calculated to determine the required air quantities, since the use of ESHF, BF and ADP (supply temperature) result in same air quantities. The formula for calculating air quantities using BF and supply temperature
19

CFM = ERSH / 1.08(Trm Tadp) (1-BF) The air quantities simultaneously offset the room sensible and room latent loads and also handles the total sensible and latent loads for which the conditioning apparatus is designed including outdoor air load and supplementary loads

CHAPTER 4: HEAT LOAD CALCULATION

The primary function of air condition is to maintain condition that are (1) conductive to human comfort (2) require by product or process within a space. To perform this function, equipment of the proper capacity must be installed and control through the year. The equipment capacity is determined by actual instantaneous peak load requirement; type of
20

control is determined by the conditions to be maintained during peak and partial load. An accurate survey of load components of the space to be air conditioned is a basic requirement for realistic estimate of heating loads. The completeness and accuracy of this survey is the very foundation of the estimate.

Figure 4.1: Top View of Test Room

21

4.1

SUMMER SEASON: 4.1.1 Inside Design Condition:

For this application we have to design heat load as per inside design temperature, humidity and equipment load for different type of bulk milk cooler. 10c DBT 55% RH Equipment load Plant Size 4.1.2 21TR Maxi 4TR Mini 10, 000 L BMC 500L BMC

32.31ft (9.85 m)*14.43 ft (4.40 m)*10.48 ft (3.19 m) Outside Design Condition:

Maximum summer design condition are recommended for laboratories and industrial applications where exceeding the room design conditions for even short period of time can be determinate to a product or process. The maximum design dry bulb and wet bulb temperature is simultaneous peak. E ach of this condition can be expected to be exceeded no more than 3 hours in a normal summer. Data for Anand at 20 Latitude. SUMMER(May) DB C F 44 111. WB 25. 6 78 WINTER(January) WB 6.1 43 RH% 58 58

RH% DB 24 24 15.6 60.08

2 Table 4.1 - Outside Design Temperature [B6] 4.2 SENSIBLE HEAT: 4.2.1 Solar Heat Gain through Glass:
22

For a given application there is a no glass in the system, that area of glass is zero so give no

overall heat transfer through glass.

Q =U A T = 0 Btu / hr = 0 watt

4.2.2

Heat Gain through Building Structure:

Heat gain through the exterior construction (walls and roof) is normally calculated at greatest heat flow. It is caused by solar heat being absorbed at exterior surface and by temperature difference between outdoor and indoor air. Both heat source are highly variable thought any one day and therefore, result in unsteady state heat flow through the exterior construction. This unsteady state flow is difficult to evaluate for each individual situation; however, it can be handle heat by means of an equivalent temperature across the structure. The heat flow through the structure may then be calculated, using the steady state heat flow equation with equivalent temperature difference.
Q =U A T

Q= heat flow, Btu/hr, Watt U =transmission coefficient Btu/hr (ft^2) (F), Watt/m^2k A = area of surface, ft^2, m^2 T= equivalent temperature difference, F, C Facing Area ft2 (m2) North 151.23 (14.05) East South West North East South East South West North West Roof Sun 1. Wall U = 0.4 Btu/hr ft2 F for 9" brick =2.27 Watt/m^2K = 0.2 Btu/hr ft2 F for building with rigid board insulation Total Q=3931.98 Btu/hr = 1151.33 Watt 0 .4(2.27) 65(36.09) 3931.98 (1151.33) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 U Btu/hrsqftF (Watt/m^2K) Temp diff F(C) Load Btu/hr (Watt)

23

4.2.3

Transmission Heat Gain except Walls:

Heat flow through the interior construction (floor, ceiling and partitions) is caused by difference in temperature of the air on both side of structure. This temperature difference is essentially constant thought the day and therefore, the heat flow can be determined from steady state heat flow equation, using the actual temperature on either side. 1. Partition For partition for 9 brick U= 1.7W/m^2k = 0.29Btu/hrft^2F For partition for 4 brick U= 2.56 W/m^2 k = 0.45Btu/hrft^2F For partition for masonry U= 3.97 W/m^2 k =0.69Btu/hrft^2F 2. Floor For floor without ceiling U=3.41W/m^2 k=0.6Btu/hrft^2F For floor with ceiling U= 2.27 W/m^2 k=0.4Btu/hrft^2F For floor on ground U=0 A. Ceiling
Q =U A T
=O tsid T u e d n esig in e sid d n esig 5 = 1 .2 5 5 11 0 =5 .2 =3 .3 6 F 1 5 C Q =4 6 .2 ( 4 .3 ) 0.2(1.1 ) 5 .2(3 .3 ) 6 3 3 1 3 6 1 5 =5 4 .4 B / h =1 3 .4 W tt 20 6 tu r 54 6 a

B. Partition
Q =U A T

T = Outside design-inside design-5

=O tsid T u e d n esig in e sid d n esig 5 =1 1 .2 5 5 1 0 =5 .2 =3 .3 6 F 1 5 C Q =8 8 .4 (7 .9 ) 0.2(1.1 ) 5 .2(3 .3 ) 2 4 6 6 3 6 1 5 =9 1 .7 B / h =2 2 .5 W tt 31 1 tu r 76 7 a

C. Floor
Q =U A T

= 498 .2(46 .28 ) 0.48 ( 2.73 ) 0(0) =0 B / hr =0W tu att

Total Q=14552.17Btu/hr=4261.03 Watt 4.2.4 Infiltration and Ventilation Heat:

24

Infiltration of air and particular moisture into conditioned space is frequently a source of sizable heat gain or loss. The quantity of infiltration air varies according to tightness of door and window , building, velocity of air .and no of people, duration of occupancy, nature of activity , any special concentration ,.At times, it is required to estimate the number of people on the basis of square feet per person ,or on average traffic given by following equation. 1. Outside air:
L arg est C M in V F entilatio n ( LC ) D B 1.08 (constat ) V T F N . of people cfm / person =C M o F A rea ( ft 2 ) cfm / ft 2 =C M F W here LC V =T otal C M in ventilatio F n

We have to consider 1 air charges per hour infiltration in the system.

OutsideAir = Air ch arg es Volume 1 / 60 = 1 4886 .12 1 / 60 = 82 CFM =139 .4CMH

2. Ventilation standard: CFM(CMH) per person Application Hospital Office Restaurant Laboratories Kitchen Smoking Recommended Minimum none 30(50.97) 25(42.48) some 15(25.49) 10(16.99) considerable 12(20.39) 10(16.99) some 20(33.98) 15(25.49) Table 4.2 - Ventilation Standard [B3] CFM per sq ft of floor .33 4.0

People ch arg es = No of people CFM / person = 3 15 ( 25 .49 ) = 45 CFM = 76 .5CM H

O utside A heat Q =C M tem diff B.F . 1.08 ir F p =127 61 .2 0.12 1.08 =1007 .30 B / hr =29 .22 W tu 5 att

Total Q=1007.30Btu/hr =294.95 Watt 4.2.5 Internal Heats:

25

Internal heat gain is the sensible and latent heat released within the air condition by the occupants, light, appliance and pipe 1. People: Heat is generated within human body by oxidation called metabolism rate. Metabolism rate vary with person and his activity level Q= no of people *heat rate (Btu/hr) (Btu/hr)(Watt) Office work 245(71.74) Standing , light work 255(74.67) Activity Sensible heat Latent heat (Btu/hr)(Watt) 205(60.03) 187(54.76) Total heat (Btu/hr)(Watt) 450(131.77) 442(129.43)

Heavy work 580(169.83) 870(254.75) 1450((424.58) Athletics 716(209.65) 1075(314.77) 1791(524.42) Table 4.3 - Internal Heat from Person for Various Activities [B3] We have to take office work condition and there are three people work in the test facility.
Q = N of people heat rate ( BTU / hr ) o =3 245 (71 .74 ) = 735 Btu / hr = 215 .22 W att

2. Light: light conversion of sensible heat by conversion of electric power into light and heat .The heat is dissipated by radiation surrounding surface by conduction and convection to surround air
Q = W / ft 2 Area of building (in ft 2 ) 3.41

Types Heat Gain Btu/hr Florescent Total light watt *1.25*3.4 Incandescent Total light watt*3.4 Here this which light is taken in testing room so assume 1 W/ft^2
Q =W / ft 2 Areaof =1 466 .23 3.4 =1585 .182 Btu / hr = 464 .16 W att building (in ft 2 )

3. Equipment: In the testing room equipment is bulk milk cooler , total heat released from 10kl bulk milk cooler is 21 TR heat from standard table .
26

Q = 21 12000 = 252000 B / hr = 73788 .23 W tu att

4. Appliance: there is no appliance in the system

Q = no of com puter = 0 B / hr = 0 w tu att w att of com puter 3.14

Total Q=254320.182 Btu/hr =74467.61 Watt Room subtotal heat Q=273811.64 Btu/hr =80174.92 Watt 10% Safety Q= 27381.16 Btu/hr =8017.49 Watt Effective room sensible heat Q= 301192.80 Btu/hr= 88192.41 Watt 4.3 LATENT HEAT 4.3.1 People:

Heat is generated within human body by oxidation called metabolism rate. Metabolism rate vary with person and his activity level.
Q = no of people 205 = 3 205 (60 .03 ) = 615 B / hr =180 .08 W tu att

4.3.2

Outside Air:

Outside heat that bypasses the cooling coil contain moisture give latent heat and this outside air is calculated from infiltration and ventilation.
O utside air heat , Q = CFM gr / lb BF 0.68 =127 65 .8 0.12 0.68 = 681 .89 Btu / hr =199 .66 W att

Total Q=1296.89Btu/hr =379.74 Watt 5%Safety Q=64.85 Btu/hr =18.99 Watt Effective room latent heat Q=1361.73Btu/hr=398.73 Watt 4.4 OUTSIDE AIR HEAT:

Outside heat is total of outside sensible heat and outside latent heat can be determined by
O ASH = CFM D (1 BF ) 1.08 T =127 61 .2 0.88 1.08 = 7386 .88 Btu / hr = 2162 .95 W att O ALH = CFM gr / lb (1 BF ) 0.68 =127 65 .8 0.88 0.68 = 5000 .59 Btu / hr =1464 .23 W att

GRAND TOTAL HEAT= SENSIBLE HEAT+ LATENT HEAT+ OASH+ OALH

27

GTH Q

=314942.005 Btu/hr =26.24TR =92.22 kW

4.5

APPRATUS DEW POINT AND AIR QUANTITY:

= Effective room sensible heat / Effective room latent heat

ERSH F = 0.995

= 301192 .80 / 302554 .53 AD = 35 .33 F =1.85 C P Supply tem peratur D ehum idifi = 7.139 e = 41 .88 F = 5.49 C
ply

er rise = (T room Tsup

) (1 BF )

= (50 41 .88 ) (1 0.12 )

Dehumidify

air quantity

= Room sensible heat /(1.08 dehum idifi

er rise )

= 301192 .80 /(1.08 7.139 ) = 39064 .20 CFM = 65901 .30 CM H

4.6

PREDICTION ANALYSIS OF HEAT LOAD FOR SUMMER AND WINTER Maximum equipment load (TR) Summe r 5.25 Winter Summe 2.7 r 26.25 Room load (TR) Total load (TR) Chiller flow rate

WEATHER DATA WITH DIFFERENT CAPACITY OF BULK MILK COOLER: Capacity of cooler(KL) required (l/s) Winter Summer Winter 23.7 4.96 4.48 2.68 1.74 1.36

10 5 3 2

21

11.5 5.25 2.7 16.75 14.2 3.17 6.5 5.25 2.7 11.75 9.2 2.22 4.5 5.25 2.7 9.75 7.2 1.84 Table 4.4 - Load Predictions for Summer and Winter Data

28

CHAPTER 5: CHILLER PLANT DESIGN

5.1 CHILLER BASICS:

The chiller can be water-cooled, air-cooled or evaporative cooled. The compressor types typically are reciprocating, scroll, screw or centrifugal. The evaporator can be remote from the condensing section on air-cooled units. This has the advantage of allowing the chilled water loop to remain inside the building envelope when using an outdoor chiller. The chilled water flows through the evaporator of the chiller. The evaporator is a heat exchanger where the chilled water gives up its sensible heat (the water temperature drops) and transfers the heat to the refrigerant as latent energy (the refrigerant evaporates or boils). 5.2 CHILLER ARRANGEMENT:

To provide some redundancy in the HVAC design, most designers will require two or more chillers. Multiple chillers also offer the opportunity to improve on overall system part load performance and reduce energy consumption. Parallel chiller plants are straightforward to design and are easily modified for variable primary flow. 5.2.1 Parallel Chiller System:

Figurer shows a parallel water-cooled chiller plant. Chilled water is circulated by the chilled water or primary pump through both chillers to the load and back to the chillers. The chilled water loop can be either constant flow or variable flow. Variable flow systems increase the complexity but offer significant pump work savings. They also resolve the issue about chiller sequencing that occurs with parallel chillers, constant flow. Variable flow systems are covered in Primary/Secondary Systems and Variable Primary Flow Design. A condenser loop is required for water-cooled chillers. This includes a condenser pump, piping and a cooling tower or closed circuit cooler. The condenser loop operates whenever the chillers operate. Pumps can be constant or variable flow. The chilled water pump is sized for the design flow rate. Figure shows one main chilled water pump providing flow to both chillers. An alternative method is to have two smaller pumps serving dedicated chillers. Another possibility is to lower the operating chillers set point to offset the mixed water temperature. This also works but has some difficulties. Lowering the chilled water set point requires the chiller to work harder, lowering its efficiency.
29

Figure 5.1: Parallel Flow Chillers [B3] 5.2.2 Series Chiller System:

Series chillers are another method of operating more than one chiller in a plant. This design concept resolves the mixed flow issues found in parallel chiller designs. The chillers can be preferentially loaded as well, allowing the designer to optimize chiller performance. Series chiller systems are straightforward to design and operate. The flow rate through each chiller is the entire system flow, that is, double the individual flow rate of the parallel chillers (two chillers). This means that the chiller evaporator must accommodate the doubled water quantity. All things being equal, this result in fewer water passes and decreased chiller efficiency. However, this efficiency loss is more than offset by increased chiller efficiency because the upstream chiller operates at warmer temperatures. Also, pressure losses are additive when the chillers are piped in series. This may increase total system pressure loss significantly. Another problem in series chiller is break down of on chiller may stop total system operation.

30

Figure 5.2: Series Flow Chiller [B3] 5.3 PIPING BASIS: 5.3.1 Open Loop Piping System:

In open loop piping system water flow through the heat exchanger and exposed to atmosphere such as cooling tower and air washer. 5.3.2 Closed Loop Piping System:

In closed loop piping system water flow is not exposed to atmosphere at any point but some time contain a expansion tank that is open to the atmosphere but water area exposed is insignificant such as chilled water system. 5.3.3 Reverse Return Vs Direct Return Piping:

Reverse return piping is designed such that the path through any load is the same length and therefore has approximately the same fluid pressure drop. Reverse return piping is inherently self balancing. It also requires more piping and consequently is more expensive.

31

Figure 5.3 - Reversed Return Piping [B3] Direct return piping results in the load closest to the chiller plant having the shortest path and therefore the lowest fluid pressure drop. Depending on the piping design, the difference in pressure drops between a load near the chiller plant and a load at the end of the piping run can be substantial. Balancing valves will be required. The advantage of direct return piping is the cost savings of less piping.

Figure 5.4 - Direct Returns Piping [B3]

5.4

TYPES OF PIPING SYSTEM:

32

5.4.1

Two pipe system:

This system is composed central water cooling and heating equipment, pump, distributed piping system and terminal control. Each terminal connected single supply and single return. Heating and cooling required according to two pipe change over system. When designing a system the flow and temperature for the system first calculated. The change over system design such that high temperature water is not damage evaporator and low temperature chilled water not damage boiler. 5.4.2 Three Pipe System:

In three pipes system there is two supplies separate for hot and cold arrangement and common return system. Three way valves are for control supply temperature as per application required and modulating flow. Three pipe systems many were proved there is common return hot and cold arrangement will excessive waste energy. 5.4.3 Four Pipe System:

In the four-pipe common load system, load devices are used for both heating and cooling as in the two-pipe system. The four-pipe common load system differs from the two-pipe system in that both heating and cooling are available to each load device, and the changeover from one mode to the other takes place at each individual load device, or grouping of load devices, rather than at the source. Thus, some of the load systems can be in the cooling mode while others are in the heating mode. There is a two different pumping system is required for two different two pipe system. Although many of these systems have been installed, many have not performed successfully due to problems in implementing the design concepts and high costly for given system. Another disadvantage of this system is that the loads have no individual capacity control as far as the water system is concerned. That is, each valve must be positioned to either full heating or full cooling with no control in between.

5.5

FLOW CALCULATION:
33

For water chilling system flow required to cool sensible heat and latent heat of load (total load in the system) is calculated by following equation
Q =W 500 T Q = total heat load in B / hr W tu att W =F low in gpm ,1 / s =E T ntering m us leaving tem in peratur 314942 .005 =W 500 7.139

e difference

F , C

W = 88.23 GPM=5.56l/s Select the flow required in the system is 90 GPM =5.67 l/s For a system we use two pipe arrangement systems so that flow is divided in equal part into two different chiller that required 45 GPM (2.83 l/s)/45 GPM (2.83 l/s) in two pipe changeover system. Recommended pipe size according to calculated flow required in the system Design water quantity Required pipe GPM (l/s) nominal size (in) 240(15.12) 4 227(14.30) 4 214(13.48) 4 160(10.08) 3 142(08.95) 3 060(03.78) 2 040(02.52) 2 Table 5.1 - Pipe Size for Required Flow Rate [B3] Form chart calculate friction loss feet /100 feet using 40 schedule steel pipe 2 in and 45 GPM water flow 3.6 feet /100 feet of water as limit of ASHARE recommended friction loss rate 1 to 4 feet/100 feet chilled water system. Most of system is design 2.5 feet/100feet friction loss wand velocity from graph 5.2ft/s. this is within the limit of so system selected pipe size is ok.

34

Figure 5.5: Friction Loss Chart for 40 Schedule Steel Pipe [B3]

35

For a Standard Data for Steel Pipe U.S Nominal size (in) 1/4 8 Nominal size in mm 40ST 80XS 3/8 10 40ST 80XS 1/2 15 40ST 80XS 1 25 40ST 80XS 2 50 40ST 80XS Schedule Wall thickness t, mm 2.24 3.20 2.31 3.20 2.77 3.73 3.38 4.55 3.91 5.54 Inside diameter d, mm 9.25 7.67 12.52 10.74 15.80 13.87 26.64 24.31 52.50 49.25 Surface area m2/m 0.029 0.024 0.054 0.054 0.050 0.044 0.084 0.076 0.165 0.155 Working pressure kPa (gauge) 1296 6006 1400 5654 1476 5192 1558 4427 1586 3799

Table 5.2 - Standard Steel Pipe Data [B2] Pressure Calculation: For a centrifugal pump 25 mwc pressure required in the system is given by following equation Head (ft) = Pressure (psi)*2.31/specific gravity Newtonian liquids have specific gravities typically ranging from 0.5 (light, like light hydrocarbons) to 1.8 (heavy, like concentrated sulfuric acid). Water is a benchmark, having a specific gravity of 1.0. Head (ft) = Pressure (psi)*2.31/specific gravity 82 =P*2.31/1.0 P=2.45 bar

5.6

TYPE OF HEAT EXCHANGERS:

36

Most heat exchangers for HVAC&R applications are counter flow shell-and-tube or plate units. While both types physically separate the fluids transferring heat, their construction is very different, and each has unique application and performance qualities. 5.6.1 Shell and Tube Heat Exchanger:

Figure 5.6 shows the counter flow path of a shell-and-tube heat exchanger. The fluid at temperature T1 enters one end of the shell, flows outside the tubes and inside the shell, and exits at the other end at temperature T2. The other fluid flows inside the tubes, entering one end at temperature t1 and exiting at the opposite end at temperature t2. In a shell-and-tube heat exchanger, a tube bundle assembly is welded or bolted inside a tubular shell. The bundle is constructed of metal tubes mechanically rolled or welded at one (U-tube) or both ends (straight-tube) into tube sheet(s) that function as headers. The shell is usually a length of pipe that has inlet and outlet connections located along one or more of its longitudinal centerlines. The shell is flanged at one or both open ends to accommodate a head assembly. The tube bundle is positioned between the shell and head assemblies such that the tube wall of the bundle mechanically separates the two flow paths. The tube bundle is assembled with tube supports, which are held together with tie rods and spacers. Units with liquid on the shell side have baffles for tube supports that direct the flow. Condensers must have baffles that have been notched on the bottom to allow the liquid condensate to flow freely to the exit nozzle. The head assembly directs the other fluid across the tube sheet(s) into and out of the tube bundle. Head assemblies are designed with pass partitions to isolate sections of the tube bundle such that the fluid must traverse the length of the unit one, two, four or more times before exiting. One of two types of head assemblies is mechanically attached to the shell. Units with multiple tube-side pass construction have a head with both an inlet and outlet connection bolted at one end with a welded cap (U-tube) or bolted reversing head (straighttube) at the opposite shell end. Single-pass units have an inlet head attached atone shell end and an outlet head attached at the other end. Many variations of the shell-and-tube design are available, some of which are described in the following paragraphs. U- Tube. Figure 5.7 shows a U-tube removable-bundle shell and-tube heat exchanger. These units are commonly called converters. Illustrate modifications of the U-tube design. Tank heaters are U-tube heat exchangers with the shell replaced by a mounting collar, which is welded to a tank. A hot fluid or steam flows inside the tubes heating the fluid in the tank by natural convection. The tank heater manufacturer should be consulted about optimizing the bundle length. While it is
37

desirable for the bundle to significantly extend into the tank the designer must consider the need for additional bundle support. Tank suction heaters differ from tank heaters because they have an additional opening that permits the fluid being heated to be pumped across the outside tube wall resulting in improved thermal performance. Figure 5.10 shows two common designs of straight-tube, shell-and-tube exchangers, one with a fixed and the other with a removable tube bundle assembly .Some straight-tube, shell-and-tube heat exchangers have a floating head bolted with a gasket to a floating tube sheet or a shell-side expansion joint. This configuration is expensive and is rarely specified in HVAC applications. The tubes in this heat exchanger are coiled in a helical configuration around a small core. A spacer is placed between the tube layers. In some designs the tubes have an oval cross section. These heat exchangers are very compact and have a relatively large surface area for their size.

Figure 5.6: Counter Path in Shell and Tube Heat Exchanger [B2]

Figure 5.7: U- Tube Shell and Tube Heat Exchanger with Removable Bundle Assembly
38

and Cast K Pattern Flanged Head [B2]

Figure 5.8: U-Tube Tank Heater with Removable Bundle Assembly and Cast Bonn Head [B2]

Figure 5.9: U-Tube Tank Suction Heater with Removable Bundle Assembly and Cast Flanged Head [B2]

Figure 5.10: Straight-Tube Floating Tube sheet Shell-and-Tube Heat Exchanger with Removable Bundle Assembly and Fabricated Channel Heads [B2] 5.6.2 Plate Type Heat Exchanger:

Plate heat exchangers consist of metal plate pairs arranged to provide separate flow paths (channels) for two fluids. Heat transfer occurs across the plate walls. The exchangers have multiple channels in series that are mounted on a frame and clamped together. The
39

rectangular plates have an opening or port at each corner. When assembled the plates are sealed such that the ports provide manifolds to distribute fluids through the separate flow paths. Illustrates the flow paths the multiple plates, called a plate pack, are supported by a carrying bar and contained by pressure plates at each end. The design of the carrying bars and pressure plate permit the units to be opened for maintenance or the addition or removal of plate pairs. The adjoining plates are gasket, welded, or brazed together. Gasket plate heat exchangers are typically limited to design pressures of 2 MPa. The type of gasket material used limits the operating temperature. Brazed plate units are designed for pressures up to 3 MPa and temperatures up to 260C. The most common plate heat exchanger is the gasket plate unit. Typically, nitride butyl rubber (NBR) gaskets are used in applications up to 110C. Ethylene-propylene terpolymer (EPDM) gaskets are available for temperatures up to 160C. The gaskets are glued or clipped onto the plates. The gasket pattern on each plate creates the counter flow paths illustrated in

Figure 5.11: Flow Path of Gasket Plate Heat Exchanger [B2] SELECTION CRITERIA OF HEAT EXCHANGER:

5.7

Selection of heat exchanger depend upon list of parameter as mentioned below

40

5.7.1

Thermal Performance:

The thermal performance of a heat exchanger is a function of the size and geometry of the heat transfer surface area. Different heat transfer surface materials also affect performance copper has a higher coefficient of heat transfer than stainless steel. Flow rates (velocity), viscosity, and thermal conductivity of the fluids are significant factors in determining the overall heat transfer coefficient U. In addition, the fluid to be heated should be on the tube side because the overall U of a shell-and-tube unit is often reduced if the fluid to be heated is on the shell side. Properly selected shell-and-tube heat exchangers use tube pass options and shell-side baffle spacing to maximize velocity (turbulence) without causing tube erosion. The ability to maximize velocity on each side of a heat exchanger is particularly important when the flow rates of the two fluids are dissimilar. However, fluid velocity in shell-and-tube heat exchanger is limited to avoid tube erosion. U-tube exchangers have lower tube-side velocity limits than straight-tube units due to the thinner tube wall in the U bends. Plate heat exchangers typically have U-factors 3 to 5 times higher than shell-and-tube heat exchangers. The high turbulence created by the corrugated plate design increases convection and increases the U-factor. The plate design achieves a large temperature cross at a 1 K approach because of the counter flow fluid path and high U-factor. 5.7.2 Pressure Drop:

Fluid velocity and normal limitations on tube length tend to result in relatively low pressure drops in shell-and tube heat exchangers. Plate units tend to have larger pressure drops unless the velocity is limited. Often a pressure drop limitation rather than a thermal performance requirement determines the surface area in a plate unit. 5.7.3 Fouling:

Often excess surface area is specified to allow for scale accumulation on heat transfer surfaces without a significant reduction of performance. This fouling factor or allowance is applied when sizing the unit. Fouling allowance is better specified as a percentage of excess area rather than as a resistance to heat transfer. Shell-and-tube exchangers with properly sized tubes can handle suspended solids better than plate units with narrow flow channels. The high fluid velocity and turbulence in plate exchangers make them less susceptible to fouling. The addition of surface area (tube length) to a shell-and-tube exchanger does not affect fluid
41

velocity, and, therefore, has little. This characteristic makes a fouling allowance practical. This is not the case in plate units. The number of parallel flow channels determines velocity in a plate heat exchanger. This means that as plate pairs are added to meet a load (heat transfer surface area) requirement, the number of channels increases and results in decreased fluid velocity. This lower velocity reduces performance and requires additional plate pairs, which further reduces performance. 5.7.4 Cost:

On applications with temperature crosses and close approaches, plate heat exchangers usually have the lowest initial cost. Wide temperature approaches often favor shell-and-tube units. If the application requires stainless steel, the plate unit may be more economical.

5.7.5

Serviceability:

Shell-and-tube heat exchangers have different degrees of serviceability. The type of header used facilitates access to the inside of the tubes. The heads illustrated in figure 5.7, 5.9, and 5.10 can be easily removed without special pipe arrangements. The tube bundles in all of the shell-and-tube units illustrated, except the fixed-tube sheet unit (figure 5.10), can be replaced after the head is removed if they are piped with proper clearance. The diameter and configuration of the tubes are significant factors in whether the inside of the tubes of straighttube units can be mechanically cleaned. Figure 5.11 shows a type of head that permits cleaning or inspection of the inside of tubes after the channel cover is removed. Plate heat exchangers can be serviced by sliding the movable pressure plate back along the carrying bars. Individual plates can be removed for cleaning, regasketing, or replacement. Plate pairs can be added for additional capacity. Complete replacement plate packs can be installed. 5.7.6 Space Requirements:

Cost-effective and efficient shell-and-tube heat exchangers have small diameter, long tubes. This configuration often challenges the designer when allocating the space required for service and maintenance. For this reason, many shell-and-tube selections have large diameters and short lengths. While this selection performs well, it often costs more than a smaller diameter unit with equal surface area. Caution should be taken to provide adequate
42

maintenance clearance around heat exchangers. In the case of shell-and-tube units, space should be left clear so the tube bundle can be removed. Plate heat exchangers tend to provide the most compact design in terms of surface area for a given space. 5.7.7 Steam:

Most HVAC applications using steam are designed with shell and-tube units. Plate heat exchangers are used in specialized industrial and food processes with steam. 5.8 TYPES OF CHILLER COMPRESSORS:

Most cooling systems, from residential air conditioners to large commercial and industrial chillers, employ the refrigeration process known as the vapor compression cycle. At the heart of the vapor compression cycle is the mechanical compressor. Its function is: 1) to pump refrigerant through the cooling system and 2) to compress gaseous refrigerant in the system so that it can be condensed to liquid and absorb heat from the air or water that is being cooled or chilled. 5.8.1 Reciprocating Compressors:

Reciprocating compressors are positive displacement machines that use the reciprocating action of a piston inside a cylinder to compress refrigerant. As the piston moves downward, a vacuum is created inside the cylinder. Because the pressure above the intake valve is greater than the pressure below it, the intake valve is forced open and refrigerant is sucked into the cylinder. After the piston reaches its bottom position it begins to move upward. The intake valve closes, trapping the refrigerant inside the cylinder. As the piston continues to move upward it compresses the refrigerant, increasing its pressure. At a certain point the pressure exerted by the refrigerant forces the exhaust valve to open and the compressed refrigerant flows out of the cylinder. Once the piston reaches it top-most position, it starts moving downward again and the cycle is repeated. These compressors are available in 3 configurations namely 1) Hermetic; 2) Semi hermetic and 3) Direct driven versions. In a hermetic unit, the motor and compressor are enclosed in a common housing, which is sealed. Because the components are not accessible for repair, the entire compressor unit must be replaced if it fails. The hermetic sealed units are most common in small capacities. In the semi-hermetic unit the motor is also part of the unit, however it is not sealed. Semi Hermetic compressors have the advantage over hermetic compressors in that they can be re43

built a number of times if necessary giving a much longer service life. In a direct drive unit the motor and compressor are separated by a flexible coupling. These types of units utilize older technology and are not commonly used today The main factors favoring reciprocating compressor is low cost and efficiency when applied in low capacities. Multiple reciprocating machines can be installed for higher building loads. Further advantages include simple controls and the ability to control the speed through the use of belt drives. Available in both air-cooled and water cooled heat rejection configurations, these chillers are available from 0.5 to 150 tons of refrigeration (TR). A major drawback of reciprocating chillers is their high level of maintenance requirements in comparison with other chiller types. Reciprocating chillers have more moving parts than centrifugal or rotary chillers, resulting in an increased need for wear-related maintenance activities. Reciprocating chillers also generate high levels of noise and vibration. Special precautions must be taken to isolate the chillers from the facility to prevent transmission of machine-generated vibrations and noise. Finally, reciprocating chillers are not well suited for applications with cooling loads in excess of 200 tons. As the units grow in capacity, their space requirements and first costs exceed those of other chiller types. In addition, the energy requirements for larger units exceed that of other chillers types. 5.8.2 Screw Compressor:

Screw compressors are positive displacement machines that use helical rotors to compress the refrigerant gas. As the rotors rotate they intermesh, alternately exposing and closing off interlobe spaces at the ends of the rotors. When an interlobe space at the intake end opens up, refrigerant is sucked into it. As the rotors continue to rotate the refrigerant becomes trapped inside the interlobe space and is forced along the length of the rotors. The volume of the interlobe space decreases and the refrigerant is compressed. The compressed refrigerant exists when the interlobe space reaches the other end. There are two types: 1) Single and 2) Twin screw configuration. A single-screw compressor uses a single main screw rotor meshing with two gate rotors with matching teeth. The main screw is driven by the prime mover, typically an electric motor. A twin-screw compressor consists of accurately matched rotors (one male and one female) that mesh closely when rotating within a close tolerance common housing. One rotor is driven while the other turns in a counter rotating motion. The twin-screw compressor allows better control and variations in suction pressure without much affecting the operation
44

efficiency. Available in air-cooled and water cooled configurations, screw chiller is available up to 750 tons of refrigeration. With a relatively high compression ratio and few moving parts, screw chillers are compact, smaller and lighter than reciprocating and centrifugal chillers of the same cooling capacity. These also offer quieter, vibration-free operation and are well known for their robustness, simplicity, and reliability. They are designed for long periods of continuous operation, needing very little maintenance. Screw compressors can overcome high lift when speed is reduced, allowing energy savings without the possibility of surge as the compressor unloads. The major drawback of screw chillers is their high first cost. For small cooling loads, reciprocating chillers are less expensive to purchase and install; for large loads, centrifugal chillers cost less. 5.8.3 Centrifugal Compressor: Centrifugal compressor is a dynamic machine that uses the rotating action of an impeller wheel to exert centrifugal force on refrigerant inside a round chamber (volute). Refrigerant is sucked into the impeller wheel through a large circular intake and flows between the impellers. The impellers force the refrigerant outward, exerting centrifugal force on the refrigerant. The refrigerant is pressurized as it is forced against the sides of the volute. Centrifugal compressors are well suited to compressing large volumes of refrigerant to relatively low pressures. The compressive force generated by an impeller wheel is small, so chillers that use centrifugal compressors usually employ more than one impeller wheel, arranged in series. Centrifugal compressors are desirable for their simple design and few moving parts. Centrifugal chillers are categorized either as positive pressure or negative pressure machines depending on the evaporator pressure condition and the type of refrigerant used. A chiller using refrigerant R-22 and R-134A is a positive-pressure machine, like reciprocating chillers centrifugal units are available in both hermetically sealed and open construction. Despite its lower operating efficiency, the hermetically sealed unit is more widely used. Due to their very high vapor-flow capacity characteristics, centrifugal compressors dominate the 200 ton and larger chiller market, where they are the least costly and most efficient cooling compressor design. Centrifugals are most commonly driven by electric motors, but can also be driven by steam turbines and gas engines. A serious drawback to centrifugal chillers has been their part load performance. When the building load decreases, the chiller responds by partially closing its inlet vanes to restrict
45

refrigerant flow. While this control method is effective down to about 20 percent of the chiller's rated output, it results in decreased operating efficiency. For example, a chiller rated at 0.60 kW per ton at full load might require as much as 0.90 kW per ton when lightly loaded. Since chillers typically operate at or near full load less than 10 percent of the time, part load operating characteristics significantly impact annual energy requirements.

5.8.4

Scroll Compressor:

The scroll compressor is a positive displacement machine where refrigerant is compressed by two offset spiral disks that are nested together. The upper disk is stationary while the lower disk moves in orbital fashion. The orbiting action of the lower disk inside the stationary disk creates sealed spaces of varying volume. Refrigerant is sucked in through inlet ports at the perimeter of the scroll. A quantity of refrigerant becomes trapped in one of the sealed spaces. As the disk orbits the enclosed space containing the refrigerant is transferred toward the centre of the disk and its volume decreases. As the volume decreases, the refrigerant is compressed. The compressed refrigerant is discharged through a port at the centre of the upper disk. Scroll compressors are a relatively recent development that is rapidly overtaking the niche of reciprocating chillers in comfort cooling. They provide small size, low noise and vibration and good efficiency. Available in air-cooled and water cooled configurations, scroll chiller capacity can reach approximately 30 tons or less, which makes them good candidates for spot cooling or make-up cooling applications. The biggest drawback is that these cannot be repaired and there have been issues of scroll compressors losing oil at low temperatures. On relatively small sizes, these do not affect the life cycle economics drastically 5.8.5 Recommendations:

Chillers use one of four types of compressor: reciprocating, scroll, screw, and centrifugal. The choice leans towards reciprocating compressors for peak loads up to 80 to 100 tons. Between 100 and 200 tons peak cooling load, two or more reciprocating compressor chillers can be used. Above 200 tons, screw compressor systems begin to become cost effective. The screw chillers are well suited for applications demanding up to 750 TR. Above these capacities,
46

centrifugal chillers are generally more cost effective where water is available for heat rejection. Centrifugal compressors traditionally provide larger capacities typically above 750 tons. The centrifugal machines offer highest peak load efficiency and operate reliably for applications demanding a steady state operation. The machines are only recommended with water-cooled condenser option. 5.9 CENTRIFUGAL PUMP:

Centrifugal type pumps are used for both condenser water and chilled water systems. They can be either inline or base mounted. The pumps must be sized to maintain the system dynamic head and the required flow rate. Normally, the pumps are located so they discharge into the chiller heat exchangers. Centrifugal pumps are non-positive displacement type so the flow rate changes with the head. The actual operating point is where the system curve crosses the pump curve. In systems with control valves, the system curve changes every time a valve setting changes. This is important because the pump affinity laws cannot be used to estimate a change if the system curve is allowed to change. Identical pumps in parallel will double the flow at the same head. Identical pumps in series will double the head. .Basic pump curve from manufacturer decide pump impeller size and impeller speed.

Figure 5.12: Pump Efficiency Curve [B3] 5.9.1 Arrangement of Pump:

47

In a large system, a single pump may not be able to satisfy the full design flow and yet provide both economical operation at partial loads and a system backup. The designer may need to consider the following alternative pumping arrangement. 1. Parallel Arrangement: When pumps are applied in parallel, each pump operates at the same pressure and provides its share of the system flow at that pressure. Generally, pumps of equal size are recommended, and the parallel pump curve is established by doubling the flow of the single pump curve. Plotting a system curve across the parallel pump curve shows the operating points for both single and parallel pump operation single pump operation does not yield 50% flow. The system curve crosses the single pump curve considerably to the right of its operating point when both pumps are running.

Figure 5.13: Pump Pressure Curve for Parallel Arrangement [B3] 2. Series Pump Arrangement: When pumps are applied in series, each pump operates at the same flow rate and provides its share of the total pressure at that flow. A system curve plot shows the operating points for both single and series pump operation single pump can provide up to 80% flow for standby and at a lower power requirement.

48

Figure 5.14: Pump Pressure Curve for Series Arrangement [B3] 5.10 FLOW CONTROL SYSTEM: Three way valves are used for regulating water liquid / water flow through heat exchanger like cooling and heating coils, air washer etc. They have single disc on the valve stem operating between two seats and have three ports. There are two type divesting (mixing) valve and mixing valve. In divesting valve one connecting port is the inlet and other two are outlet port, while in the mixing valve there two inlet ports and third one is outlet port. 5.10.1 Diverting Valve:

The diversity valve can operate as a two (open and shut) position valve and also as a modulating valve, by changing the type of control. The bypass of the chilled water ensure continuous water flow the chiller even if number of zone in the system do not call for cooling and so the chilled water respective coil is stopped . A two way solenoid valve is used instead of diversity valve, but this will be drawback of (I) when the solenoid valve goes off on room thermostat, there is no bypass chilled water and affect the chiller and chiller will be freeze up water. (ii) When solenoid valve goes off disturbing noise is produced as its plunger drop down. The diverting does not produce such type of noise .so that most of system uses three way valves instead of two way valve. If the full load valve motor move the valve to the fully open position. As the load is come down valve motor modulate the flow. Thus chilled water flow through cooling coil and so its capacity is modulate according to load.

49

Figure 5.16: Three Way Bypass and Mixing Valve [B2] This valve has two inlet and one outlet port and Chilled water supply line is connected to one inlet port and the second inlet port is connected to the return water line from cooling coil and third port is connected to two mixing outlet . At full load there is no mixing of water and according to load mixing process is done In most cases, a mixing valve can perform the same function as a diverting or bypass valve if the companion actuator has a very high spring rate. Otherwise, water hammer or noise may occur when operating near the seat. 5.11 SELECTED EQUIPMENT:

According to design we required 30 TR chiller, Apparatus temperature 2 C, dehumidification 4 C temperature required and 45 GPM (10368 LPH) flow .we selected Plate heat exchanger have a higher overall heat transfer compare to shell and tube type heat exchanger, lower initial cost, for a compact design space requirement is lower, and easy to service compare to shell and tube heat exchanger and for recommended choice of compressor 30TR capacity choose reciprocating compressor. According to ASHARE 6.3.2.2.2 two change over more efficient now day select two piping arrangement, parallel pumping and chiller arrangement Specification of chilled heat exchanger Plate heat exchanger (stainless steel) IDMC made and 10.65 m2 heat transfer area 15 TR DX Chillers Cold fluid
50

Hot fluid

Flow rate Inlet temperature Outlet temperature Hydrostat pressure Specification for condensing unit Condensing unit made by Danfoss 15 TR capacity Model HGM 160A06 Refrigerant = R22 High pressure =25 bar Low pressure =8 bar 400V3 -50Hz Specification of pump Kirlosker brother made centrifugal pump Head = 15 to 25 m RPM = 2844 Flow= 3.1 lps

6200 LPH -2C -2C 9 kg/cm2

11290 LPH 6C 2C 9 kg/cm2

KW/HP=1.5/2.0, Bronze Impeller diameter =138 mm Specification of measuring instrument Pressure transmitter for pressure measuring WIKA made 0-25 bar Current 4 -20mA RTD Temperature measuring device PT 100 Yokogawa 0C to 100C Flow switch to measure water flow FM4WP Mukund electrical Max temperature 150C Max pressure 11 Kg/cm2, nominal diameter 50mm, Normal flow 170

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CHAPTER 6: TEST ROOM LAYOUT

Testing room for bulk milk cooler is to test at different ambient temperature and maintain ambient temperature .In these arrangement chillers arrange so that heating and cooling room. As per ISO 1983:5708 bulk milk cooler company work on that basis we required 15 to 50 with stability of 0.2c around the surface of bulk milk cooler. 6.1 COOLING PROCESS:

In the cooling arrangement used direct expansion chiller (plate heat exchanger) by company made. cooling system comprise vapor compression system evaporator , condensing unit (receiver , compressor , condenser , expansion valve ) and their capacity on the basis of calculation 30TR .In two pipe arrangement use two PHE chiller and for one PHE used two condensing unit so there are two PHE chillier 15 TR and four condensing unit . We used two centrifugal pumps for water circulation 3.13 l/s capacity .Pump suck water from sump 500liter syntax tank and two PHE outlet, discharge water goes to air handling unit and recirculation through PHE. As same way refrigerant cycle comprise evaporator (PHE), receiver, compressor, condenser, expansion valve, solenoid valve. R22 refrigerant extract heat from water and cool water. 6.2 HEATING PROCESS:

In heating process of room used solar water heating system 300 liter and boiler 2 kg steam / hr capacity company available unit circulate water from solar heating or boiler to hot tank arrangement. At the time of heating application steam or warm water delivered with help of hot water tank, pump suck hot water at the time suction of chiller water closed and open the hot water valve and same during the time received from air handling unit PHE suction close and hot water tank valve open .This system is made up to 50"c temperature condition. 6.3 BULK MILK COOLER TEST:

In the test room testing of bulk milk cooler by using water and cool the water 35C to 4C .System also comprise one pipe connection for bulk milk cooler set 35C hot water temperature and fill up water according requirement after completion of test water back to cold water tank.
52

Figure 6.1: Test Room Layout

6.4

BILL OF QUANTITIES:
53

Condensing Unit CDU Model - HGM 160 / Danfoss with controls MS Stand for CDU Copper piping Cabling Installation material Chilled water pump 45 GPM at 25 MWC, monoblock/bronze impeller Steel pipe Pipe 50 NB Nitrile Rubber insulation Ball Valve Non Return Valve Strainer 3 way valve Temperature Indicator Pressure indicator Flow switch Temperature sensor Expansion tank 1000 liters (syntax tank) Installation material AHU Ceiling suspended cooler 13 TR / 33000 CMH De-super heater Solar water heating system Installation material Automation Scada Pressure transmitter Temperature transmitter Installation material Electrical Panel MCC Servo voltage stabilizer 50 KVA Lighting Cabling Installation material PHE Chiller 15 TR DX PHE/R22 - SW 40 Installation material PUF Panel PCGI 0.63mm PUF 40kg/m3 Installation material Sliding Door Sliding Door - 4.3m (w) x 3.2m (h) Installation material
54

Qty 4 1 1 lot 1 lot 1 lot 2 1 lot 1 lot 6 17 1 2 2 2 2 1 1 1 lot 2 1 1 1 lot 1 20 34 1 lot 1 1 1 lot 1 lot 1 lot 2 1 lot 1 lot 1 lot 1 1 lot

Labour Work AHU Door PUF Panel SCADA Cabling Water Piping CDU Total cost Table 6.1 - Bill of Material

1 lot 1 lot 1 lot 1 lot 1 lot 1 lot 1 lot 42,00 ,000

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CHAPTER 7: THERMAL PERFORMANCE OF CHILLER HEAT EXCHANGER

7.1 HEAT TRANSFER AND PRESSURE DROP CALCULATION:

The designed for gasketed plate heat exchanger is highly specialized in nature considering the variety of designs available for the plate and arrangements that may possibly sits various duties. Manufacture has developed their own design procedure applicable to the exchangers that they market. Here IDMC LIMITED made own plate heat exchanger for various application fluids exchanges. For this company used plate data that mentioned below table from standard plate data we select the no of plate and calculate the no of plates required for given heat duty required and analyze heat transfer and pressure drop calculation as per requirement of flows and refrigerant check the heat transfer and pressure drop within acceptable limit or not. There is a parallel flow heat exchanger and data from required design. Data sheet for Plate heat exchanger: Items Fluids Flow rates (kg/s) Temperature in (0C) Temperature out (0C) Total fouling resistance (m2K/W) Hot Fluid Cooling water 3.13 6 2 0.000086 Cold Fluid R22 1.72 -2 -2 0.000044

Specific heat (J/kg.K) 4178 1.171X103 Viscosity (N.s/m2) 7.66X10-4 2.67X10-4 Thermal conductivity (W/m.K) 0.617 0.0977 Density (kg/m3) 995 1.285X103 Table 7.1 Plate Heat Exchanger Data Sheet [B7]

The Construction Data for Proposed Plate Heat Exchange: Plate Material Plate thickness, t (mm) Chevron angle , (degree)
56

SS316 0.6 60

Total number of plates, Nt 26 Enlargement factor, 1.36 No of passes, Np One pass/one pass Port diameter, Dp(mm) 100 Pack length, Lc(mm) 8.2 Vertical port distance , LV(mm) 1055 Horizontal port distance, Lh(mm) 225 Thermal conductivity (w/m.K) 16.5 Table 7.2 Construction Data for Plate Heat Exchanger

Figure 7.1: Dimension View of Plate Heat Exchanger [B7] 7.2 STEPWISE PERFORMANCE ANALYSIS: 7.2.1 Required Heat Duties:

For a given application of heat exchanger required a cool water dehumidification temperature and apparatus dew point. Here for capacity of bulk milk cooler required chiller water flow rate 3.13l/s , cool water at apparatus dew point and required dehumidification so that from heat capacity equation required heat exchanger duty for temperature 6C to 2C with specific heat of water assume city water 4178J/kg K.
57

Qh = mCp T = 3.13 4178 (6 2) = 52 ,308 .56 = 52 .31 kW

7.2.2

Sizing of Heat Exchanger:

The temperature difference for parallel flow heat exchanger at inlet and outlet is determined by temperature difference of two fluids at inlet and outlet.
T1 = 8 0 c T2 = 4 0 c

The effective number of plates is total no of plate subtract two plate for use holding heat exchanger.
Ne = Nt 2 = 26 2 = 24

The effective flow length between the vertical ports is

Leff = Lv =1055 mm =1.055 m

Plate pitch can be determined by total pack length of heat exchanger divided no of plates
P= = Lc Nt

82 26 = 3.15 mm

Mean channel flow gap for one plate can be determined by plate pitch subtract by thickness of plate
b = p t =3.1 0.6 5 = 2 .5 m 5 m

The one Channel flow area is multiplication of width of plate and mean channel flow gap
Ach = b Lw = 2.55 10 3 0.325 = 8.29 10 4 m 2

Single Plate heat transfer area is determined by effective area of one plate that given by plate manufacturer divided by effective no of plate
58

A1 = =

Ae Ne

10 .15 24 = 0.4229 m 2

The projected area A1p is determined by

A1 p = LP Lw = 0.955 0.325 = 0.31037 m 2

The enlargement factor specified by manufacturer but it can be verified by single plate area to projected area of plate
= A1 / A1 p
0.4229 0.31037 =1.36 =

The Channel hydraulic/equivalent diameter is determined by

Dh = = 2b

2 2.55 10 3 1.36 = 3.75 10 3 m

The number of Channel per pass is

Nep = = N t 1 2N p

26 1 2 1 =12

7.2.3

Heat Transfer Analysis:

Mass flow rate per channel for cold fluid total mass flow rate for cold fluid for maximum flow rate of cooling water divided by no of channel per pass of particular cooling fluid
3.13 12 = 0.261 kg / s mch =

Mass velocity Gch

59

G ch = =

m ch Ach

0.261 0.000829 = 341 .83 kg / m 2 .s

The hot fluid Reynolds number

Reh = = Gh Dh

341 .83 0.00375 7.60 10 4 = 1553 .47

Flow rate per channel for cold fluid

mcc = 1.72 = 0.144 kg / s 12

Mass velocity Gcc

G cc = = m cc Ach

0.144 0.000829 = 173 .30 kg / m 2 s

Reynolds Number for cold fluid

Gcc Dh c 173 .70 0.00375 = 2.67 10 4 = 2439 .60 Rec =

The hot fluid convective heat transfer coefficient hh can be determined using Nusselt number correlation suggest McAdams for Laminar flow 2*103<Re<1*106. Nusset number based on hydraulic diameter of plate that convective heat transfer to conduction heat transfer

60

N uh

h D = h h = 0.3(Re) 0.663 (Pr) 1 / 3 b k w

0.17

N uh = 0.3(1553 .47 ) 0.663 (5.19 )1 / 3 N uh = 67 .82 hh D h = 67 .82 k 67 .82 0.617 hh = 0.00375 = 11,158 .65 w / m 2 .k

The Cold fluid heat transfer coefficient hc can be determined by.

N uc = 0.3( 2439 .60 ) 0.663 (3.2) v 3 = 77 .86 77 .86 0.0977 hc = 0.00375 = 2028 .43 w / m 2 .k

For clean overall heat transfer UC determined by

1 1 1 0.0006 = + + Uc hc hh 16 .5 1 1 0.0006 + + 2028 .43 11158 .65 16 .5 2 U c =1615 .58 w / m .k =

The fouled overall heat transfer

1 1 = + 0.000044 + 0.000086 Uf Uc f =1335 .16 w / m 2 .k U

The corresponding cleanliness factor is

CF = Uf Uc = 1335 .16 = 0.82 1615 .58

The actual heat duties for clean and fouled condition can be determined by
Qc =U c Ae Tm Q f =U f Ac DT m

Tm = =

T1 T2 1n ( DT 1 / T2 )

8 4 ln( 8 / 4)

Actual heat transfer given by

= 5.77 0 c

61

 c =1615 .58 10 .15 5.77 Q =94 ,617 .25 W att =94 .62 kW f =1335 .16 10 .15 5.77 Q = 78 ,194 .31W att = 78 .19 kW

Percentage of over surface design

OS = 100U c R f = 100 1615 .58 (0.000044 + 0.000086 ) = 21 .00 %

7.2.4

Pressure Drop Analysis:

The fluid friction co-efficient for hot and cold fluid determined by
fh = = 1.441 (Re h ) 0.206

1.441 (1553 .47 ) 0.206 = 0.317 1.441 fc = (Re c ) 0.206 1.441 (785 .74 ) 0.206 = 0.364 =

The frictional pressure drop from hot & cold streams

4 fLeff N p G 2 b (P ) h = Dh 2 w
(P ) h =

0.2

4 0.317 01 .05 1 (341 .83) 2 0.00375 2 995 = 20 ,847 .05 Pa 4 0.364 1.05 (173 .70 ) 2 0.00375 2 1.285 10 3 = 4771 .29 Pa

(P ) c =

The Pressure drop in port is calculated by

(Gp) h = = 3.31

( Dp) 2 4

mh

(0.1) 2 4 = 421.44kg / m 2 .s

62

(Gp) c = =

( Dp) 2 4 1.72

mc

(0.1) 2 4 = 172.08kg / m 2 .s
(p p ) h = = 1.4 N p G p 2
2

1.4 1 ( 421 .44 ) 2 2 985 = 126 .22 Pa (p p ) c = = 1.4 Np Gp 2 2

1.4 1 (172 .08 ) 2 2 1.285 10 3 = 16 .13 Pa

Total pressure drop can be determined by summation of friction and port pressure drop Hot fluid side pressure drop
(p t ) h = ( Dp c ) h + ( Dp p ) h = 20847 .05 +126 .22 = 20973 .27 Pa = 0.21bar < 0.5bar

Cold fluid side pressure drop

(p t ) c = ( Pc ) c + (PP ) c = 4771 .29 +16 .13 = 4787 .42 Pa = 0.045 bar

As per calculation of heat transfer and pressure drop heat exchanger is sufficient for chiller plant to achieve an ambient condition in bulk milk cooler testing laboratory and also 21% over surface design allow due to cleaning of plate which is acceptable. 7.3 DATA ANALYSIS FOR HEAT TRANSFER WITH DIFFERENT CHILLER Chiller flow rates(l/s) 1.0 1.5 2.0 Required heat duties Q(Watt) 16748 25122 33496
63

FLOW RATES: Actual heat capacity Qact(Watt) 67072 70800 73154

2.5 3.0 3.5

41780 74700 55436 76500 58618 76800 Table 7.3 Chiller Heat Transfer Analysis

7.3.1

Heat Transfer Trends for Chiller Mass Flow Rates:

90000 80000 Heat exchange (Watt) 70000 60000 50000 40000 30000 20000 10000 0 1 2 3 4 5 6 Chiller flow (l/s) Chiller flow Required heat duty Actual heat capacity

Figure 7.2: Heat Transfer Trends for Chiller Flow Rate

CHAPTER 8: BULK MILK COOLER TEST

8.1 10 KL CLOSED TYPE BULK MILK COOLER TEST:

Standard cooling capacity for 10kl bulk milk cooler using two condensing unit hermetic type by Danfoss made 28.64 KW capacities each.

64

Figure 8.1: 10KL Bulk Milk Cooler Set Up

8.1.1

Room Temperature and Chiller Test:

65

Figure 8.2: Chiller Arrangement Supply temperature (C)

Time (min) 4:00 4:15 4:30 4:45 5:00 5:15 5:30 5:45 6:00 6:15 6:30

Chiller 1 Flow rate GPM (l/s)

Chiller 2 Flow rate GPM (l/s)

Average room temperature (C)

39.79(2.507) 39.43(2.485) 7.50 10.30 39.81(2.508) 39.57(2.493) 5.48 10.21 39.76(2.505) 39.62(2.497) 5.46 10.13 39.73(2.503) 39.64(2.498) 5.47 10.30 39.82(2.509) 39.55(2.492) 5.44 10.20 39.77(2.506) 39.51(2.490) 5.49 10.16 39.79(2.507) 39.56(2.493) 5.41 10.29 39.76(2.505) 39.60(2.495) 5.39 10.24 39.80(2.508) 39.58(2.494) 5.42 10.18 39.75(2.505) 39.56(2.493) 5.40 10.15 39.73(2.503) 39.52(2.490) 5.38 10.10 Table 8.1 - Chiller and Room Temperature Test for 10KL BMC

8.1.2 Time (min) 4:00 4:15

Bulk Milk Cooler Test: Suction pressure (Bar) 4.86 5.00 Discharge pressure (Bar) 19.24 20.24 Evaporator out temperature (C) 33.31 32.53
66

Liquid line temperature (C) 43 48

Water temperature (C) 35 31.2

4:30 4:45 5:00 5:15 5:30 5:45 6:00 6:15 6:30

5.16 5.06 5.20 5.13 4.78 4.56 4.41 3.99 3.59

21.00 29.81 52 21.33 27.01 51 21.32 24.21 50 21.20 21.28 51 20.68 16.21 52 20.44 10.26 50 19.89 5.01 47 18.95 1.12 41 18.26 0.5 41 Table 8.2 - 10KL Bulk Milk Cooler Test

27.6 24.4 21 17.7 14.6 11.6 8.9 6.3 3.9

8.1.3 (1)

Calculation for Heat Removed from Condenser:

At 4:00 PM

Suction Pressure P0 =4.86 bar, Discharge Pressure P1 = 19.24 bar, Evaporator out temperature Te= 33.31 C Liquid line temperature T3=43C Using this data from p - h chart getting Enthalpy values h1 =274 kJ/kg, h2=335 kJ/kg, h4=103 kJ/kg= h3, Q = m*(h1- h4) kJ/s 28.67=m*(274-103) m = 0.167 kg/s So heat rejected from compressor Qrej = m*(h2- h3) kJ/s = 0.167*(335-103) =38.74 kW 8.1.4 As Per Calculation at 4:00 PM Heat Removed from Condenser Same Procedure for Another Time .Total Room Load the Time of Testing and Required Chiller Flow Rates: Time (min) Product load TR Total load Flow GPM(L/s) 4:00 4:15 4:30 4:45 5:00 5:15 22.05 21.21 21.47 21.85 21.12 21.26
67

TR 26.87 26.00 26.28 26.71 25.90 25.19

(TR*3) 80.64(5.08) 78.00(4.91) 78.84(4.97) 80.13(5.05) 77.70(4.90) 75.57(4.76)

5:30 5:45 6:00 6:15 6:30

22.75 27.70 83.10(5.24) 22.56 27.49 82.47(5.20) 21.26 26.06 78.18(4.93) 20.77 25.45 76.35(4.81) 21.28 26.09 78.27(4.93) Table 8.3 - Total Room Load for 10KL BMC

8.2

CLOSED TYPE BULK MILK COOLER TEST:

5KL bulk milk cooler test at outside ambient temperature 39C and inside design temperature 10C. Bulk milk cooler installed with two hermetic compressors with capacity of 14.66 KW each unit as shown in below.

68

Figure 8.3: 5KL Bulk Milk Cooler Set Up

69

8.2.1

Room Temperature and Chiller Test: Time (min) 2:00 2:15 2:30 2:45 3:00 3:15 3:30 3:45 4:00 4:15 4:30 Chiller 1 Flow rate GPM (L/s) Supply temperature Average room temperature (C)

(C) 50.79(3.201) 10.02 10.30 51.29(3.232) 8.29 10.21 51.43 (3.241) 6.35 10.13 51.39(3.238) 5.25 10.30 51.36(3.236) 5.21 10.20 51.42(3.240) 5.18 10.16 51.34(3.235) 5.05 10.29 51.37(3.237) 4.87 10.24 51.40(3.239) 4.63 10.18 51.42(3.240) 4.57 10.15 51.45(3.242) 4.39 10.10 Table 8.4 - Chiller and Room Test for 5KL BMC

8.2.2 Time (min)

5KL Bulk Milk Cooler Test: Suction pressure (Bar) Discharge pressure (Bar) Evaporator out temperature
70

Liquid line temperature (C)

Water temperature (C)

(C) 2:00 2:15 2:30 2:45 3:00 3:15 3:30 3:45 4:00 4:15 4:30 6.21 6.20 6.07 5.52 5.17 4.83 4.48 3.79 3.45 3.10 3.08 20.34 23.1 46.0 19.65 19.0 45.1 18.62 16.2 44.2 18.96 13.8 43.4 18.61 09.4 43.1 17.93 07.2 42.8 17.58 05.4 42.0 16.21 04.0 40.7 15.86 02.2 40.2 15.52 01.5 39.0 15.23 0.50 38.6 Table 8.5 - 5KL Bulk Milk Cooler Test 35.0 30.7 26.9 23.5 20.2 17.0 14.0 11.5 9.1 6.5 4.1

8.2.3 (1)

Calculation for Heat Removed from Condenser:

At 2:00 PM

Suction Pressure P0 =6.21 bar, Discharge Pressure P1 = 20.34 bar, Evaporator out temperature Te= 20.34 C Liquid line temperature T3 =46 C Using this data from p - h chart getting Enthalpy values h1 =271 kJ/kg, h2=319 kJ/kg, h4=110 kJ/kg= h3, Q = m*(h1- h4) kJ/s 14.66=m*(271-110) m = 0.091 kg/s So heat rejected from compressor Qrej = m*(h2- h3) kJ/s = 0.091*(319-110) =19.031 kW 8.2.4 As Per Calculation of 2:00 PM Same Calculation for Another Time. Total Time (min) 2:00 2:15 2:30 Product load TR 10.82 10.64 10.33 Total load TR 14.69 14.50 14.15
71

Room Load at the Time of Testing and Required Chiller Flow Rates: Flow GPM(L/s) (TR*3) 44.07(2.78) 43.50(2.74) 42.45(2.67)

2:45 3:00 3:15 3:30 3:45 4:00 4:15 4:30

10.32 14.14 42.42(2.67) 10.21 14.02 42.06(2.65) 10.48 14.32 42.49(2.71) 10.55 14.40 43.20(2.72) 10.86 14.73 44.19(2.78) 11.27 15.19 45.57(2.87) 11.26 15.18 45.54(2.86) 11.26 15.18 45.54(2.86) Table 8.6 - Total Room load for 5KL BMC

8.3

2KL CLOSED TYPE BULK MILK COOLER TEST:

For 2KL bulk milk cooler tested under average outside ambient temperature 40C and inside ambient 38C. Bulk milk cooler installed with two hermetic type
compressors capacity of 6.23 KW of each unit. 8.3.1 Room Temperature and Chiller Result: Time (min) 03:55 04:10 04:25 04:40 Chiller Flow rate GPM (l/s) 1.12 1.15 1.13 1.20 Supply temperature (C) 21.00 18.25 15.24 14.20
72

Average room temperature (C) 38.34 38.21 38.24 38.17

04:55 05:10 05:25 05:40 05:55 06:10 06:25 06:40

1.18 13.25 38.24 1.14 11.78 38.31 1.12 11.25 38.18 1.16 10.49 38.16 1.19 10.25 38.22 1.18 09.80 38.28 1.20 09.50 38.15 1.17 09.10 38.02 Table 8.7 - Chiller and Room Test for 2KL BMC

8.3.2

2KL Bulk Milk Cooler Test: Suction pressure (Bar) Discharge pressure (Bar) Evaporator out temperature Liquid line temperature (C) 35.0 30.9 26.9 23.5 20.4 17.4 14.7 12.5 10.4 8.4 6.4 4.0 Water temperature (C)

03:55 04:10 04:25 04:40 04:55 05:10 05:25 05:40 05:55 06:10 06:25 06:40

(C) 18.97 32.4 47.7 18.97 25.0 48.0 18.62 19.4 46.4 17.93 13.6 44.9 17.24 10.3 43.8 17.24 8.0 43.0 16.55 6.2 41.8 15.72 5.4 40.9 15.52 3.8 39.7 15.17 2.3 38.9 15.17 1.5 37.9 14.83 0.4 37.8 Table 8.8 - 2KL Bulk Milk Cooler Test

8.3.3

Calculations for Heat Removed from Condenser:

73

(1)

At 3:55 PM

Suction Pressure P0 =6.55 bar, Discharge Pressure P1 = 18.96 bar, Evaporator out temperature Te= 32.4 C Liquid line temperature T3 =47.7C Using this data from p - h chart getting Enthalpy values h1 =281 kJ/kg, h2=318 kJ/kg, h4=111 kJ/kg= h3, Q = m*(h1- h4) kJ/s 6.23=m*(281-111) m = 0.037 kg/s So heat rejected from compressor Qrej = m*(h2- h3) kJ/s = 0.037*(318-111) =7.59 kW 8.3.4 Total Room Load at the Time of Testing and Required Chiller Flow Rates: Time (min) 07:55 08:10 08:25 08:40 08:55 09:10 09:25 09:40 09:55 10:10 10:25 10:40 Product Total load Flow GPM(L/s) load TR TR (TR*3) 4.31 5.391 16.17(1.02) 4.31 5.391 16.17(1.02) 4.83 5.964 17.89(1.13) 4.31 5.391 16.17(1.02) 4.36 5.446 16.34(1.03) 4.42 5.512 16.54(1.04) 4.54 5.644 16.93(1.07) 4.67 5.787 17.36(1.09) 4.64 5.754 17.26(1.08) 4.63 5.743 17.23(1.08) 4.70 5.820 17.46(1.10) 4.70 5.820 17.46(1.10) Table 8.9 - Total Room Load for 2KL BMC

74

CHAPTER 9: RESULT AND DISCUSSION

9.1 For 10 KL BULK MILK COOLER:

10KL bulk milk cooler testing at outside temperature 39C and inside temperature 10C. We obtained almost uniform temperature as per ISO 5708:1983 mentioned. For room average temperature installed six number of RTD sensor use three for left wall and three for right wall and equally spaced from air handling unit . For 10KL and 10C inside temperature three way controls valve is fully open and achieve full chiller flow rate that maintain room temperature. 9.1.1 Time (min) 4:00 4:15 4:30 4:45 5:00 5:15 5:30 5:45 6:00 6:15 6:30 Comparison of Chiller Flow Rate and Required Flow Rate: Predict Flow GPM(L/s) (TR*3) 80.64(5.08) 78.00(4.91) 78.84(4.97) 80.13(5.05) 77.70(4.90) 75.57(4.76) 83.10(5.24) 82.47(5.20) 78.18(4.93) 76.35(4.81) 78.27(4.93) Chiller 1 Flow rate GPM (L/s) 39.79(2.507) 39.81(2.508) 39.76(2.505) 39.73(2.503) 39.82(2.509) 39.77(2.506) 39.79(2.507) 39.76(2.505) 39.80(2.508) 39.75(2.505) 39.73(2.503)
75

Chiller 2 Flow rate GPM (L/s) 39.43(2.485) 39.57(2.493) 39.62(2.497) 39.64(2.498) 39.55(2.492) 39.51(2.490) 39.56(2.493) 39.60(2.495) 39.58(2.494) 39.56(2.493) 39.52(2.490)

Table 9.1 - Compare chiller flow rate for 10KL BMC

9.1.2

Average Room Temperature Trend:

Figure 9.1: Average Room Temperature Trend for 10KL BMC 9.1.3 Predictable and Experimental Chiller Flow Trend:

76

5.4 5.2 Flow rate (l/s) 5 4.8 4.6 4.4 4.2

4: 30 6: 30 4: 00 5: 00 5: 30 6: 00

Predict flow Experiment flow

Time (min)

Figure 9.2: Chiller Flow Trend for 10KL

9.2

For 5KL BULK MILK COOLER:

For 5KL bulk milk cooler test at outside room average temperature 39C and inside temperature 10C we obtained uniform room temperature at the time of test three way control valve 70 % open and flow rate is decrease that meet the required chiller water flow and for this only one. 9.2.1 Comparison of Chiller Flow Rate and Required Flow Rate: Time (min) 2:00 2:15 2:30 2:45 3:00 3:15 3:30 3:45 4:00 4:15 4:30 Predict Flow GPM(L/s) (TR*3) 44.07(2.78) 43.50(2.74) 42.45(2.67) 42.42(2.67) 42.06(2.65) 42.49(2.71) 43.20(2.72) 44.19(2.78) 45.57(2.87) 45.54(2.86) 45.54(2.86)
77

Chiller 1 Flow rate GPM (L/s) 50.79(3.201) 51.29(3.232) 51.43 (3.241) 51.39(3.238) 51.36(3.236) 51.42(3.240) 51.34(3.235) 51.37(3.237) 51.40(3.239) 51.42(3.240) 51.45(3.242)

Table 9.2 - Compare Chiller Flow Rate for 5KL BMC

9.2.2

Average Room Temperature Trend:

Figure 9.3: Average Room Temperature Trend for 5KL 3

Chiller flow(l/s) 2.5

3.5

9.2.3

Prediction and Experimental Chiller Trend 2

1.5 1 0.5 0
Ti m e 2: 15 2: 45 3: 15 3: 45 4: 15

78

Time(min)

Figure 9.4: Chiller Flow Trend for 5KL

9.3

FOR 2KL BULK MILK COOLER:

For a 2kl bulk milk cooler test outside temperature 40C and inside temperature 38C for this condition 35% three way control valve open and achieve temperature and flow rate as per requirement of test. 9.3.1 Comparison of Chiller Flow Rate and Required Flow Rate: Time (min) Predict Flow GPM(L/s) 03:55 (TR*3) 16.17(1.02) Chiller Flow rate GPM (L/s) 1.12

04:10 16.17(1.02) 1.15 04:25 17.89(1.13) 1.13 04:40 16.17(1.02) 1.20 04:55 16.34(1.03) 1.18 05:10 16.54(1.04) 1.14 05:25 16.93(1.07) 1.12 05:40 17.36(1.09) 1.16 05:55 17.26(1.08) 1.19 06:10 17.23(1.08) 1.18 06:25 17.46(1.10) 1.20 06:40 17.46(1.10) 1.17 Table 9.3 - Compare Chiller Flow Rate for 2KL BMC

79

9.3.2

Average Room Temperature Trend:

Figure 9.5: Average Room Temperature Trend for 2KL BMC 9.3.3 Prediction and Experimental Chiller Trend:

80

1.25 1.2 Chiller flow(l/s) 1.15 1.1 1.05 1 0.95 0.9

3: 55 4: 25 4: 55 5: 25 5: 55 6: 25

Prediction flow Experiment flow

Time(min)

Figure 9.6: Chiller Flow Trend for 2KL BMC

CHAPTER 10: CONCLUSION

From designing and experimental point of conclude that for any air condition system complete information require where it is installed after getting primary information calculation of heat load is important based on required application that include all heat source .Based on heat load calculation find chiller flow required to achieve temperature and selection of cooling equipment as per heat load .In this case different capacity of bulk milk cooler test so that equipment load vary set the control valve system as per predict load for different capacity of bulk milk cooler and weather data for summer and winter condition. From experiment view we tested different types of bulk milk cooler chiller heat exchanger is enough to maintain ambient condition as we set three way control valve according design heat load calculation so that water flow rate change for different types of bulk milk cooler and outside design temperature as we calculated that achieve uniform temperature as customer said where bulk milk cooler will use. Achieve uniform ambient temperature as mentioned ISO 5708:1983 bulk milk cooler section and dispatch to customer as they told
81

ambient condition.

82

REFERENCES
PAPERS: 1. Alka Bani Agrawal, R.K. Dave and Vipin Shrivastava, Replacing harmful refrigerant R22 in bulk milk cooler, Indian Journal of Science and Technology. Vol.2 No. 9 (Sep 2009), ISSN: 0974- 6846
2.

F. Illan and A.Viedma, Using ice slurry as a secondary refrigerant for charge reduction in industrial facility, Universidad Politecnica de C artegena, Spain, Fernando.illan@upct.es

3. F.A. Ansari, A.S. Mokhtar, K.A. Abbas and N.M. Adam, A Simple Approach for

Building Cooling Load Estimation, American Journal of Environmental Sciences 1 (3): 209-212, 2005, ISSN 1553-345X 4. F.C.Houghten, Heat and Moisture Losses bi Human Body and Their Relation to Air Conditioning Problem, American Journal of Physiology, Vol 88, 1929
5. Hartman, Thomas, All Variable Speed Centrifugal Chiller Plants ASHRAE Journal,

September 2001. ASHRAE, Atlanta Ga 6. S.Akdemir, Designing of cold stores and choosing of cooling equipments, Journal of applied sciences 8(5):788-794, 2008
7. William P. Bahnfleth, Eric B. Peyer,Energy use characteristic of variable primary flow

chiller water pumping system, Grumman/Butkus Associates, Evanston, IL, USA, wbahnfleth@psu.edu BOOKS:
1. ASHRAE Fundamentals Handbook ASHRAE. Atlanta, 2000 2. ASHRAE HVAC Systems and Equipment Handbook ASHRAE. Atlanta, 2001

3.

Carrier, Handbook of Air Conditioning System Design, A Mei Ya Taiwan Edition ,Mcgraw Hill Company New York

4. C. P. Arora, Refrigeration and Air Conditioning, 2nd Edition, Tata McGraw-Hill

Company, 2007
5. ISO 5708:1983, Bulk Milk Cooler, 1st Edition, 2010 6. P.N.Ananthnarayanan, Basic Refrigeration and Air Conditioning, 3rd Edition, Tata

McGraw-Hill Company, 2005

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7. R. K. Shah, Fundamental of Heat Exchanger Design, John Wiley & Sons, 2003 8. R.K. Rajput, Refrigeration and Air Conditioning, 1st Edition, S.K.Kataria and Sons, 2004 9. Ross Montgomery, Fundamental HVAC Control System, 2nd Edition, Elsevier, 2003

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APPENDIX -A
Friction Factor and Nusset Number Correlation for Gasket-Plate Heat Exchanger with Chevron Plates [B7]: 1. Tait etal, =60 chevron plates: f =12.065Re-0.74 10< Re<80

=0.3323 Re-0.042 1450< Re<11460

Nu=0.2 Re0.75 Pr0.4 10< Re<720 =0.248Re0.7 Pr0.4 1450< Re<11460 2. Muley and Maglik, =60 chevron plates: f =51.5/Re Re<16

=17.0Re-0.6 16< Re<100

=2.48Re-0.2 Re>800 Nu=0.572 Re0.5 Pr1/3 =0.1090Re0.78 Pr1/3 20< Re<210 Re>800

3. Muley and Maglik, Mixed chevron plate with =30 & 45 angle: f= {(40.32/ Re) 5+ (8.21 Re-0.5)5}0.2 2< Re<200 = 1.27 Re-0.15 Nu=0.471 Re0.5 Pr1/3 =0.10Re0.78 Pr1/3 20< Re<400 Re>1000 Re>1000

4. McAdam Correlation for 2*103< Re<1*106 for =60 chevron angle: f= 1.441/( Re)0.206 Nu=0.3(Re) 0.663(Pr) 1/3(b/w)0.17

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