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In many facilities, chiller and condenser systems are the largest energy consuming component of the plant. Operating a chiller at its peak performance saves energy, as well as maintenance costs, and can keep the facility&#;s loads properly maintained. Chiller performance varies significantly with operating conditions, and any opportunity to improve efficiency and extended equipment life is greatly desired by any facility manager. One major indicator of chiller performance is the historical values of the chiller approach temperatures. These temperatures show the heat transfer efficiency and can be a precursor to a potential issue in the system. With proper, routine monitoring of approach temperatures, the chiller&#;s operating life and operating efficiency are greatly increased.
Condenser approach temperature is simply defined as the difference between the condenser liquid refrigerant temperature and the outlet condenser water temperature. The closer these temperatures are to each other, the more efficient the heat transfer. Similarly, the evaporator approach temperature is the difference between the evaporator refrigerant temperature and the leaving chilled water temperature. Most later model chillers provide the approach temperatures on the chiller control panel or remotely accessible.
Approach temperatures should be routinely monitored to ensure that the system is running at the maximum efficiency. Reaching maximum chiller efficiency occurs when the facility is producing the greatest tonnage at the lowest kilowatt usage. This typically equates to running at 70 to 75 percent, along with the lowest entering condenser water temperature (ECWT). High chiller approach temperatures usually mean reduced heat transfer, increased energy consumptions, and a reduction in refrigeration capacity. High approach temperatures should be investigated as they are usually an indication of a severe problem:
Fouled/Contaminated tubes (biofilm, scale, sludge, corrosion, etc.)
Non-condensable gases present (Air in the refrigerant)
Low refrigerant charge or altogether loss of charge
Incorrect cooling tower operation
Irregular water flow to chiller
It&#;s critical to keep approach temperatures at an operable level. This requires effective water treatment systems that help protect equipment and manage costs. Ensuring these temperatures are ideal leads to great efficiencies with less power consumption. Protecting the cooling water system also eliminates many maintenance costs. Use recirculating systems, closed loops, once through systems, as well as solid water treatment. Maintaining a good protective program allows for optimized operations.
There are many ways to keep chiller temperatures at the normal rate like daily logging for operating history and baselines, increasing tube cleanliness, and effective condenser water treatment. Chem-Aqua is a leader in chiller optimization using custom water treatment solutions. They specialize in custom designed water treatment programs for boiler, cooling, and process water systems. These reliable and durable systems help their customers to minimize their energy, water, and maintenance costs while ensuring safe and reliable operation of these critical systems. Contact Chem-Aqua today to learn more about their products to improve chiller efficiencies and how to save money by keeping condensation systems running efficiently.
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An industrial chiller protects processing equipment despite costing a small fraction of most of these facilities. It also increases production, specifically enhancing accuracy and speed of production in food, beverage, and pharmaceutical among other industries. Therefore, it is a no brainer that the equipment should be sized properly to perform these duties to perfection. Understanding the various factors that affect chiller performance lays the foundation for correct sizing.
Fig 1: Process Cooling in the Beverages Industry
What are the essential chiller sizing factors?
One chiller size cannot cater for all cooling loads. Some processes require little fluid while others cannot survive without high flow rates. Similarly, cooling fluids are very choosy when it comes to ambient conditions. Customer preferences are also vital. When you look at these and many other factors, you realize the importance of systematic chiller sizing process.
1. An ideal fluid
What fluid will you use for the process? This can be tricky considering that the fluid should be suitable in terms of both compatibility and performance. It is important to consider how well the fluid will perform in light of long-term integrity of the system. A corrosion inhibitor is a valuable inclusion as it protects the metallic parts of the chiller from early degradation. If a process fluid cannot harbor this inhibitor, you might need to pick another fluid. Also important are thermal properties of the fluid. What are the freezing and boiling points? Does the fluid have suitable viscosity? Answering such questions will help determine the performance of the fluid under different environments. For fluid temperatures above 4 ºC, usually water is the preferred fluid due to its good thermal and physical-chemical properties. However, for lower temperatures water cannot be used as we will be very close or below the freezing point. For this cases, usually, a mixture of water and glycol is used for chillers. This combination working in a temperature range of &#; 25°C to 80°C.
2. Suitable Ambient Air Conditions
You do not want to ignore the ambient conditions when you are sizing the chiller. The performance of any chiller is affected by ambient temperature. When ambient dry bulb or wet bulb temperatures increase, the condensing temperature increase so the chiller power consumption is higher. Ambient temperature has also some effect on the electronics, compressors and pumps and other equipment temperature sensitive. Increased ambient temperature combined with heat generated during operation can mean shorter lifespan for these components. Think about the highest temperature at which chiller components can work normally.
3. Carefully determined chiller cooling capacity
Calculating the cooling load is necessary to size chillers correctly. The formula below will help determine the cooling capacity required. kW = 4.186 x m 3/h x Temperature Difference (delta T) / 3.6 BTU/ hour = 500 x GPM x Temperature Difference (delta T) To measure temperature difference, use a thermometer or a thermocouple. These readings should be taken at the water inlet and exit points and then the difference computed. Flow rate of water is taken at outlet line of the equipment using a flow meter. Use the above formula for all the equipment that need cooling and add the results. With the total BTU or kW, you can now calculate the tons of cooling needed using this other formula. Tons o refrigeration = kW / 3.517 # Tons of refrigeration = (BTU/hr) / (12,000)
Reasons to size industrial chiller correctly
Poor chiller sizing is a common problem in industries. This can be through either oversizing or undersizing. Instances of oversized chillers are common because facility managers often expect cooling loads to increase with time. However, oversizing the cooling plant will lead to an unnecessary increase in the capital cost. Moreover, the cooling plant will work at partial loads most of the hours of the year. Eventually, this eats into the annual operating efficiency of the facility. The results of using an undersized industrial chiller are obvious and can have detrimental effects. If the unit is undersized, you can be sure it will not be able to offer sufficient cooling at full load conditions. Expert help is often the answer for these types of projects because getting it wrong can mean huge losses. ARANER offers a wide range of chillers. Each unit comes with all the components necessary for easy installation and efficient performance. As you would expect, the company has a highly talented and knowledgeable team of experts. In case you are having problems sizing your chiller, you can initiate a discussion here for the most professional assistance.
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