TopChiller Centrifugal Water Chiller Manufacturer and Supplier China

Centrifugal Water Chiller-An Ultimate Buying Guide by TopChiller.

Various industrial processes produce excess heat that is essential to be removed out for the normal operation of the machines present there.

Therefore, an economical way to cool large industries is to install a Centrifugal Water Chiller.

A Centrifugal Water Chiller is a machine that uses a cooling tower and compressor for chilling the water, using the vapor compression cycle.

Whether you want an efficient cooling system in the industry, process plant, or energy plant, you can use the Centrifugal Water Chiller.

However, a proper understanding of the construction and functioning of your Centrifugal Water Chiller helps in choosing its best application.

Centrifugal Water Chiller Cooling Tower

What is Centrifugal Water Chiller?

The Centrifugal Water Chiller is a machine that uses a vapor compression cycle for cooling the water.

A Centrifugal Water Chiller is made up of an evaporator, economizer, expansion valve, compressor, and condenser that uses the vapor compression process for efficiently cooling various machines.

It feeds a water loop with the heat obtained from the cooled water as well as the heat from the compressor. Moreover, a cooling tower keeps the water loop cold.

A Centrifugal Water Chiller is commonly used and liked by industrialists due to its low number of moving parts.

Also, it is simple to care for and lasts for a longer time. Moreover, it has a small footprint and a high cooling capacity.

Many industries including the brine, food, beverage, and plastic manufacturing industries require the Centrifugal Water Chiller for the normal functioning of various machines.

Centrifugal Water Chiller Designed by TopChiller

What are the Components of Centrifugal Water Chiller?

The Centrifugal Water Chiller includes a compressor, motor, evaporator, condenser, external flash tank, style economizer, oil system, and automatic expansion valve.

Also, it has some other components including an inlet guide vane, refrigerant piping, control panel, starter, safety equipment, and insulation or the isolators.

1. The compressor is a high-efficiency, semi-hermetic part. The Centrifugal Water Chiller has a two-stage type compressor.

2. The impeller is made of a high-strength special aluminum alloy and is integrated with a return channel that allows for static pressure recovery in the flow path.

3. To avoid condensation, the motor must be liquid refrigerant cooled and insulated with anti-humidity materials. It will work with 380-13,800V, 50/60Hz, and 3Ph.

For real-time monitoring by the control panel, the motor must have a both-end support structure and built-in motor coil temperature sensors.

4. The motor coil must be specially insulated for refrigerant resistance and oil resistance for the applied oil.

5. For optimal partial load efficiency and stable operation in low load conditions, a variable diffuser should be used.

Also, an independent motor controlling the variable diffuser with a corresponding IGV opening ratio must be given.

6. Bearings of the ball or tilting pad style must be used. It should have an additional oil sump for continuous lubrication after the oil pump is turned off.

To reduce flow loss at the impeller’s entry, the inlet guide vane should have several vanes.

7. Two bearing temperature sensors (one for spare) must be mounted to measure and control the temperature of high-speed radial and axial bearings in real-time for stable operation.

Centrifugal Water Chiller Semi-Hermetic Compressor

What are the Features of Centrifugal Water Chiller?

A Centrifugal Water Chiller comprises the following features.

• Evaporator and condenser assembly
• Hermetic two-stage centrifugal compressor-motor assembly with integral lubrication device and economizer cycle
• The instrument and control panel are pre-wired
• A charge of oil
• Wiring and oil system interconnection to the main control panel
• Integral oil heaters
• Separation pads

Centrifugal Water Chiller Control Panel

How Does Centrifugal Water Chiller Work?

The refrigeration cycle is made up of four basic steps.

1. Evaporator

In a Centrifugal Water Chiller, the evaporator is the heat exchanger that extracts heat from the chilled water entering it.

The most popular heat exchanger configuration is a shell and tube, heat exchanger.

The refrigerant is transformed from a liquid to gas as a result of the heat. A flooded evaporator is a cost-effective alternative to be used here.

The tubes are filled with chilled water, and the refrigerant completely submerges the tubes in the shell.

1. Compressor

The rotational kinetic energy of a compressor of Centrifugal Water Chiller is converted to the dynamic energy of the fluid flow.

The refrigerant reaches the pump impeller, is accelerated, and then exits outward. Magnetic bearing technology and a DC (direct current) motor drive are used in a frictionless Centrifugal Water Chiller compressor.

By converting energy into pressure and heat, this compressor increases the pressure of the refrigerant.

1. Condenser

A condenser, like an evaporator, is usually a shell and tube heat exchanger.

The condenser is a device that extracts heat from refrigerant gas further aiding in the pressurized refrigerant liquidizing.

The heat increases the temperature of the condenser water in circulation.

The heat is then carried away by the condenser water to the cooling tower, where it is expelled into the atmosphere.

1. Expansion Device

After condensing to a vapor, the refrigerant passes through a device that reduces strain. A basic orifice plate or an electronic modulating valve may also be used.

Centrifugal Water Chiller Working Principle

What are the Applications of Centrifugal Water Chiller?

The applications of a Centrifugal Water Chiller include

• Provision of cool water for chilling large industries
• Chilling brine in industries
• Involved in comfort cooling
• Maintaining the temperature in food and beverage industries
• Regulating processes in chemical industries
• Plastic manufacturing units

Applications of Centrifugal Water Chiller

How to Choose a Suitable Centrifugal Water Chiller for your Application?

When buying a Centrifugal Water Chiller, the following considerations must be carefully considered.

• At full and part load operation, the performance characteristic and system power management must be in place.

The refrigeration capacity of the Centrifugal Water Chiller must be flexible to accommodate the cooling load of the industry to ensure effective operation.

• When deciding on the type of chiller to use, keep in mind the minimum load that it will be able to handle.

Screw compressors will unload to about 10%, reciprocating compressors to about 25%, and a Centrifugal Water Chiller to about 20% to 25%.

If this turn-down ratio is inadequate to meet the building’s minimum cooling needs, multiple units or units with multiple turn-down ratios can be used.

• If the cooling tower water system runs at the lowest possible temperature, optimum energy efficiency will be reached in water-cooled machinery.

Data from Centrifugal Water Chiller producers may be used to assess the minimum permissible condenser water temperature.

The Centrifugal Water Chiller power consumption is decreased by around 2% with every 1°C drop in the water temperature entering the condenser, according to the requirements.

When the condenser water temperature is below 24°C, the Centrifugal Water Chiller can perform best.

The cooling water temperature should be as low as possible to reduce the compressor’s energy usage.

The compressor energy input is usually reduced by 2% for every 1°C rise in chilled water temperature.

• There must be a maximum temperature differential between the condenser and the heat exchangers.

A large temperature differential would result in lower water flow rates and, as a result, less pumping capacity.

Sufficient water treatment can be used to keep the heat exchange surfaces clean such that optimum heat transfer efficiency can be achieved.

Why do you Need a Centrifugal Water Chiller for your Application?

Many factors may lead experts to prefer a Centrifugal Water Chiller to others. When large industries need cooling, water-cooled centrifugal technology is the best choice.

Centrifugal Water Chiller is often a viable choice because it can provide the necessary cooling capacity in a limited footprint while still maintaining high performance.

Moreover, it can provide high capacity while retaining excellent energy efficiency (Our Centrifugal Chillers equipped with VFD can provide COP > 6 full load and IPLV > 10), resulting in low operating costs for the user.

What Are the Typical Operating Conditions of Centrifugal Water Chiller?

The Air-Conditioning and Refrigeration Institute (ARI) certifies a broad variety of products, including the Centrifugal Water Chiller, by offering test specifications and certification.

Furthermore, the Centrifugal Water Chiller provides engineers and owners with third-party assurance that this can work as the manufacturer claims.

A variety of Centrifugal Water Chiller can be compared for construction and performance using the ARI test criterion.

The standard ARI rating condition is:

• Leaving chilled water at 44 degrees Fahrenheit
• 2.4 GPM/ton chilled water flow rate
• The temperature of the water entering the condenser is 85 degrees Fahrenheit.
• 3.0 GPM/ton condenser water flow rate
• 0.00025 fouling factor for the condenser

The following formula can be used to explain the temperature change in the fluid for either the condenser or the evaporator.

Q = W × C × ΔTF

What is the Oil System of Centrifugal Water Chiller?

• The control valve and semi-hermetic oil pump for controlling and supplying oil.
• A built-in, oil-resistant, insulated, and refrigerant-resistant oil pump motor.
• An oil separator for reducing oil presence on heat exchangers,
• The oil heater maintains the temperature and viscosity of the oil.
• An oil cooler with a durable heat exchanger is present at the back of the filter.

Centrifugal Water Chiller Oil Separator

What is the Piping System in Centrifugal Water Chiller?

• It is essential to build or connect an accurate piping system. The evaporator and condenser nozzles are usually made of 10kg/cm2 flange.
• As is customary, the inlet nozzle is on the lower side and the outlet is on the upper side.
• All piping should be assisted individually so that no tension or pressure is transmitted to the Centrifugal Water Chiller, and there is enough room for maintenance.
• It is also needed to mount an air-vent cock, a drain valve, and piping on each water box of the evaporator and condenser.
• Strainers should be used on each inlet of the evaporator and condenser to filter foreign materials.
• It is recommended that a thermometer should be mounted in the heat exchanger if foreign materials flow into it.

Piping System in Centrifugal Water Chiller

How to Maintain your Centrifugal Water Chiller?

Staff must be qualified for proper operation and maintenance of the Centrifugal Water Chiller.

Out-of-compliance practices are often ignored before it is too late. The best way to secure your Centrifugal Water Chiller is to provide regular safety and operations training.

Increase the temperature of the supplied chilled water and set a timer to adjust the water temperature as the ambient air temperature increases.

On a Centrifugal Water Chiller, raising the chilled water supply temperature by around 2°F reduces Centrifugal Water Chiller energy consumption by up to 5%.

Reduce the temperature of the condenser water. A 3°F drop in the temperature of cooling tower water returned to the condenser decreases energy consumption by approximately 3%.

Water exiting the cooling tower should have a set point as low as the manufacturer requires for water entering the condenser.

Maintenance

• Every 8 to 10 years or 25,000 to 30,000 operating hours, you should perform a compressor teardown or an overhaul inspection.
• There is no need to calibrate the temperature controls regularly.
• Examine the whole device visually.
• Examine the electrical and safety systems.
• Tighten electrical ties, recruit service contractors, run a meager test on the engine, and inspect the transfer resistors visually.
• Annually, or as directed by the American Standard Inc. 1999 Air Conditioning Clinic, perform the leak test.
• Change the oil according to the time the manufacturer recommends.
• Replace the oil filters once a year or as required.
• Condenser tubes are inspected visually once a year.
• Check the oil sump heater’s work.
• Hire a professional or an expert who specializes in water treatment.
• Condenser tubes should be cleaned as appropriate and mechanical brush cleaning should be done once a year.
• Pump strainers on the waterside should be cleaned every three years.

How to Install your Centrifugal Water Chiller?

The installation of Centrifugal Water Chiller is quite simple.

No oil cooler or purge device connections are required in Centrifugal Water Chiller; only the evaporator and condenser need water piping. Moreover, it has a simple power link.

Installation instructions can be found in the manual of Centrifugal Water Chiller.

According to the manual, the position of the Centrifugal Water Chiller allows for adequate airflow and maintenance access.

• It should be anchored and protected in compliance with the manufacturer’s requirements.
• It should not be placed near a heat source (other condenser exhaust, ventilation ducts, etc).
• The machine equipment is completely plumbed for the Centrifugal Water Chiller. Field piping is sized and mounted per specifications.
• Don’t pressure measure the unit’s reservoir until the fluid piping has been flushed clean.
• Fill the tank with the proper amount of glycol and warmth.
• Check if the field wiring is accurate and ready to print. There are no loose ties or terminations.
• The key control of Centrifugal Water Chiller should be switched on for at least 8 hours before start-up.

This is needed for the compressor crankcase heaters to warm up sufficiently before the unit starts up.

• Make sure that the refrigeration leaks have been tested in the system.

Centrifugal Water Chiller Piping Installation

How to Troubleshoot your Centrifugal Water Chiller Problems?

Bad operating practices can shorten the life of a Centrifugal Water Chiller as well as reduce its performance.

The majority of these procedures are the product of one of two circumstances.

1. Attempting to get a Centrifugal Water Chiller to do what it wasn’t intended to do, never allows it to cope up with the desired function.

1. Increasing the rate of chilled water flow through the Centrifugal Water Chiller is a popular procedure.

More cooling water would be usable with a higher flow rate, according to the theory.

Increasing the flow rate above the manufacturer’s specified cap, on the other hand, decreases the operating performance of the Centrifugal Water Chiller.

Flow rates higher than those suggested increase the rate of erosion in the tubes. As a result, the tubes collapse earlier rather than later.

A Centrifugal Water Chiller helps to chill the air and create the ideal atmosphere for the normal functioning of various machines.

The Centrifugal Water Chiller is related to a variety of problems, but the following are the most common ones.

Lack of Oil

If there is a refrigerant leak that causes low oil in the Centrifugal Water Chiller, the oil pump may be broken, or it has low superheated, there will be an oil loss.

Low/High Pressure

Split control assembly capillary, poor water supplies, mud covering on the tubing, a blocked water pump, or a low refrigerant are the most common causes of low pressure.

If the water-cooled condenser has an accumulation of minerals that affects the water content, or if the condenser has little or no flow, the Centrifugal Water Chiller can experience a high-pressure problem.

The temperature of the cooling water tank, despite this, can be above 80 degrees Fahrenheit.

 Fuse has Blown or Starter Ride

If the engine, cables, or compressor are over-amped or shortened, fuse blown occurs. The best approach is to search for grounds and connect your Centrifugal Water Chiller appropriately.

There is no Flow

If the pressure or flow switches in the water circuit and does not receive the proper volume of flow, there may be a slow flow.

It is even possible that the water valve is turned off or that the water pump is blocked. Also, the flow transfer paddle is normally broken in most situations.

It is not Reaching the Desired Temperature

The evaporator could be iced up from the inside or the antifreeze could be broken in this case.

Centrifugal Water Chiller Troubleshooting

What are Safety Tips for the Centrifugal Water Chiller?

Cutouts for safety control inputs are processed and, if necessary, the Centrifugal Water Chiller is shut down or the guide vanes are provided to protect it from potential damage caused by the following conditions:

• Very hot bearing temperature
• Low oil pressure
• Low cooler refrigerant temperature/pressure
• High motor winding temperature
• High discharge temperature High or low pressure in the condenser
• Inadequate water cooler and condenser flow
• Excessive engine acceleration time
• Excessive starter transfer time
• Lack of motor current signal
• Excessive motor amps
• Excessive compressor surge
• Fuse for the control circuit
• Fuse for the control module
• The damaged oil heater
• Fuse for the oil pump motor.

How to Increase the Working Efficiency of your Centrifugal Water Chiller?

• Chilled Water Reset

This technique includes raising the chilled water supply temperature setpoint to meet the cooling load’s requirements. In an automatic chiller controller, reset is often performed as part of the control routines.

• Reduce Condenser Water Temperature

Reducing the condenser water temperature reduces compressor power requirements in the same way as raising the chilled water setpoint does.

Compressor power consumption can be decreased by 0.5 percent to 1% by lowering the temperature of the condenser water by one degree.

• Monitor and Maintain the Approach Temperatures

Shell-and-tube heat exchangers, such as condensers and evaporators, require routine maintenance to maintain optimal heat transfer characteristics.

Solids appear to collect on internal tube surfaces when water passes through the condenser and evaporator tubes, necessitating annual “rodding” to eliminate the scale and restore heat transfer coefficients.

• Retrofits with Variable Speeds should be Considered

Variable speed drives can support nearly any part of a Centrifugal Water Chiller. In reality, in new systems and large retrofits, most existing energy codes require VFDs for these components.

Moreover, the cost of a VFD has also fallen significantly in recent years to make it easily accessible for all.

There is a significant advantage to VFDs for Centrifugal Water Chiller, which can be seen through the fixed- and variable-speed Centrifugal Water Chiller performance, but only if condenser water temperature relief is also applied.

Another way to conserve electricity for VFDs is to use cooling tower fans.

Variable-speed fan motors not only conserve fan energy (a fan at 50% speed pulls 12.5 percent of the power of a fan running at 100%) but also have more efficient temperature control.

Variable speed pumping can save electricity, but it necessitates a thorough examination of other parts of the machine.

On the chilled water side, switching from constant to variable flow can require substantial and expensive renovations to control valves and control sequences.

The current variable flow capability of the Centrifugal Water Chiller must also be examined.

The economic viability of variable chilled water pumping can be hampered by the low flow limits of the Centrifugal Water Chiller.

Variable flow management on the condenser water side can be restricted by Centrifugal Water Chiller flow requirements or cooling tower fouling or freezing issues.

If pumps on a constant flow system are oversized, regulating pump flow by lowering speed versus flow restriction using a balancing value, even without introducing variable flow during system service, can provide a strong payback.

• Less is more – Savings are Maximized When Having Several Parallel Computers

At part-load, the Centrifugal Water Chiller plant operates more smoothly. For instance, it can operate at optimum efficiency between 40% and 60% of its peak capacity.

A control scheme that runs more pieces of equipment at lower speeds, rather than a staging scheme that requires operating equipment to reach maximum capacity, may benefit cooling tower fans and system pumps that are piped in parallel.

Running more equipment in cooling towers of the Centrifugal Water Chiller maximizes the heat transfer surface area at all operating points, increasing performance and lowering the pressure rises.

Taking advantage of pump savings and working at optimal pump performance points is important for the system’s efficiency.

Any changes to the control system, though, must take into account the minimum Centrifugal Water Chiller and cooling tower flow limits.

• Increase the Temperature of the Supply

The chilled water source temperature in most industrial schemes is between 40 and 45 degrees Fahrenheit.

During peak hours, this usually allows for adequate dehumidification by the Centrifugal Water Chiller.

Supply air temperature reset management can help conserve resources in a variety of ways.

First, raising supply temperatures can help avoid over-dehumidification of spaces and unnecessary latent cooling where cold supply air temperatures are not needed (acceptable humidity levels and no zones at peak load).

More specifically, higher source air setpoints allow for a higher chilled water supply temperature, which improves Centrifugal Water Chiller performance significantly.

In general, for every degree that the chilled water source temperature is raised, Centrifugal Water Chiller efficiencies rise by around 2%.

To maximize energy savings, other control functions should be explored.

VFDs on all or some elements, as previously said, should be considered. Besides, a careful examination of fixed points, temperature resets, and other basic control sequence adjustments are typically accurate and inexpensive.

Of course, these strategies aren’t suitable for all schemes. Your ideal approach would be special and would most likely involve a technical review including energy demands, budget, environment, and many other factors.

Centrifugal Water Chiller Temp Maintenance

FAQ of Centrifugal Water Chiller.

How Does the Compressor of A Centrifugal Water Chiller Work?

The rotational kinetic energy of the Centrifugal Water Chiller is converted into the dynamic energy of the fluid flow.

The refrigerant exits bypassing and accelerating through the path outwards. This leads to the raised pressure of the refrigerant.

This raise in pressure is because of the conversion of kinetic energy into pressure and heat, leading to the functioning of the compressor.

What Causes Surging in A Centrifugal Water Chiller?

The surging can most probably be caused by defective tubes, decreased refrigerant charge, or contaminants in the refrigerant.

It may be responsible for uncontrolled water flow rates and condenser water temperature.

However, low surge problems of the Centrifugal Water Chiller can be improved with the use of VFDs or bypassing hot gas.

What is the Difference Between a Centrifugal Water Chiller and Screw Chiller?

When it comes to a Centrifugal Water Chiller, it can provide better efficiency at full load whereas, a Screw Compressor Chiller is good at part-load efficiency.

Even at 10% capacity, a screw compressor stays stable, whereas a Centrifugal Water Chiller starts surging when it reaches 20% to40% capacity.

What type of refrigerant is used in Centrifugal Water Chiller?

In a Centrifugal Water Chiller, the refrigerants such as R-410A, R-404A, R-407C, and R-134a are mostly used.

These refrigerants are specialized for Industrial process refrigeration. However, these refrigerants cannot be used for a chiller with scroll compressors.

What is the Best Chiller Efficiency of Your Centrifugal Water Chiller?

The best Centrifugal Water Chiller efficiency refers to producing the highest tonnage while using the lowest kilowatts.

With 70-75% load and entering the water at the lowest rate, maximum efficiency can be obtained.

What is the Capacity Range of the Centrifugal Water Chiller?

The capacity range of a Centrifugal Water Chiller ranges from 0.53 kW per ton or lower to 0.68 kW per ton.

It also depends upon if it is a semi-hermetic refrigerant cooled unit or has open-type compressor motors.

What is the Size of the Centrifugal Water Chiller?

The size of a Centrifugal Water Chiller ranges to almost 9000 tons. The greater the size of the Chiller, the greater is the capacity.

Which Centrifugal Water Chiller Has the Highest Efficiency?

A Centrifugal Water Chiller that has the highest efficiency is the one that uses HCFC-123.

The efficiency of such a unit is down to 0.49 kilowatts per ton (kW/ton) at full load and ARI conditions.

100% Quality Tested Centrifugal Water Chiller