TopChiller Water Cooled Centrifugal Chiller Manufacturer and Supplier

Water Cooled Centrifugal Chiller- An Ultimate Buying Guide by TopChiller.

A Water Cooled Centrifugal Chiller has a centrifugal compressor that is specifically designed in a large capacity chiller.

The compressor is made up of a single or more centrifugal impeller.

All other types of Chillers are classified according to the type of their compressor.

A Water Cooled Centrifugal Chiller uses a vapor compression refrigeration process to provide cooling to the industrial mechanism, machinery, and products.

It is commonly available in capacities ranging from 100 to 3000 tons as a prefabricated machine.

A Water Cooled Centrifugal Chiller that is available incapacity of more than 8500 tons operates as a built-up machine.

A Water Cooled Centrifugal Chiller as a prefabricated machine is used in the manufacturing industries of aircraft, ships, and vehicles.

In this buying guide, we will go through some important aspects related to Water Cooled Centrifugal Chiller.

Water Cooled Centrifugal Chiller uses Vapor Compression Refrigeration Process

What is a Water-Cooled Centrifugal Chiller?

A Water Cooled Centrifugal Chiller uses water as a medium to provide cooling in different industrial applications. It is an aerodynamic or turbine-type refrigeration system.

It moves the gas by changing rotational kinetic energy to dynamic energy.

A Water Cooled Centrifugal Chiller uses a vapor compression cycle to cool the water and remove the heat absorbed by the chilled water.

It also removes the heat from the compressor to a re-circulation of a water loop cooled by a cooling tower. It processes the water in a centrifugal refrigeration circuit to generate cooling.

It works with a direct current motor drive and uses magnetic bearing technology.

A Water Cooled Centrifugal Chiller is mostly used in semi-conductor, food, chemical, and automotive industries.

Its compressor uses multiple prime movers which include DC motors, AC motors with frequency varying drives, diesel engines, gas turbines, and steam turbines.

By regulating the speed of the centrifugal compressor you can enhance the capacity of the Water Cooled Centrifugal Chiller.

A variable inlet guide vane can be used for capacity control for a water-cooled chiller system.

Water Cooled Centrifugal Chiller

What is the Working Principle of a Water-Cooled Centrifugal Chiller?

Water Cooled Centrifugal Chiller is a refrigeration machine. It utilizes the vapor compression principle to cool the water.

It also removes the heat from the chilled water and compressor by using cooling towers. It has two working circuits.

1. Centrifugal Refrigeration Circuit

The centrifugal refrigeration circuit of a Water-Cooled Centrifugal Chiller is used to cool down the water that is used as a heat exchange medium.

It has four major components compressor, condenser, evaporator, and expansion valve.

All these components perform specific functions.

2. Water Circuit

The water circuit of a Water-Cooled Centrifugal Chiller is used to cool down your application by flowing chilled water through your application.

It consists of a reservoir tank, water boxes, pump, filters, and a heat exchanger.

The refrigeration cycle of a Water-Cooled Centrifugal Chiller starts from the endothermic process of evaporation.

In this process, the refrigerant is boiled and changes its state from liquid to gas.

This gas is then sent to the compressor which is composed of a prime mover and a centrifugal compressor.

It then converts the kinetic energy of the gas into pressure by raising its temperature and pressure.

This processed refrigerant is then sent to the heat exchanger for condensation. There it processes the refrigerant and removes heat from it.

In the process of condensation, the refrigerant is condensed from a gas state to a liquid. It takes away the extra heat to the cooling tower where heat is dissipated to the atmosphere.

After the exothermic process of condensation, the liquid refrigerant is driven through a device known as an expansion valve that reduces the pressure of the liquid.

Working Principle of a Water-Cooled Centrifugal Chiller

What are the Components of Water Cooled Centrifugal Chiller?

The major components of a Water-Cooled Centrifugal Chiller are;

• An Evaporator
• A Centrifugal Compressor
• A Condenser
• An Expansion Valve
• Water Boxes
• Control Panel
• Power Unit
• An Evaporator

A Water Cooled Centrifugal Chiller uses a shell and tube-type evaporator that acts as a heat exchanger.

An evaporator dissipates the heat from incoming water. It requires heat to change the processed liquid into a gas.

A flooded evaporator is highly energy efficient in this regard. This chilled water then circulates it in the tube.

A refrigerant submerges the tubes in the shell completely.

• A Centrifugal Compressor

A Centrifugal Compressor is responsible for converting rotational kinetic energy to the dynamic energy of flood flow.

The refrigerant in the process begins to the pump impeller and flows outwards in the radial direction and then exits.

It uses magnetic bearing technology and a DC motor.

The main components of a centrifugal compressor are casing and inlet, impellers, diffuser, and collector.

The centrifugal compressor of a Water-Cooled Centrifugal Chiller can be of two types; Single stage centrifugal compressor and Multi-stage centrifugal compressor.

• A Condenser

Just like a tube and shell-type evaporator, the condenser is also a shell and tube heat exchanger.

The condenser dissipates the heat from the refrigerant gas and condenses it into a liquid and ejects the excess heat to the atmosphere.

• An Expansion Valve

An expansion device is used to reduce the pressure of the refrigerant liquid.

You can choose a simple orifice plate or an electronic modulating valve for higher efficiency.

• Water Boxes

The water boxes are mounted to the evaporator and condenser.

The main purpose of water boxes is to segregate the inlet and outlet. They can be open-ended or closed-ended.

• Control Panel

The control panel of a Water-Cooled Centrifugal Chiller monitors.

The overall performance of the system and generates alarms in any irregular condition to prevent big losses.

It is placed on your Water Cooled Centrifugal Chiller.

• Power Unit

The power unit controls the electricity flow throughout the components of the Water Cooled Centrifugal Chiller.

It is usually composed of a starter, speed controller and circuit breaker, etc.

Water Cooled Centrifugal Chiller Compressor Details

What are the Main Features of Water Cooled Centrifugal Chiller?

Features of Water Cooled Centrifugal Chiller:

Folding features make your Water Cooled Centrifugal Chiller prominent from others.

1. High Cooling Capacity.

The main feature is its centrifugal compression, which provides a high cooling capacity.

It operates via an impeller, much like a water pump. The impeller compresses the refrigerant.

2. Longer Lifespan

A Water Cooled Centrifugal Chiller doesn’t need replacement as often as an air-cooled centrifugal chiller.

3. Inaudible Operation

Water Cooled Centrifugal Chiller operates smoothly and quietly. The flow of water throughout the system doesn’t result in the same noisy expansion and contraction that you can hear in the air-cooled chiller.

Quiet operation is particularly important in some environments such as hospitals and schools, where noise can cause disturbance to occupants.

4. Energy Efficiency

The film coefficient is 10 to 100 times better in Water Cooled Centrifugal Chiller versus other chillers consumes very low electrical power.

This means that a water-cooled chiller transfers heat more efficiently. The result is savings in energy costs.

5. No Open Space Needed

Water Cooled Centrifugal Chiller is placed inside buildings, which makes them ideal for companies that don’t have access to enough outdoor space.

While Air-cooled centrifugal chiller needs to stay outdoors in an open space with plenty of fresh air to operate.

6. Safety

A water-cooled chiller uses water as a refrigerant instead of toxic chemicals. This makes it safer for people who operate it.

7. Two Compressors

The Water-Cooled Centrifugal Chiller can be used with two compressors to further enhance the capability of your application.

8. Closed Loop Control Operation

Closed-loop control operation of the water-cooled centrifugal system provides very precise and accurate control of cooling rate which is very much essential for some industries like the plastics industry.

What are the advantages of a Water-Cooled Centrifugal Chiller for your Application?

The water-cooled chiller is cooled by Freon refrigerant to perform the endothermic process of evaporation in the evaporator to absorb the heat of refrigerant water.

The Freon wet steam after evaporation is compressed into high-temperature and pressure gas by the centrifugal compressor.

It condenses in the water-cooled condenser of Water Cooled Centrifugal Chiller and turns into liquid. After that, it enters the evaporator for recycling through the expansion valve throttle.

Hence, making 7 degrees Celsius to 12 degrees Celsius air terminal air conditioning chilled water supply.

Some of the Advantages of a Water-Cooled Centrifugal Chiller for your Application:

1. A Water Cooled Centrifugal Chiller offers a high-speed rotating impeller to perform more efficiently without wasting energy.
2. It has a large gas transmission capacity and large single machine capacity for your application.
3. A Water Cooled Centrifugal Chiller has less vulnerable parts and delivers reliable cooling effects.
4. Its compact structure, smooth operation, small vibration, low noise add to its high efficiency.
5. A Water Cooled Centrifugal Chiller features a small weight index of unit refrigerating capacity.
6. The refrigerant is not mixed with lubricating oil, evaporator, and condenser of good heat transfer performance.
7. EER value of a Water-Cooled Centrifugal Chiller is higher than an air-cooled centrifugal chiller, which can be adjusted continuously within 10%~100%.

Low Noise Water Cooled Centrifugal Chiller

How a Water-Cooled Centrifugal Chiller is Different from an Air-Cooled Centrifugal Chiller?

The main reason for their difference is their condensers, the way of heat dissipation.

A Water Cooled Centrifugal Chiller has a cooling tower so it features higher efficiency than an air-cooled centrifugal chiller.

Another reason for its higher efficiency is that it condenses the refrigerant on the ambient temperature wet bulb temperature, which is less than the ambient dry bulb temperature.

The lower condensation means higher efficiency. A Water Cooled Centrifugal Chiller has some additional components like cooling towers, condenser water pumps, makeup water pumps, or TES reservoirs.

It is usually smaller in size as compared to the air-cooled centrifugal chiller.

While air-cooled centrifugal chiller is used where there is water shortage. It uses a current of ambient air.

It uses air as a medium to provide a cooling effect to different industrial applications. It has a lower refrigerant condensing temperature than Water Cooled Centrifugal Chiller.

How to Calculate the Efficiency of Water Cooled Centrifugal Chiller for your Application?

The efficiency of a Water-Cooled Centrifugal Chiller depends on the amount of energy consumed and the cooling delivered.

You can calculate the efficiency of Water Cooled Centrifugal Chiller for your application.

The complete method of calculating the efficiency of a chiller is not rocket science; the efficiency of a Water-Cooled Centrifugal Chiller is measured in “Coefficient of Performance” also known as COP.

The coefficient of performance is the ratio between the amount of cooling effect a Water-Cooled Centrifugal Chiller produces and the amount of electric power is consumed to produce cooling.

Both of these values should be measured in KW (Kilowatts).

For example:

A Water Cooled Centrifugal Chiller that produces 2300KW of cooling or 7,847,924.7 BTUs per Hour in metric units. The electrical power requirements to generate this are 450KW.

The metric calculation of the efficiency of a Water-Cooled Centrifugal Chiller will be;

2300KW/ 450KW = 5.1. The COP is 5.1, which means that every 1kw of electric power is input, which will produce 5.1KW of cooling effect.

Remember one thing that the coefficient of performance varies with the cooling load on different chillers.

The manufacturer of Water Cooled Centrifugal Chiller should be able to give the design data of COP.

So, you can compare it with the performance of your Water Cooled Centrifugal Chiller to diagnose operational issues.

What are the Industrial Applications of a Water-Cooled Centrifugal Chiller?

Water Cooled Centrifugal Chiller is vastly applied in large-scale industrial applications. Some of its major industrial applications are appended below.

1. Semiconductor Industry

A semiconductor industry uses a Water-Cooled Centrifugal Chiller for the manufacturing of imaging devices like semiconductors, digital cameras, and LCDs.

2. Food Industry

A Water Cooled Centrifugal Chiller is applied in the food and beverage industry to prevent bacteria and germs by providing constant cooling.

It is also used in the process of sterilizing mineral water. It provides a stable cooling of about 10 to 30 degrees Celsius to cool down the manufacturing machinery in the food industry.

3. Automotive Industry

A Water Cooled Centrifugal Chiller provides constant cooling by long operating hours in the automotive industry to drying the oven of painting facility and other applications that require high cooling load.

4. Chemical Industry

The chemical industry mostly uses a Water-Cooled Centrifugal Chiller as a source of chilled water supply to dehumidify the air for the manufacturing process of oxygen and nitrogen.

5. Additional Applications

A Water Cooled Centrifugal Chiller can also be applied in the manufacturing industry of vehicles, aircraft, and ships, etc.

It can also be used as a heat pump for both cooling and heating. They can be used to cool brine in various industrial processes.

Industrial Applications of a Water-Cooled Centrifugal Chiller

How to Select Right Water Cooled Centrifugal Chiller for your Application?

When selecting a Water-Cooled Centrifugal Chiller, it is a crucial step to match the working conditions and situations of your application with the performance, functions, and other features of a Water-Cooled Centrifugal Chiller.

If you will not pay attention to the right selection of the Water Cooled Centrifugal Chiller you may not obtain efficient and maximum results for your application.

You can choose the right Water Cooled Centrifugal Chiller by considering the following well-researched steps.

Steps to Choose the Right Water Cooled Centrifugal Chiller

Step 1: Determine the Temperature of Circulated Water

You can determine the temperature of the circulated water of Water Cooled Centrifugal Chiller from the optimal temperature of your application (it could be a device or an object to be cooled)

1- Calculate the value of the optimum temperature of your application to be cooled.

2- Calculate the value of the temperature of the circulated water of a Water-Cooled Centrifugal Chiller.

Match both of these temperatures to choose the right Water Cooled Centrifugal Chiller for your application.

Step 2: Inspect the Site for Installation

In the second step, you need to decide about the location that whether to install the Water Cooled Centrifugal Chiller indoor or outdoor.

Choose outdoor installation if you want to prevent the exhaust heat and air from flowing indoors or if you have a small space.

Choose indoor installation for your Water Cooled Centrifugal Chiller if you want it to be closer to your application, shorten the piping (it reduces the pipes cost and pressure loss).

Step 3: Determine the Cooling Capacity

It is important to calculate the cooling capacity required for your application from the flow rate, temperature difference, etc.

You can determine the cooling capacity by using simple mathematical formulas.

Step 4: Check the Lifting Height or Pump Capacity

Determine the required lifting height of the Water Cooled Centrifugal Chiller for your application based on the features of pipe-like length, pipe diameter, and joints.

Check out whether the pump capacity of the selected Water Cooled Centrifugal Chiller is enough.

What is the Installation Procedure of a Water-Cooled Centrifugal Chiller for your Application?

You can install your Water Cooled Centrifugal Chiller by following the procedure given below.

1. Installation Environment

• A Water Cooled Centrifugal Chiller should be installed at distance from heat or fire.

• If it is going to be installed closer to heat-generating equipment like boiler thermal radiation effects should be kept in consideration.
• Always select the site where the indoor temperature does not exceed 46 Degrees Fahrenheit.
• Select the site with less dust and dirt.
• The site should have sufficient light for easy maintenance and inspection purposes.
• The room should be high enough for entering the crane or fork lifter.

2. Confirmation of Site

For proper personal and equipment safety confirmation;

• Confirm that the site is suitable as per requirements of Water Cooled Centrifugal Chiller.
• Confirm that holes made are of proper size.
• Dimensions of room are as per requirement.

3. Construct the Base

The Compressor consists of relatively fewer movable parts and is stable, so the live load for the base is small.

The specific dimensions of the base are shown in the manufacturer manual. The base should also have drainage in its surroundings.

In case of corrosion of the Water Cooled Centrifugal Chiller footing, the base should be of the following characteristics

• The maximum level difference should be 2.5mm.
• For easy maintenance and inspection of the refrigerant unit, the base should be higher than 110mm.
• It is essential to have a drain ditch around your Water Cooled Centrifugal Chiller.
• The installation base must be a concrete structure, which can bear the running weight of your cooled centrifugal chiller.

4. Carrying

• Check all the parts that are mentioned in the list of your Water Cooled Centrifugal Chiller in case of any deficiency or discrepancy the manufacture should be approached in writing.
• The lifting position is marked on it. After confirming the installation of the base, place the unit on the shock pad with the help of a crane.

CAUTION Please lift the unit in strict accordance with the lifting marks on the outer package otherwise it can damage your water-cooled chiller or application.

5. Piping

• After leveling the unit, connect all the pipes as per the instructions mentioned in the manufacturer manual.
• All the pipes are marked near the inlet and outlet for reference when connecting the pipe. It is essential to connect the pipe according to the marks on the unit.

6. Electrical Wiring

Carry out the electrical connections as prescribed in the manual of your Water Cooled Centrifugal Chiller.

Base Construction for Water Cooled Centrifugal Chiller Installation

How to Increase the lifespan of Water Cooled Centrifugal Chiller?

The life of Water Cooled Centrifugal Chiller is normally about 25 to 30 years. But using different steps and precautions you can enhance the life of your Water Cooled Centrifugal Chiller.

And this will be the bonus life of the Water Cooled Centrifugal Chiller for your application.

1. Preventive Maintenance.

It is a key to the success of increasing the lifespan of Water Cooled Centrifugal Chiller for your application. Preventive maintenance contains Dusting, greasing, calibrations, cleaning, etc.

All the preventive maintenance practices must be carried out on your Water Cooled Centrifugal Chiller and no preventive maintenance is referred.

All the nuts and bolts required locking must be locked by using a proper locking wire.

2. No Quality Compromise.

Quality should not be compromised at all, at all stages of production must be quality controlled.

Quality also contains the use of proper and appropriate tools and parts. If replacement of any component is required do not use substandard parts.

3. Flow Rate Adjustment.

The adjustment of the flow rate of chilled water used in the Water Cooled Centrifugal Chiller must be made very precisely to enhance the life period of your Water Cooled Centrifugal Chiller.

4. Condenser Water Treatment.

Water used in condensers and pipes may cause the pipes to be corroded or scaled and clogged.

To avoid this some chemical treatment may be made to the water used for this purpose.

5. Check Oil.

Check the oil on periodic inspection if the oil level is decreased find the cause of any leakage is there repair it and top up the oil level, oil samples should be sent to the oil testing lab for oil specifications examination.

Water Cooled Centrifugal Chiller Oil Checking

How to Troubleshoot Water Cooled Centrifugal Chiller?

Some of the Water Cooled Centrifugal Chillers are provided with the display board which indicates the error code in case of any problem occurs in your Water Cooled Centrifugal Chiller.

You can consult the manufacturer manual for decoding error codes and troubleshooting. Some of the problems and their causes are given below for your convenience.

1. High-Pressure Discharge

High-pressure discharge is very common in Water Cooled Centrifugal chillers and its main cause is bad water treatment systems. Make sure your building has a strict water treatment.

Low-Pressure Discharge

One issue that causes low-pressure discharge is if the suction valve is partially closed, so check that. It’s uncommon but it could happen.

Refrigerant undercharge can cause low-pressure discharge.

You will need to make checks on the system to that it has enough refrigerant charge. If you find any problem, then it needs to be topped up.

Low Suction Pressure

The low suction pressure could be down to a low refrigerant charge. Check out your centrifugal refrigeration system signs of this and top up if needed.

Don’t forget to check for leaks as well. If the pressure becomes too high in the Water Cooled Centrifugal Chiller, it might have vented through the safety relief valves.

High Suction Pressure

Now if you experience a high-pressure warning on the suction line.

It happens when the excessive load is probably the main one and that is where the cooling load is just too much for the Water Cooled Centrifugal Chiller to handle.

FAQ of Water Cooled Centrifugal Chiller.

What is Centrifugal Phenomenon in a Water-Cooled Centrifugal Chiller?

The centrifugal force in a Water-Cooled Centrifugal Chiller is an inertial force that acts on all objects when viewed in a rotating frame of reference.

It is directed away from an axis of rotations and passes through the coordinate system’s origin.

Why Water Cooled Centrifugal Chiller is more Popular?

Water Cooled Centrifugal is Chiller is popular in the family of industrial chillers because it provides a very rapid heat exchange rate due to its centrifugal compressor.

How to Convert British thermal units in Tons?

BTU is an abbreviation of a British thermal unit, and one British thermal unit (BTU) is the amount of heat used to raise or decrease the temperature of one pound of water by 1 degree Fahrenheit.

12000 BTUs   One Ton

For example, if a Centrifugal Water Cooled Chiller has a cooling capacity of 18000 BTU, The capacity in Tons will be

18000/12000 1.5 Tons

What should be Calibrations Periods of Water Cooled Centrifugal Chiller?

In your Centrifugal Water Chiller system, some of the components and measuring devices need to be calibrated periodically.

Must get your instruments and components be calibrated well in time to avoid any ambiguity or confusion.

The period will be mentioned in the manufacturer manual, this period may vary from 6 months to one year.

What is a Preset Temperature of a Water-Cooled Centrifugal Chiller?

The preset temperature of your Water Cooled Centrifugal Chiller is the temperature that you are required to maintain at your work center in normal working conditions.

What is a Centrifugal Compressor Surge?

The Surge in a centrifugal compressor can be simply defined as a situation where a flow reverses from the discharge side back into the compressor casing which causes damage to the compressor.

Why is Water Cooled Centrifugal Chiller used in Datacenters?

In data centers, the Water Cooled Centrifugal Chiller is used due to its flexible performance and efficiency. It is designed to obtain higher efficiency.

Where you can Use a Water-Cooled Centrifugal Chiller?

Due to its efficiency and other characteristics, the Water Cooled Centrifugal Chiller can be used in the following places.

• Data centers.
• Rail transit.

What are the Advantages of a Two Stages compression?

The Water-Cooled Centrifugal Chiller may use two stages of Compression to achieve high efficiency.

The improved Two-stage compressing cycle improves the energy efficiency and reduces the operational as compared to the previous one-stage Water Cooled Centrifugal Chiller.

Its variable diffuser provides the facility of a wider operation range at a low-load condition and prevents stall from discharge gas for stable functioning.

Does a Centrifugal Compressor like a Centrifugal Pump?

The methods used to design a centrifugal pump are the same as those to design a centrifugal compressor. But still, there is one important difference: the need to deal with cavitations in pumps.

100% Quality Tested Water Cooled Centrifugal Chiller