Chiller Plant Design Course for mechanical engineer

This course provides a comprehensive understanding of chiller plant design, focusing on the theoretical and practical aspects of creating energy-efficient, sustainable, and reliable chiller systems. Participants will learn about different types of chillers, including air-cooled and water-cooled chillers, and the components that make up chiller systems such as compressors, evaporators, condensers, and expansion devices.

1. Chiller Plant Design

2. Table of Content Introduction Typical Piping Design Concepts Plant Sizing Plant Power & Control System

3. Introduction Chiller plant produces chilled water at set temperature (typically 6.7 oC /44oF) Distributed to Air Handling unit or Fan Coil Unit. Minimized refrigeration charge inside the building. Higher specific heat of water means lower energy required and volume for energy delivery.

4. Type of compressor Scroll <60TR Reciprocating <100TR Screw 70-500TR Centrifugal 300-3000 TR

5. What? Heat rejection method Air cooled Using Air cooled condenser Water cooled Using water cooled condenser and cooling tower Type: Shell & tube Tube & tube (refrigerant to water) Fin and tube (Refrigerant to air)

6. Typical Piping Design Concept Series & Parallel chillers Chiller configuration

7. Series & Parallel Chiller LOAD LOAD Characteristics -Series: Single flow higher delta T -Parallel: Double flow standard delta T

8. Chilled Water Plant Type

9. Water Cooled Chilled Water Plant -Dedicated pumping

10. Water Cooled Chilled Water Plant -Common pumping

11. Air Cooled Chiller Plant -Common pumping

12. Water Cooled Chilled Water Plant -Primary Secondary loop

13. Water Cooled Chilled Water Plant -Variable Primary Flow

14. Plant Sizing Plant capacity must consider maximum and minimum anticipated load. Base load chiller can be provided to cater for base load (usually night load). Alternatively independent system can be provided to serve base load e.g server room, control room, security room etc. Minimum chiller operating load shall be considered. Screw compressor >12.5% Centrifugal ≈ >30% (above surging range) Operating chiller frequently at low load may cause chiller freezing and coil burst due to expansion Higher chiller capacity better efficiency.

15. Short Exercise AHU load AHU 1: 30 TR (8 hrs ) AHU 2: 50 TR (8hrs) AHU 3: 20 TR (24 hrs ) No plant shut down allowed Determine Each AHU chilled water flowrate . Chiller capacity Cooling tower capacity Chilled water pump flowrate Condenser water pump flowrate Make-up water tank capacity (2% losses) Expansion tank capacity (assume 25 cu.m volume of pipe) This is hypothetical case only. In real condition, water cooled chiller is not available at that capacity.

16. The End