A chiller is a
water-cooled air conditioning system that cools inside air, creating a more
comfortable and productive environment. Chillers are also used in the
manufacturing environment to provide "process" cooling to equipment
in an effort to maximize productivity.
With large
facilities, such as commercial buildings, hospitals, universities, government
facilities and theme parks, the cost of energy to generate cooling in excess of
50 tons is cost prohibitive with air-cooled units. Water-cooled chillers produce
higher tonnage at lower costs per ton, creating greater energy efficiency. A
typical home has 3-5 tons of cooling capacity.
How a Complete
Chiller System Works
Chillers circulate
chilled water to air-handlers in order to transfer heat from air to water. This
water then returns to the evaporator side of the chiller where the heat is
passed from the water to a liquid refrigerant (Freon). The refrigerant leaves
the evaporator as a cold vapor and enters the compressor where it is compressed
into a hot vapor. Upon leaving the compressor, the vapor enters the condenser
side of the chiller where heat is transferred from the refrigerant to the water
side of the condenser where it is circulated to an open cooling tower for the
final removal of heat via evaporation in the cooling tower.
What is Chiller
Efficiency?
Chiller efficiency
is the amount of energy (electricity) it takes to produce a "ton" of
cooling. It is expressed as kw/ton. All chillers have a designed kw/ton
efficiency that was established when the chiller was commissioned. Plant
design, water treatment, maintenance practices, chiller age, cooling tower
design, cooling load and plant operations dramatically effect chiller operating
efficiency and operating costs.
Chiller Operation,
Service and Maintenance
A chiller "operator" is known by several titles,
including Stationary Engineer, HVAC Engineer and Service Technician. Operation
and maintenance includes collecting and logging data from various gauges,
controls and meters located on or near the chiller. Service contractors, who
specialize in equipment repair, are contracted when major repairs or overhauls
are required.
There are
essentially three types of maintenance performed on chillers; water chemistry,
mechanical maintenance and operational procedures. Water chemistry is
maintained to keep proper balance and minimize the effects of scale, corrosion
and micro-biological / debris fouling. Mechanical maintenance includes proper
lubrication, adequate liquid refrigerant, oil levels and pump curve tests.
Operational procedures include eddy-current tests, oil analysis, calibration of
gauges and meters and other various tests.
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