Training Module

Central AC Plant(Chiller)

Definition

ller is a machine that removes heat from a liquid via a

pour-compression or absorption refrigeration cycle. This liquid
n then be circulated through a heat exchanger to cool air or
uipment as required.

e Ton of Refrigeration 1 TR

= Q xCp x (Ti To) / 3024

R
=
=

mass flow rate of coolant in kg/hr

is coolant specific heat in kCal /kg deg C
inlet, temperature of coolant to evaporator (chiller) in 0C
outlet temperature of coolant from evaporator (chiller) in 0C
= 12,000 BTU (British Thermal Unit)
3.517 KW OR KJ/s
3024 Kcal/Hour

Foundational Principles
Compression
Gases are compressible liquids are not
Gases get hot when compressed

Heat flow
Heat flows from high temperature to low

Fluid flow
Fluids flow from high pressure to low

Goal of a chiller
Maintain desired temperature in a building
Remove heat within a building and reject it to the
ambient environment
Heat sources
Internal gains: lights, people & equipment
External gains: solar, transmission
Infiltration

Chillers Classification

ers are classified on following principle of operation:

por Compression Chiller

por absorption Chiller

apor Compression Chiller further classified based on compressors as follow

ciprocating Compressor
tatory Screw Compressors
entrifugal Compressors
roll Compressors

apor Absorption Chiller further classified as follows:

mple Salt & Water System

ater Spray Absorption refrigeration
ngle Pressure absorption refrigeration

Chillers Classification

Chillers Classification
Reciprocating

Scroll

Centrifugal

Screw

Vapor absorption chiller

Chiller General Layout

generator

condenser

evaporator

absorber

Vapor Compression
chiller

Vapor Absorption
chiller

HVAC System General Layout

Basic Vapour

The high pressure superheated gas

is cooled in several stages in the
Compression
condenserComponents

Low pressure liquid

refrigerant in evaporator
absorbs heat and changes to
Condenser
a gas

3The superheated vapor

enters the compressor

High
where
itsPressure
pressure is
raised Side

4
Expansion
Device

Compressor

1
Evaporator

Low
Pressure
Side

Vapour Compression Cylce

Vapour Absorption Cycle

Basic Vapour Compression Components

Maintain desired temperature in a building
Remove heat within a building and reject it to the
ambient environment
Heat sources
Internal gains: lights, people & equipment
External gains: solar, transmission
Infiltration

Basic Vapour Compression Components

Maintain desired temperature in a building
Remove heat within a building and reject it to the
ambient environment
Heat sources
Internal gains: lights, people & equipment
External gains: solar, transmission
Infiltration

Chiller - Components
Compressor
Prime mover for refrigerant
Raises the pressure of the refrigerant high enough to allow
heat to be rejected to the outdoor environment.
Lowers pressure of refrigerant in evaporator to allow heat to
be
absorbed from fluid being chilled

Technologies
Centrifugal, rotary screw, reciprocating, scroll

Expansion Device
Throttles liquid refrigerant from higher condensing pressure
to lower evaporating pressure
Throttling process yields a mixture of gas (flash) and liquid
at a low temp.

Types

Thermostatic expansion
Orifice plate

System

Screw Chiller Lube Oil Circuit

.

Chiller - Components
Working Fluid Refrigerant
Chlorofluorocarbons (CFCs)
such as R11, R12, R113, R114, R115
Hydrochlorofluorocarbons (HCFCs)
such as R22, R123, R124, R141b, R142b
Hydrofluorocarbons (HFCs)
such as R32, R125, R134a, R143a, R152a

Chiller - General Safeties

Refrigerant Discharge Pressure High - HP

Refrigerant discharge Temperature High
Refrigerant Suction Pressure Low - LP
Low Refrigerant Level
Anti- Freeze
Chilled / Condenser water flow- low
Low/ High condenser water temperature
Low Oil discharge Pressure
Low Oil temperature
Chilled water approach temperature
Compressor motor Temperature
Single phase preventer
Low / High voltage alarm

Diesel Generator Safety Instructions

To avoid burns, be alert for hot parts and hot fluids in lines, tubes and
compartments.

Always use tools that are in good condition. Use only genuine OEM
replacement
parts.

Chiller Start /Stop Procedure

Switching "OFF" Chiller
Check the power supply in Chiller panel on Panel
Ensure all necessary valves are in open condition i.e. chilled /
condenser water line.
Switch ON the required no. of Primary/ Condenser Pump(s) and
cooling tower fan (s)
Ensure required no. of Secondary Pumps are started
Switch ON the Chiller in auto mode by selecting Auto on display unit
Check the inlet and outlet water temperature and all electrical
parameters
Check & Maintain the water level in cooling tower.
Check and note all parameters
Record the readings as per the log sheet and schedule
Switching "OFF" Chiller
Give Stop command at display unit
Check the equipment for stop condition
Switch OFF CT fan, Condenser, primary and secondary pumps
Close all the necessary valves i.e. Chilled / Condenser water line of

Chiller - Preventive Maintenance Overview

Maintain a daily report log book

Daily

Keep Condenser tube cleaned

Half Yearly

Keep Evaporator tube cleaned

Yearly

Ensure leak free Unit i.e. leak test

Monthly

Sustain Proper water Treatment

Daily

Analyze oil & Refrigerant

Electrical Panel
Check chiller safeties

Half Yearly

Quarterly
-

Quarterly

THANK YOU