4.

HVAC and Refrigeration System

4. HVAC AND REFRIGERATION SYSTEM
Syllabus
HVAC and Refriera!i"n Sys!e#$ Vapor compression refrigeration cycle, Refrigerants,
Coefficient of performance, Capacity, Factors affecting Refrigeration and Air
conditioning system performance and savings opportunities.
Vapor absorption refrigeration system$ Woring principle, !ypes and comparison "it#
vapor compression system, Saving potential
4.% In!r"du&!i"n
!#e Heating, Ventilation and Air Conditioning $HVAC% and refrigeration system transfers
t#e #eat energy from or to t#e products, or building environment. &nergy in form of
electricity or #eat is used to po"er mec#anical e'uipment designed to transfer #eat from a
colder, lo"(energy level to a "armer, #ig#(energy level.
Refrigeration deals with the transfer of heat from a low temperature level at the heat
source to a high temperature level at the heat sink by using a low boiling refrigerant.
!#ere are several #eat transfer loops in refrigeration system as described belo")
*n t#e Figure 4.+, t#ermal energy moves from left to rig#t as it is e,tracted from t#e space
and e,pelled into t#e outdoors t#roug# five loops of #eat transfer)
Ind""r air l""'. *n t#e leftmost loop, indoor air is driven by t#e supply air fan
t#roug# a cooling coil, "#ere it transfers its #eat to c#illed "ater. !#e cool air t#en
cools t#e building space.
C(illed )a!er l""'. -riven by t#e c#illed "ater pump, "ater returns from t#e cooling
coil to t#e c#iller.s evaporator to be re(cooled.
Refrieran! l""'. /sing a p#ase(c#ange refrigerant, t#e c#iller.s compressor pumps
#eat from t#e c#illed "ater to t#e condenser "ater.
C"ndenser )a!er l""'. Water absorbs #eat from t#e c#iller.s condenser, and t#e
condenser "ater pump sends it to t#e cooling to"er.
C""lin !")er l""'. !#e cooling to"er.s fan drives air across an open flo" of t#e #ot
condenser "ater, transferring t#e #eat to t#e outdoors.
0ureau of &nergy &fficiency 1+
Fiure 4.% Hea! Transfer *""'s In Refriera!i"n Sys!e#
4. HVAC and Refrigeration System
Air+C"ndi!i"nin Sys!e#s
-epending on applications, t#ere are several options 2 combinations, "#ic# are available
for use as given belo")
Air Conditioning $for comfort 2 mac#ine%
Split air conditioners
Fan coil units in a larger system
Air #andling units in a larger system
Refriera!i"n Sys!e#s ,f"r 'r"&esses-
Small capacity modular units of direct e,pansion type similar to domestic
refrigerators, small capacity refrigeration units.
Centrali3ed c#illed "ater plants "it# c#illed "ater as a secondary coolant for
temperature range over 4
5
C typically. !#ey can also be used for ice ban formation.
0rine plants, "#ic# use brines as lo"er temperature, secondary coolant, for typically
sub 3ero temperature applications, "#ic# come as modular unit capacities as "ell as
large centrali3ed plant capacities.
!#e plant capacities upto 45 !R are usually considered as small capacity, 45 6 745 !R
as medium capacity and over 745 !R as large capacity units.
A large industry may #ave a ban of suc# units, often "it# common c#illed "ater pumps,
condenser "ater pumps, cooling to"ers, as an off site utility.
!#e same industry may also #ave t"o or t#ree levels of refrigeration 8 air conditioning
suc# as)
Comfort air conditioning $75
5
6 74
5
C%
C#illed "ater system $9
5
6 +5
5
C%
0rine system $sub(3ero applications%
!"o principle types of refrigeration plants found in industrial use are) Vapour
Compression Refrigeration $VCR% and Vapour Absorption Refrigeration $VAR%. VCR
uses mec#anical energy as t#e driving force for refrigeration, "#ile VAR uses t#ermal
energy as t#e driving force for refrigeration.
4.. Ty'es "f Refriera!i"n Sys!e#
Va'"ur C"#'ressi"n Refriera!i"n
Heat flo"s naturally from a #ot to a colder body. *n refrigeration system t#e opposite
must occur i.e. #eat flo"s from a cold to a #otter body. !#is is ac#ieved by using a
substance called a refrigerant, "#ic# absorbs #eat and #ence boils or evaporates at a lo"
pressure to form a gas. !#is gas is t#en compressed to a #ig#er pressure, suc# t#at it
transfers t#e #eat it #as gained to ambient air or "ater and turns bac $condenses% into a
li'uid. *n t#is "ay #eat is absorbed, or removed, from a lo" temperature source and
transferred to a #ig#er temperature source.
!#e refrigeration cycle can be broen do"n into t#e follo"ing stages $see Figure 4.7%)
0ureau of &nergy &fficiency 17
4. HVAC and Refrigeration System
% + . :o" pressure li'uid refrigerant in t#e evaporator absorbs #eat from its surroundings,
usually air, "ater or some ot#er process li'uid. -uring t#is process it c#anges its state
from a li'uid to a gas, and at t#e evaporator e,it is slig#tly super#eated.
. + / !#e super#eated vapour enters t#e compressor "#ere its pressure is raised. !#ere
"ill also be a big increase in temperature, because a proportion of t#e energy input into
t#e compression process is transferred to t#e refrigerant.
/ + 4 !#e #ig# pressure super#eated gas passes from t#e compressor into t#e condenser.
!#e initial part of t#e cooling process $; ( ;a% desuper#eats t#e gas before it is t#en turned
bac into li'uid $;a ( ;b%. !#e cooling for t#is process is usually ac#ieved by using air or
"ater. A furt#er reduction in temperature #appens in t#e pipe "or and li'uid receiver $;b
( 4%, so t#at t#e refrigerant li'uid is sub(cooled as it enters t#e e,pansion device.
4 + % !#e #ig#(pressure sub(cooled li'uid passes t#roug# t#e e,pansion device, "#ic#
bot# reduces its pressure and controls t#e flo" into t#e evaporator.
Fiure 4..$ S&(e#a!i& "f a 0asi& Va'"r C"#'ressi"n Refriera!i"n Sys!e#
*t can be seen t#at t#e condenser #as to be capable of re<ecting t#e combined #eat inputs
of t#e evaporator and t#e compressor= i.e. $+ ( 7% > $7 ( ;% #as to be t#e same as $; ( 4%.
!#ere is no #eat loss or gain t#roug# t#e e,pansion device.
Alternative Refrigerants for Vapour Compression Systems
!#e use of CFCs is no" beginning to be p#ased out due to t#eir damaging impact on t#e
protective troposp#eric o3one layer around t#e eart#. !#e ?ontreal @rotocol of +A91 and
t#e subse'uent Copen#agen agreement of +AA7 mandate a reduction in t#e production of
o3one depleting C#lorinated Fluorocarbon $CFC% refrigerants in a p#ased manner, "it# an
eventual stop to all production by t#e year +AAB. *n response, t#e refrigeration industry
#as developed t"o alternative refrigerants= one based on Hydroc#loro Fluorocarbon
$HCFC%, and anot#er based on Hydro Fluorocarbon $HFC%. !#e HCFCs #ave a 7 to +5C
o3one depleting potential as compared to CFCs and also, t#ey #ave an atmosp#eric
lifetime bet"een 7 to 74 years as compared to +55 or more years for CFCs $0randt,
0ureau of &nergy &fficiency 1;
4. HVAC and Refrigeration System
+AA7%. Ho"ever, even HCFCs are mandated to be p#ased out by 7554, and only t#e
c#lorine free $3ero o3one depletion% HFCs "ould be acceptable.
/ntil no", only one HFC based refrigerant, HFC +;4a, #as been developed. HCFCs are
comparatively simpler to produce and t#e t#ree refrigerants 77, +7;, and +74 #ave been
developed. !#e use of HFCs and HCFCs results in slig#tly lo"er efficiencies as compared to
CFCs, but t#is may c#ange "it# increasing efforts being made to replace CFCs.
Abs"r'!i"n Refriera!i"n
!#e absorption c#iller is a mac#ine, "#ic# produces c#illed "ater by using #eat suc# as steam,
#ot "ater, gas, oil etc. C#illed "ater is produced by t#e principle t#at li'uid $refrigerant%, "#ic#
evaporates at lo" temperature, absorbs #eat from surrounding "#en it evaporates. @ure "ater is
used as refrigerant and lit#ium bromide solution is used as absorbent
Heat for t#e vapour absorption refrigeration system can be provided by "aste #eat e,tracted from
process, diesel generator sets etc. Absorption systems re'uire electricity to run pumps only.
-epending on t#e temperature re'uired and t#e po"er cost, it may even be economical to generate
#eat 2 steam to operate t#e absorption system.
-escription of t#e absorption refrigeration concept is given belo")
!#e refrigerant $"ater%
evaporates at around 4
5
C
under t#e #ig# vacuum
condition of 144mmHg in
t#e evaporator. W#en t#e
refrigerant $"ater%
evaporates, t#e latent #eat of
vapori3ation taes t#e #eat
from incoming c#illed "ater.
!#is latent #eat of
vapori3ation can cool t#e
c#illed "ater "#ic# runs
into t#e #eat e,c#anger
tubes in t#e evaporator by
transfer of #eat to t#e
refrigerant $"ater%.
*n order to eep evaporating,
t#e refrigerant vapor must be
disc#arged from t#e
evaporator and refrigerant
$"ater% must be supplied. !#e
refrigerant vapor is absorbed
into lit#ium bromide solution
"#ic# is convenient to absorb
t#e refrigerant vapor in t#e
absorber. !#e #eat generated
in t#e absorption process is
led out of system by cooling
"ater continually. !#e
absorption also maintains t#e
vacuum inside t#e evaporator.
0ureau of &nergy &fficiency 14
4. HVAC and Refrigeration System
As lit#ium bromide
solution is diluted, t#e
effect to absorb t#e
refrigerant vapor reduces.
*n order to eep absorption
process, t#e diluted lit#ium
bromide solution must be
made concentrated lit#ium
bromide.
Absorption c#iller is
provided "it# t#e solution
concentrating system by
t#e #eating media suc# as
steam, #ot "ater, gas, oil,
"#ic# performs suc#
function is called
generator.
!#e concentrated solution
flo"s into t#e absorber and
absorbs t#e refrigerant
vapor again.
*n order to carryout above
"ors continually and to
mae complete cycle, t#e
follo"ing t"o functions are
re'uired.
$+% !o concentrate and
li'uefy t#e evaporated
refrigerant vapor,
"#ic# is generated in
t#e #ig# pressure
generator.
$7% !o supply t#e
condensed "ater to t#e
evaporator as
refrigerant$"ater%
For t#ese function,
condenser is installed.
A typical sc#ematic of t#e absorption refrigeration system is given in t#e Figure 4.;.
:i(0r("ater absorption refrigeration systems #ave a Coefficient of @erformance $CD@% in
t#e range of 5.B4 ( 5.15 and can provide c#illed "ater at B.1
o
C "it# a cooling "ater
temperature of ;5
o
C. Systems capable of providing c#illed "ater at ;
o
C are also
available. Ammonia based systems operate at above atmosp#eric pressures and are
capable of lo" temperature operation $belo" 5
o
C%. Absorption mac#ines of capacities in
t#e range of +5(+455 tons are available. Alt#oug# t#e initial cost of absorption system is
#ig#er t#an compression system, operational cost is muc# lo"er(if "aste #eat is used.
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4. HVAC and Refrigeration System
E1a'"ra!i1e C""lin
!#ere are occasions "#ere air conditioning, "#ic# stipulates control of #umidity up to 45
C for #uman comfort or for process, can be replaced by a muc# c#eaper and less energy
intensive evaporative cooling.
!#e concept is very simple and is t#e same as t#at used in a cooling to"er. Air is broug#t
in close contact "it# "ater to cool it to a temperature close to t#e "et bulb temperature.
!#e cool air can be used for comfort or process cooling. !#e disadvantage is t#at t#e air is
ric# in moisture. Eevert#eless, it is an e,tremely efficient means of cooling at very lo"
cost. :arge commercial systems employ cellulose filled pads over "#ic# "ater is sprayed.
!#e temperature can be controlled by controlling t#e airflo" and t#e "ater circulation
rate. !#e possibility of evaporative cooling is especially attractive for comfort cooling in
dry regions. !#is principle is practiced in te,tile industries for certain processes.
4./ C"##"n Refrieran!s and 2r"'er!ies
A variety of refrigerants are used in vapor compression systems. !#e c#oice of fluid is
determined largely by t#e cooling temperature re'uired. Commonly used refrigerants are
in t#e family of c#lorinated fluorocarbons $CFCs, also called Freons%) R(++, R(+7, R(7+,
R(77 and R(457. !#e properties of t#ese refrigerants are summari3ed in !able 4.+ and t#e
performance of t#ese refrigerants is given in !able 4.7.
0ureau of &nergy &fficiency 1B
Fiure 4./ S&(e#a!i& "f Abs"r'!i"n Refriera!i"n Sys!e#
4. HVAC and Refrigeration System
Table 4.% 2r"'er!ies "f C"##"nly used Refrieran!s
Refrieran!
0"ilin
2"in! 33
,
"
C-
Free4in
2"in! ,
"
C-
Va'"r
2ressure 3
,52a-
Va'"r
V"lu#e 3
,#
/
6 5-
En!(al'y 3
*i7uid ,58
6 5-
Va'"r
,58 6 5-
R ( ++ (7;.97 (+++.5 74.1; 5.B++15 +A+.45 ;94.4;
R ( +7 (7A.1A (+49.5 7+A.79 5.51157 +A5.17 ;41.AB
R ( 77 (45.1B (+B5.5 ;44.14 5.5B4+; +99.44 455.9;
R ( 457 (44.45 ((( 4+4.;5 5.547;4 +99.91 ;47.;+
R ( 1
$Ammonia%
(;;.;5 (11.1 79A.A; 5.4+A4A 959.1+ 491.1B
* At -10
o
C
** At Standard Atmospheric Pressure (101.325 kPa)
Table 4.. 2erf"r#an&e "f C"##"nly used Refrieran!s3
Refrieran!
E1a'"ra!in
2ress ,52a-
C"ndensin
2ress ,52a-
2ressure
Ra!i"
Va'"r
En!(al'y ,58 6
5-
CO2
33
&arn"!
R ( ++ 75.4 +74.4 B.+4 +44.4 4.5;
R ( +7 +97.1 144.B 4.59 ++B.; 4.15
R ( 77 7A4.9 ++A7.+ 4.5; +B7.9 4.BB
R ( 457 ;4A.B +;59.B ;.14 +5B.7 4.;1
R ( 1+1 7;B.4 ++BB.4 4.A; +5;.4 4.19
* At -15
o
C Eaporator !emperature" and 30
o
C Condenser !emperature
** C#P &arn"! $ Coe%%icient o% Per%ormance $ !emp.Eap. & (!emp.Cond. -!empEap.)
!#e c#oice of refrigerant and t#e re'uired cooling temperature and load determine t#e
c#oice of compressor, as "ell as t#e design of t#e condenser, evaporator, and ot#er
au,iliaries. Additional factors suc# as ease of maintenance, p#ysical space re'uirements
and availability of utilities for au,iliaries $"ater, po"er, etc.% also influence component
selection.
4.4 C"#'ress"r Ty'es and A''li&a!i"n
For industrial use, open type systems $compressor and motor as separate units% are
normally used, t#oug# #ermetic systems $motor and compressor in a sealed unit% also find
service in some lo" capacity applications. Hermetic systems are used in refrigerators, air
conditioners, and ot#er lo" capacity applications. *ndustrial applications largely employ
reciprocating, centrifugal and, more recently, scre" compressors, and scroll compressors.
Water(cooled systems are more efficient t#an air(cooled alternatives because t#e
temperatures produced by refrigerant condensation are lo"er "it# "ater t#an "it# air.
Cen!rifual C"#'ress"rs
0ureau of &nergy &fficiency 11
Fiure 4.4 Cen!rifual C"#'ress"r
4.9 Re&i'r"&a!in C"#'ress"r
&"#'ress"r&"#'ress"r
4. HVAC and Refrigeration System
Centrifugal compressors are t#e most efficient type $see Figure 4.4% "#en t#ey are
operating near full load. !#eir efficiency advantage is greatest in large si3es, and t#ey
offer considerable economy of scale, so t#ey dominate t#e maret for large c#illers. !#ey
are able to use a "ide range of refrigerants efficiently, so t#ey "ill probably continue to
be t#e dominant type in large si3es.
Centrifugal compressors #ave a single ma<or moving part ( an impeller t#at compresses
t#e refrigerant gas by centrifugal force. !#e gas is given inetic energy as it flo"s t#roug#
t#e impeller. !#is inetic energy is not useful in itself, so it must be converted to pressure
energy. !#is is done by allo"ing t#e gas to slo" do"n smoot#ly in a stationary diffuser
surrounding t#e impeller.
!o minimi3e efficiency loss at reduced loads, centrifugal compressors typically t#rottle
output "it# inlet guide vanes located at t#e inlet to t#e impeller$s%. !#is met#od is
efficient do"n to about 45C load, but t#e efficiency of t#is met#od decreases rapidly
belo" 45C load.
Dlder centrifugal mac#ines are not able to reduce load muc# belo" 45C. !#is is
because of FsurgeG in t#e impeller. As t#e flo" t#roug# t#e impeller is c#oed off, t#e gas
does not ac'uire enoug# energy to overcome t#e disc#arge pressure. Flo" drops abruptly
at t#is point, and an oscillation begins as t#e gas %'utters bac and fort# in t#e impeller.
&fficiency drops abruptly, and t#e resulting vibration can damage t#e mac#ine. ?any
older centrifugal mac#ines deal "it# lo" loads by creating a false load on t#e system,
suc# as by using #ot gas bypass. !#is "astes t#e portion of t#e cooling output t#at is not
re'uired.
Anot#er approac# is to use variable(speed drives in combination "it# inlet guide
vanes. !#is may allo" t#e compressor to t#rottle do"n to about 75C of full load, or less,
"it#out false loading. C#anging t#e impeller speed causes a departure from optimum
performance, so efficiency still declines badly at lo" loads. A compressor t#at uses a
variable(speed drive reduces its output in t#e range bet"een full load and appro,imately
#alf load by slo"ing t#e impeller speed. At lo"er loads, t#e impeller cannot be slo"ed
furt#er, because t#e disc#arge pressure "ould become too lo" to condense t#e refrigerant.
0elo" t#e minimum load provided by t#e variable(speed drive, inlet guide vanes are used
to provide furt#er capacity reduction.
Re&i'r"&a!in C"#'ress"rs
!#e ma,imum efficiency of reciprocating
compressors $see Figure 4.4% is lo"er t#an
t#at of centrifugal and scre" compressors.
&fficiency is reduced by clearance volume
$t#e compressed gas volume t#at is left at
t#e top of t#e piston stroe%, t#rottling losses
at t#e intae and disc#arge valves, abrupt
c#anges in gas flo", and friction. :o"er
efficiency also results from t#e smaller si3es
of reciprocating units, because motor losses
and friction account for a larger fraction of
energy input in smaller systems.
Reciprocating compressors suffer less efficiency loss at partial loads t#an ot#er types,
and t#ey may actually #ave a #ig#er absolute efficiency at lo" loads t#an t#e ot#er types.
Smaller reciprocating compressors control output by turning on and off. !#is eliminates all
part(load losses, e,cept for a s#ort period of inefficient operation "#en t#e mac#ine starts.
0ureau of &nergy &fficiency 19
Fiure 4.: S&r"ll C"#'ress"r
Fiure 4.; S&re) C"#'ress"r
4. HVAC and Refrigeration System
:arger multi(cylinder reciprocating compressors commonly reduce output by disabling
$FunloadingG% individual cylinders. W#en t#e load falls to t#e point t#at even one cylinder
provides too muc# capacity, t#e mac#ine turns off. Several met#ods of cylinder unloading
are used, and t#ey differ in efficiency. !#e most common is #olding open t#e intae
valves of t#e unloaded cylinders. !#is eliminates most of t#e "or of compression, but a
small amount of po"er is still "asted in pumping refrigerant gas to(and(fro t#roug# t#e
unloaded cylinders. Anot#er met#od is blocing gas flo" to t#e unloaded cylinders,
"#ic# is called Fsuction cutoff.G
Variable(speed drives can be used "it# reciprocating compressors, eliminating t#e
complications of cylinder unloading. !#is met#od is gaining popularity "it# t#e drastic
reduction in costs of variable speed drives.
S&re) C"#'ress"rs
Scre" compressors, sometimes called F#elical rotaryG
compressors, compress refrigerant by trapping it in t#e
Ft#readsG of a rotating scre"(s#aped rotor $see Figure
4.B%. Scre" compressors #ave increasingly taen over
from reciprocating compressors of medium si3es and
large si3es, and t#ey #ave even entered t#e si3e
domain of centrifugal mac#ines. Scre" compressors
are applicable to refrigerants t#at #ave #ig#er condensing pressures, suc# as HCFC(77
and ammonia. !#ey are especially compact. A variety of met#ods are used to control t#e
output of scre" compressors. !#ere are ma<or efficiency differences among t#e different
met#ods. !#e most common is a slide valve t#at forms a portion of t#e #ousing t#at
surrounds t#e scre"s.
/sing a variable(speed drive is anot#er met#od of capacity control. *t is limited to oil(
in<ected compressors, because slo"ing t#e speed of a dry compressor "ould allo"
e,cessive internal leaage. !#ere are ot#er met#ods of reducing capacity, suc# as suction
t#rottling t#at are in#erently less efficient t#an t#e previous t"o.
S&r"ll C"#'ress"rs
!#e scroll compressor is an old invention t#at #as finally come to
t#e maret. !#e gas is compressed bet"een t"o scroll(s#aped vanes.
Dne of t#e vanes is fi,ed, and t#e ot#er moves "it#in it. !#e moving
vane does not rotate, but its center revolves "it# respect to t#e
center of t#e fi,ed vane, as s#o"n in Figure 4.1. !#is motion
s'uee3es t#e refrigerant gas along a spiral pat#, from t#e outside of
t#e vanes to"ard t#e center, "#ere t#e disc#arge port is located. !#e
compressor #as only t"o moving parts, t#e moving vane and a s#aft
"it# an off(center cran to drive t#e moving vane. Scroll
compressors #ave only recently become practical, because close
mac#ining tolerances are needed to prevent leaage bet"een t#e
vanes, and bet"een t#e vanes and t#e casing.
!#e features of various refrigeration compressors and application
criteria is given in t#e !able 4.;.
0ureau of &nergy &fficiency 1A
4. HVAC and Refrigeration System
Table 4./ C"#'aris"n "f Differen! Ty'es "f Refriera!i"n 2lan!s
(Source ( Ashrae ) *endor +n%ormation)
S.
N"
2ara#e!ers
Va'"ur C"#'ressi"n C(illers
Va'"ur Abs"r'!i"n C(iller
:i0r Ammonia
Reciprocating Centrifugal Scre" Single &ffect -ouble &ffect Half &ffect !riple &ffect Single Stage
+
Refrigeration !emp. Range $0rine 2
Water%
>1 to (;5
o
C >1 to (5
o
C >1 to (74
o
C Above B
5
C /pto 6;;
5
C
7 &nergy *nput &lectricity &lectricity &lectricity
Heat $Steam 2
Hot Water 2
Hot
Dil2-irect
Fired%
Heat $Steam 2
Hot Water 2
Hot Dil2
-irect Fired%
Heat $Hot
Water%

Heat
$Steam 2Hot
Dil 2-irect
Fired %
Heat $Steam2 Hot
Water 2 Hot Dil%

;
Heat *nput !emp. Range (?a,imum
(?inimum
( ( (
?inimum
94
o
C
?inimum
+;5
o
C
?inimum
44
o
C
?inimum
+A5
o
C
?inimum 94
o
C
4
!ypical &nergy to !R Ratio
Air Conditioning !emp. Range5.1(5.A W2!R 5.B;W2!R
5.B4 W2!R 4555 cal2!R 7414 cal2!R 1455 cal2!R 7555 cal2!R 4B+4 cal2!R
Sub3ero !emp. Range+.74 to 7.4
W2!R
((((( +.74 to 7.4
W2!R
((((( ((((( ((((( ((((( BBBB cal2#r
4 Refrigerant
R++,R+7;,R+;4a
Ammonia
R77, R+7
R77, R+;4a
Ammonia
@ure Water @ure Water @ure Water @ure Water @ure Ammonia
B Absorbent (((((( (((((( ((((((
Water(:i0r
solution
Water(:i0r
solution
Water(:i0r
solution
Water(:i0r
solution
Ammonia(
:i0r solution
1
!ypical single unit capacity range
Air Condition temp. range +(+45 !R ;55 !R 8 above 45(755 !R
;5 !R 8
above
;5 !R 8 above
;5 !R 8
above
45 !R 8
above
;5 !R 8 above
Sub3ero temp. range +5(45 !R (((((( 45(755 !R ((((( ((((( ((((( ((((( ;5 !R 8 above
9 !ypical CD@ at @art :oad upto 45C
Reduces at part
load
Reduces at part
load
*mproves by
+4(75C
?arginal *mprovement at @art :oad Eo variation
A
!ypical *nternal @ressure :evels (:o"
(Hig#
!ypical *nternal !emp. :evels
5.+4(5.45 bar a
+.75(+.45 bar a
(74 to 45
o
C
7.4(;.4 bar a
++(+7 bar
(4 to 45
o
C
7(4.4 bar
+9(75 bar
(74 to 45
o
C
4(B mm Hg
$abs%
B5(15 mm Hg
$abs%
>4 to 14
o
C
4(B mm Hg
$abs%
;15(;A5 mm
Hg $abs%
>4 to >+;5
o
C
4(B mm Hg
$abs%
B5(15 mm Hg
$abs%
>4 to +;5
o
C
4(B mm Hg
$abs%
7 g2cm
7
$a%
>4 to +B5
o
C
+.7g2cm
7
$a%
+9 g2cm7$a%
(74 to >+45
o
C
0ureau of &nergy &fficiency 95
4. HVAC and Refrigeration System
S.
N"
2ara#e!ers
Va'"ur C"#'ressi"n C(illers
Va'"ur Abs"r'!i"n C(iller
:i0r Ammonia
Reciprocating Centrifugal Scre" Single &ffect -ouble &ffect Half &ffect !riple &ffect Single Stage
+5
!ypical Cooling to"er capacity range
per +55 !R of c#illers
(Air conditioning !emperature Range
( Sub3ero temp. range

+;5
+A5
+75
(((((
+75
+B5
7B5
(((
755
(((
;15
(((
+15
(((
7A5
7A5
++
!ypical ?ae(up "ater 'uantity range
in :trs2Hr.
(Air Conditioning temperature range
(Sub3ero temp. range
B17
A9;
B75
(((
B75
9;5
+;44
(((
+5;4
(((
+A+4
(((
995
(((
+455
+455
+7
?aterial of construction
(Henerator
((( ((( ((( Cu(Ei or Stainless Steel Carbon Steel
(Absorber ((( ((( ((( Cu(Ei Carbon Steel
(&vaporator
Copper 2 Carbon
steel
copper 2 Carbon
steel
Copper2
Carbon steel
Cu(Ei Carbon Steel
(Condenser
Copper 2 Carbon
steel
Copper 2 Carbon
steel
Copper 2
Carbon steel
Cu(Ei

Carbon Steel
(Solution Heat &,c#ange ((( ((( ((( Carbon Steel Carbon Steel
(Solution @ump ((( ((( (((
Cast *ron
Hermatically Sealed $Canned motor type%
Cast *ron "it#
?e#.Seal
(Refrigerant pump ((( ((( (((
Cast *ron
Hermatically Sealed $Canned motor type%
Eot needed
+; &,pected :ife 74(;5 years +4(75 years 45 years
+4
Eormally &,pected Repairs 2
?aintenance
@eriodic Compressor Dver#aul
!ube Replacement after +(+7 years
!ube Replacement
due to Corrosion
@ractically no
repairs
+4
Factory Assembled pacaged Dr Site
Assembled
Factory Assembled
Factory
Assembled upto
7;5 !R in A2C
8 sub3ero
range
+B 0eneficial &nergy Sources
:o" cost
&lectricity
:o" cost
&lectricity
:o" cost
&lectricity
a% Waste Heat
b% :o" cost steam 2 :o" cost fuels
0ureau of &nergy &fficiency 9+
4. HVAC and Refrigeration System
S.
N"
2ara#e!ers
Va'"ur C"#'ressi"n C(illers
Va'"ur Abs"r'!i"n C(iller
:i0r Ammonia
Reciprocating Centrifugal Scre"
Single
&ffect
-ouble
&ffect
Half &ffect
!riple
&ffect
Single Stage
+1 Critical @arameters
(&lectricity
supply
(:ubrication
System
(Compressor
Dperation 8
?aintenance
(&lectrical
@o"er @anel
?aintenance
((((
a% Vacuum in C#iller
b% @urge System for Vacuum
c% Corrosion *n#ibitors in Absorbent
d% Surfactants in Absorbent
e% Cooling Water !reatment
f% Cooling Water !emperature
g% Heat Source !emperature
Sudden @o"er
failure for 44(
B5 min. or more
can disturb t#e
distillation
column for
continuous
operation.
Eeeds -.H.set
if t#ere is
fre'uent po"er
failure for
periods longer
t#an ;5 min.
0ureau of &nergy &fficiency 97
4. HVAC and Refrigeration System
4.9 Sele&!i"n "f a Sui!able Refriera!i"n Sys!e#
A clear understanding of t#e cooling load to be met is t#e first and most important part of
designing 2 selecting t#e components of a refrigeration system. *mportant factors to be considered
in 'uantifying t#e load are t#e actual cooling need, #eat $cool% leas, and internal #eat sources
$from all #eat generating e'uipment%. Consideration s#ould also be given to process c#anges
and 2 or c#anges in ambient conditions t#at mig#t affect t#e load in t#e future. Reducing t#e load,
e.g. t#roug# better insulation, maintaining as #ig# a cooling temperature as practical, etc. is t#e
first step to"ard minimi3ing electrical po"er re'uired to meet refrigeration needs. Wit# a
'uantitative understanding of t#e re'uired temperatures and t#e ma,imum, minimum, and average
e,pected cooling demands, selection of appropriate refrigeration system $single(stage 2 multi(
stage, economi3ed compression, compound 2 cascade operation, direct cooling 2 secondary
coolants% and e'uipment $type of refrigerant, compressor, evaporator, condenser, etc.% can be
undertaen.
4.; 2erf"r#an&e Assess#en! "f Refriera!i"n 2lan!s
!#e cooling effect produced is 'uantified as tons of refrigeration.$!R%.
+ !R of refrigeration I ;574 Cal2#r #eat re<ected.
!#e refrigeration !R is assessed as !R I J ,C
p
, $!
i
6 !
o
% 2 ;574
W#ere J is mass flo" rate of coolant in g2#r
C
p
is coolant specific #eat in Cal 2g deg C
!
i
is inlet, temperature of coolant to evaporator $c#iller% in
5
C
!
o
is outlet temperature of coolant from evaporator $c#iller% in
5
C.
!#e above !R is also called as c#iller tonnage.
!#e specific po"er consumption W2!R is a useful indicator of t#e performance of
refrigeration system. 0y measuring refrigeration duty performed in !R and t#e
iloWatt inputs, W2!R is used as a reference energy performance indicator.
*n a centrali3ed c#illed "ater system, apart from t#e compressor unit, po"er is also
consumed by t#e c#illed "ater $secondary% coolant pump as "ell condenser "ater
$for #eat re<ection to cooling to"er% pump and cooling to"er fan in t#e cooling
to"er. &ffectively, t#e overall energy consumption "ould be to"ards)
Compressor W
C#illed "ater pump W
Condenser "ater pump W
Cooling to"er fan W, for induced 2 forced draft to"ers
!#e specific po"er consumption for certain !R output "ould t#erefore #ave to
include)
Compressor W2!R
C#illed "ater pump W2!R
Condenser "ater pump W2!R
Cooling to"er fan W2!R
0ureau of &nergy &fficiency 9;
4. HVAC and Refrigeration System
!#e overall W2!R is t#e sum of t#e above.
!#e t#eoretical Coefficient of @erformance $Carnot%, CD@

Carnot
( a standard measure of
refrigeration efficiency of an ideal refrigeration system( depends on t"o ey system
temperatures, namely, evaporator temperature !
e
and condenser temperature !
c
"it# CD@
being given as)
CD@
Carnot
I !
e
2 $!
c
( !
e
%
!#is e,pression also indicates t#at #ig#er CD@
Carnot
is ac#ieved "it# #ig#er evaporator
temperature and lo"er condenser temperature.
0ut CD@
Carnot
is only a ratio of temperatures, and #ence does not tae into account t#e
type of compressor. Hence t#e CD@ normally used in t#e industry is given by
Cooling effect $W%
CD@ I
@o"er input to compressor $W%
"#ere t#e cooling effect is t#e difference in ent#alpy across t#e evaporator and e,pressed
as W. !#e effect of evaporating and condensing temperatures are given in t#e Figure 4.9
and Figure 4.A belo")
*n t#e field performance assessment, accurate instruments for inlet and outlet c#illed
"ater temperature and condenser "ater temperature measurement are re'uired, preferably
"it# a least count of 5.+
5
C. Flo" measurements of c#illed "ater can be made by an
ultrasonic flo" meter directly or inferred from pump duty parameters. Ade'uacy c#ec
of c#illed "ater is needed often and most units are designed for a typical 5.B9 m
;
2#r per
!R $; gpm2!R% c#illed "ater flo". Condenser "ater flo" measurement can also be made
by a non(contact flo" meter directly or inferred from pump duty parameters. Ade'uacy
c#ec of condenser "ater is also needed often, and most units are designed for a typical
5.A+ m
;
2#r per !R $4 gpm 2 !R% condenser "ater flo".
*n case of air conditioning units, t#e airflo" at t#e Fan Coil /nits $FC/% or t#e Air
Handling /nits $AH/% can be measured "it# an anemometer. -ry bulb and "et bulb
0ureau of &nergy &fficiency
Fiure 4.< Fiure 4.=
94
4. HVAC and Refrigeration System
temperatures are measured at t#e inlet and outlet of AH/ or t#e FC/ and t#e refrigeration
load in !R is assessed as =
( )
;574
# # K J
!R
out in

=
W#ere, J is t#e air flo" in m
;
2#
is density of air g2m
;
h
in
is ent#alpy of inlet air Cal2g
h
out
is ent#alpy of outlet air Cal2g
/se of psyc#ometric c#arts can #elp to calculate #
in
and #
out
from dry bulb, "et bulb
temperature values "#ic# are, in(turn measured, during trials, by a "#irling
psyc#rometer.
@o"er measurements at, compressor, pumps, AH/ fans, cooling to"er fans can be
accomplis#ed by a portable load analy3er.
&stimation of air conditioning load is also possible by calculating various #eat loads,
sensible and latent based on inlet and outlet air parameters, air ingress factors, air flo",
no. of people and type of materials stored.
An indicative !R load profile for air conditioning is presented as follo"s)

Small office cabins I 5.+ !R 2m

7

?edium si3e office i.e., I 5.5B !R2 m

7
+5 6 ;5 people occupancy
"it# central A2C

:arge multistoried office I 5.54 !R2 m

7
comple,es "it# central A2C
In!era!ed 2ar! *"ad Value ,I2*V-
Alt#oug# t#e W2 !R can serve as an initial reference, it s#ould not be taen as an
absolute since t#is value is derived from +55C of t#e e'uipmentLs capacity level and is
based on design conditions t#at are considered t#e most critical. !#ese conditions occur
may be, for e,ample, during only +C of t#e total time t#e e'uipment is in operation
t#roug#out t#e year. Conse'uently, it is essential to #ave data t#at reflects #o" t#e
e'uipment operates "it# partial loads or in conditions t#at demand less t#an +55C of its
capacity. !o overcome t#is, an average of W2!R "it# partial loads ie *ntegrated @art
:oad Value $*@:V% #ave to be formulated.
!#e *@:V is t#e most appropriate reference, alt#oug# not considered t#e best, because it
only captures four points "it#in t#e operational cycle) +55C, 14C, 45C and 74C.
Furt#ermore, it assigns t#e same "eig#t to eac# value, and most e'uipment usually
0ureau of &nergy &fficiency 94
4. HVAC and Refrigeration System
operates at bet"een 45 C and 14C of its capacity. !#is is "#y it is so important to
prepare specific analysis for eac# case t#at addresses t#e four points already mentioned,
as "ell as developing a profile of t#e #eat e,c#angerLs operations during t#e year.

4.: Fa&!"rs Affe&!in 2erf"r#an&e > Enery Effi&ien&y "f
Refriera!i"n 2lan!s
Desin "f 2r"&ess Hea! E?&(aners
!#ere is a tendency of t#e process group to operate "it# #ig# safety margins "#ic#
influences t#e compressor suction pressure 2 evaporator set point. For instance, a process
cooling re'uirement of +4
5
C "ould need c#illed "ater at a lo"er temperature, but t#e
range can vary from B
5
C to say +5
5
C. At +5
5
C c#illed "ater temperature, t#e refrigerant
side temperature #as to be lo"er, say 64
5
C to >4
5
C. !#e refrigerant temperature, again
sets t#e corresponding suction pressure of refrigerant "#ic# decides t#e inlet duty
conditions for "or of compression of t#e refrigerant compressor. Having t#e optimum 2
minimum driving force $temperature difference% can, t#us, #elp to ac#ieve #ig#est
possible suction pressure at t#e compressor, t#ereby leading to less energy re'uirement.
!#is re'uires proper si3ing of #eat transfer areas of process #eat e,c#angers and
evaporators as "ell as rationali3ing t#e temperature re'uirement to #ig#est possible value.
A +
5
C raise in evaporator temperature can #elp to save almost ; C on po"er
consumption. !#e !R capacity of t#e same mac#ine "ill also increase "it# t#e evaporator
temperature, as given in !able 4.4.
Table 4.4 Effe&! "f Varia!i"n in E1a'"ra!"r Te#'era!ure "n C"#'ress"r 2")er C"nsu#'!i"n
E1a'"ra!"r
Te#'era!ure ,
@
C-
Refriera!i"n
Ca'a&i!y
3
,!"ns-
S'e&ifi& 2")er
C"nsu#'!i"n
In&rease in
5A6!"n ,B-
4.5 B1.49 5.9+ (
5.5 4B.51 5.A4 +B.5
(4.5 44.A9 +.59 ;;.5
(+5.5 ;1.75 +.74 44.5
(75.5 7;.+7 +.B1 +5B.5
* Condenser temperature ,0
0
C
!o"ards rationali3ing t#e #eat transfer areas, t#e #eat transfer coefficient on refrigerant
side can be considered to range from +455 6 7955 "atts 2m
7
M.
!#e refrigerant side #eat transfer areas provided are of t#e order of 5.4 S'm.2!R and
above in evaporators.
Condensers in a refrigeration plant are critical e'uipment t#at influence t#e !R capacity
and po"er consumption demands. Hiven a refrigerant, t#e condensing temperature and
corresponding condenser pressure, depend upon t#e #eat transfer area provided,
effectiveness of #eat e,c#ange and t#e type of cooling c#osen. A lo"er condensing
temperature, pressure, in best of combinations "ould mean t#at t#e compressor #as to
"or bet"een a lo"er pressure differential as t#e disc#arge pressure is fi,ed by design
0ureau of &nergy &fficiency 9B
4. HVAC and Refrigeration System
and performance of t#e condenser. !#e c#oices of condensers in practice range from air
cooled, air cooled "it# "ater spray, and #eat e,c#anger cooled. Henerously si3ed s#ell
and tube #eat e,c#angers as condensers, "it# good cooling to"er operations #elp to
operate "it# lo" disc#arge pressure values and t#e !R capacity of t#e refrigeration plant
also improves. Wit# same refrigerant, R77, a disc#arge pressure of +4 g2cm
7
"it# "ater
cooled s#ell and tube condenser and 75 g2cm
7
"it# air cooled condenser indicate t#e ind
of additional "or of compression duty and almost ;5 C additional energy consumption
re'uired by t#e plant. Dne of t#e best option at design stage "ould be to select generously
si3ed $5.B4 m
7
2!R and above% s#ell and tube condensers "it# "ater(cooling as against
c#eaper alternatives lie air cooled condensers or "ater spray atmosp#eric condenser
units.
!#e effect of condenser temperature on refrigeration plant energy re'uirements is given in
!able 4.4.
Table 4.9 Effe&! "f Varia!i"n in C"ndenser Te#'era!ure "n C"#'ress"r 2")er C"nsu#'!i"n
C"ndensin
Te#'era!ure ,
@
C-
Refriera!i"n
Ca'a&i!y ,!"ns-
S'e&ifi& 2")er
C"nsu#'!i"n
,5A 6 TR-
In&rease in
5A6TR ,B-
7B.1 ;+.4 +.+1 (
;4.5 7+.4 +.71 9.4
45.5 75.5 +.4+ 75.4
* -eciprocatin. compressor usin. --22 re%ri.erant.
Eaporator temperature.-10
0
C
Main!enan&e "f Hea! E?&(aner Surfa&es
After ensuring procurement, effective maintenance #olds t#e ey to optimi3ing po"er
consumption.
Heat transfer can also be improved by ensuring proper separation of t#e lubricating oil
and t#e refrigerant, timely defrosting of coils, and increasing t#e velocity of t#e secondary
coolant $air, "ater, etc.%. Ho"ever, increased velocity results in larger pressure drops in
t#e distribution system and #ig#er po"er consumption in pumps 2 fans. !#erefore, careful
analysis is re'uired to determine t#e most effective and efficient option.
Fouled condenser tubes force t#e compressor to "or #arder to attain t#e desired capacity.
For e,ample, a 5.9 mm scale build(up on condenser tubes can increase energy
consumption by as muc# as ;4 C. Similarly, fouled evaporators $due to residual
lubricating oil or infiltration of air% result in increased po"er consumption. &'ually
important is proper selection, si3ing, and maintenance of cooling to"ers. A reduction of
5.44
5
C temperature in "ater returning from t#e cooling to"er reduces compressor po"er
consumption by ;.5 C $see !able 4.B%.
0ureau of &nergy &fficiency 91
4. HVAC and Refrigeration System
Table 4.; Effe&! "f 2""r Main!enan&e "n C"#'ress"r 2")er C"nsu#'!i"n
C"ndi!i"n
E1a'. Te#'
,
@
C-
C"nd.
Te#'
,
@
C-
Refriera!i"n
Ca'a&i!y
3
,!"ns-
S'e&ifi& 2")er
C"nsu#'!i"n
,5A6!"n-
In&rease in
5A6T"n
,B-
Eormal 1.7 45.4 +1.5 5.BA (
-irty condenser 1.7 4B.+ +4.B 5.94 75.4
-irty evaporator +.1 45.4 +;.9 5.97 +9.;
-irty condenser
and evaporator
+.1 4B.+ +7.1 5.AB ;9.1
* 15 ton reciprocatin. compressor /ased s0stem. !he po1er consumption is 'o1er than that
%or s0stems t0pica''0 aai'a/'e in +ndia. 2o1eer" the percenta.e chan.e in po1er
consumption is indicatie o% the e%%ect o% poor maintenance.
Mul!i+S!ain F"r Effi&ien&y
&fficient compressor operation re'uires t#at t#e compression ratio be ept lo", to reduce
disc#arge pressure and temperature. For lo" temperature applications involving #ig#
compression ratios, and for "ide temperature re'uirements, it is preferable $due to
e'uipment design limitations% and often economical to employ multi(stage reciprocating
mac#ines or centrifugal 2 scre" compressors.
?ulti(staging systems are of t"o(types) compound and cascade 6 and are applicable to all
types of compressors. Wit# reciprocating or rotary compressors, t"o(stage compressors
are preferable for load temperatures from 675 to 649
5
C, and "it# centrifugal mac#ines for
temperatures around 64;
5
C.
*n multi(stage operation, a first(stage compressor, si3ed to meet t#e cooling load, feeds
into t#e suction of a second(stage compressor after inter(cooling of t#e gas. A part of t#e
#ig#(pressure li'uid from t#e condenser is flas#ed and used for li'uid sub(cooling. !#e
second compressor, t#erefore, #as to meet t#e load of t#e evaporator and t#e flas# gas. A
single refrigerant is used in t#e system, and t#e "or of compression is s#ared e'ually by
t#e t"o compressors. !#erefore, t"o compressors "it# lo" compression ratios can in
combination provide a #ig# compression ratio.
For temperatures in t#e range of 64B
5
C to 6+5+
5
C, cascaded systems are preferable. *n
t#is system, t"o separate systems using different refrigerants are connected suc# t#at one
provides t#e means of #eat re<ection to t#e ot#er. !#e c#ief advantage of t#is system is
t#at a lo" temperature refrigerant "#ic# #as a #ig# suction temperature and lo" specific
volume can be selected for t#e lo"(stage to meet very lo" temperature re'uirements.
Ma!&(in Ca'a&i!y !" Sys!e# *"ad
-uring part(load operation, t#e evaporator temperature rises and t#e condenser
temperature falls, effectively increasing t#e CD@. 0ut at t#e same time, deviation from
t#e design operation point and t#e fact t#at mec#anical losses form a greater proportion of
t#e total po"er negate t#e effect of improved CD@, resulting in lo"er part(load efficiency.
!#erefore, consideration of part(load operation is important, because most refrigeration
applications #ave varying loads. !#e load may vary due to variations in temperature and
0ureau of &nergy &fficiency 99
4. HVAC and Refrigeration System
process cooling needs. ?atc#ing refrigeration capacity to t#e load is a difficult e,ercise,
re'uiring no"ledge of compressor performance, and variations in ambient conditions,
and detailed no"ledge of t#e cooling load.
Ca'a&i!y C"n!r"l and Enery Effi&ien&y
!#e capacity of compressors is controlled in a number of "ays. Capacity control of
reciprocating compressors t#roug# cylinder unloading results in incremental $step(by(
step% modulation as against continuous capacity modulation of centrifugal t#roug# vane
control and scre" compressors t#roug# sliding valves. !#erefore, temperature control
re'uires careful system design. /sually, "#en using reciprocating compressors in
applications "it# "idely varying loads, it is desirable to control t#e compressor by
monitoring t#e return "ater $or ot#er secondary coolant% temperature rat#er t#an t#e
temperature of t#e "ater leaving t#e c#iller. !#is prevents e,cessive on(off cycling or
unnecessary loading 2 unloading of t#e compressor. Ho"ever, if load fluctuations are not
#ig#, t#e temperature of t#e "ater leaving t#e c#iller s#ould be monitored. !#is #as t#e
advantage of preventing operation at very lo" "ater temperatures, especially "#en flo"
reduces at lo" loads. !#e leaving "ater temperature s#ould be monitored for centrifugal
and scre" c#illers.
Capacity regulation t#roug# speed control is t#e most efficient option. Ho"ever, "#en
employing speed control for reciprocating compressors, it s#ould be ensured t#at t#e
lubrication system is not affected. *n t#e case of centrifugal compressors, it is usually
desirable to restrict speed control to about 45 C of t#e capacity to prevent surging. 0elo"
45 C, vane control or #ot gas bypass can be used for capacity modulation.
!#e efficiency of scre" compressors operating at part load is generally #ig#er t#an
eit#er centrifugal compressors or reciprocating compressors, "#ic# may mae t#em
attractive in situations "#ere part(load operation is common. Scre" compressor
performance can be optimi3ed by c#anging t#e volume ratio. *n some cases, t#is may
result in #ig#er full(load efficiencies as compared to reciprocating and centrifugal
compressors. Also, t#e ability of scre" compressors to tolerate oil and li'uid refrigerant
slugs maes t#em preferred in some situations.
Mul!i+le1el Refriera!i"n f"r 2lan! Needs
!#e selection of refrigeration systems also depends on t#e range of temperatures re'uired
in t#e plant. For diverse applications re'uiring a "ide range of temperatures, it is
generally more economical to provide several pacaged units $several units distributed
t#roug#out t#e plant% instead of one large central plant. Anot#er advantage "ould be t#e
fle,ibility and reliability accorded. !#e selection of pacaged units could also be made
depending on t#e distance at "#ic# cooling loads need to be met. @acaged units at load
centers reduce distribution losses in t#e system. -espite t#e advantages of pacaged units,
central plants generally #ave lo"er po"er consumption since at reduced loads po"er
consumption can reduce significantly due to t#e large condenser and evaporator surfaces.
?any industries use a ban of compressors at a central location to meet t#e load.
/sually t#e c#illers feed into a common #eader from "#ic# branc# lines are taen to
different locations in t#e plant. *n suc# situations, operation at part(load re'uires e,treme
care. For efficient operation, t#e cooling load, and t#e load on eac# c#iller must be
monitored closely. *t is more efficient to operate a single c#iller at full load t#an to
operate t"o c#illers at part(load. !#e distribution system s#ould be designed suc# t#at
individual c#illers can feed all branc# lines. *solation valves must be
provided to ensure t#at c#illed "ater $or ot#er coolant% does not flo"
0ureau of &nergy &fficiency 9A
4. HVAC and Refrigeration System
t#roug# c#illers not in operation. Valves s#ould also be provided on branc# lines to
isolate sections "#ere cooling is not re'uired. !#is reduces pressure drops in t#e system
and reduces po"er consumption in t#e pumping system. *ndividual compressors s#ould
be loaded to t#eir full capacity before operating t#e second compressor. *n some cases it is
economical to provide a separate smaller capacity c#iller, "#ic# can be operated on an
on(off control to meet pea demands, "it# larger c#illers meeting t#e base load.
Flo" control is also commonly used to meet varying demands. *n suc# cases t#e
savings in pumping at reduced flo" s#ould be "eig#ed against t#e reduced #eat transfer
in coils due to reduced velocity. *n some cases, operation at normal flo" rates, "it#
subse'uent longer periods of no(load $or s#ut(off% operation of t#e compressor, may result
in larger savings.
C(illed Aa!er S!"rae
-epending on t#e nature of t#e load, it is economical to provide a c#illed "ater storage
facility "it# very good cold insulation. Also, t#e storage facility can be fully filled to
meet t#e process re'uirements so t#at c#illers need not be operated continuously. !#is
system is usually economical if small variations in temperature are acceptable. !#is
system #as t#e added advantage of allo"ing t#e c#illers to be operated at periods of lo"
electricity demand to reduce pea demand c#arges ( :o" tariffs offered by some electric
utilities for operation at nig#t time can also be taen advantage of by using a storage
facility. An added benefit is t#at lo"er ambient temperature at nig#t lo"ers condenser
temperature and t#ereby increases t#e CD@.
*f temperature variations cannot be tolerated, it may not be economical to provide a
storage facility since t#e secondary coolant "ould #ave to be stored at a temperature
muc# lo"er t#an re'uired to provide for #eat gain. !#e additional cost of cooling to a
lo"er temperature may offset t#e benefits. !#e solutions are case specific. For e,ample,
in some cases it may be possible to employ large #eat e,c#angers, at a lo"er cost burden
t#an lo" temperature c#iller operation, to tae advantage of t#e storage facility even
"#en temperature variations are not acceptable. *ce ban system "#ic# store ice rat#er
t#an "ater are often economical.
Sys!e# Desin Fea!ures
*n overall plant design, adoption of good practices improves t#e energy efficiency
significantly. Some areas for consideration are)
-esign of cooling to"ers "it# FR@ impellers and film fills, @VC drift
eliminators, etc.
/se of softened "ater for condensers in place of ra" "ater.
/se of economic insulation t#icness on cold lines, #eat e,c#angers,
considering cost of #eat gains and adopting practices lie infrared
t#ermograp#y for monitoring ( applicable especially in large c#emical 2
fertili3er 2 process industry.
Adoption of roof coatings 2 cooling systems, false ceilings 2 as applicable, to
minimi3e refrigeration load.
Adoption of energy efficient #eat recovery devices lie air to air #eat
e,c#angers to pre(cool t#e fres# air by indirect #eat e,c#ange= control of
relative #umidity t#roug# indirect #eat e,c#ange rat#er t#an use of duct
#eaters after c#illing.
0ureau of &nergy &fficiency A5
4. HVAC and Refrigeration System
Adopting of variable air volume systems= adopting of sun film application for
#eat reflection= optimi3ing lig#ting loads in t#e air conditioned areas=
optimi3ing number of air c#anges in t#e air conditioned areas are fe" ot#er
e,amples.
4.< Enery Sa1in O''"r!uni!ies
a- C"ld Insula!i"n
*nsulate all cold lines 2 vessels using economic insulation t#icness to minimi3e #eat
gains= and c#oose appropriate $correct% insulation.
b- 0uildin En1el"'e
Dptimise air conditioning volumes by measures suc# as use of false ceiling and
segregation of critical areas for air conditioning by air curtains.
&- 0uildin Hea! *"ads Mini#isa!i"n
?inimise t#e air conditioning loads by measures suc# as roof cooling, roof painting,
efficient lig#ting, pre(cooling of fres# air by air( to(air #eat e,c#angers, variable
volume air system, otpimal t#ermo(static setting of temperature of air conditioned
spaces, sun film applications, etc.
e- 2r"&ess Hea! *"ads Mini#isa!i"n
?inimi3e process #eat loads in terms of !R capacity as "ell as refrigeration level,
i.e., temperature re'uired, by "ay of)
i% Flo" optimi3ation
ii% Heat transfer area increase to accept #ig#er temperature coolant
iii% Avoiding "astages lie #eat gains, loss of c#illed "ater, idle flo"s.
iv% Fre'uent cleaning 2 de(scaling of all #eat e,c#angers
f- A! !(e Refriera!i"n A6C 2lan! Area
i% &nsure regular maintenance of all A2C plant components as per
manufacturer guidelines.
ii% &nsure ade'uate 'uantity of c#illed "ater and cooling "ater flo"s,
avoid bypass flo"s by closing valves of idle e'uipment.
iii% ?inimi3e part load operations by matc#ing loads and plant
capacity on line= adopt variable speed drives for varying process load.
iv% ?ae efforts to continuously optimi3e condenser and evaporator
parameters for minimi3ing specific energy consumption and ma,imi3ing capacity.
v% Adopt VAR system "#ere economics permit as a non(CFC
solution.
0ureau of &nergy &fficiency A+
4. HVAC and Refrigeration System
CDESTIONS
%. :ist a fe" types of air conditioning systems in use.
..
+ !R of refrigeration is
a% 45 Cal2#our b% ;574 Cal2#our c% +555 Cal2#our d% +55 Cal2#our
/.
&,plain "it# a setc# t#e "oring principle of a vapour compression
refrigeration plant
4. &,plain t#e "oring principle of vapour absorption refrigeration system.
9.
Df t#e follo"ing, "#ic# #as 3ero o3one depletion potentialN
a% R++ b% R77 c% HFC +;4a d% HCFC77
;.
:ist a fe" energy efficiency improvement options in a refrigeration plant.
:.
Eame different types of compressors used in refrigeration system.
<.
!#rottling as a means of capacity control applies to
Reciprocating compressor b% Scre" compressor c% Scroll Compressor d%
Centrifugal compressor
=. &,plain t#e p#enomenon of surge in a centrifugal compressor.
%@.
W#at is t#e refrigeration load in !R "#en +4 m
;
2#r of "ater is cooled from
7+
5
C to +4
5
CN *f t#e compressor motor dra"s 7A W, c#illed "ater pump
dra"s 4.B W, condenser "ater pump dra"s B.+ W and Cooling !o"er fan
dra"s 7.1 W, "#at is overall W2!RN
%%.
&,plain t#e term *ntegrated @art :oad Value $*@:V%.
%..
&,plain t#e impact of condensing and evaporation temperatures on
compressor po"er consumption.
%/.
0riefly list various energy conservation opportunities in a refrigeration
plant.
REFERENCES
+. !ec#nology ?enu on &nergy &fficiency $E@C%
7. ASHRA& Hand 0oo
;. E@C Case Studies
4. Vendor *nformation

0ureau of &nergy &fficiency A7