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ChillerOperation PDF
ChillerOperation PDF
CONDENSER
Inlet Temp (Entering Condenser Water, originated as Cooling Tower Leaving Water)
Most chillers are designed for a max condenser inlet water temperature of 85F. If the entering condenser water
temperature exceeds 85 degrees the efficiency of the chiller is reduced by as much as 2% per degree above 85F.
Outlet Temp (Leaving Condenser Water, becomes cooling tower entering water)
Refrigerant Temp
LiquidLineTemp?
Subcooling?
Excess Approach
Condenser approach is the difference between liquid refrigerant temperature as measured on the liquid line, and
leaving condenser water temperature. Normal condenser approach is 0 to 3 degrees.
If condenser approach is 4 or more, it's an indication your water cooled chiller has fouled tubes.
Evaporator approach can be used to evaluate the refrigerant charge. Take all readings with the water cooled
chiller at full load.
In a 1 pass evaporator, approach should be 10 to 14.
In a 2 pass evaporator, approach should be 7 to 10.
In a 3 pass evaporator, approach should be 3 to 6.
A higher than normal evaporator approach can indicate an undercharge. A lower than normal evaporator
approach can indicate an overcharge.
This is the calculated full load approach minus the target approach. Approach is the difference between the
leaving condenser water temperature and the saturated condenser refrigerant temperature. It is a measure
of the heat transfer efficiency between the condenser water and the condenser refrigerant.
As condenser tubes foul or division plate gaskets leak or tubes get blocked etc, the approach temperatures will
increase. The program takes the actual approach temperature, factors it up to a full load approach by taking into
account the % load, and then subtracts the target approach or what the approach should be with clean tubes at
full load. The result is the Excess Approach. Each 1F of excess approach reduces efficiency by approximately
2%.
Pressure
Entering condenser water and leaving condenser water pressure?
Non Condensable
In low pressure refrigerant chillers (R-11, R-123) air can leak into the chiller and if the purge does not remove the
air or non-condensable it will accumulate in the condenser adding to the condenser pressure. Non-Cond is a
measure of the amount of air in PSI added to the condenser. 1 PSI of air reduces the efficiency by approximately
5%.
If condenser approach is 4 or more and the condensing water delta t is low, it's an indication of non-
condensables in the condenser, insulating the tubes and reducing heat rejection to the water.
Pressure drop
EVAPORATOR SIDE
Inlet Temp (Entering into the Evaporator from load Chilled Water)
Excess Approach
Evaporator approach is the difference between evaporating temperature measured at the well(?) in the
evaporator, and leaving chilled water temperature.
This is the calculated full load approach minus the target approach. Approach is the difference between the leaving
evaporator water temperature and the saturated evaporator refrigerant temperature (suction line temp?). It is a measure
of the heat transfer efficiency between the evaporator water and the evaporator refrigerant. If refrigerant is leaking from the
chiller or evaporator tubes foul or division plate gaskets leak or tubes get blocked etc the approach temperatures will increase.
The program takes the actual approach temperature factors it up to a full load approach by taking into account the % load and
then subtracts the target approach or what the approach should be with clean tubes at full load. The result is the Excess
Approach. Each 1F of excess approach reduces efficiency by approximately 2%.
Pressure Drop
"Water cooled chiller" means that the refrigerant in the condenser releases heat to water instead of air.
When this difference, which is called lift, exceeds design conditions, refrigerant flow will reverse through the
impellers, which causes the squeal, and can lead to other problems.
Surging can be caused by non-condensables, fouled condenser tubes, low condenser water flow, high entering
condensing water temperature, and low refrigerant charge.
Surging can damage the thrust bearings and impeller, so if you hear your centrifugal water cooled chiller surging,
find and correct the problem immediately.
Cooling Towers
Look for the temperature of the water entering the cooling tower to drop about 10F as it passes through
the cooling tower.
Cooling tower approach: is the difference between the web bulb temp of the air entering the cooling
tower, and the temperature of the cooled water leaving the cooling tower. Cooling tower approach is a
significant indication of the efficiency of the water to air heat transfer taking place in the cooling tower.
In geographical locations where 78F web bulb temp would be considered an average outdoor ambient,
look for the cooling tower approach to be 5 to 7 F. (7 would be considered optimum).