I I
Conference reports
Comptes-rendus de conferences
Report of a seminar held at the
ASHRAE annual meeting
Detroit, M i c h i g a n , U S A , 24 J u n e 1979
The influence of design parameters on centrifugal chiller
performance
Influence des parametres de
conception sur les performances
d'un refroidisseur centrifuge
On r#sume les interventions de
quatre conf#renciers qui ont
part/c/p6 ~ un seminaire sur /e
th#me ci-dessus. C. Will/am A/oi
de la soci#t# Carrier Air
Conditioning expose en particulier
/'influence des temp#ratures
extr#mes dans le condenseur et
I'#vaporateur et /es effets de
I'encrassement. Le m#me doma/ne
est #tudi# par Keith E. Starner de
York D/vision of Borg- Warner
Corporation mais i/insiste sur
I'uti/isation des ai/ettes et des
dispos/tifs augmentant /a
turbulence des flu/des pour
am#/iorer le transport de chaleur.
Thomas E. Watson de la soci#t#
Westinghouse Electric rappelle les
caract#ristiques des compresseurs
en pr#cisant /eur me/lleure uti//stion
en fonction des t#ches
accomplir. Le dernier orateur,
Lewis R. Smith, /ngenieur Conseil,
traite aussi du rendement des
compresseurs et sugg#re
d'#conomiser de I'#nergie en
utilisant diff#rents frigor/g#nes en
6t# et en hirer.
The contributions of four
panelists to a seminar on this
theme are summarised. C.
William Aloi (Carrier Air
Conditioning Company)
discussed particularly the
influence of temperature heads
in the condenser and
evaporator and the effects of
fouling. The same general area
was tackled by Keith E. Starner
(Borg-Warner Corporation) but
Volume 2 Number 6 November 1979
he discussed the use of finning
and turbulators to increase heat
transfer. Thomas E. Watson
(Westinghouse Electric
Corporation) reviewed
compressor characteristics, and
how best to match them to
various duties. The final
speaker, Lewis R. Smith,
Consultant, also discussed
compressor performance and
suggested that power could be
saved by using different
refrigerants in the summer and
winter.
Manufacturers of centrifugal
chillers in the United States are
being challenged by consultants
and users to meet increasingly
demanding energy conservation
goals. In some instances,
unrealistic targets and criteria have
been set, apparently due to the
lack of understanding of physical
restraints and/or performance
producing principles. This seminar
was designed to serve as a tutorial
regarding these matters.
The first speaker was C. William
Aloi (Carrier Air Conditioning
Company). In thinking about
power reduction, remember that
power varies directly with
polytropic head (a function of the
difference between the evaporating
and condensing temperatures) and
refrigerant weight flow (a function
of the required cooling duty).
Power also varies inversely with
compressor efficiency. Weight
flow and efficiency vary only
0140-7007/79/060245-04 $02.00
© 1979 IPC Business Press Ltd. and IIR.
slightly with evaporating and
condensing conditions.
If entering condenser water goes
from 30 to 35°C, power
consumption is up 23% (head
14%, weight flow 5%, efficiency
3%). Similarly, if leaving chilled
water is taken from 6.7 to 4.4°C,
power is up 10%, while raising it
from 6.7 to 10°C decreases
consumption by 14%.
In another example, raising the
fouling factor from
8.55 x 10 -5 m2kW -1 in both
vessels to 1.71 x 10 -4 m 2 kW -1 in
the cooler and
3.42 x 10 -4 m 2 kW -1 in the
condenser increases power
consumption by 35% (head 24%,
efficiency 6%, weight flow 2%).
The power consumption increase
with 90/10 Cu Ni tubes (frequently
associated with heavy fouling) vs.
copper is 10% (head 7%,
efficiency 2%, weight flow 1%).
Restricting the water temperature
rise through the cooler to4.5
compared to 13°C increases
energy consumption by 15%,
including pumping power. The
opposite is true with the
condenser. For a rise of 8
compared to 3°C, the total power
requirement is up 9%, in spite of a
sizeable reduction in pumping
power.
It also should be realized that a
38% increase in heat transfer
surface reduces power
consumption by less than 9%,
although it sharply increases the
cost and size of the chiller.
Allowing refrigerant to leak out or
non-condensibles to leak in
reduces the effective heat transfer
surface, which increases power
consumption.
The next speaker was.Keith E.
Starner (Borg-Warner
Corporation). The fouling factor's
influence on condenser design is
such that each fouling factor transfer surface. There is one refrigerant side augmentation in
assumption requires a new set of combination which will minimize the form of split fins or spines on
design parameters to meet the total surface required. the tubing exterior, improved liquid
permissible water temperature rises drain control, gas velocity control,
and pressure drops with stated At a given design point it is found and control of non-condensible
differences between leaving water that the required condenser heat gases (first paper from ASHRAE
and condensing and evaporating transfer surface, with plain bore, research project is now being
temperatures. The increase in 26 fpi (fins/inch) tubing, increases reviewed).
fouling factor lowers design water 38% when the design fouling In the evaporator, the use of
velocity and increases the required factor goes from 8.55 x 10 -s m 2
turbulators can cut the surface
heat transfer surface and length of kW -~ to 1.71 x 10 -4 m 2 kW -1.
required by 28%, but going to
water travel. The control of fouling 4.275 x 10 -5 m 2 kW -1 calls for
in service only is of benefit relative The addition of turbulators
57% additional surface, although
to first cost, if it results in a lower (twisted tapes or springs) reduces
still 20% below plain bore.
design fouling factor. Recent the surface required at
Doubling internal surface area does
AS H RAE research indicates that 8.55 x t0 ~s m 2 kW -~ by 10%, but
not give further improvement at
for certain waters the fouling going to 1.71 x 10 -4 m = kW -~ now
clean tube condition, because
factor stays below requires a 42% increase in surface.
there is no fouling advantage vs.
4.275 x 10-4m2kW-lup to 60°C If the inside area is doubled by
turbulators, but drops increased
surface temperature, unless using internal fins, the heat
surface requirement at
suspended solids are present. transfer surface required at 8.55 x 4.275 x 10 -5 m 2 kW -1 to 29%
10 -S m 2 kW -~ is 29% less than
(34% below plain bore).
A fixed compressor head/kW per with plain bore tubing, and at
unit of refrigeration point can be 1.71 x 10 -4 m 2 kW -1 is still 10%
A waterside augmentation
achieved through many less. technique is more effective when
combinations of evaporating and combined with refrigerant side
condensing temperatures, each Further condensing surface augmentation, than when it is
with a different amount of heat reduction can be achieved by used alone. With outside
augmentation, such as increased
nucleation sites, and doubled
waterside area, it is possible at
4.275 x 10 -s m 2 kW -1 fouling
factor to cut the evaporator
surface area requirement by 58%
compared to standard 26 fpi
tubing. This percentage
effectiveness increases as the
clean tube condition is
approached.

The third speaker was Thomas E.

Watson (Westinghouse Electric
Corporation). The design and
selection of the compressor for a
03
given duty involves many trade-
offs. The goal is to get the lowest
energy consumption per unit of
regrigeration. This requires good
efficiency over a wide range for
the required head. For a given
compressor design the efficiency
usually drops off as the speed is
increased. While the refrigerant
flow, or units of refrigeration, is
Suction vapour flow directly proportional to the speed,
Efficiency ronges System specific work (he~l) the head capability is proportional
A - Very good X - Heat recovery to the square of the speed.
B - Good Y - Cooling hot doy
C - Feir Z - Cooling cool doy
D - Poor In choosing a refrigerant, one with
E - Bad
a low isentropic head is desirable,
because it allows lower impeller tip
speeds. A refrigerant with a high
Fig. 1 C o m p r e s s o r p e r f o r m a n c e at c o n s t a n t speed w i t h various v a n e settings
acoustic velocity, in relation to the
Fig. I P e r f o r m a n c e d ' u n c o m p r e s s e u r a vitesse constante avec differentes dispositions tip speed, is desirable, because it
d "a u bes results in a higher efficiency. A

International Journal of Refrigeration

reasonably low volume of varies with its specific design and with the isentropic efficiencies
refrigerant flow per unit of with the volume of suction vapour form a compressor map. Five areas
refrigeration is desirable, because it flow. The specific work of efficiency, identified by shading
limits the size of the compressor. isentropically required is directly and by letters A through E, are
Good heat transfer properties are related to the temperature lift, i.e. indicated. Also shown are three
desirable, because they reduce the condensing temperature minus system requirement curves marked
actual head requirements. Finally, evaporating temperature, and X, Y and Z. Curve Y may be
it is desirable that the refrigerant varies with the refrigerant used. considered as the design
have a high ideal co-efficient of requirements for operation at
performance. For a specific compressor design operating conditions for
operating at a fixed speed and cooling. The unit may also be
It is desirable to keep condensing using a given refrigerant, a single operated for heat recovery, curve
pressures (temperatures of water curve will represent approximately X, where water for heating is
and refrigerant) low and the temperature lift for a range of desired at a higher temperature
evaporating pressures capacities when the specific work than normal cooling tower water
(temperatures of refrigerant and is plotted against the suction temperatures. The unit will also
chilled liquid) high, because: vapour volume flow. When operate with condenser cooling
less compressor energy rise per capacity controls, including water temperatures considerably
unit of mass - lower head; more prerotational inlet vanes or variable lower than design operating
refrigeration effect per unit of width parallel wall diffusers are conditions. Such operation is
mass - lower flow; lower energy used, a series of curves for the indicated by curve Z. Note that
consumption, because power is various control settings will result. only curve Y shows operation in
the product of head and flow. Such a set of curves is illustrated the very highest efficiency range
in Fig. 1. These curves together and that curve Z shows
In selecting components, do not
oversize the compressor. A
properly sized compressor gives
the widest possible range and the
best overall efficiency. Select heat
exchangers which give high
evaporating pressures and low
condensing pressures. The
condensers should be selected for
the lowest practical entering water
temperature. If tower by-pass is
required, control should be from
the condensing pressure, not the
water temperature.
In most applications, use multiple
chillers. For widest ranges of load
they should be in series. Thermal
storage should be used in both
heat recovery and straight cooling
applications, both to reduce
demand charges and take
advanntage of off-peak rates.
Specify as low a fouling factor as
is practical and keep the tubes
clean. In all applications where
close humidity contol is not
required, use leaving chilled liquid
reset to allow that temperature to
rise as the load drops off. Careful
cooling tower sizing, good water
treatment, and good tower Suction vapour flow
maintenance will reduce both the
compressor head and the energy Efficiency ranges System specific work (head}
consumption. A- Very good X Heat recovery
B- Good Y Cooling hot day
C- Fair Z Cooling cool day
D- Poor
The final speaker was Lewis R. E- Bad
Smith (Consultant). As you have
heard, the specific work or head
developed by a centrifugal Fig. 2 Compressor performance at various speeds
compressor is a function of the tip
speed of its impeller squared and Fig. 2 Performance d'un compresseur a differentes vitesses

Volume 2 Number 6 November 1979 247

Power
supply
3 phase
Converter A
Conve~rtar, B
Stator A
. . . . i ~
Rotor A
Motor load
Fig. 3 Brushless synchronous motor drive suitable for hermetic systems
Fig. 3 Moteur synchrone sans balais adapte aux systemes hermeuques
consistently lower efficiencies than
either curve X or curve Y. Of
particular interest, it is seen that at
reduced capacities, the efficiencies
generally become poorer.
To improve performance at heat
recovery operating conditions, as
illustrated by curve X, it is
proposed that different refrigerants
be used for summer and for winter
operation with perhaps the
capacities for winter operation
reduced. For example, in summer
use refrigerants R12 and R l l and
in winter use refrigerants Rl14 and
R 113 respectively,
The cycle efficiencies of certain
refrigerants are poor, particularly
Rl14. Rl14 cycle efficiency may
be improved by the use of a
special heat exchanger installed in
the cooler (evaporator) above the
tube bundle. This heat exchanger
248
i' On-off control I
(I converter A I
:+) [ rectifier_rC It
L I
i'm - - " 1
On-off control I
i static switches J
[SI and $2 l
i _#
iJ Voltage I Rectifier C -
I sensor
[vs
I
jI
CcmmOn shaft t "--~ ~ J ~
Rectifier D
may also function as an eliminator
by bending the fins, if it is of plate
fin and tube type.
One method of reducing power
requirements at reduced capacity
is to use mutliple chillers on an
installation. A system using three
chillers can divide the load at
reduced capacity several different
ways at each part load condition.
It is suggestged that micro-
computors, micro-processors or
programmed controllers be used to
divide the load between the units
to minimize the total power
requirement at each load level.
Fig. 2 is a compressor performance
map where variable speed is used.
Higher efficiencies at lower specific
head requirements can be obtained
by this method of capacity control.
To obtain variable speed with
TransformerTij-~• _T,
i1'Static
~I switch
$2
i
Phase i ~Phase 2
T/
it,, ooooo
3 I
Stator B
Transformer
phases (secondaries)
Rotor B J
electric motor drive, a synchronous
motor can be used with a
polyphase rectifier and inverter,
both using silicon controlled
rectifiers, producing a variable
frequency motor power supply.
The synchronous motor reduces
the need for an expensive variable
frequency 'tank circuit'. The use of
a higher output frequency (when
loaded) can eliminate the need for
speed increasing gears to drive the
compressor at higher speeds than
can be obtained with two pole
motors operating on commercial
frequencies.
Fig. 3 indicates one brushless
synchronous motor drive with
rectifier, inverter and a method of
starting, which could be used in
hermetic systems.
A. B. Medbery (Fedders
Corporation)
-l~ernatienat. Journe! of. Refrigerat4on