ICE 407 CONTROL AND OPTIMIZATION OF UNIT

OPERATIONS

GROUP 2
Objectives
● Learn about the chiller process and its basic
controls

● Types of chillers and its refrigeration system

● Methods of chiller optimization

1
General Description /
Working Principle

3
 INTRODUCTION
● What is a Chiller?
○ A cooling water circulation device. It

is a general term for a device that

controls the temperature by
circulating a liquid

○ A chiller can supply chilled water

continuously while circulating water

in a cooling device.
INTRODUCTION
● What is a Chiller?
○ Refrigeration machine that produces chilled water, to cool inside air for air
conditioning system
○ Chillers are a key component of air conditioning systems for large
buildings. They produce cold water to remove heat from the air in the
building. They also provide cooling for process loads such as file-server
rooms and large medical imaging equipment. As with other types of air
conditioning systems, most chillers extract heat from water by
mechanically compressing a refrigerant.
INTRODUCTION
● An industrial chiller is a refrigeration system used to lower the temperature of
machinery, industrial spaces, and process fluids by removing heat from the
system and transferring it elsewhere.

Why Use a Chiller?

● Industrial chiller systems are beneficial for applications where strict operational
temperatures are required. When integrated with heat-sensitive processes,
chillers will prevent thermal damage to process equipment and ensure no
alterations to the final products from exposure to unsuitable temperatures.
Working Principles
Industrial chillers work based on the following principles of operation;

1. Phase Change- A liquid coolant undergoes a phase change into a gas

when heated, and when the gaseous coolant is supercooled, it
condenses back into a liquid.

2. Heat Flow- Heat energy always flows from an area of high

concentration to an area of lower concentration.

3. Boiling Point- Reducing the pressure over a liquid decreases its boiling
point and increasing the pressure increases its boiling point.
How Does a Chiller Work?
An industrial chiller system is driven by one of two operational principles:

1. Heat absorption. chillers integrate heat exchangers that pull heat away from any
associated processes and dissipate them exteriorly.

2. Vapor compression. chillers achieve a cooling effect by circulating coolant in pipes

through the processes requiring cooling. This will pull heat from any associated
processes into the coolant, which is then circulated to a refrigerant system that cools the
chiller fluid and prepares it for a new cycle of process cooling.
9
2
Basic Parts /
Components

10
1. Evaporator
○ In the evaporator, the refrigerant

returns to being a gas, becomes very

cold, and absorbs heat. It is in the
evaporator where the refrigerant
and fluid interact and where heat is
removed from the fluid to be
transferred to the refrigerant. Three
common types of evaporators are
copper coil, shell and tube, and
plate.
● Evaporator on an air cooled chiller ● Evaporator on a water cooled chiller
2. Compressor
○ The compressor takes low-
pressure and low-temperature
refrigerant and compresses it
until it becomes a high-pressure
and high-temperature gas.
Three types of compressors are
centrifugal, turbocor, and screw.
● Centrifugal type compressor ● Screw type compressor
● Reciprocating type compressor ● Scroll type compressor
3. Condensers
○ The compressed gas flows
through coils in the condenser,
where air or water moves over the
coils to remove heat from the
refrigerant. Once the refrigerant
loses its heat, it condenses into a
liquid.
● Water cooled chiller condenser ● Air cooled chiller condenser
4. Expansion valve
○ The expansion valve, which
may also be known as a
thermostatic or electronic
expansion valve, controls the
amount of refrigerant that
passes between the condenser
and evaporator and changes
the flow based on the cooling
load..
● Electronic expansion valve ● Pilot operated thermal expansion valve
● Thermal expansion valve
5. Power unit: The power unit is

either mounted directly to the chiller or

it can be seperated and mounted to the
wall of the plant room with power
cables running between them. The
purpose of the power unit is to control
the flow of electrical power to the
chiller.
● Electrical power unit
6. Controls: The controls unit is

typically mounted on the chiller. It’s

purpose is to monitor the various
aspects of the chillers performance
and control these by making
adjustments.

● Chiller controls unit

7. Water boxes: Water boxes are
mounted to the evaporators and also
the condensers of water cooled ● Chiller water box, open ended
chillers. The purpose of the water
box is to direct flow as well as as to
segregate the entrance and exit.

● Chiller water box, closed end

24
3
Different Types

25
2 Types of chillers based on
refrigeration cycle:
○ Vapour compression chiller – Vapor
compression chillers use a mechanical
compressor powered by electricity,
steam, or gas turbines. They produce
cooling using the “vapor compression”
refrigeration cycle (similar to a home air
conditioning unit).
2 Types of chillers based on
refrigeration cycle:
○ Absorption refrigeration chiller –

In an absorption chiller, the

generator uses a high-temperature
energy source, usually steam or hot
water, which flows through the
tubes and boils off the refrigerant
into vapor. The vapor moves to the
condenser and the concentrated
solution returns to the absorber.
Refrigeration cycle –
vapour compression cycle
Absorption refrigeration cycle
Comparison of vapour compression and
absorption chillers
Vapour Compression Chiller Absorption Water Chiller
Use a Compressor to move refrigerant around Use heat to drive the refrigeration cycle. Energy
the system. Energy source for the compressor is source are steam, hot water or burning of oil or
an electric motor natural gas
Vary by type of compressor such as Use of absorption refrigeration cycle
reciprocating, scroll, screw, centrifugal.
Lower initial cost Higher initial cost due to additional cost of heat
transfer tubes & absorbent
In emergency situation, continuous electricity Minimal electricity needed for generator during
required for electricity-driven chillers. emergency situations
Not applicable Waste heat recovery -Wasted energy can be
used to fuel an absorption chiller
Not applicable Application in Cogeneration system
2 Types of chillers based on heat rejection:
● Air-cooled chiller – An industrial air-
cooled chiller is a refrigeration system
that cools fluids and works in tandem
with a facility's air handler system. A
chiller has four main parts: an
evaporator, compressor, condenser, and
expansion valve. An air-cooled chiller
works by absorbing the heat from
processed water.
2 Types of chillers based on heat rejection:

● Water cooled chiller – A water-cooled

chiller is one of the types of chillers
that removes heat from it to cool the
water used in projects or industrial or
domestic structures and re-enters the
water into the operation cycle. In fact,
chillers transfer heat from a space that
needs temperature control and
transfer it to another space.
Chillers By the Type of Compressor
● Screw Chillers: They come in
both water-cooled and air-
cooled types. They use the force
and movement of one or
sometimes two screws. The
screws compress the main
refrigerant inside. They come
in large capacities of 400+ tons.
Chillers By the Type of Compressor
● Scroll Chiller: These models use
a set of interlocking scrolls.
These scrolls are set inside the
compressor and pressurize the
refrigerant. They can be air-
cooled or water-cooled.
However, they have smaller
capacities than screw chillers.
4
Applications

38
Industrial:
● Industrial operations create
heat through the use of friction,
high-powered equipment, and
furnaces or ovens. To increase
the lifespan of heavy-duty
equipment, a chiller circulates
cooled liquid through
equipment in order to maintain
efficiency and productivity.
Work Environment:
● On the manufacturing floor,
temperatures can rise rapidly when
equipment is in full operation,
creating an unsuitable working
environment. To protect employee
safety, industrial operations use
chillers to keep working conditions
at the proper temperature.
Plastic Manufacturing:
● Plastic is a very temperature-
sensitive material that can be
damaged by being too hot and
needs to be properly cooled. The
correct cooling temperature of a
mold determines the quality of
the final product. Chillers are
used to provide a cooling bath
that maintains the quality of
plastic products.
Metal Plating:
● The metal plating industry uses
high-temperature electroplating
or electroless in the plating
process. The bonding of a
coating on metal produces
extreme temperatures requiring
heavy-duty chillers to remove
the heat from the plated metal.
Food Production:
● The food industry has strict
regulations regarding the
storage temperatures of
ingredients and products.
Chillers for the food
industry operate much like a
traditional cooling system
for food.
Power Generation:

● Power plants generate a great

deal of heat to produce
electrical power. Chillers cool
components and processes by
absorbing the heat they
generate.
Medical Industry:
● Medical equipment requires precise
temperature control. MRI scanners,
CT scanners, and LINAC machines
produce heat that has to be removed
and controlled. Chillers provide a
constant source of cool temperatures
to ensure the efficient operation of
critical equipment.
Pharmaceutical:
● Medicines require the use of chilled
water in the manufacturing process
and need precise temperature control.
Chillers have the accuracy and
precision for the chilling process and
can be central process chillers or
compact process chillers. The four
basic types of pharmaceutical chillers
are reciprocating, screw-driven,
centrifugal, and absorption.
Laser:
● Laser chillers are designed to cool
laser equipment or laser processes.
For a laser to perform at peak
efficiency, it has to maintain an
optimal wavelength. CO2, high-power
exciters, and ion lasers have to be
precise and accurate. They depend on a
chiller water cooling system.
5 Problems or Sample
Accident involving
the operation of chiller

48
Common Problems That Affect Chillers
1. Corrosion: Chillers use metal tubes
(usually made of copper or carbon steel)
to transfer water between the chiller and
the climate-controlled space. The
simple presence of oxygen in water can
cause corrosion. It can cause leaks that
will damage the chiller, reduce its
efficiency, and possibly damage the area
surrounding the chiller.
2. Poor Maintenance: If proper maintenance aren’t taken, the chiller can
corrode, clog, lose efficiency, or experience a number of other issues. An air-
cooled chiller’s condenser can be blocked by debris or become caked in dirt,
which also lowers efficiency.

3. Electrical Issues: If there is a grounding issue or a power supply failure,

the chiller may detect this and shut itself off. Overloading the chiller can cause
it to overheat, which will likely result in failure. Wires and cables can become
loose or damaged after maintenance or due to negligence, which can result in
chiller malfunctions.
5. Improper Operation
The manufacturer’s guidelines should always be followed. Forcing the

equipment to perform something it was not intended for and ignoring the

consequences of a certain action will make the chiller more prone to a variety of

complications.

6. Oversizing/Under-sizing

Under-sizing can result in insufficient airflow, which means that the

chiller will not be able to achieve its full cooling capacity. Oversizing might

restrict the low-load operations, which will result in higher operating costs due

to excessive cycling.
7. Insufficient Cooling Capacity: One of the most common issues is when the
chiller fails to provide the required cooling capacity. This can be due to factors
such as incorrect sizing, scaling or fouling of heat exchangers, refrigerant leaks,
or a malfunctioning compressor.

8. Refrigerant Leaks: Chillers rely on refrigerants to absorb and dissipate heat.

Refrigerant leaks can occur due to worn-out gaskets, corroded pipes, or faulty
connections. These leaks not only reduce the cooling efficiency but can also have
environmental implications due to the release of harmful substances.
9. Condenser Issues: The condenser in a chiller is responsible for releasing
heat from the refrigerant. Problems with the condenser, such as fouling,
airflow restrictions, or mechanical failures, can lead to high discharge
pressures, reduced cooling efficiency, and compressor overheating.

10. Compressor Malfunctions: The compressor is the heart of a chiller system,

and any malfunction can significantly impact its performance. Common
compressor issues include motor failures, refrigerant leakage, oil
contamination, valve problems, or excessive vibration.
Accident involving Preventive Measures
the operation of chiller
● Adequate Training
● Electrical Accidents
● Proper Ventilation
● Mechanical Failures
● Regular Maintenance
● High-Pressure Hazards
● Safety Devices and Alarms
● Thermal Burns
● Personal Protective Equipment (PPE)
● Slips, Trips, and Falls
● Clear Signage and Safety Procedure
● Emergency Preparedness
6
Chiller
Optimization

55
by Allyne L. Vergara
Minimizing the Operating Cost
● The yearly cost of operating the total cooling system can
typically be broken down as follows:

M1 (Fans) 10%
M2 (CT Pumps) 15%
M3 (Compressors) 60%
M4 (CH Pumps) 15%
TOTAL: 100%
1. Minimizing the temperature difference across the chiller
by minimizing the cooling tower water temperature and
maximizing the chilled water temperature

● Minimizing the temperature of the cooling tower water is one of the most
effective contributors to chiller optimization. Conventional control systems in
the past produced constant cooling tower temperatures of 75°F (23.9°C) or
higher.

● It is an enemy of efficiency and therefore of optimization to maintain a utility

at a constant value. Each 10°F (5.6°C) reduction in the cooling tower water
temperature will reduce the yearly operating cost of the compressor by
approximately 15%.
2. Minimizing pumping costs by transporting only as much
water as is required to meet the load and by using variable-
speed pumping

● When the chilled water pump station consists of several pumps, only
one of which is variable-speed, additional pump increments are started
when PSH-1 in Figure 8.13g signals that the pump speed controller
setpoint is at its maximum.

● When the load is dropping, the excess pump increments are stopped on
the basis of flow, detected by FSL-2. In order to eliminate cycling, the
excess pump increment is turned off only when the actual total flow has
dropped to less than 90% of the capacity of the remaining pumps.
3. Minimizing cooling tower operating costs
by approach optimization
● Minimizing Tctws
○ As shown in Figure 8.13h, an optimization control loop is required in order to

maintain the cooling tower water supply continuously at an economical

minimum temperature. This minimum temperature is a function of the wet-
bulb temperature of the atmospheric air. The cooling tower cannot generate a
water temperature that is as low as the ambient wet bulb, but can approach it.
The temperature difference between Tctws and Twb is called the approach, as
was shown in Figure 8.13d.
4. Operating chillers at the load at which their efficiency is
the highest and by meeting partial loads with parttime
operation at maximum efficiency

● When demand is low, operating costs can be reduced by

operating the chillers part of the time at peak efficiency rather
than continuously at partial loading. Efficiency tends to be lower
at partial loads because of losses caused by friction drop across
suction dampers, pre-rotation vanes, or steam governors.
5. Making coolant when least expensive, if night
storage is available

● The total cost of cooling can also be reduced by making the coolant when

it is less expensive to make it and placing it in storage until it is needed.

When a variety of equipment is available to meet the cooling load of the
plant, the total cost of operation can also be minimized by always using
the most efficient combination of equipment.
6. Making load allocation on the basis of
maximizing operating efficiency

● Optimized Storage

○ If storage tanks are available, it is cost-effective to generate the

daily brine or chilled water needs of the plant at night, when it is the
least expensive to do so, because ambient temperatures are low and
night-time electricity is less expensive in some areas.
● If the chiller needs to be off for a longer period than the thermal
capacity of the distribution system can provide, three options are
available:

1. Storage tanks can be added to increase the water volume.

2. A second chiller can be started (not the one that was just
stopped).
3. The load can be distributed among several chillers of
different sizes, keeping some in continuous operation
while cycling others.
● Optimized Load Allocation

○ In simple load allocation systems, only the starting and stopping of the
chillers is optimized. In such systems, when the load is increasing, the
most efficient idle chiller is started, and when the load is dropping, the
least efficient one is stopped.

○ In more sophisticated systems, the load distribution between operating

chillers is also optimized. In such systems, the realtime efficiency of
each chiller is calculated. This determines the incremental cost for the
next load change for each chiller.
7. Initiating maintenance if a drop in
efficiency is detected
● Minimum Maintenance
○ In addition to energy optimization, the system is also optimized from a

maintenance point of view by keeping all compressor running times

approximately the same. This is accomplished by the use of the horsepower
table in the top left of Figure 8.13x.

○ Note: the total energy savings obtained by this control system amounts to about

20%.
● Optimized Controls
○ One of the goals of optimization is to maximize the rangeability of the
multistage refrigeration units. This rangeability will be maximum when
the two stages approach their surge limits at the same time. This can be
guaranteed by redistributing the load between the stages in such a
manner that they maintain equal distance from their respective surge
lines as the load drops.
The goals of chiller optimization include:
● Minimizing the temperature difference across the chiller by minimizing the cooling
tower water temperature and maximizing the chilled water temperature

● Minimizing pumping costs by transporting only as much water as is required to meet

the load and by using variable-speed pumping

● Minimizing cooling tower operating costs by approach optimizationOperating chillers

at the load at which their efficiency is the highest and by meeting partial loads with
parttime operation at maximum efficiency

● Making coolant when least expensive, if night storage is available

● Making load allocation on the basis of maximizing operating efficiency

● Initiating maintenance if a drop in efficiency is detected

REFERENCES:
● Air Cooled Chillers: Principle, Types, Applications, and Benefits. (n.d.). Www.iqsdirectory.com.
https://www.iqsdirectory.com/articles/chiller/air-cooled-chillers.html

● Evans, P. (2017, May 15). Chillers - Main components. The Engineering Mindset.
https://theengineeringmindset.com/chillers-main-components/

● How Does a Chiller Work? | Industrial Chiller Working Principles. (n.d.). Waterchillers.com.
https://waterchillers.com/blog/post/how-does-a-chiller-work

● Industrial chiller units application in Bangladesh | Earnest. (2020, May 30). https://earnest.com.bd/about-
industrial-chillers-application/

● The Basics of Chillers. (n.d.). HVAC Investigators. https://www.hvacinvestigators.com/webinars/the-

basics-of-chillers-how-they-work-where-theyre-used-and-common-problems/
THANK YOU GROUP 2
BANZON, JHOVAN M.
BAUTISTA, ALAN KING E.
BUENO, MYLENE F.
CALLANGA, RICHARD M.
CASAS, MATEUS N.
CASTILLO, MARK JOSHUA M.
CLAUS, JOHN HENRY F.
DALISAY, MARY LYKA D.

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