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Air Cooled Chiller - How they work, working principle, Chiller basics

WEBVTT
Kind: captions
Language: en

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Hi there guys, Paul here from
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TheEngineeringMindset.com.
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In this video we're gonna be
looking at air cooled chillers
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to work out and learn how they work.
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Now air cooled chillers are
very common especially in newer,
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smaller, medium, high rise
buildings such as office blocks
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and exhibition halls, you
know, these kinds of buildings.
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Now air cooled chillers
do not use cooling towers,
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they dump their heat, the
unwanted heat straight into
00:00:31.650 --> 00:00:33.683
the ambient atmospheric air.
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They therefore need to
be placed outside too.
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You will usually find them
on the roof of a building
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or maybe on the ground floor, you know,
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around by the car parks,
something like this.
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But if you have a look on the roof,
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if you get up to somewhere
high, look across some buildings
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in a city you'll probably see
like there's an air cooled
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chiller here, some more here,
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there's some condensing units here,
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there's some more here.
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They're very common
across these kind of small
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to medium sized buildings
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and they're usually on the roof just
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because of the space requirements.
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So they're very popular
simply because they take up
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a lot less space compared
to a water cooled chiller.
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They also, they don't need
water to dissipate their heat,
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whereas obviously a water
cooled chiller would,
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it would dump its heat into
a secondary condense loop
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and push that up into the cooling towers,
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so you'd also lose water
from the system there.
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However, air cooled chillers
are less efficient compared
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to water cooled chillers
because they don't use
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the latent heat of evaporation.
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But anyway, let's jump straight in
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and just see how these things work.
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So first of all, we've got
the simplified 3D schematic
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of a typical air cooled chiller system.
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You can see we've got the
two air cooled chillers up
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on the roof and they've
both got small chiller pumps
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on their circulation pumps,
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so they'll return water
in and push that through
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the evaporator and then push
that cooler water back out into
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these headers, these will
run along and then enter into
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the main pumps over here.
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The main pumps will then push that water,
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usually one of them will run at a time,
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that might be duty standby.
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And that will then push
that chilled water around
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the building to where it's
needed often to the AHU,
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the fan coil units, et cetera, et cetera
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around the building.
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Once that has been used,
it will then return
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and would come out, so it probably go in
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at around six degrees Celsius,
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which is about 43 degrees Fahrenheit
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and it will then leave
here back into the return,
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at about 12 degrees Celsius
or 54 degrees Fahrenheit.
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Now all of this will then add up into,
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these are known as risers
and that water will then,
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are still called chilled water even though
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it's now a warmer, but it
will in return so this sort
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of return chilled water and
it will make its way back up,
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up to the top here where
it will then enter off into
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the chillers and repeat that cycle.
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So let's now have a look
around the chillers to see
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the main components and then
after that we're gonna have
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a look at a bit more detail
on how they actually work.
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So first of all, if we look
at the air cooled chiller from
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an isometric view, you'll
see that on the top is
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the condenser cooling fans.
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Now when these rotate, they
suck air in the ambient air from
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the outside and they pull
this in through these grills
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and through the these holes
and also for these wheels here,
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so they pull all this
air in and then they push
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that air out through the top.
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And as that air comes across there,
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it will take off some of the
heat away from these pipes
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and then push that out and
away into the ambient air,
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so that will take the heat
away from the refrigerant,
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and we'll look at that slightly later.
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But if you imagine, say
you've got a cup of hot tea,
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if you imagine this is
sealed there and it's hot,
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then you would blow across
the top of this to push some
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of that heat away and cool
it down so you can drink it
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and that's much like
what the fans are doing,
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they're just pushing that heat away.
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Although this would be a sealed unit
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with a hot refrigerant inside.
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But the real world fans
just look at something
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a little bit like this, just a
slow down animation I've done
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here so you can see that just
rotates a very small motor
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on them and there's a number
of these on the top there.
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So then if we just kind of
change the view there a bit.
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And the next part we'll look
at there is the compressor.
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So the compressor is
obviously the driving force
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of the refrigerant around the system.
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In this case I've just put
a screw compressor in here,
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it's usually a screw or a
scroll or reciprocating.
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So a real screw compressor
would look something like this,
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but if you wanna know a
bit more about compressors
00:04:45.980 --> 00:04:48.220
and how they work I'll highly
recommend you to check out one
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of our other videos,
chiller compressor type
00:04:50.530 --> 00:04:53.200
so I'll put a link up here as well,
00:04:53.200 --> 00:04:55.080
but if you ever hear them,
we'll just go through in a bit
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of detail on all the
different types of compressors
00:04:57.300 --> 00:04:59.483
and how they work very basically.
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But anyway, so the
compressor pushes and forces
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the refrigerant off through these tubes
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and off into the headers
here and off into towards
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the condenser, so these
are the condensers,
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we'll see that in just a minute,
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but the refrigerant will
leave here as a high pressure,
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high temperature, super heated vapor.
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And if we then change the
view of this one again,
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so then you can see,
obviously this part here
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is known as the condenser,
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so the hot refrigerant
is coming from there,
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from the compressor and
it will pass through
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the tubes within this condenser.
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And you'll see there's a number of loops,
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we'll have a look in detail
of how that works as well
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and shortly, but it'll pass through here
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and make its way out and
then into this header here.
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And by the time it leaves the condenser,
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the refrigerant will be a high pressure,
00:05:48.500 --> 00:05:51.350
medium temperature, saturated liquid.
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And obviously as we saw earlier,
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the condenser cooling fans
are going to be putting out,
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you can see all the way
through this one now.
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So these fans will be putting
air across these hot pipes
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and that will be sucking the air away
00:06:02.700 --> 00:06:06.163
and pushing that out into
the ambient atmosphere.
00:06:07.000 --> 00:06:10.113
So if we change the
view again on this one,
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then you can see on this end
all the refrigerant will then
00:06:15.880 --> 00:06:19.600
collect up after it's
cool down in the condenser
00:06:19.600 --> 00:06:21.830
and it will then flow into these headers
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and make its way down
into the filter dryer
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that will then pass through
there and make its way off
00:06:28.230 --> 00:06:31.030
and up into the expansion valve.
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So again, by the time the
refrigerant starts then makes its
00:06:33.980 --> 00:06:36.860
way to the expansion valve,
the refrigerant should now be
00:06:36.860 --> 00:06:40.990
a high pressure, medium
temperature saturated liquid.
00:06:40.990 --> 00:06:43.563
We just changed the view
on this one as well.
00:06:45.820 --> 00:06:48.270
And from this one we can see
that the refrigerant after it's
00:06:48.270 --> 00:06:51.140
passed through the filter dryer
and into the expansion valve
00:06:51.140 --> 00:06:54.970
is then gonna make its way
and pass into the evaporator.
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So this big tank at the
bottom underneath this stuff,
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this is the evaporator.
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So this is where the return chilled water,
00:07:04.180 --> 00:07:07.350
you remember this, this water
just here, the return water.
00:07:07.350 --> 00:07:09.805
So that's where that's
going to enter into it,
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pass through the evaporator
00:07:11.380 --> 00:07:13.513
and make its way back out much cooler.
00:07:14.940 --> 00:07:17.410
So we've got one entrance
which is coming in
00:07:17.410 --> 00:07:20.120
and that's coming from the
buildings and the AHU's
00:07:20.120 --> 00:07:22.900
and fan coil units it makes
its way through there.
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We'll have a look inside
this one shortly as well
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and that will then make
its way out back off around
00:07:28.220 --> 00:07:31.000
the building to the AHU
and the fan coil units
00:07:31.000 --> 00:07:32.373
to provide that cooling.
00:07:33.530 --> 00:07:36.830
& the water will usually flow
in, in the opposite direction
00:07:36.830 --> 00:07:40.240
to the flow of refrigerant
and that's where you get your
00:07:40.240 --> 00:07:43.140
maximum heat transfer and your LMTD
00:07:43.140 --> 00:07:45.143
or log mean temperature difference.
00:07:46.060 --> 00:07:49.720
So when the refrigerant has
now left the expansion valve,
00:07:49.720 --> 00:07:52.830
it will then be a low
pressure, low temperature,
00:07:52.830 --> 00:07:57.280
liquid vapor mixture it will
00:07:57.280 --> 00:07:59.310
and absorb all the unwanted heat
00:07:59.310 --> 00:08:01.060
that's come back from the building.
00:08:05.950 --> 00:08:09.370
Once a refrigerant has
passed through the evaporator
00:08:09.370 --> 00:08:12.660
and is making its way
back to the compressor
00:08:12.660 --> 00:08:16.040
to start the circuit again,
then the refrigerant will
00:08:16.040 --> 00:08:19.160
be leaving the evaporator
as a low pressure,
00:08:19.160 --> 00:08:22.580
low temperature saturated vapor.
00:08:22.580 --> 00:08:24.740
So that is the basic
cycle then passes around.
00:08:24.740 --> 00:08:26.580
Remember the refrigerant
never leaves the system
00:08:26.580 --> 00:08:28.597
is a closed system, it just
passes round and around
00:08:28.597 --> 00:08:31.850
and around around through
these main components.
00:08:31.850 --> 00:08:34.050
So let's have a look at
how each component works
00:08:34.050 --> 00:08:35.273
in a bit more detail.
00:08:36.700 --> 00:08:38.430
So we've got an animated version here
00:08:38.430 --> 00:08:40.620
so you can see inside the chiller,
00:08:40.620 --> 00:08:42.810
the air cooled chiller to see
what's happening in there.
00:08:42.810 --> 00:08:45.050
So first of all, we've got the compressor
00:08:45.050 --> 00:08:48.100
and again it's a screw type
that doesn't necessarily have
00:08:48.100 --> 00:08:49.740
to be in every case.
00:08:49.740 --> 00:08:52.200
Check out our other
videos to see about that.
00:08:52.200 --> 00:08:54.360
So the refrigerant is gonna
be pumped out of this is gonna
00:08:54.360 --> 00:08:56.060
be pushed out there by the compressor
00:08:56.060 --> 00:08:57.730
and that's gonna leave as a high pressure,
00:08:57.730 --> 00:09:00.350
high temperature, super heated vapor
00:09:00.350 --> 00:09:01.590
and that's gonna make its way
00:09:01.590 --> 00:09:03.873
to the headers of the condenser.
00:09:04.870 --> 00:09:06.980
Now just give you a real
world example here of some
00:09:06.980 --> 00:09:10.300
of the headers so this is
a distribution headers here
00:09:10.300 --> 00:09:12.220
pushing that through,
this one has got the flow
00:09:12.220 --> 00:09:15.060
and return so it goes
there and comes back,
00:09:15.060 --> 00:09:18.460
you can see it then runs
into the filter dryer there.
00:09:18.460 --> 00:09:21.710
But anyway, we'll have a
look at that in just a second
00:09:21.710 --> 00:09:23.060
so it's coming from the compressor
00:09:23.060 --> 00:09:26.010
and it's making its way through
these distribution channels
00:09:26.010 --> 00:09:29.210
and you can see teeing off there
and going through the coils
00:09:29.210 --> 00:09:32.950
within this condenser
to dissipate it's heat.
00:09:32.950 --> 00:09:34.720
And then we've got the
condenser cooling fan
00:09:34.720 --> 00:09:37.210
so these would be rotating
and that will be pulling
00:09:37.210 --> 00:09:40.970
the cooler ambient air across these coils
00:09:40.970 --> 00:09:43.330
remember here we've got the flow returning
00:09:43.330 --> 00:09:45.570
it makes its way all
the way around the loop,
00:09:45.570 --> 00:09:47.310
have a look at that as
well in just a second.
00:09:47.310 --> 00:09:50.740
So that's gonna pull the air
across that and extract all
00:09:50.740 --> 00:09:53.890
the heat away from the
surface of this pipe,
00:09:53.890 --> 00:09:55.420
these fins which are in between it,
00:09:55.420 --> 00:09:58.240
they're incredibly thin and
they're very easy to damage
00:09:58.240 --> 00:10:01.430
as well as to be careful if
you're working or touching these
00:10:01.430 --> 00:10:04.910
and these fins basically help
to transfer that heat away
00:10:04.910 --> 00:10:08.630
from the pipes and out into
the stream of the flow of air,
00:10:08.630 --> 00:10:11.910
so that increases the
heat transfer surface area
00:10:11.910 --> 00:10:15.370
and the effectiveness
of the heat exchanger.
00:10:15.370 --> 00:10:18.570
Now we can start to see some
of that refrigerant as it's
00:10:18.570 --> 00:10:20.710
coming in off this distribution header
00:10:20.710 --> 00:10:23.620
and passing through the coil
so you can see it's made
00:10:23.620 --> 00:10:25.750
its way around the first part there
00:10:25.750 --> 00:10:27.623
and it's already start to cool down,
00:10:28.640 --> 00:10:31.710
will then make its way into
the second part so this is
00:10:31.710 --> 00:10:36.520
a free pass condenser, four
pipe free pass condenser,
00:10:36.520 --> 00:10:39.340
one pass, two pass and
then the third pass back
00:10:39.340 --> 00:10:40.713
and in towards the exit.
00:10:41.870 --> 00:10:44.740
And then finally you
can see it's cooled all
00:10:44.740 --> 00:10:47.400
the way down and it's
made its way off into
00:10:47.400 --> 00:10:48.817
this collection headers, so by the time
00:10:48.817 --> 00:10:52.680
the refrigerant leaves the
condenser at these points here,
00:10:52.680 --> 00:10:54.380
that should all be a high pressure,
00:10:54.380 --> 00:10:57.193
00:10:58.600 --> 00:11:00.640
So that refrigerant will then
make its way through this
00:11:00.640 --> 00:11:04.270
collection header and down
towards the filter dryer.
00:11:04.270 --> 00:11:07.660
Now the filter dryer, all it's
gonna really do is it just
00:11:07.660 --> 00:11:09.058
absorbs any water to stop,
00:11:09.058 --> 00:11:11.570
the water would become like
an acid so it will stop
00:11:11.570 --> 00:11:14.277
that passing through and
it will also take some of,
00:11:14.277 --> 00:11:15.962
you know, just filter it a bit,
00:11:15.962 --> 00:11:19.280
get out oils and things like
this to stop it making its way
00:11:19.280 --> 00:11:22.190
off into the compressor really.
00:11:22.190 --> 00:11:24.140
So once it's passed through there it'll
00:11:24.140 --> 00:11:28.070
then make its way up
into the expansion valve.
00:11:28.070 --> 00:11:29.760
Now just to show you a real world example,
00:11:29.760 --> 00:11:33.080
we've got a filter dryer
here passing along and up
00:11:33.080 --> 00:11:35.410
and into an expansion valve just there.
00:11:35.410 --> 00:11:37.300
This is a thermal expansion valve.
00:11:37.300 --> 00:11:39.890
You can see it's got the
computer tube going off there
00:11:39.890 --> 00:11:43.870
to the other side of the
evaporator that's what controls it.
00:11:43.870 --> 00:11:46.700
If you want to learn more
about how the expansion valves
00:11:46.700 --> 00:11:49.860
work on chillers, I'd highly
encourage you to watch our
00:11:49.860 --> 00:11:52.250
video on chiller expansion valves,
00:11:52.250 --> 00:11:54.470
I'd also add a link up here as well,
00:11:54.470 --> 00:11:56.020
so you can have a look at that.
00:11:56.020 --> 00:11:58.190
But basically we just go
through different scenarios
00:11:58.190 --> 00:12:00.660
and how they work and the
different types of varieties
00:12:00.660 --> 00:12:03.293
that you'll find so have
a look at that video.
00:12:04.750 --> 00:12:08.300
refrigerant will then leave
00:12:08.300 --> 00:12:11.670
the expansion valve and that
will make its way then off into
00:12:11.670 --> 00:12:14.526
the evaporator and now the
refrigerant here as it leaves
00:12:14.526 --> 00:12:17.170
the expansion valve is
going to be a low pressure,
00:12:17.170 --> 00:12:20.390
low temperature, liquid vapor mixture.
00:12:20.390 --> 00:12:23.560
And that will then come
into the evaporator
00:12:23.560 --> 00:12:26.990
kind of spray into these,
these cold water box
00:12:26.990 --> 00:12:28.990
but there's a refrigerant inside it
00:12:30.260 --> 00:12:33.480
and the refrigerant will then split apart
00:12:33.480 --> 00:12:35.930
and enter it into these different tubes.
00:12:35.930 --> 00:12:38.850
Now this is known as a shell
and tube heat exchanger,
00:12:38.850 --> 00:12:41.650
so one fluid would be in the tubes
00:12:41.650 --> 00:12:43.940
and another fluid would be in the shell.
00:12:43.940 --> 00:12:46.300
So in this case, the
refrigerant is gonna be the one
00:12:46.300 --> 00:12:49.880
that passes through the shell,
this is slightly different
00:12:49.880 --> 00:12:52.030
to a water cooled chillers
where it would actually be
00:12:52.030 --> 00:12:54.610
the other way around but anyway, so yes,
00:12:54.610 --> 00:12:57.390
the refrigerant passes
through here and it will start
00:12:57.390 --> 00:13:00.150
to give up or absorb some
of the thermal energy
00:13:00.150 --> 00:13:01.220
that's coming in.
00:13:01.220 --> 00:13:03.410
We'll have a look at that
in just a second as well.
00:13:03.410 --> 00:13:06.961
So by the time the refrigerant
leaves the evaporator,
00:13:06.961 --> 00:13:10.170
at this point here and
it's about to go off into
00:13:10.170 --> 00:13:12.860
the compressor, that should
then be a low pressure,
00:13:12.860 --> 00:13:16.270
00:13:16.270 --> 00:13:19.630
Now if you remember, we
had the chilled water,
00:13:19.630 --> 00:13:22.500
the flow and also the return
coming into this evaporator
00:13:22.500 --> 00:13:24.520
so we'll have a look at that as well.
00:13:24.520 --> 00:13:28.770
So then passing through the
evaporator, we've then got
00:13:28.770 --> 00:13:31.610
the chilled water coming
in so it's passing in,
00:13:31.610 --> 00:13:33.627
it's coming in the return water there
00:13:33.627 --> 00:13:37.650
and then making its way through
and out around the building
00:13:37.650 --> 00:13:40.570
to provide that air conditioning
and it's absorbing all
00:13:40.570 --> 00:13:42.820
the heat from the unwanted
heat from the building
00:13:42.820 --> 00:13:44.780
and bringing that back to the evaporator,
00:13:44.780 --> 00:13:47.380
where it'll exchange the
heat with the refrigerant,
00:13:47.380 --> 00:13:49.800
so the refrigerant never
leaves these tubes,
00:13:49.800 --> 00:13:53.660
it's always contained within
them and the water then passes
00:13:53.660 --> 00:13:56.660
around on the outside of the tubes
00:13:56.660 --> 00:14:00.490
to absorb that thermal
energy and take it away.
00:14:00.490 --> 00:14:03.050
Also notice that there are
some restrictions within
00:14:03.050 --> 00:14:05.760
the heat exchanger, these
are known as baffles.
00:14:05.760 --> 00:14:08.720
And what happens is the
chilled water enters here
00:14:08.720 --> 00:14:12.120
and you'll get much greater
heat transfer if the flow
00:14:12.120 --> 00:14:15.750
of water is turbulent or
the fluid is turbulent,
00:14:15.750 --> 00:14:19.200
so you add these baffles in
and that will cause the water
00:14:19.200 --> 00:14:22.910
to change direction
sharply in the animation
00:14:22.910 --> 00:14:25.450
it's a bit smooth here, but
it should really be very
00:14:25.450 --> 00:14:28.790
turbulent in there passing
through and colliding
00:14:28.790 --> 00:14:32.500
and move across the surface of these tubes
00:14:32.500 --> 00:14:36.480
and taking more and more
of that thermal energy away
00:14:36.480 --> 00:14:40.280
so that it leaves as a very
cool liquid when it's going
00:14:40.280 --> 00:14:42.300
around the building again.
00:14:42.300 --> 00:14:44.760
So you can see it's, it's fairly similar
00:14:44.760 --> 00:14:47.560
to the water cooled chiller,
00:14:47.560 --> 00:14:50.610
this is a setup mostly for
a water cooled chiller here,
00:14:50.610 --> 00:14:52.700
where it's got a different
loop which goes off
00:14:52.700 --> 00:14:55.010
to a cooling tower and you've
got more pumps, et cetera.
00:14:55.010 --> 00:14:57.900
So you can see why the other
version is more popular,
00:14:57.900 --> 00:15:02.250
but the water cooled chiller
is much more efficient.
00:15:02.250 --> 00:15:05.270
Now, if you want to learn how
a water cooled chiller works
00:15:05.270 --> 00:15:07.410
then check out our video
here on chiller basics,
00:15:07.410 --> 00:15:09.230
how do they work?
00:15:09.230 --> 00:15:11.220
You're going to go into a
quite a bit of detail also,
00:15:11.220 --> 00:15:13.860
I'd highly recommend that you check out
00:15:13.860 --> 00:15:16.530
the second video here, the
part two of how they work
00:15:16.530 --> 00:15:18.963
when we go into it in much greater detail.
00:15:19.970 --> 00:15:21.510
But anyway, that is it for this video.
00:15:21.510 --> 00:15:22.850
Thank you very much for watching
00:15:22.850 --> 00:15:24.610
I hope this has helped you learn
00:15:24.610 --> 00:15:27.680
how air cooled chillers
work, at least the basics.
00:15:27.680 --> 00:15:28.770
If you have any questions,
00:15:28.770 --> 00:15:31.140
please leave them in the
comment section below.
00:15:31.140 --> 00:15:33.300
Also, don't forget to
like, subscribe and share
00:15:33.300 --> 00:15:36.160
and also check out our website
00:15:36.160 --> 00:15:38.393
Once again, thank you
very much for watching.

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