Condensers for water coolers. In this article, we are going to look at the condenser of a chiller. The condenser is located between the compressor and the expander. High pressure hot refrigerant vapor enters the condenser and liquid refrigerant leaves the condenser.
Scroll down for chiller condenser YouTube tutorial
The capacitor is usually not insulated. The heat inside the condenser is unwanted and will simply be vented to the atmosphere. So if you lose heat in the technical room, in most cases it does not matter. However, if the engine room is also cooled by refrigeration, it makes a lot of sense to insulate it and reject all the heat back into the building, but if the engine room is only cooled by outside air, then this is not the case. yes it counts.
What is the capacitor used for?
The condenser collects all the unwanted heat from the building and transfers it to the condenser water loop, where it will be expelled from the building through the cooling tower.
Unwanted heat from the building enters the evaporator and is carried by the refrigerant to the compressor to be hermetically packed. This heat is then transported through the compressor and to the condenser. The condenser then collects this heat and transfers it from the refrigerant to the water circulating in the condenser water loop. Coolant and water never meet or mix, they are always separated by a metal wall, only heat is transferred between them.
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The condenser water is pumped to the cooling tower. The cooling tower is usually located on the roof and rejects this heat from the condenser water to the surrounding air, whereby the condenser water is cooled and the atmospheric air is heated.
Once the condenser water has cooled, it returns to a much cooler temperature, ready to pick up more heat from the condenser again. The condenser water leaves at approximately 32 degrees Celsius (90 degrees Fahrenheit) and returns at 27 degrees Celsius (81 degrees Fahrenheit).
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Underneath the condenser shell, we have several tubes inside. These go from one extreme to the other. Depending on the design, the condenser water will flow straight through all or half of the tubes, then go around and back out the same end. It's all about increasing efficiency and reducing size.
The tubes contain the condenser water. Outside the tubes is the refrigerant that leaves the compressor. The two fluids are always separated by the tube wall. They are completely isolated from each other.
Condenser water comes from the cooling tower, to the condenser through the inlet in the "water box" (the end cap). The removable water box section is removed for tube cleaning. The condenser water flows through the tubes to the end, hits the other water box at the end, does a 180 degree turn, back through the tubes, and out the first water box.
There is a baffle between the inlet and outlet in the first water box. It is only there to separate and divert the flow to the correct tubes.
Hot compressed refrigerant will exit the compressor and begin to fill this void in the condenser. The hot refrigerant vapor will fill the space between the tubes containing the condenser water.
When the hot refrigerant comes in contact with the cooler surface of the condenser tubes, the refrigerant will condense into a liquid on the surface of the tubes. By doing so, heat will be transferred through the tube wall to the cooler.
The condenser water passes through the condenser, reaches the final water box, does a 180 degree turn and comes back, always capturing the last possible heat with maximum efficiency. During this time, the liquid refrigerant collects in liquid form at the bottom of the condenser. It will exit here at the bottom and flow into the regulator. The heated water from the condenser will now go to the cooling tower.
When the refrigerant leaves the compressor and goes down the condenser, it must be at a much higher temperature than the condenser return (inlet) water coming back from the cooling tower. The condenser water enters at about 27°C (81°F), so the refrigerant must be at a temperature higher than this.
If the refrigerant is at the same temperature as the condenser return water, the chiller will not be able to return the captured heat back to the building and therefore the building will not be able to cool.
Similarly, if the cooling tower cannot reject the heat sent to it, it will return to the same temperature. For example. if it gets up to 32 degrees Celsius and the cooling tower can't reject that heat (perhaps there's recirculation or the water is spilling instead of spraying, or there's a problem with the baffles) and the water goes right back into the condenser, no more you will be able to expel the heat from the compressor and this will eventually cause the high pressure cooler to cut out.
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Above you can see two thermal images of a chiller. Picture on the left on the discharge line coming out of the compressor, the centrifugal compressor is on top, and the hot compressed refrigerant is coming out through the discharge line to the condenser. You can see that it will be around 55 degrees Celsius.
The thermal image on the right shows the inlet and outlet of the chiller condenser. You can see the water coming back from the cooling tower at about 17.6 degrees Celsius and leaving at 25.9 degrees Celsius and coming back to the cooling tower.
You should have noticed that these numbers are for a slightly different temperature range than the schematic we were looking at earlier. This is simply because the schematic shows design figures at a high load, while they are actual figures at a lower load. There will always be a difference between design and reality. It depends on the cooling load of the chiller and the outside ambient temperature.
Now with this type of cooling tower where the condenser water goes in and then it's sprayed through the cooling tower to remove that heat, reject it and dissipate it to the atmosphere, it's an open system whereas this loop here is closed. system this loop here is an open system so water gets sprayed and air and dirt etc. You can enter this system. And what goes into this system is sent to the condenser.
Two types of cooling towers are used, open circuits and closed circuits. Open loops are the most common, they spray hot water from the condenser into ambient air, effectively cooling the water using the latent heat of evaporation.
However, this is a problem as we have an effect known as fouling that occurs within the condenser water pipe and condenser heat exchanger.
Dirt and other particles will accumulate on the pipe and heat exchanger surfaces and form a layer of insulation.
This buildup is basically small deposits of salt, scale, dirt, mineral buildup, and also bacterial growth. Like I said, this insulates the tubing, which reduces the efficiency and cooling capacity of the chillers. This can be treated with a rigorous chemical dosing regimen. Unfortunately, this alone will not be enough to stop it, it will only be enough to reduce or mitigate it. Alternatively, you can ask specialists to come and clean it.
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| Chiller-isolation-valves jcool |
In the discharge and liquid line of the cooler, we will find two large valves. These can be closed off and used to isolate all the refrigerant in the condenser. So if you need to take it apart, the refrigerant can be pumped up and moved through the condenser and these can be sealed to keep all that refrigerant in. DO NOT TOUCH UNLESS AUTHORIZED
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