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Attached you will find an example of how to calculate your chiller performance and arrive at a cooling water requirement for each of your chillers. I have done this quite hurriedly and I apologize if the calculations are not organized as well as they could be. You will note that I have purposely left the basic design input data in unlocked, Yellow cells. You will also note that from the basic data you've furnished and from what I've taken from the Trane website, your chillers can barely generate 400 Tons of refrigeration (TR) when you are circulating 1,600 gpm of cooling water. That means if you maintain the same water temperatures around the condenser, you will not be able to obtain the 550 TR that you claim the chillers can put out.

Bear in mind that you stated in your opening post that you want to 'optimize an under-utilized cooling tower'. Therefore, I assume you don't need the 500+ TR and can settle for much less. This will take a bit of load off of your cooling water tower(s). There several reasons I have taken this method to show you the manner of 'optimizing' your chiller assignment:

1. I want to use this method to show you ' as well as all other Chem E students on this forum - the type and quality of calculations that are going to be expected of you when you undertake your first industrial job. You will note the use of sketch(es), attached references, equations, project identity, dates, Revision Number, and ample definition and explanation of the logic employed and the equations used. This is the type and quality of documentation that is required as a minimum when you are a professional engineer.

2. I want to emphasize the technique of how you can employ detailed, reference data by using Excel workbooks to contain your project. By attaching your reference data, you allow the reader facile access to the data employed and speed up the reader's process of confirming the results and accepting your logical answer. The easier you make it for your peers to check and confirm your work, the better off you will be ' on all fronts.

3. Note that I have not worked out your problem for you. I have shown you the way (by example) to use present engineering techniques to document your solution. If, upon reviewing my calculations, you find it difficult to understand how I came up with one of the answers then you have a serious problem of not being prepared to confront this Thermodynamic process and its industrial application. I chose to respond to your query because I consider you more fortunate than most other engineering students striving to obtain their degrees in Chemical Engineering. This industrial problem you have confronting you is a perfect example of what you must resolve successfully if you are to go on to a rich and rewarding career in engineering. This real-life problem teaches you that you do not become an engineer by going to a university. You become a professional engineer after the university has taught you how to learn to become one. Your industrial experience will teach you how to become an engineer ' if you are willing to study and look for the actual experience in real projects and challenges.

4. Look carefully at the presentation of data. Some of the basic data that you gave was erroneous and the Thermodynamic values from NIST confirm this. When you are working on industrial problems you do not have a professor checking your work. If you are not lucky you will have no one checking your work. For that reason, you cannot afford to make mistakes in establishing basic data. Such mistakes will lead to the totally wrong answer and you cannot afford to make such costly errors. Always confirm your basic data. Always seek to obtain peer checks ' which is, in reality, what I'm doing for you.

5. Study carefully the basis, the scope, and the nature of the application given you. In this case, you have verified what most of us pros already know: you have a refrigeration cycle application problem and it will involve basic thermodynamics and its application if you are to resolve what is needed to operate efficiently and at low costs of operation. Note that the calculations do not give you a Primer or an orientation on refrigeration thermodynamics. You are expected to already have this knowledge under your belt. If you don't, then it is time to return to basics and start studying the application of the basic thermodynamics. It is essential that you identify and accurately calculate the required cooling capacity expected from the cooling towers. Without this information, you are locked at a standstill and can go no further in resolving how best to control the cooling water towers.

6. After starting this thread with deficient basic data, you have returned to cooperate and furnish more details and data ' plus a description of what basically is being asked of you. This is commendable on your part and I applaud such a positive attitude. It shows you recognized that you were faulty in your communications initially, but have since corrected your method of communicating with others. This type of self-recognition will aid you tremendously if you continue to apply it in the future.

7. Your total scope also involves process analysis and calculations on the cooling tower(s) and that portion will involve simultaneous heat and mass transfer ' another challenging technical exercise. I presume you are also ready to tackle that part. But you cannot initiate that portion until you clearly identify the range of cooling loads that will be imposed on the tower(s) by the chiller condenser(s). The identification of the design Wet Bulb temperature will go a long way in helping you arrive at a reasonable estimate on what to expect from you cooling tower(s). A check with your local airport or meteorological government office may furnish you with this information. Try to obtain the local design wet bulb value ' not just one or a few random ones.

I hope the workbook contributes to your organizing a work plan and also identifying all the basic parameters that you need to arrive at a recommended method of controlling the operation of the cooling water towers. If you (or any other reader) have any comments or critiques on the calculations and the logic employed, please do not hesitate to make them known. I sincerely hope that that this thread attracts some of our more talented and experienced members and their comments and critiques are graciously welcomed. I am looking forward to some of our members to add valuable comments and recommendations to your request in order to have a thread that is fruitful and profitable to all students participating in this forum.

Remember that I earlier stated that you were welcomed to the real world? Hopefully, you may now be getting the flavor of how real-world engineering problems are resolved. They require you accurately describe and communicate your data and your needs. They also involve you working with others to obtain data and/or information. Note that although I didn't know the interstage pressures, I assumed some basic data and calculated the required interstage pressures in order to arrive at a complete description of what is generating the total heat load on the cooling water tower(s). Since we are no longer in a class room and there is no text book associated with the problem, we can't expect others to give us all the basic data we require to resolve the problem. We have to go out and get it ourselves. I presume you will cross-check and confirm my interstage figures with actual field data obtained from the actual machines.

Good Luck!


 R_134a_Chiller.xls   

285KB

  

249 downloads

Fred:Attached you will find an example of how to calculate your chiller performance and arrive at a cooling water requirement for each of your chillers. I have done this quite hurriedly and I apologize if the calculations are not organized as well as they could be. You will note that I have purposely left the basic design input data in unlocked, Yellow cells. You will also note that from the basic data you've furnished and from what I've taken from the Trane website, your chillers can barely generate 400 Tons of refrigeration (TR) when you are circulating 1,600 gpm of cooling water. That means if you maintain the same water temperatures around the condenser, you will not be able to obtain the 550 TR that you claim the chillers can put out.Bear in mind that you stated in your opening post that you want to 'optimize an under-utilized cooling tower'. Therefore, I assume you don't need the 500+ TR and can settle for much less. This will take a bit of load off of your cooling water tower(s). There several reasons I have taken this method to show you the manner of 'optimizing' your chiller assignment:1. I want to use this method to show you ' as well as all other Chem E students on this forum - the type and quality of calculations that are going to be expected of you when you undertake your first industrial job. You will note the use of sketch(es), attached references, equations, project identity, dates, Revision Number, and ample definition and explanation of the logic employed and the equations used. This is the type and quality of documentation that iswhen you are a professional engineer.2. I want to emphasize the technique of how you can employ detailed, reference data by using Excel workbooks to contain your project. By attaching your reference data, you allow the reader facile access to the data employed and speed up the reader's process of confirming the results and accepting your logical answer. The easier you make it for your peers to check and confirm your work, the better off you will be ' on all fronts.3. Note that I have not worked out your problem for you. I have shown you the way (by example) to use present engineering techniques to document your solution. If, upon reviewing my calculations, you find it difficult to understand how I came up with one of the answers then you have a serious problem of not being prepared to confront this Thermodynamic process and its industrial application. I chose to respond to your query because I consider you more fortunate than most other engineering students striving to obtain their degrees in Chemical Engineering. This industrial problem you have confronting you is a perfect example of what you must resolve successfully if you are to go on to a rich and rewarding career in engineering. This real-life problem teaches you that you do not become an engineer by going to a university. You become a professional engineer after the university has taught you how to learn to become one. Your industrial experience will teach you how to become an engineer ' if you are willing to study and look for the actual experience in real projects and challenges.4. Look carefully at the presentation of data. Some of the basic data that you gave was erroneous and the Thermodynamic values from NIST confirm this. When you are working on industrial problems you do not have a professor checking your work. If you are not lucky you will have no one checking your work. For that reason, you cannot afford to make mistakes in establishing basic data. Such mistakes will lead to the totally wrong answer and you cannot afford to make such costly errors. Always confirm your basic data. Always seek to obtain peer checks ' which is, in reality, what I'm doing for you.5. Study carefully the basis, the scope, and the nature of the application given you. In this case, you have verified what most of us pros already know: you have a refrigeration cycle application problem and it will involve basic thermodynamics and its application if you are to resolve what is needed to operate efficiently and at low costs of operation. Note that the calculations do not give you a Primer or an orientation on refrigeration thermodynamics. You are expected to already have this knowledge under your belt. If you don't, then it is time to return to basics and start studying the application of the basic thermodynamics. It is essential that you identify and accurately calculate the required cooling capacity expected from the cooling towers. Without this information, you are locked at a standstill and can go no further in resolving how best to control the cooling water towers.6. After starting this thread with deficient basic data, you have returned to cooperate and furnish more details and data ' plus a description of what basically is being asked of you. This is commendable on your part and I applaud such a positive attitude. It shows you recognized that you were faulty in your communications initially, but have since corrected your method of communicating with others. This type of self-recognition will aid you tremendously if you continue to apply it in the future.7. Your total scope also involves process analysis and calculations on the cooling tower(s) and that portion will involve simultaneous heat and mass transfer ' another challenging technical exercise. I presume you are also ready to tackle that part. But you cannot initiate that portion until you clearly identify the range of cooling loads that will be imposed on the tower(s) by the chiller condenser(s). The identification of the design Wet Bulb temperature will go a long way in helping you arrive at a reasonable estimate on what to expect from you cooling tower(s). A check with your local airport or meteorological government office may furnish you with this information. Try to obtain the localwet bulb value ' not just one or a few random ones.I hope the workbook contributes to your organizing a work plan and also identifying all the basic parameters that you need to arrive at a recommended method of controlling the operation of the cooling water towers. If you (or any other reader) have any comments or critiques on the calculations and the logic employed, please do not hesitate to make them known. I sincerely hope that that this thread attracts some of our more talented and experienced members and their comments and critiques are graciously welcomed. I am looking forward to some of our members to add valuable comments and recommendations to your request in order to have a thread that is fruitful and profitable to all students participating in this forum.Remember that I earlier stated that you were welcomed to the real world? Hopefully, you may now be getting the flavor of how real-world engineering problems are resolved. They require you accurately describe and communicate your data and your needs. They also involve you working with others to obtain data and/or information. Note that although I didn't know the interstage pressures, I assumed some basic data and calculated the required interstage pressures in order to arrive at a complete description of what is generating the total heat load on the cooling water tower(s). Since we are no longer in a class room and there is no text book associated with the problem, we can't expect others to give us all the basic data we require to resolve the problem. We have to go out and get it ourselves. I presume you will cross-check and confirm my interstage figures with actual field data obtained from the actual machines.Good Luck!

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