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SAMSA - Continuum Chillers

PRESTO PRODUCTS, INC.

SOUTH BOSTON, VIRGINIA

CENTRIFUGAL CHILLER ADDITION

The focus of this project was to increase plant chilled water supply and add some redundant capacity. The opportunity presented itself to match condenser and chilled water flows. When outside air temperatures drop below 35°F., a chilled water economizer application could satisfy process water temperature requirements without mechanical cooling.

Considerations for equipment selection were based on overall system performance, type of refrigerant used, type of compressor compression, chiller physical size and delivery date. The chiller design would need to maintain 163 net tons of refrigeration at a 44°F. entering chilled water temperature @ 33.5°F. leaving chilled water temperature. Condenser rejection design would be at 85°F. entering condenser water temperature @ 96.3° F. leaving condenser water temperature.

Presto Products' design engineers had expressed several requirements:

1) The system would need to be as energy efficient as possible.

2) The purchase of new refrigeration equipment would use HFC -134a.

3) The system would be required to operate under a wide range of chilled water and condenser water temperatures with varying process cooling loads.

SAMSA, Inc. provided a McQuay PEH 063 water-cooled centrifugal compressor chiller. This unit would infinitely track process cooling loads. The McQuay PEH 063 is a flooded R-134a chiller which we equipped with Hot Gas Bypass to provide the greatest reduced load chiller efficiency. The McQuay PEH 063 would be located in a existing loading dock now turned into a new mechanical chiller room. We custom designed the unit condenser and cooler shells to provide the most efficient kw/ton while controlling unit cost. McQuay custom built the unit and their MicroTech micro processor control panel to complement our installation parameters.

SAMSA, Inc. worked with Presto Products engineers as they custom designed the installation phase of their new McQuay PEH 063 centrifugal chiller. Presto's engineers were responsible for the design of the equipment room, equipment placement and the piping scheme. The cooling tower water circuit also is used when outside air temperatures are below 35°F. which allows the customer to bypass mechanical cooling and provide process cooling requirements with only the cooling tower

The BAC evaporative cooling tower capacity was oversized to accommodate the use of the cooling tower for process cooling requirements during colder ambient temperatures. The energy savings enjoyed by shutting down mechanical cooling equipment and diverting process cooling water to the cooling tower closed loop not only reduces chiller maintenance costs, but allows for scheduled repairs on auxiliary equipment. The cooling tower fan is connected to a variable frequency drive which tracks condenser rejection loads above 35°F. and process cooling loads below 35°F. As outside ambient temperatures drop, cooling towers become extremely efficient.

Presto Products, Inc. furnished and installed all necessary condenser and chilled water piping, valves, drain valves, chemical treatment access valves, ( i.e. tower blow down), makeup water, pressure gauges and thermometers for a completely operational system.

All of Presto's process water and rejection water throughout this plant is controlled by Direct Digital Controls. The use of DDC controls improve system performance which allows tighter control as compared to conventional controllers. The user friendly programable logic which will be used to adapt future processes to this system simplifies this complicated installation to a comfortable human interface.

SAMSA, Inc. provided the chiller in this project and worked hand in hand with Presto Products' design engineers with the direct purchase of all additional equipment to complete this installation.

SAMSA, Inc. provided start up and warranty service on the new chiller. All manufacturers supplied one year parts warranty on their equipment.

SAMSA, Inc. is a must for your next project when innovative ideas are paramount.