Chiller Compressor Power Limiting for Liquid Droplet Carryover
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Solution Overview
Problem
Chiller efficiency is decreased and mechanical components are damaged due to liquid droplet carryover into the compressor, which occurs when the compressor provides a higher suction flow rate, increasing gas velocity and exceeding the design velocity limit of the evaporator.
Innovation Solution
Implementing a controller that uses pressure sensors to predict energy levels and modify input power or motor current to the prime mover, limiting further power or current increase to prevent liquid droplet flow into the compressor, thereby reducing or eliminating liquid droplet carryover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the compressor provides a higher suction flow rate, then productivity is improved, but liquid droplet carryover occurs and reliability deteriorates
Solution Approach 1:
The controller continuously monitors evaporator pressure and condenser pressure, calculates the predicted energy level associated with liquid droplet flow, compares it to the operating energy level, and dynamically adjusts the input power or current to the prime mover based on this feedback loop to prevent liquid droplet carryover
Solution Approach 2:
The system changes the operating parameters (input power or current) of the prime mover based on the comparison between predicted energy level and operating energy level, adjusting these parameters to maintain optimal operation and prevent liquid droplet carryover into the compressor
2Productivity
If the compressor provides a higher suction flow rate, then productivity is improved, but chiller efficiency decreases due to liquid droplet carryover
Solution Approach 1:
The controller uses pressure feedback from evaporator and condenser sensors to calculate predicted energy level and dynamically adjusts prime mover input power or current, preventing liquid droplet carryover that would reduce chiller efficiency while maintaining high productivity
Solution Approach 2:
The system predicts the energy level associated with liquid droplet flow before it becomes a problem, and takes preliminary action by modifying input power or current to prevent liquid droplet carryover, thereby avoiding efficiency losses before they occur
3Productivity
If the compressor provides a higher suction flow rate, then productivity is improved, but mechanical components are damaged by liquid droplet carryover
Solution Approach 1:
The controller continuously monitors system conditions through pressure sensors and dynamically adjusts prime mover input power or current based on the predicted energy level comparison, preventing liquid droplet carryover that would damage mechanical components while maintaining high suction flow rate
Solution Approach 2:
The system provides beforehand protection by predicting the energy level associated with liquid droplet flow and taking preventive action by modifying input power or current before liquid droplets can reach and damage the mechanical components of the compressor
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively manages compressor operation to reduce or eliminate liquid droplet flow, enhancing chiller efficiency and protecting mechanical components by limiting power or current to prevent liquid droplet carryover into the compressor.
Implementation Method 1
an evaporator that receives a first flow of refrigerant, transfers heat to the first flow of refrigerant
Implementation Method 2
The refrigerant may undergo one or more phase changes within the refrigerant piping system, such that liquid refrigerant and vaporous refrigerant may both be present
Implementation Method 3
a compressor that receives the second flow of refrigerant via tubing between the evaporator and the compressor
Implementation Method 4
a second pressure sensor that detects a second pressure of refrigerant in a condenser of the chiller
Implementation Method 5
The refrigerant may undergo one or more phase changes within the refrigerant piping system
Data Source
AI summary
A chiller includes an evaporator, a compressor including a prime mover, a first pressure sensor that detects a first pressure in the evaporator, a second pressure sensor that detects a second pressure in a condenser, and a controller. The controller determines a predicted energy level of the compressor based on the first pressure and the second pressure, the predicted energy level associated with liquid droplet flow into the compressor, compares the predicted energy level to an operating energy level, and modifies the at least one of the input power and the input current to the prime mover based on the comparison satisfying a modification condition.