Systems and methods for cooling electrical equipment
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Solution Overview
Problem
Conventional cooling systems are inefficient under varying load conditions and environmental conditions, leading to high energy consumption and maintenance costs, particularly in climates with high ambient temperatures and high latent loads, due to their inability to scale down energy use effectively and maintain efficient operation.
Innovation Solution
A cooling system comprising a first refrigerant circuit, a free cooling circuit, a chilled water circuit, and a second refrigerant circuit, with control valves and pumps that dynamically switch between free cooling and chilled water cooling based on ambient temperature, allowing for efficient condensation of refrigerant and reducing compressor usage during high ambient conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling systems operate at high ambient temperatures, then cooling capacity is maintained, but energy consumption increases dramatically
Solution Approach 1:
The system dynamically switches between different cooling modes (air-cooled DX, evaporative assist, water-cooled chiller) based on ambient temperature conditions. The control system adjusts the operational state of each component in real-time to optimize energy consumption while maintaining required cooling capacity across varying temperature conditions.
Solution Approach 2:
The system changes operational parameters by switching between different cooling circuits and modes depending on ambient temperature. At low ambient temperatures, air-cooled DX mode is used; at high ambient temperatures, evaporative assist or water-cooled chiller modes are activated to maintain efficient operation and reduce energy consumption.
2Use of energy by moving object
If compressor speed is reduced to match low load demand, then energy use decreases, but minimum flow constraints prevent effective scaling
Solution Approach 1:
The cooling system is segmented into multiple independent circuits (air-cooled DX circuit, evaporative assist circuit, water-cooled chiller circuit) that can operate independently or in combination. This segmentation allows the system to match cooling output to load demand more precisely by activating only the necessary circuits, avoiding the minimum flow constraints of single-compressor systems.
Solution Approach 2:
The system employs multiple cooling circuits that can serve different functions and operate in different modes. The air-cooled DX circuit handles base loading, the evaporative assist circuit provides supplemental cooling in high ambient conditions, and the water-cooled chiller circuit handles peak loads or provides free cooling, creating a universal system that adapts to various operating conditions.
3Use of energy by moving object
If refrigerant systems operate under low ambient temperature conditions, then cooling efficiency improves, but system stability deteriorates due to slugging and uneven heat distribution
Solution Approach 1:
The control system dynamically adjusts the metering device and refrigerant flow based on ambient temperature and load conditions. Under low ambient temperature conditions, the system modulates refrigerant flow to prevent slugging while maintaining efficient heat distribution across the evaporator coil, ensuring both efficiency and stability.
Solution Approach 2:
The system incorporates feedback control through the metering device and control valves that monitor refrigerant conditions, ambient temperature, and load demand. This feedback mechanism prevents liquid slugging by adjusting refrigerant flow to match actual evaporation needs, maintaining system stability while preserving cooling efficiency under varying ambient conditions.
4Use of energy by moving object
If evaporative assist cooling is used to improve kW/ton performance, then energy efficiency increases, but maintenance costs and operational complexity increase
Solution Approach 1:
The evaporative assist system is dynamically controlled to operate only when ambient conditions favor evaporative cooling and when the cooling load requires supplemental capacity. The control system monitors ambient temperature, humidity, and cooling demand to activate or deactivate the evaporative assist mode, optimizing energy efficiency while minimizing maintenance requirements by limiting operation to favorable conditions.
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
The system maximizes free cooling and mechanical cooling efficiency by using free cooling when ambient temperatures are low and switching to chilled water cooling at high temperatures, reducing energy consumption and maintenance costs across a range of environmental conditions.
Implementation Method 1
a main condenser in fluid communication with the first refrigerant circuit and in communication with a cooling tower water source
Implementation Method 2
an evaporator in fluid communication with the second refrigerant circuit and in communication with a chilled water source
Implementation Method 3
in communication with a cooling tower water source
Data Source
AI summary
The cooling systems of the present disclosure include a first refrigerant circuit in thermal communication with a heat load and in fluid communication with a main condenser, a free cooling circuit in fluid communication with the main condenser and a free-cooled water source, a chilled water circuit in fluid communication with the main condenser and an evaporator, and a second refrigerant circuit in fluid communication with the evaporator and a secondary condenser. The free cooling circuit is in thermal communication with the first refrigerant circuit via the main condenser, the chilled water circuit is in thermal communication with the first refrigerant circuit via the main condenser, and the second refrigeration circuit is in thermal communication with the chilled water circuit and the free cooling circuit. The second refrigeration circuit cools a fluid flowing in the chilled water circuit. Methods of operating a cooling system are also disclosed.