Advisor: Dr. Shangchao Lin Prototyping and Testing of an Economizer in a Gas Cycled Chiller System Sponsor: Dr. Salvador Quitaleg Team 4 Members: Steven Hutto Breck Dorsey Kenneth Martin Brandon Van Guoxin Wang Advisor: Dr. Shangchao Lin

Project Background A large percentage of energy consumption stems from the need of cooling Danfoss Turbocor is dedicated to the design, manufacture, marketing and support of the world's most efficient commercial refrigerant compressors Flash Tank Economizer as a separation chamber  Economizers implemented into Danfoss’s R&D test rig Guoxin 2 Guoxin Wang

Overall Objectives  Select between flash tank or heat exchanger economizer   Design Cycle 1 - Component design and configuration   Design Cycle 2 – Feedback Changes from DC1 and new concepts  Review DC2 and make any final configuration changes   Create Detailed Design Documentation for Custom Prototyping   Fabricate two renditions of the final design   Burst and Proof Testing for Economizer Standards Through system cycle calculations on the two types of economizers. To work hand in hand with the chiller system to always increase efficiency For burst testing and proof testing which will comply to UL standard 3 Guoxin Wang  

Focused Objectives Design Cycle 1 - Component design and configuration Select between flash tank or heat exchanger economizer Design Cycle 1 - Component design and configuration  Design Cycle 2 – Feedback Changes from DC1 and new concepts Review DC2 and make any final configuration changes Create Detailed Design Documentation for Custom Prototyping Fabricate two renditions of the final design Burst and Proof Testing for Economizer Standards Through system cycle calculations on the two types of economizers. To work hand in hand with the chiller system to always increase efficiency For burst testing and proof testing which will comply to UL standard 4                Guoxin Wang  

Introduction to our system Figure 1: Circuit Diagram for multi-stage compressor using Flash Tank Economizer. Guoxin 5                Guoxin Wang  

Morphological Chart 6               Kenneth Martin  

Design Concepts (Morphological Chart) Requirements Functional Parameters Solutions to the Functions Pressure Vessel Construction Style Single Mold Capped 3 Piece Pressure Vessel Material 1040 Carbon Steel Integrate w/ Current Test Rig System Piping Material Copper Schedule 20 Steel Schedule 80 Steel Stainless Steel Pipe Coupling Method Welding 1:1 Coupler Expansion Coupler Throttling Coupler Effective Control of Economizer Entrance Valve Control Digital Buoy Sensor Mechanical Buoy Sensor Thermocouple Thermocouple and Mechanical Buoy Sensor Expansion Valve Type Lennox Danfoss  Emmerson Honeywell Fluid Gauge Systems Mechanical Dial Gauge Visual Tube Gauge Design Concepts (Morphological Chart) Design 1 7               Kenneth Martin  

Design 1 – Capped 3 piece pressure vessel Saturated Liquid to Evaporator Vapor To Compressor Mechanical Buoy System Baffle Filter Danfoss Expansion Valve Mixed State Fluid From Condenser Horizontal orientation 1-5/8” pipe diameters 1:1 Coupler piping method Buoy System Capped ends Mechanical fluid level gauge Threaded Capped Ends for Pressure Vessel Mechanical Fluid Gauge 8               Kenneth Martin  

Design Concepts (Morphological Chart) Requirements Functional Parameters Solutions to the Functions Pressure Vessel Construction Style Single Mold Capped 3 Piece Pressure Vessel Material 1040 Carbon Steel Integrate w/ Current Test Rig System Piping Material Copper Schedule 20 Steel Schedule 80 Steel Stainless Steel Pipe Coupling Method Welding 1:1 Coupler Expansion Coupler Throttling Coupler Effective Control of Economizer Entrance Valve Control Digital Buoy Sensor Mechanical Buoy Sensor Thermocouple Thermocouple and Mechanical Buoy Sensor Expansion Valve Type Lennox Danfoss  Emmerson Honeywell Fluid Gauge Systems Mechanical Dial Gauge Visual Tube Gauge Design Concepts (Morphological Chart) Design 2 9               Kenneth Martin  

Design 2 – single mold Horizontal Carbon Steel Flash Tank Economizer with 1 5/8” copper, to be controlled by a thermocouple control system and a Danfoss expansion valve Saturated Liquid to Evaporator Vapor To Compressor Baffle Filter Danfoss Expansion Valve Mixed State Fluid From Condenser Thermocouple Control System Visual Tube Fluid Gauge Danfoss Control Valve Figure 2: Horizontal Flash Tank Guoxin 10               Kenneth Martin  

Design Concepts (Morphological Chart) Requirements Functional Parameters Solutions to the Functions Pressure Vessel Construction Style Single Mold Capped 3 Piece Pressure Vessel Material 1040 Carbon Steel Integrate w/ Current Test Rig System Piping Material Copper Schedule 20 Steel Schedule 80 Steel Stainless Steel Pipe Coupling Method Welding 1:1 Coupler Expansion Coupler Throttling Coupler Effective Control of Economizer Entrance Valve Control Digital Buoy Sensor Mechanical Buoy Sensor Thermocouple Thermocouple and Mechanical Buoy Sensor Expansion Valve Type Lennox Danfoss  Emmerson Honeywell Fluid Gauge Systems Mechanical Dial Gauge Visual Tube Gauge Design Concepts (Morphological Chart) Design 3 11               Kenneth Martin  

Design 3 – Capped 3 Piece with visual fluid gauge Saturated Liquid to Evaporator Vapor To Compressor Mechanical Buoy System Baffle Filter Danfoss Control Valve Mixed State Fluid From Condenser Horizontal orientation 1-5/8” pipe diameters 1:1 Coupler piping method Thermocouple Capped ends Visual fluid level gauge Thermocouple Control System Threaded Capped Ends for Pressure Vessel Visual Tube Fluid Gauge Danfoss Expansion Valve Figure 2: Horizontal Flash Tank 12               Kenneth Martin  

Pugh Matrix Weighted Total 44 40 47 13 Kenneth Martin Criteria Importance Factor Design 1 Design 2 Design 3 Safety 5 2 3 Performance 4 Reliability Ease of Use Cost 1 Maintenance Weighted Total 44 40 47 Kenny 13               Kenneth Martin  

Concept Evaluation Weighted Total 44 47 Design 1 vs Design 3: Mechanical Fluid Gauge vs Visual Tube Gauge Design 1 vs Design 3:Buoy Control System vs Thermocouple Control System Design 1 vs Design 3: Mechanical Control vs Electrical Control System Design 1 & Design 3 utilize a 3 piece pressure vessel Design 1 & Design 3 can be accessed via the capped sections in order to maintain the system over time Criteria Importance Factor Design 1 Design 3 Safety 5 2 3 Performance 4 Reliability Ease of Use Cost 1 Maintenance Weighted Total 44 47 14               Kenneth Martin  

Pugh Matrix Weighted Total 44 40 47 15 Kenneth Martin Criteria Importance Factor Design 1 Design 2 Design 3 Safety 5 2 3 Performance 4 Reliability Ease of Use Cost 1 Maintenance Weighted Total 44 40 47 Kenny 15               Kenneth Martin  

Flash Tank Specifications Size Material Vessel shape Diameter Length Volume Material Vessel shape Special opening closures Quick opening heads(Autoclaves) Pressure and Temperature ratings that determine wall thickness Price ~$4000 per tank  Breck 16               Breck Dorsey

Baffle Filter Also called a demister or De-entrainment mesh Mounted at the 1-5/8"outlet pipe leading to compressor Separates gas from liquid to avoid damage to compressor blades and to increase efficiency  Effective at collecting 100% of particles larger than 8 microns diameter How it works 1. Vapor stream carrying entrained liquid droplets passes through demister and vapor moves freely through mesh 2. The inertia of the droplets causes them to contact the wire surfaces and coalesce 3. The large, coalesced droplets formed in the mesh ultimately drain and drop to vessels bottom Price ~$250  Breck 17               Breck Dorsey 

Control Valve & Thermocouples Supplied by Danfoss Turbocor  How it works Superheated vapor temperature measured by thermocouples is related to the fluid level in flash tank Control valve operates to maintain a desired level of fluid, so that a constant rate of liquid is sent to evaporator KVS 42, suction modulation control valve 1-5/8" inlet and outlet Price ~$50 - control valve             $60 - thermocouples Breck 18               Breck Dorsey 

Potential Challenges CAD construction of overall design Cost evaluation for design Material and component acquisition Compatibility of systems/assembly Control system testing 19               Breck Dorsey 

3 Month Project Plan Major Activities Completed Two Week Look Ahead Chiller and Economizer Research Computational Analysis of the Economizers  Design cycle 1 & 2 Two Week Look Ahead Design cycle 2 review Design Finalization Detail Design Documentation Prototyping Plan 20               Breck Dorsey 

Conclusion  Horizontal orientation allows for a larger baffle filter, which promotes more effective liquid vapor separation   Carbon steel is a good material for construction of   tank  Estimated cost is approximately $8360   (not including labor) 21              Breck Dorsey 

References [1] "ThermoFlo User Manual." ThermoFlo User Manual, n.d. Web. 20 Oct. 2016. [2] "Chapter 11." SpringerReference (n.d.): n. pag. Web. 22