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

Background A large percentage of energy consumption stems from the need of heating and cooling Danfoss Turbocor is dedicated to the design, manufacture, marketing and support of the world's most efficient commercial refrigerant compressors Flash Tank Economizer vs Heat Exchanger Economizer Economizers in R&D test rig 4

Project Scope Computational analysis of economizers Design parts and assembly method Design a control system to monitor and control the economizer Identify most efficient means of manufacturing to optimize price and timing Assemble and install working prototype into current R&D test rig Evaluate design efficiency, and possible improvement points  1

Customer Needs Identify the most efficient type of economizer through computational analysis of economizers in chiller systems Design the chosen economizer that can be integrated into the existing gas cycled test rig Conform to all R&D Test Rig Standards (UL Standards) Machine and prototype  two renditions of the final design Secondary prototype will be used for destructive testing  2

Objectives System cycle calculations of different economizers types Select between flash tank and heat exchanger economizer Component design and configuration Develop a control strategy and integration method Fabricate two renditions of the final design Installation Burst Testing (Destructive Testing) Perform Proof Testing ( UL Standards) Calculating the energy efficiency gains obtained through the economizer after installation 3

Concept Evaluation / Calculations 7

Concept Evaluation / Calculations Cont.

HOQ Customer Requirements - Performance - Reliability - Hardware Brand Engineering Characteristics      - Cost      - Efficiency      - Capacity      - Safety      - Weight      - Controls      - Size      - Power Consumption Customer Requirements  - Performance  - Reliability  - Hardware Brand  - System Control Plan  - Fluid Type - Ease of Use

HOQ

Overall Plan 14

Future Plans - Design Feedback meeting with sponsor - Two Design cycles - Cad Drawings - Purchasing - Assembly (Welding, cutting, drilling) - Installation - Testing 10

Specifics/Applications 5

Morphological Chart

Design Concepts (Morphological Chart) Requirements Functional Parameters Solutions to the Functions Increase Efficiency of Current System Economizer Type Flash Tank Heat Exchanger Fit Into Current Testing Facility Economizer Orientation Vertical Horizontal Integrate w/ Current Test Rig System Piping Size 1” 1-1/2” 1-5/8” 2” 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 Pressure Vessel Construction Pressure Vessel Materials Carbon Steel (Required by UL Standards) Design Concepts (Morphological Chart)

Solutions to the Functions Requirements Functional Parameters Solutions to the Functions Increase Efficiency of Current System Economizer Type Flash Tank Heat Exchanger Fit Into Current Testing Facility Economizer Orientation Vertical Horizontal Integrate w/ Current Test Rig System Piping Size 1” 1-1/2” 1-5/8” 2” 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 Pressure Vessel Construction Pressure Vessel Materials Carbon Steel (Required by UL Standards) Design 1

Design 1 Saturated Liquid to Evaporator Vapor To Compressor Mechanical Buoy System Baffle Filter Danfoss Expansion Valve Mixed State Fluid From Condenser Horizontal Carbon Steel Flash Tank Economizer with 2” Schedule 20 piping, to be controlled by a mechanical buoy system and a Danfoss expansion valve Pros: Simple mechanical control system, Higher Efficiency than HX economizer

Solutions to the Functions Requirements Functional Parameters Solutions to the Functions Increase Efficiency of Current System Economizer Type Flash Tank Heat Exchanger Fit Into Current Testing Facility Economizer Orientation Vertical Horizontal Integrate w/ Current Test Rig System Piping Size 1” 1-1/2” 1-5/8” 2” 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 Pressure Vessel Construction Pressure Vessel Materials Carbon Steel (Required by UL Standards) Design 2

Vapor To Compressor Design 2 Thermocouple Control System Vertical carbon steel flash tank economizer with 1- 5/8” copper piping, to be controlled by a mechanical buoy system and a thermocouple based control valve. Pros: Better control of fluid level , vertical design channels vapor directly to the vapor outlet and is more space conscientious Baffle Filter Mechanical Buoy System Mixed State Fluid From Condenser Saturated Liquid to Evaporator Control Valve (Thermocouple Based) Danfoss Expansion Valve

Design Concept 1 Material -Austenitic steel for flash tank -Copper for pipes Labor -Cutting steel and copper to correct lengths -Drilling holes for copper pipes -Welding tank and tubes together Safety -Proper selection of materials -Pressure test *All other components are supplied by Turbocor 6

Concept Selection

Potential Challenges 1.Danfoss Turbocor needs develop the flash tank type of economizer circuit.    (1)  Efficiency    (2)  Energy 2.Material and component acquisition 3.CAD construction of overall design 4.Cost evaluation for design 5.Compatibility of systems  8

Relevant Data - Working Fluid - Pressure - Temperature - Volume - Enthalpy - Flow rate of fluid - Work produced/consumed 9