1. 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

2. 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

3. 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

4. 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

5. 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

6. Concept Evaluation / Calculations7

7. Concept Evaluation / Calculations Cont.

8. 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

9. HOQ

10. Overall Plan 14

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

12. Specifics/Applications5

13. Morphological Chart

14. 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)

15. 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

16. 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

17. 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

18. 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

19. 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

20. Concept Selection

21. 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

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