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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 1 Mammoth Product Training Evaporative Condensing
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 2 EVAPORATIVE CONDENSING What is it?
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 3 Condensers Condensers in refrigeration systems reject the heat absorbed by the refrigerant in the evaporator & the compressor KW (heat of compression) Three typical Condenser types: Air, Water and Evaporative cooled
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 4 The Power of Evaporation The Thermodynamic Properties of Water at Saturation Latent heat of vaporization = 1036 btu/lb H2O Water changing state from liquid to gas at 100f absorbs 1036 btu/lb
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 5 Evaporative Cooling Vs Evaporative Condensing Both systems use evaporation of water to cool. Evap cooling --- cools room air. Evap Condensing ---cools refrigerant gas, no moisture is added to the space.
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 6 Evaporative Condenser Construction Draw Through Design. Stainless Steel Housings and Sump. Prime Copper Tube Bundle.
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 7 EVAPORATIVE CONDENSING How it works.
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 8 How It Works Water is sprayed over a finless condenser coil Evaporation assists in the rejection of condenser heat to the atmosphere
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 9 How it Works: Water Spray on Condenser Coil
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 10 Why Evaporative Condensing? 30% to 40% less compressor KW consumed than air cooled condensing Less Air over coil, therefore quieter than air cooled condensing Less coil required so less space on roof for equipment than air cooled.
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 11 ASHRAE Systems and Equipment Handbook “In comparison with an air-cooled condenser, an evaporative condenser requires less coil surface and airflow to reject the same heat, or alternatively, greater operating efficiencies can be achieved by operating at a lower condensing temperature”
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 12 ASHRAE Systems and Equipment Handbook “Also, evaporative condensers typically provide lower condensing temperatures than the cooling tower/water-cooled condenser because the heat and mass transfer steps (between the refrigerant and the cooling water and between the water and ambient air) are more efficiently combined in a single piece of equipment”
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 13 Evaporative Condensing ARI - WB = 75 88 F SCT = 95 to 105 F SET = 45 F
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 14 ASHRAE Systems and Equipment Handbook “Evaporative condensers reduce the water pumping and chemical treatment requirements associated with cooling tower/refrigerant condenser systems”
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 15 Water Consumption Evaporated water of 1.6 gph/ton Nominal bleed rate of ½ evaporation rate Total water consumption of 2.4 gph/ton
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 16 ASHRAE Systems and Equipment Handbook “Evaporative condensers are, therefore, the most compact for a given capacity”
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 17 How It Works Condensing temperature becomes a function of the ambient wet bulb temp The wet bulb depression under the dry bulb temperature, typically 15 to 30 degrees, leads to lower condensing temps than with air- cooled condensing Design condensing temperatures range from 90 to 105 degrees
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 18 Corresponding Pressure for R-22 Condensing Temp of 130F = 300psig Corresponding Pressure for R-22 Condensing Temp of 100F = 200psig Evaporative Condenser Air-cooled Condenser
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 19 Reduced Connected kW Typical 100 Ton Air Cooled Condenser 205 Operating Amps 135 kW Typical 100 Ton Evap Cooled Condenser 157 Operating Amps 103 kW Wire Size # 350 MCM Wire Size # 2/0
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 20 Where Can Evaporative Condensing be Used? Base design is for 75 degree wet bulb temperatures Only a few locations have up to a 81 degree design wet bulb Can be used anywhere cooling towers are used Appropriately applied everywhere
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 21 Advantages over Air Cooled Packages Better Acoustics ▼ Because evap condensers move less air than air cooled units they typically are quieter. ▼ In many areas Lot line noise is becoming a real issue. Greater Compressor Life ▼ Evap Condensing Compressors work at lower pressures compared to Compressors applied to Air Cooled Condensers and therefore should last longer
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 22 Advantages over Air Cooled Packages Typically a Smaller Footprint ▼ Because evap condensers move less air than air cooled units they typically are smaller.
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 23 Lower amp draw ▼ With lower amperage required, evap condensing can be used for applications with limited existing power supply Evap Condensing - Benefits:
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 24 Lower Operating Cost 30-40% less compressor kW consumed than air-cooled condensing Can compete favorably with centrifugal chilled water systems Reduced kW is the result of lower condensing temperatures
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 25 Evaporative Condenser Construction Details Ease of Serviceability Corrosion Resistance Long Life Reliability Quiet Operation Pleasing Aesthetics Desirable Design Features:
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 26 To prevent the possibility of water getting into the building, use a continuously welded stainless steel pan under the sump Evaporative Condenser Construction Details
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 27 Utilize a fully welded, double sloped stainless steel sump Evaporative Condenser Construction Details
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 28 Interlocking stainless panels with no fasteners on the inside Evaporative Condenser Construction Details
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 29 Stainless coil supports Evaporative Condenser Construction Details
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 30 Stainless and ABS tube sheets Evaporative Condenser Construction Details
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 31 Evap condenser coil in the sump Evaporative Condenser Construction Details
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 32 Evaporative Condenser Construction Details Spray Tree Assembly
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 33 Evaporative Condenser Construction Details Moisture Eliminator
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 34 Evaporative Condenser Construction Details Direct Drive Condenser Fans All Stainless Steel Mounting Frame
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 35 Evaporative Condensing
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 36 Condenser Top Hinges Up
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 37 Direct Drive Fans
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 38 Easy Access to Components
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 39 Designed for Serviceability
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 40 All Stainless Steel and Non-Corrosive
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 41 Full Access to Condenser Coil
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 42 Spray Nozzles Visible for Inspection
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 43 Spray Nozzles
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 44 Spray Nozzles
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 45 Pump suction strainer easily removable without tools
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 46 Pump suction strainer easily removable without tools
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 47 Latest design enhancements – Ultraline evap condensers now available up to 350 tons – Penthouse up to 600 tons in a single sump – Sump basin is double-sloped to be self-draining – All water-side components made of non-corrosive materials - even fan venturis are stainless steel – Condensers fans hinged for easy service access – Basin inlet opens up easily for complete access – Air and water flow increased for even greater efficiency Evaporative Condensing
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 48 Water Treatment
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 49 Water Treatment Objectives CONTROL and BALANCE of WATER CHEMISTRY to MINIMIZE: ▼ CORROSION ▼ SCALE ▼ BIOFOULING ▼ USE of WATER and to MAXIMIZE: ▼ HEAT TRANSFER
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 50 Chemical Treatment Inhibitor- reduces scale and corrosion Biocide- alternate between two to prevents biological contamination Chemical pumps- inject chemical into sump Controller- monitors water and activates chemical pumps and bleed
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 51 Chemical Water Treatment
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 52 Effective Chemical Water Treatment ¬ Maintain desired cycles of concentration Maintain prescribed biocide feed ® Maintain prescribed scale and corrosion inhibitor feed ¯ Periodically monitor the system In 4 Easy Steps!
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 53 ASHRAE Systems and Equipment Handbook “All evaporative condensers should be treated to restrict biological growth”
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 54 Oxidizing Biocides Chlorine Bromine Ozone Iodine
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 55 Nonoxidizing Biocides Mehtylene bis(thiocyanate) (MBT) Decyl thioethanamine (DTEA) Tetrakis(hydroxymethyl)phosphonium sulfate Dibromo-nitrilopropionamide (DBNPA)
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 56 Nonchemical Methods Scale control ▼ Magnetic and Electromagnetic cause minerals to precipitate into particles that can be removed by blowdown or flushing Biological control ▼ Ozone ▼ UV light ▼ Copper and silver metallic ions (1 ppm)
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 57 Solids Management: Sources Sump Debris ♦ Inorganic: dust, dirt, sand ♦ Organic: leaves, pollen, grass ♦ Dolphin “powder”
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 58 Solution: Basin Sweeping Reduces cleaning routines by 5x Controls solids build-up in tower basin
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 59 Centrifugal Action Separator
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 60 Separator
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 61 Dedicated Pump
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 62 Purge Filter (Optional)
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 63 HydroBoosters: Pattern of Influence
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 64 HydroBoosters: Installation Issues Submergence: Only 2-3 inches required
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 65 Sweeper in Mammoth Sump
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© 2004 Venmar CES Inc.© 2006 CES Group - Confidential 66 THANK YOU
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