Ice Plant

DEPARTMENT OF MECHANICAL ENGINEERING SAINT LOUIS UNIVERSITY BAGUIO CITY

DESIGN OF ICE PLANT AND COLD STORAGE PLANT WITH AN AIR CONDITIONING SYSTEM

Progress Report No. 3

GROUP NO. 8 MEMBERS: Aben, Christian Louie B. Aromin, Christian Froi C. Onia, Christian Arvin L. Palos, Joshua D.

DESIGN OF ICE PLANT AND COLD STORAGE PLANT WITH AN AIR CONDITIONING SYSTEM

IV.

CENTRALIZE REFRIGERATION REFRIGERAT ION SYSTEM A single refrigeration system that will serve the whole plant: A. Schematic diagram of the whole system B. Evaporator system: parallel / series C. P-H diagrams of the processes D. Each

building

should

be

labeled

with

their

respective

temperature requirements and the product/s stored. E. The amount of refrigeration, mass flow, volume flow in the piping system. Indicate the directional flows. F. Mass and flow of air in the air conditioned ducting system.

V.

DESIGN OF THE EVAPORATOR FOR EACH SECTION

VI.

SELECTION OF CONDENSER

VII.

SELECTION OF COMPRESSOR (SIZE, CAPACITY, ETC.)

VIII. DESIGN/SELECTION DESIGN/SELECT ION OF OTHER AUXILIARY EQUIPMENT (COOLING TOWER, PUMPS, FANS, BLOWERS, DUCTING SYSTEM, ETC.)

a) P-H diagrams of the processes

V.

DESIGN OF THE EVAPORATOR FOR EACH SECTION

TLP - Low Profile Evaporators

Overview: The LP Low Profile Unit Cooler line offers a compact flush to ceiling design featuring internally enhanced tube technology. Storage space is optimized by a compact, slim profile, which provides uniform air distribution through the coil for maximum heat transfer performance. Many models also available as value-priced pre-assembled units.

Certification:

• Ample electrical and header compartments • Lower heater wattage

Features: • Streamlined cabinet style • High efficiency and high strength fan guard • Front access • Higher capacity • Compact • Internally enhanced tubing • More uniform air flow • Reverse cycle & 3 pipe hot gas available • Convenient mounting brackets

• PSC Motors • Proven motor/fan/motor mount design • Liquid line solenoid valve wire harness factory installed • Schrader valve on suction header  • Positive slope, hinged drain pan • Central drain connections (approximate) • Universal drain fitting • Large 3/4” ID (3/4” MPT) drain hole • Factory installqed distributor nozzle • 460/1/60 PSC motor only

Options: Optional Features ( Factory Mounted):

-30°F and above room temperatures

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 Air, electric and hot gas defrost (reverse cycle or 3 pipe) models

• EC motors with SmartSpeed® Technology (Patent Pending) 

• Compatible with SmartVap™ Electronically Controlled System

Capacity: 

• Heat exchanger - shipped loose

Medium Temp. models from 4,300 to 39,000 BTUH @10°F TD, R404A

• Heresite Coating 

Low Temp. models from 3,070 to 34,400

• Copper or GW Aluminum “Gold Coat” Fins

BTUH @10°F TD, R404A

• Wire fan guard

Electrical:

• Painted Cabinet

SPECIFICATIONS: Application: 

R404A, R22, R407C

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115/1/60

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208-230/1/60

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208-230/3/60

Medium and Low Temperature Applications

VI.

SELECTION OF CONDENSER

TrilliumSeries™ Condenser The TrilliumSeries™ Condenser uses a patented Dry -Coil Adiabatic™ Design that saves energy, reduces refrigerant charge, and lowers operating costs. With the use of proprietary logic and EcoFlex controls, the On-Demand Adiabatic™ Pre -Cooler uses water only on the hottest days to maintain condensing temperatures that typical air cooled technology cannot achieve. Because of this, the TrilliumSeries™ Condenser is the lowest total cost of ownership product for supermarket refrigeration systems.

Ownership Benefits In a variety of climate conditions, the TrilliumSeries™ Condenser provides the lowest total cost of ownership compared to air cooled units.

Installation Advantages o 60% lower refrigerant charge may help meet EPA’s Greenchill Certification o

Compact and lighter in weight

o

Single point electrical connection

o Direct drive VSEC motors and Whisper Quiet Fans are standard

System Energy Savings Reduce Monthly Energy Bills

o For new stores, reduces overall system size by operating at lower condensing temperatures

•

Reduced condensing temperature

•

Less compressor work

o

Exempt from Title 24 legislation

Direct drive VSEC motors minimize fan energy required •

o For refrigeration upgrades, increases system capacity without changing out expensive racks •

Economic Advantages

o

Attractive payback timeframes

o

Lower total cost of ownership

Annual 37.2% System Energy Reduction for El Paso, Texas

Peak Energy Savings Up to 43.5% peak energy reduction compared to air cooled units by operating compressors at significantly lower condensing temperatures •

Average Payback Period by Region Notes for the Average Payback by Region Graph: 1. Average payback periods based on curre nt analyses performed. Specific payback periods vary. Utility prices (electricity, water, etc) vary by state and system details vary by job. 2. Northeast region includes MA, MD, CT, DC, NJ, NY, PA, RI. 3. Midwest region includes MN, MO. 4. Southwest region includes LA, TX, Southern CA. 5. Northwest region includes Northern CA, OR, and UT.

o Peak energy is more expensive than off peak energy o

Reduces peak demand charges

o Potential for substantial state and local energy rebates

Average Peak Energy Reduction %kW by State

Rebates Most states offer utility incentives and rebates which further decrease the initial investment of the TrilliumSeries™ Condenser.

Type of Rebate

Example based on www.dsireusa.org Custom Measures and Retro-commissioning: $0.11/kWh saved up to 75% of incremental cost

Custom

Refrigeration

• Refrigeration Equipment: $35-$1000/unit • Air Conditioning and Refrigeration: $0.09 – $0.15/kWh saved

VFDs on Fan Motors or Other Controls

• Variable Frequency Drives: $80/HP • Refrigeration Controls: $75-$100/Controller

Dsireusa.org is a website with information on state, local, utility, and federal incentives and policies that promote renewable energy and energy efficiency. Established in 1995 and funded by the U.S. Department of Energy, DSIRE is an ongoing project of the N.C. Solar Center and the Interstate Renewable Energy Council. For custom rebates, an analysis of the overall system energy savings from air cooled to the TrilliumSeries™ Condenser may be necessary and is available from Baltimore Aircoil Company.

Optional Built-in Energy Tracking / Alarms Optional alarms for the fans, pumps • and valves reduce high head pressure instances

Optional energy monitoring • maintains efficient operation over the life of the product

On-Demand Adiabatic™ PreCooler Water is used ONLY when the • ambient temperatures require it o Water spray saturates and cleans the On-Demand Adiabatic™ Pre -Cooler media of any dust and debris •

No water treatment is required

• water

Free draining prevents stagnant

LEED® Points available for water efficient landscaping (WE credit 1) based on 2009 LEED for Retail and Commercial Interior rating system •

o Water from the drain and overflow can be used for irrigation or other nonpotable uses •

Controls Options

o Water Quality Sensor (Option) – Flushes the sump based on a factory preset conductivity level to minimize water use. o Water Monitoring (Option) – This option monitors the amount of purged water and maintains efficient operation over the life of the product.

Sound Levels

Easy Maintenance Requires the same time to maintain as an air cooled condenser •

•

Water treatment is not required

o Water is turned on only when ambient temperature requires it o Water spray saturates and cleans the On-Demand Adiabatic™ Pre -Cooler media of any dust and debris On-Demand Adiabatic™ Pre -Cooler • media acts as a filter to prevent debris from Average Annual Water Use Compared to Evaporative Condensers

reaching the microchannel

Low Sound

o Can be removed without tools for easy coil inspection

•

Whisper Quiet Fans are standard

Direct drive VSEC fan motors vary the • fan speed eliminating sudden starts and stops

Clean-out ports on both ends of water distribution header facilitate easy cleaning •

The EcoFlex Controls maintain a • clean sump Pump and strainer are easily accessible from the access hatch •

Adiabatic™ Pre-Cooler, and daily automatic

sump clean out Critical components are stocked and • ship within 24-hours Manual discrete spray system (water bypass) standard •

Easy Access to Pumps and Valves

Charge Reduction 60% less charge than comparable air • cooled condensers Reduced charge could help meet EPA’s Greenchill commitments •

Lowers greenhouse gas emissions of the supermarket refrigeration system •

Discrete Spray System Durable materials of construction • extend the life of the unit •

Sump and drain pans drain freely

Ability to switch fans from automatic • to manual fan override in case of control signal loss Access hatch sensor shuts off the fan • when the hatch is opened •

UL Approved unit

Coated microchannel independently • tested per G85-A4 for 3,000+ hours Unit Refrigerant Charge Reduction

Peace of Mind All units are equipped with state of • the art EcoFlex controls, On-Demand

The TrilliumSeries™ Condenser program

allows you to select the optimum TrilliumSeries™ Condenser based on  ASHRAE design conditions and weather profile by bin data that are pre-populated by city and state.

VII. SELECTION OF COMPRESSOR (SIZE, CAPACITY, ETC.)

Copeland Scroll™ Compressors for Refrigeration Because of their unmatched reliability, Copeland Scroll™ compressors are being used more and more in commercial refrigeration as contrac tors and original equipment manufacturers (OEMs) seek new ways to utilize the technology in supermarket, foodservice and healthcare applications.

Copeland Scroll K5 Compressor  

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7.5 –15 horsepower for supermarket, walk-in, and industrial applications Approved for low, medium, & high temperature applications R-404A, R-407A, R-407C, R-134a ready Enhanced Vapor Injection (EVI) available for best total store efficiency Improvements in low condensing performance for better real world benefit (AEER) Equipped with CoreSense Diagnostics for advanced reliability

Copeland Scroll CO2 Compressor  

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Leverages reliability of proven Copeland Scroll technology Designed For CO2 pressure and lubrication requirements Hermetic design to reduce potential for leaks Digital modulation available from 10 – 100%

Copeland Scroll ZS*KA Compressor   

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1-4 horsepower applications Evaporating temperatures from -25°F to 45°F R-404A, R507, R-134a, R-407A/C, & R22 Recommended for walk-in refrigerators and freezers, soft serve machines, frozen beverage machines

Copeland Scroll ZFKV Compressor  

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4 –15 horsepower low temp optimized compressor R-404A, R-407A, & R-407C ready Designed for Enhanced Vapor Injection (EVI) performance gains Improved system capacity (~50%) and efficiency (~20%) Digital modulation available from 10100%

Copeland Scroll ZBKC Compressor  

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2-15 horsepower compressors optimized for medium & high temperature applications R-404A, R-407C & R-134a ready Improved efficiency from 10-15% annually Digital modulation available from 10100%

Copeland Scroll Transport Compressors 

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Best in class energy efficiency and pull-down Precision temperature control through digital modulation Corrosion protection and superior reliability for demanding environments

Copeland Scroll Outdoor Condensing Unit - XJ Series 

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Scroll compressor unit with CoreSense™ Diagnostics provides superior reliability High efficiency compressor, fan and coil result in energy savings of 20% or more over standard systems Slim profile, lightweight and quiet operation offer flexible installation options

http://www.emersonclimate.com/enus/Products/Compressors/Scroll_Compressors/copeland_scroll_refrigeration/Pages/copeland_scroll_for_refrige ration_applications.aspx#sthash.e6MyeYPG.dpuf 

Table 27.1: COMPRESSOR POWER Power

Efficiency

Brake

Standard

(hp)

(%)

(hp)

(hp)

Wk1 = 0.4609

40

1.15225

2

brake power = power/efficiency = 0.4609 hp / 0.4 = 1.15225 hp ≈ 2 hp

Wk2 = 39.9672

40

99.918

100

Wk3 = 4.6003

40

11.5

12

Wk4 = 1.4437

40

3.6093

4

Wk5 = 0.4813

40

1.2033

2

Wk6 = 0.4337

40

1.0843

2

Wk7 = 0.1663

40

.4158

1

Wk10 = 0.152

40

.38

1

Wk11 = 0.1739

40

.4348

1

WkA = 106.1355

40

265.3388

266

VIII. DESIGN/SELECTION OF OTHER AUXILIARY EQUIPMENT (COOLING TOWER, PUMPS, FANS, BLOWERS, DUCTING SYSTEM, ETC.) A. COOLING TOWER

Paragon Induced Draft Towers

Delta’s Paragon® Induced Draft, counter flow design is available in single module capacities from 55 to 250 cooling tons.

Manufactured since 1981, the Paragon® tower has been very well received in both commercial and industrial applications. Paragon’s unique design provides unlimited flexibility of modular operation, future upgrade capability and location convenience.

Standard Features: •

Seamless Engineered Plastic (HDPE) Shell

•

Corrosion Proof Construction

•

Direct Drive Fan System

•

Totally Enclosed VFD Rated Motors

•

Factory Assembled for Simple Installation

•

20 Year Shell Warranty

•

Low Pressure Drop Self Propelled PVC Water Distribution System

•

High Efficiency PVC Fill

•

Made in the USA

Basic Specs

Detailed Features

A self-propelled PVC distribution system incorporating a rotating sprinkler head and lateral distribution arms with integral drift eliminators. An inspection port is provided in the cooling tower shell at the lateral arm elevation for adjustment. (Non-rotating water distribution system is also available). Wet Decking:

A continuous wrapped spiral configuration of lightweight PVC, bonded and packed for maximum film cooling efficiency. Fan Assembly:

All Delta Cooling Towers are factory assembled to the fullest extent possible for ease of installation and shipment. The following features are standard on our Paragon® Series Induced Draft Cooling Towers: Shell:

A seamless engineered polyethylene cylindrical (HDPE) molded shell, with co nical transition for motor/fan assembly, louvered inlets and fitting orientation. Louvered inlets are designed for 360° air distribution. There are no joints, seams, panels, gaskets, bolts, fasteners or caulking like conventional towers. Sump:

Sump is integral with cooling tower shell, creating a one-piece seamless structure. Water Distribution System:

The fan assembly consists of a fan ring, propeller, motor and guard. The fan ring is coated with premium plasite coating ideal for the harshest corrosive environments. An adjustable pitch propeller fan, fiberglass reinforced polypropylene with a silica alloy hub, is directly driven by a totally enclosed VFD Premium rated motor designed for cooling tower duty. A fan guard is included that allows protection from the propeller and access to the motor. Motor:

Totally enclosed air over (TEAO) VFD rated motor with 1.15 service factor, designed for 208 or 230/460V 3 phase 60 cycle operation and suitable for outdoor service. Motor is provided with a 5-year motor manufacturers warranty. Fitting Connections:

PVC fittings are provided for inlet, outlet, overflow, drain and make-up connections at standard orientation locations. Orientation for special requirements is available for new and replacement installations. Hardware:

All fasteners are 304 stainless steel. Anchor and lifting lugs are aluminum.

Cutaway View

2 - Lightweight And Heavy Duty: Plastic is lighter than conventional cooling towers and average wall thickness is 5-10 times sheet metal towers.

3 - Leak Proof Sump: Molded as Unitary (OnePiece) Structure that has no joints to leak or require recaulking and sealing 4 - Water Distribution System: Self-propelled multiple PVC rotating arm system evenly distributes the water 5 - Drift Eliminator: Polyethylene drift eliminators prevent water droplets from leaving the tower 6 - Fill Material: high efficiency spiral wound PVC cellular design for maximum cooling 1 - Corrosion-Proof Shell: HDPE Plastic Construction can not corrode and is backed by 15 Year Warranty

7 - Direct Drive Air Moving System: Totally enclosed PVC rated cooling tower motor powers fiber-reinforced polypropylene axial propeller fan.

http://www.deltacooling.com/paragon-induced-draft-towers/#sthash.5u6znWyb.dpuf

B. PUMP

Refrigeration Circulation Pump

Product Description Specifically designed for refrigeration cold plate circulation, this pump allows you to adjust water flow accordingly to your system. This 8050 features a positive displacement, three chamber diaphragm, self-priming to 4 feet vertical––and EPDM™ valves for proven ability and longer life. 

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Model Numbers • Model # 8050 -261-105

Aftermarket

• Model # 8050 -261-105

OEM

Features & Benefits 

Continuous Duty Motor

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• Cold Plate Circulation

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• Self -Priming up to 4’ 

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• Run Dry Capability

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• 12 VDC Motor

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• Seamless Motor Shell -Waterproof

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• 30 PSI Pressure

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Specifications / Replacement Parts 



Name :

Refrigeration Circulation Pump

Model # OEM/Aftermarket :

8050-261-105 OEM, 8050-261-105 Aftermarket

Description:

12 VDC-CE Version, No switch, Continuous Duty Motor, Cold

Plate, Refrigeration Pump.

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Dimensions : Flow Rate GPM/LPM :

7.25" x 4.25" x 4.40" [184x108x112mm] 0.5 GPM

[1.9 LPM]

Amps (Max) : 

1.5

Max Pressure :

30 PSI [2.1 BAR]

Refrigeration Circulation Pump

Product Description Specifically designed for refrigeration cold plate circulation, this pump allows you to adjust water flow accordingly to your system. This 2095 features a positive displacement, three chamber diaphragm, self-priming to 4 feet vertical––and EPDMâ valves for proven ability and longer life. 

Model Numbers

• Model # 2095-273-200 Aftermarket • Model # 2095-273-200 OEM

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Features & Benefits 

Continuous Duty Motor

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• Cold plate circulation

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• Self -Priming up to 4’ 

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• Run Dry Capability

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• 12 VDC Motor

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• Seamless Motor Shell -Waterproof

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• 70 PSI

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Specifications / Replacement Parts 

Name :

Refrigeration Circulation Pump

Model # OEM/Aftermarket :

2095-273-200 OEM, 2095-272-200

Aftermarket Description:

12 VDC-CE Version, No switch, Continuous Duty

Motor, Cold Plate, Refrigeration Pump.

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Dimensions : Flow Rate GPM/LPM :

6.25" x 6" x 4.6" [159x152x117mm] 1.5 GPM

[5.7 LPM]

Amps (Max) : 

3.5

Max Pressure :

70 PSI [4.9 BAR]

C. FANS

Haiku™ / S3150-A2

Model Name/# Cocoa Haiku™ / S3150-A2

Number of Airfoils

Fan Diameter

3

60 in. (1524 mm)

Motor Type

Motor & Assembly Finish

EC motor with a digital inverter drive

Black White

Controller Included Yes, remote

Airfoil Material

Controller Features

Bamboo

On/Off

Airfoil Finish

Sleep Mode Off Timer

Caramel

Whoosh Mode Reverse

Mount and Drop Tube

Watts (min/max)

Standard length, included (10.2 in. / 260

2/30 W (fan only)

mm)

Hanging Weight

Ambient Operational Temperature Change

13.2 lb (6 kg)

32°–120° F (0–49° C)

Number of Fan Speeds

Environment

7

For indoor use only

Operating Voltage

Fan Mode Indicator

100–240 VAC, 1Φ

LED display

Operating Frequency

Warranty*

50–60 Hz

Limited lifetime

RPM (min/max)

Energy Information at High Speed**

35/175 RPM

Airflow: 5,365 CFM

Amps (min/max)

Electricity Use: 11W (w/out light) Airflow Efficiency: 485 CFM/watt

0.05 - 0.363 A View DOE Label ** Many standard ceiling fans feature only three speeds, so ENERGY STAR ® tests CFM at high, medium and low speeds. Haiku's measured "high speed" is actually just the fifth of its six/seven speeds. * Limited Lifetime Warranty applies to U.S. and Canada purchases only. Outside U.S. and Canada; 1 year warranty.

D. BLOWERS

InLine-Series Fan Centrifugal Exhaust Blower

The KCH Inline Series exhaust blower is completely weatherproof and fully corrosion resistant. This tubular centrifugal inline blower offers straight airflow design for duct installations requiring minimal space, low noise characteristics, and high efficiency. These blowers can be fabricated from a wide variety of materials such as:     

PVC FRP Polypropylene Stainless Steel Epoxy coated carbon steel

Each unit is complete with TEFC motor with cover, formed inlet cone, backward inclined wheel, and V-belt drive.

Fan Specs for CI & NH Fan Ratings:

The fans shall be tested and rated according to AMCA Standard 210. They shall be certified by the Air Movement and Control Association (AMCA) and shall be licensed to bear the AMCA seal. Fans shall be model CI or NH as manufactured by KCH Services, Inc. Fan Units:

Provide factory-assembled and tested fan units consisting of housing, wheel, fan shaft, bearings, access door, corrosion resistant support structure, drive, motor, drain, and OSHA approved belt guard and shaft cover.

Fan Corrosion Resistance:

 All fan parts in contact with the airstream shall be resistant to corrosion by chemicals in the air stream. Fan housings shall be PVC, Polypropylene, or FRP Material. Fan Wheels:

Wheels to be keyed to shafts. Steel wheels to be minimum Class II construction and coated with FRP. Solid FRP, Stainless Steel, or Hastelloy wheels can be offered as an alternative. Wheels to be statically and dynamically balanced after assembly and before shipment. Fan Bearings:

Provide heavy-duty grease lubricated, precision anti-friction ball or roller, self-aligning, pillow block type bearings selected for minimum average life (AFBMA L 50) of 100,000 hours. Fan Drive:

Provide V-belt drive, selected for 1.5 services factor. Belts shall be provided in matched sets. Fan Arrangement:

Fans to be arrangement 9 for motors of less than 40 H.P. and Arrangement 1 for motors 40 H.P. and above. Fan Base:

Provide slide rail motor base. Fan Motors:

Provide totally enclosed fan cooled motors, 230/460 volt, 3 phase, 60 hertz. 1800 RPM or 3600 RPM. Fan Access Doors:

Provide bolted access door in housing scroll. Provide stainless steel bolts with bolt surface inside housing capped and sealed. Fan Drain Connection:

Provide 1" - 1 1/2" dia. coupling drain connection at lowest point of housing. Fan Connections:

Provide flanged or flexible type inlet and flanged outlet connections.

HARTZELL TURBO PRESSURE BLOWER Request Quote

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Features: 

Sizes 14" to 26" wheel diameters, available in Arrg. 1, 4, 8, 9, and 10

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CFM from 100 to 5,250 with SP up to 60"

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Designed for applications with high static pressure and low flow requirements and features a compact design, easy installation, and low maintenance Housings are continuously welded heavy gauge steel Type PB turbo blower wheel is fabricated high strength aluminum and steel using a spun front plate and formed blades and is available in AMCA Type A or B spark resistant construction Type SB turbo blower wheel is fabricated steel or stainless steel with a spun front plate and formed blades Available in clockwise or counter clockwise rotation with six standard discharge positions and rotatable housing Options and accessories are available

REFERENCES: Kent’s Mechanical Engineering Handbook

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