EP2321593B1 - Improved operation of a refrigerant system - Google Patents
Improved operation of a refrigerant system Download PDFInfo
- Publication number
- EP2321593B1 EP2321593B1 EP09805559.3A EP09805559A EP2321593B1 EP 2321593 B1 EP2321593 B1 EP 2321593B1 EP 09805559 A EP09805559 A EP 09805559A EP 2321593 B1 EP2321593 B1 EP 2321593B1
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- EP
- European Patent Office
- Prior art keywords
- refrigerant
- economizer
- cylinder module
- module
- valve
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B1/00—Compression machines, plants or systems with non-reversible cycle
- F25B1/10—Compression machines, plants or systems with non-reversible cycle with multi-stage compression
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B41/00—Fluid-circulation arrangements
- F25B41/20—Disposition of valves, e.g. of on-off valves or flow control valves
- F25B41/22—Disposition of valves, e.g. of on-off valves or flow control valves between evaporator and compressor
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2400/00—General features or devices for refrigeration machines, plants or systems, combined heating and refrigeration systems or heat-pump systems, i.e. not limited to a particular subgroup of F25B
- F25B2400/13—Economisers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2600/00—Control issues
- F25B2600/25—Control of valves
- F25B2600/2509—Economiser valves
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2700/00—Sensing or detecting of parameters; Sensors therefor
- F25B2700/19—Pressures
- F25B2700/193—Pressures of the compressor
- F25B2700/1931—Discharge pressures
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2700/00—Sensing or detecting of parameters; Sensors therefor
- F25B2700/21—Temperatures
- F25B2700/2106—Temperatures of fresh outdoor air
Definitions
- the present invention relates to a refrigerant system having an economizer module and a reciprocating compressor. More particularly, the present invention relates to a method and system for operating the refrigerant system in various modes of loading and unloading.
- suction pressure (P3) and discharge pressure (P4) of economizer cylinder module 32 may not be included in refrigerant system 10. Pressures (P3) and (P4) may be less significant than suction pressure (P1) and discharge pressure (P2) of main cylinder module 30, which are used to analyze conditions at evaporator 22.
- refrigerant system 110 includes connector refrigerant line 170 located between main refrigerant line 142c and economizer refrigerant line 144b, and third valve 172 installed in connector refrigerant line 170.
- valves 124, 126 and 172 have variable openings such that refrigerant system 110 has additional flexibility to position valves 124, 126 and 172 at an intermediate position between fully open and fully closed.
- Refrigerant system 110 is able to operate in eight different operating modes, based on a position of valves 124, 126 and 172.
- the operating modes are generally ordered from highest to lowest cooling capacity. For purposes of the description below, a higher level of unloading corresponds to a lower cooling capacity.
- Four of the eight operating modes shown in Table 2 for refrigerant system 110 are feasible in refrigerant system 10 of FIG. 1 .
- system 110 provides even greater flexibility and control for unloading, as compared to refrigerant system 10 of FIG. 1 .
- system 110 also provides for greater cooling capacity than system 10 when the economizer cycle is not being used.
- main cylinder module 130 Due to a limited capacity of main cylinder module 130, less cooling is provided in evaporator 122 in this mode, as compared to a mode in which all refrigerant from economizer refrigerant line 144b were flowing through economizer cylinder module 130.
- first valve 124 is open, and second valve 126 and third valve 172 are closed.
- This operating mode was also feasible in refrigerant system 10 and was described above as mid-level unloading in Table 1.
- the economizer cycle is blocked in operating mode four. Because valve 172 is closed and economizer cylinder module 132 is thus not used, operating mode four provides less cooling as compared to operating mode two (i.e. full loading without economizer), and is therefore designated as an unloading mode. Additional unloading may be accomplished by partially closing first valve 124.
- Operating modes seven and eight are not common; if refrigerant system 110 operates in either of these modes, typically it is temporary operating mode and is used to avoid shutting down refrigerant system 110. Either of modes seven and eight may be adjusted to mid-level unloading or even a low level unloading by only partially closing one of the valves designated as being closed in Table 2. For example, if valve 124 is partially closed in either operating mode seven or eight, system 110 may operate between a low and mid-level unloading, depending on a specific position of valve 124.
- refrigerant system 110 provides superior flexibility during unloading, as well as the feasibility to achieve a greater cooling capacity when the economizer module is not being used.
- refrigerant system 110 includes both valves 124 and 126 in combination with connector refrigerant line 170 and valve 172.
- valve 124 or valve 126 may be eliminated.
- economizer module 18 and 118 is a heat exchanger.
- FIG. 3 is an alternative example in which economizer module 218 is a flash tank.
- the refrigerant exiting the high pressure heat exchanger is split into two refrigerant streams prior to entering the economizer heat exchanger.
- the single refrigerant stream from the high pressure heat exchanger passes through expansion device 219, where it is partially expanded to an intermediate pressure and temperature.
- the refrigerant entering flash tank 218 is usually in a two-phase thermodynamic state.
- float flow control device 221 is configured to open when a liquid level in the flash tank reaches a predetermined level or provide a certain restriction to a refrigerant flow to maintain a desired refrigerant level.
- the refrigerant exiting flash tank 218 through refrigerant line 244 has low vapor and high liquid content, which enhances cooling capacity in the evaporator.
- the refrigerant system and operating method described herein may easily be implemented into existing refrigerant systems.
- the refrigerant systems may include supermarket refrigerant systems, container refrigerant systems, truck/trailer refrigerant systems, rooftop air conditioning and heat pump refrigerant systems, and residential air conditioning refrigerant systems.
- the valves may be installed in existing refrigerant lines, and in some cases, a connector refrigerant line may also be added between the economizer refrigerant line and the main refrigerant line.
- the valves and connector refrigerant line described herein may also be incorporated into the design of new refrigerant systems.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Air Conditioning Control Device (AREA)
- Engine Equipment That Uses Special Cycles (AREA)
Description
- The present invention relates to a refrigerant system having an economizer module and a reciprocating compressor. More particularly, the present invention relates to a method and system for operating the refrigerant system in various modes of loading and unloading.
- Refrigerant systems are used to condition air in an environment by controlling the temperature and/or the humidity of the air. In a typical air conditioning or refrigeration system, a compressor delivers a compressed refrigerant to an outdoor high pressure heat exchanger, known as a condenser or a gas cooler. If the refrigerant in the outdoor heat exchanger, when cooled, condenses into a liquid this heat exchanger is commonly referred to as a condenser. If the refrigerant exiting the compressor is at a thermodynamic state above critical point, then the refrigerant upon cooling in the heat exchanger may not condense into a liquid but would simply be cooled to a lower temperature. In this case, this heat exchanger is commonly referred to as a gas cooler. From the high pressure heat exchanger, the refrigerant passes through an expansion device, and then to an indoor heat exchanger, known as an evaporator. In the evaporator, the air is blown over the evaporator external surfaces to lower a temperature of the air, and moisture may also be removed from the air to lower its humidity. From the evaporator, the refrigerant is returned back to the compressor.
- An economizer cycle may be used in a refrigerant system to increase the capacity and efficiency of the system. When the economizer cycle is actuated, a portion of the refrigerant is tapped from a main refrigerant circuit at a position downstream of the high pressure heat exchanger. The tapped refrigerant is expanded to a lower intermediate pressure and temperature, at which point it passes through an economizer module, which is commonly called an economizer heat exchanger, to further cool high pressure refrigerant in the main refrigerant circuit. The tapped refrigerant is returned back to the compressor, typically at an intermediate pressure. The main refrigerant travels to the evaporator where it has a greater thermodynamic cooling potential (cooling capacity), due to the fact that it has been additionally cooled in the economizer heat exchanger. An economizer cycle can also be achieved through the use of a flash tank, instead of the economizer heat exchanger, as known in the art.
- In one design, the refrigerant system may use a reciprocating compressor having two separate sets of cylinder modules, which are configured to receive and compress two separate refrigerant streams. An economizer cylinder module may be used to compress the tapped refrigerant from the economizer module, whereas a main cylinder module may be configured for compressing the main refrigerant from the evaporator. Downstream of the compressor, the two refrigerant streams are combined before flowing back to the high pressure heat exchanger.
- During operation of the refrigerant system, there may be conditions in which it is ineffective to use the economizer cycle, even though the refrigerant system is operating at or near full load. For example, if the ambient air temperature is high and the suction pressure entering the compressor is also high then the economizer cycle engagement may not add any additional cooling and thus the economizer cycle may be disengaged, even if there is a high cooling demand (i.e. full load). At other times, it may be beneficial to operate a refrigerant system in a mode that limits the cooling capacity by limiting a flow of refrigerant through the system, which may be referred to as unloading. The unloading can be achieved by disengaging the economizer circuit or providing bypass operation. There is a need for improved flexibility to vary a cooling capacity for a refrigerant system having an economizer cycle and a reciprocating compressor with a dedicated economizer cylinder module.
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US 2006/288719 A1 discloses a refrigerant system here the main refrigerant stream passes consecutively through both main and economizer cylinder modules of a compressor. -
US 2006/037336 A1 discloses a refrigerant system with a first valve in the main refrigerant line, a second valve in the economizer refrigerant line and a connecting valve in a connecting line downstream of the other two valves, such that there are two modes of loading available for the compressor. - The invention provides method and system for operating a refrigerant system having a reciprocating compressor with a main cylinder module and an economizer cylinder module, as set forth in
claims 1 and 5. In the context of this application a single cylinder module may be substituted by bank of cylinder modules. The refrigerant system provides cooling by circulating a refrigerant through a high pressure heat exchanger, an economizer module, an evaporator, and at least one of the main cylinder modules and at least one of the economizer cylinder modules. The flow of refrigerant into the main cylinder module may be controlled as a function of an operating mode of the refrigerant system, which includes various modes of loading and unloading based, in part, on a cooling demand. The flow of refrigerant into the economizer cylinder module may separately be controlled as a function of the operating mode. The refrigerant system includes a connector line between a first main refrigerant line and a second economizer refrigerant line, providing a valve configured to redirect refrigerant from the economizer cylinder module to the main cylinder module or from the main cylinder module to the economizer cylinder module. The valve in the connector refrigerant line is located downstream of a valve in the second refrigerant line and upstream of a valve in the first refrigerant line. -
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FIG. 1 is a schematic of a refrigerant system which is outside the scope of the claims including an economizer module, a reciprocating compressor having a first inlet connected to a main refrigerant line and a second inlet connected to an economizer refrigerant line, a first valve in the main refrigerant line, and a second valve in the economizer refrigerant line. -
FIG. 2 is a schematic of an embodiment of the refrigerant system fromFIG. 1 , which is within the scope of the claims and includes a connector line and corresponding valve between the main refrigerant line and the economizer refrigerant line. -
FIG. 3 is a schematic of a flash tank that may be used in the economizer module as an alternative to an economizer heat exchanger. -
FIG. 1 is a schematic ofrefrigerant system 10 includingcompressor 12, highpressure heat exchanger 14,first expansion device 16,economizer module 18,second expansion device 20,evaporator 22,first valve 24,second valve 26 andcontroller 28.Refrigerant system 10 is configured to circulate a refrigerant throughsystem 10 to provide cooling and condition an air stream (not shown) passing throughevaporator 22. -
Compressor 12 is a reciprocating compressor and includesmain cylinder module 30 andeconomizer cylinder module 32. It is recognized that one or both ofmain cylinder module 30 andeconomizer cylinder module 32 may include more than one cylinder and more than one cylinder module. In an exemplary embodiment,main cylinder module 30 has higher displacement thaneconomizer cylinder module 32.Compressor 12 includesfirst suction inlet 34, which is connected tomain cylinder module 30, andsecond suction inlet 36, which is connected toeconomizer cylinder module 32. Similarly,compressor 12 also includesfirst discharge outlet 38 extending frommain cylinder module 30 andsecond discharge outlet 40 extending fromeconomizer cylinder module 32.System 10 is designed such thatmain cylinder module 30 andeconomizer cylinder module 32 each receive a distinct refrigerant stream for compression. As shown inFIG. 1 ,main cylinder module 30 is configured to receive refrigerant fromevaporator 22 andeconomizer cylinder module 32 is configured to receive refrigerant fromeconomizer module 18. - Two refrigerant streams exit
compressor 12 viafirst outlet 38 andsecond outlet 40 respectively. Before entering highpressure heat exchanger 14, the refrigerant streams are recombined such that highpressure heat exchanger 14 receives one refrigerant stream. In highpressure heat exchanger 14 operating as a condenser, the vapor refrigerant condenses to form liquid refrigerant. In an alternative embodiment ofrefrigerant system 10, highpressure heat exchanger 14 may be substituted with a gas cooler, where refrigerant stays in a single phase thermodynamic state. - Once the refrigerant exits high
pressure heat exchanger 14, the refrigerant may again be split into two refrigerant streams. A main refrigerant stream flows throughmain refrigerant line 42a; an economizer refrigerant stream flows through tap line 44a, also referred to as economizer refrigerant line 44a. The refrigerant in tap refrigerant line 44a passes throughfirst expansion device 16 in order to lower its temperature and pressure before passing througheconomizer module 18.Expansion device 16, as well assecond expansion device 20, may include a capillary tube, an orifice, a thermostatic expansion device, or an electronic expansion device. - Inside
economizer module 18, the refrigerant flowing through tap line 44a further decreases a temperature of the main refrigerant stream passing throughmain refrigerant line 42a.Economizer module 18 is used to provide additional cooling capacity to the main refrigerant stream. In an exemplary embodiment,economizer module 18 is a heat exchanger. An alternative embodiment ofmodule 18 is described in further detail below. Also, as known, the economizer refrigerant flow may be tapped downstream (instead of upstream) ofeconomizer module 18. Such system configurations are within the scope and can equally benefit from the invention. - After exiting
economizer module 18, the main refrigerant stream passes throughsecond expansion device 20, and then toevaporator 22 throughmain refrigerant line 42b. The main refrigerant is evaporated insideevaporator 22 by removing heat from air passing over external surfaces ofevaporator 22. Mainrefrigerant line 42c connectsevaporator 22 toinlet 34 ofmain cylinder module 30, and the refrigerant flows through mainrefrigerant line 42c to undergo compression in a separate compression path in themain cylinder module 30.First valve 24 is located in mainrefrigerant line 42c and regulates a flow of the main refrigerant betweenevaporator 22 andcompressor 12. The economizer refrigerant stream flows directly fromeconomizer module 18 tocompressor 12 through economizerrefrigerant line 44b.Second valve 26 is located ineconomizer line 44b and regulates a flow of the economizer refrigerant betweeneconomizer module 18 andcompressor 12. More specifically, economizerrefrigerant line 44b connects tosecond inlet 36 ofcompressor 12. - The system of
FIG.1 includes the use ofvalves compressor 12, and more specifically to control a flow of refrigerant throughmain cylinder module 30 andeconomizer cylinder module 32. An amount of cooling provided byrefrigerant system 10 may be controlled by controlling a circulation of the refrigerant throughmain cylinder module 30 andeconomizer cylinder module 32, as described further below. A cooling capacity ofrefrigerant system 10 may be varied by operating the system in loading or unloading modes. These operational modes are also described in further detail below. -
Valve 24 is used to control the flow of refrigerant intomain cylinder module 30, which directly impacts an amount of cooling provided byevaporator 22. As more refrigerant is pumped throughcylinder module 30, more refrigerant is circulated throughevaporator 22, which results in increased amount of cooling of air passing over theevaporator 22. Similarly,valve 26 controls flow of refrigerant througheconomizer cylinder module 32. As more refrigerant is pumped throughcylinder module 32, more refrigerant is circulated througheconomizer module 18, which provides additional cooling to the refrigerant in main refrigerant line. As described below,valves evaporator 22. - For a refrigerant system similar to
system 10, but not includingvalves system 10, which may be undesirable for several reasons. Inrefrigerant system 10 ofFIG. 1 , three levels of unloading are made feasible byvalves Refrigerant system 10 is able to operate in four different operating modes shown in Table 1 below, depending on a position ofvalves Table 1 Operating Mode First Valve 24 Second Valve 26Comments Full loading with economizer Open Open Typical for high pressure ratio. Would be identical if valves Mid-level unloading Open Closed Economizer cycle blocked Full unloading A Closed Open Unloading with discharge flow cooling Full unloading B Closed Closed Unloading without discharge flow cooling - In the scenario in which both
valves refrigerant system 10 operates the same as a refrigerant system not havingvalves compressor 12. In the full loading mode of Table 1, the economizer cycle is being utilized sincevalve 26 is open. In the economizer mode,economizer module 18 uses refrigerant in the tapped refrigerant line 44a to further cool refrigerant in the mainrefrigerant line 42a such that the main refrigerant provides additional cooling to the air inevaporator 22. This operating mode is referred to as "Full loading with economizer" sincevalve 26 ineconomizer line 44b is open and bothcylinder modules - The economizer cycle is generally used when a ratio of discharge pressure to suction pressure in
compressor 12 is high (typically when the system operates at pressure ratio above 3). As such, the pressure at the suction or inlet ofcompressor 12 is typically low, which is a function of low pressure insideevaporator 22. A low evaporator pressure typically correlates to a low ambient air temperature. In that case,refrigerant system 10 may operate in the economizer mode (i.e.valve 26 open) to further decrease the air temperature. - In the second mode shown in Table 1 and designated as "Mid-level unloading", the economizer cycle is blocked by closing
valve 26, which prevents refrigerant from circulating througheconomizer module 18. As such, refrigerant in the tapped refrigerant line essentially stops providing cooling to refrigerant in the main refrigerant line ineconomizer module 18. This mid-level unloading mode may commonly be used at low to moderate pressure ratio applications (typically in pressure ratio range from 1 to 3). When the air requiring cooling is at a high temperature,refrigerant system 10 provides higher cooling capacity when the economizer cycle is not active. A higher ambient air temperature commonly results in a high pressure in the evaporator. As such, a high ambient air temperature usually correlates to a low pressure ratio (discharge to suction). The pressure ratio may commonly be monitored or calculated to determine whether to engage or disengage the economizer cycle. - In the third mode of Table 1, labeled as "Full unloading A",
valve 24 is blocked such that the only refrigerant flowing throughcompressor 12 is the tapped refrigerant fromeconomizer module 18. Becausevalve 26 is closed, refrigerant stops circulating throughevaporator 22 and ceases to provide cooling to air passing throughevaporator 22. This high level of unloading may be used when there is little to no cooling load required, yet it is desirable to continue operatingrefrigerant system 10, instead of completely shutting it down. By flowing the tapped refrigerant line fromeconomizer module 18 throughcompressor 12, discharge cooling may be provided tocompressor 12. - Finally, the last fourth mode shown in Table 1 and is designated as "Full unloading B" is a mode in which both
valves refrigerant system 10 and is no longer able to provide cooling to air passing throughevaporator 22. Similar to the "Full unloading A" mode above,refrigerant system 10 may operate in this mode when there is minimal, if any, cooling load present. It is recognized that this last mode is an unusual operating condition and additional steps may need to be taken to ensure thatcompressor 12, as well as other equipment inrefrigerant system 10, does not overheat. -
Valves valves valves Valves valves valve 24 may not be fully closed and, in this case,refrigerant system 10 will not have a full unloading operation. - Operation of
valves controller 28, which determines a most effective mode of operation based on particular parameters insiderefrigerant system 10. Depending on sensed parameters,controller 28 adjustsvalves controller 28 may adjust the valves from fully open, fully closed or an intermediate position. To determine an operating mode and hence a position ofvalves controller 28 may include, but are not limited to, a temperature insideevaporator 22, a set point temperature of the air to be conditioned, a pressure at an inlet of compressor 12 (i.e. suction pressure), and a pressure at an outlet of compressor 12 (i.e. discharge pressure). -
System 10 includes various sensors that communicate withcontroller 28. As shown inFIG. 1 ,temperature sensor 50 may be associated withevaporator 22 for sensing a temperature (T1) inevaporator 22. It is recognized thatsensor 50 may include more than one temperature sensor positioned at various locations atevaporator 22. Several pressure sensors are also included inrefrigerant system 10. As described above, the ratio of discharge pressure to suction pressure forcompressor 12 may be used to determine an operating mode ofrefrigerant system 10. The suction pressure usually correlates to the pressure of therefrigerant exiting evaporator 22 and may commonly be measured atsuction inlet 34 of mainrefrigerant line 42c. However, ifvalve 24 is closed, refrigerant is not able to flow throughsuction inlet 34. Therefore,first pressure sensor 52 may be included in mainrefrigerant line 42c at a position upstream offirst valve 24 to measure suction pressure (P1) of the main refrigerant.Second pressure sensor 54 may be located nearfirst discharge outlet 38 ofmain cylinder module 30 to sense a discharge pressure (P2) of the mainrefrigerant exiting compressor 12.Pressure sensor 56 may also be located ineconomizer line 44b to measure a pressure (P3) ineconomizer line 44b; andpressure sensor 58 may be located nearsecond discharge outlet 40 ofeconomizer cylinder module 32 to measure a discharge pressure (P4) at the exit fromeconomizer cylinder module 32. In some embodiments, suction pressure (P3) and discharge pressure (P4) ofeconomizer cylinder module 32 may not be included inrefrigerant system 10. Pressures (P3) and (P4) may be less significant than suction pressure (P1) and discharge pressure (P2) ofmain cylinder module 30, which are used to analyze conditions atevaporator 22. - Data from
sensors controller 28, as shown inFIG. 1 . In addition,temperature sensor 60 may be used to measure an ambient air temperature (AT), which is also an input tocontroller 28.User input 62 may include a set point temperature (SPT) for the air to be cooled inevaporator 22. It is recognized that additional sensors and additional inputs tocontroller 28 not shown inFIG. 1 , may be included inrefrigerant system 10. Based on the various inputs tocontroller 28,controller 28 regulates a position ofvalves refrigerant system 10 operates efficiently and avoids nuisance shutdowns. - In the example shown in
FIG. 1 ,refrigerant system 10 includesfirst valve 24 in mainrefrigerant line 42c betweenevaporator 22 andcompressor 12, andsecond valve 26 in economizerrefrigerant line 44b betweeneconomizer module 18 andcompressor 12. In another example, a refrigerant system may include only one ofvalves -
FIG. 2 is a schematic ofrefrigerant system 110, which is an alternative embodiment ofrefrigerant system 10 ofFIG. 1 . Similar torefrigerant system 10,refrigerant system 110 includescompressor 112, highpressure heat exchanger 114,first expansion device 116,economizer module 118,second expansion device 120,evaporator 122, first valve 124,second valve 126,controller 128, and variable frequency drive (VFD) 129.Refrigerant system 110 operates in a similar manner torefrigerant system 10 described above.Compressor 112 includesmain cylinder module 130 andeconomizer cylinder module 132. Eachcylinder module cylinder modules FIG. 2 , first valve 124 is installed in mainrefrigerant line 142c betweenevaporator 122 and inlet 134 tomain cylinder module 130;second valve 126 is installed in economizerrefrigerant line 144b betweeneconomizer module 18 andinlet 136 ofeconomizer cylinder module 132. Unlikerefrigerant system 10,refrigerant system 110 includes connectorrefrigerant line 170 located between mainrefrigerant line 142c and economizerrefrigerant line 144b, andthird valve 172 installed in connectorrefrigerant line 170. In preferred embodiments,valves refrigerant system 110 has additional flexibility to positionvalves - In
refrigerant system 10 shown inFIG. 1 ,valves evaporator 22 tomain cylinder module 30 and fromeconomizer module 18 to economizercylinder module 32. However, it is not possible inrefrigerant system 10 to redirect refrigerant from mainrefrigerant line 42c to economizerrefrigerant line 44b, and vice versa. As such,refrigerant system 10 prevents the main refrigerant stream from flowing througheconomizer cylinder module 32 and the economizer stream from flowing throughmain cylinder module 30.Refrigerant system 110 overcomes these limitations by installingconnector line 170 between mainrefrigerant line 142c and economizerrefrigerant line 144b.Valve 172 in connectorrefrigerant line 170 is preferably a bi-directional valve such that refrigerant can flow in either direction between mainrefrigerant line 142c and economizerrefrigerant line 144b. Thereforerefrigerant system 110 offers additional flexibility and control in terms of loading and unloading. -
Refrigerant system 110 is able to operate in eight different operating modes, based on a position ofvalves refrigerant system 110 are feasible inrefrigerant system 10 ofFIG. 1 . As described further below,system 110 provides even greater flexibility and control for unloading, as compared torefrigerant system 10 ofFIG. 1 . Moreover,system 110 also provides for greater cooling capacity thansystem 10 when the economizer cycle is not being used.Table 2 Operating Mode First Valve 124 Second Valve 126Third Valve 172Comments 1. Full loading with economizer Open Open Closed High pressure ratio. This mode also feasible in system 10 (see Table 1). Same as if there are no valves 2. Full loading without economizer Open Closed Open Low pressure ratio 3. Low to mid-level unloading Open Open Open Flow from both economizer and main line through main line 4. Mid-level unloading Open Closed Closed This mode also feasible for refrigerant system 10 (see Table 1). 5. Mid-level unloading Closed Closed Open Evaporator flow only through economized cylinder module 6. Mid to high level unloading Closed Open Open Flow from both main and economizer line through economized cylinder module 7. Full unloading Closed Open Closed Discharge flow cooling. This mode is also feasible for refrigerant system 10 (see Table 1). 8. Full unloading Closed Closed Closed This mode is also feasible for refrigerant system 10 (see Table 1). - Two "Full loading" operating modes are shown above in Table 2. First, the "Full loading with economizer" mode was described above in reference to
refrigerant system 10. Since bothvalves 124 and 126 are open, andvalve 172 is closed, this mode is the same as a system having no valves in lines 142 and 144. The second "Full loading" operating mode, referred to in Table 2 as "Full loading without economizer", is not feasible forrefrigerant system 10 and allows for increased loading (i.e. increased cooling capacity) when the economizer cycle is not being used for low pressure ratio operation. - As described above in reference to
FIG. 1 and Table 1, it may not be efficient to use the economizer cycle under some conditions, such as at low pressure ratio operation. In this case,refrigerant system 110 achieves a greater cooling capacity thanrefrigerant system 10 when the economizer cycle is blocked. In the second mode referred to as "Full loading without economizer",valve 126 is closed, andvalves 124 and 172 are open. As such, a portion of refrigerant fromevaporator 122 flows from mainrefrigerant line 142c through connectorrefrigerant line 170 and intoeconomizer cylinder module 132. The remaining refrigerant fromevaporator 122 flows throughmain cylinder module 130. As such,main cylinder module 130 andeconomizer cylinder module 132 operate in parallel to compress the main refrigerant fromevaporator 122. By using all of the cylinder modules incompressor 112, instead of onlymain cylinder module 130,refrigerant system 110 is able to circulate a greater amount of refrigerant throughevaporator 122. This allowsevaporator 122 to generate more cooling during those times when the economizer cycle is not being used, but a high cooling capacity is desired. - It is recognized that the level of unloading may be adjusted for any given mode based on a position of
valves - In operating mode three, designated as low to mid-level unloading, all three
valves refrigerant line 144b flows through connectorrefrigerant line 170 and is combined with main refrigerant in mainrefrigerant line 142c. In this mode, a greater portion, if not all of the refrigerant, flows throughmain cylinder module 130, andeconomizer cylinder module 132 compresses a minimal amount of refrigerant. Due to a limited capacity ofmain cylinder module 130, less cooling is provided inevaporator 122 in this mode, as compared to a mode in which all refrigerant from economizerrefrigerant line 144b were flowing througheconomizer cylinder module 130. - For operating mode four, first valve 124 is open, and
second valve 126 andthird valve 172 are closed. This operating mode was also feasible inrefrigerant system 10 and was described above as mid-level unloading in Table 1. The economizer cycle is blocked in operating mode four. Becausevalve 172 is closed andeconomizer cylinder module 132 is thus not used, operating mode four provides less cooling as compared to operating mode two (i.e. full loading without economizer), and is therefore designated as an unloading mode. Additional unloading may be accomplished by partially closing first valve 124. - In operating mode five
valves 124 and 126 are closed, whilethird valve 172 in connectorrefrigerant line 170 is open. Sincevalve 126 is closed, the economizer cycle is blocked, similar to operating mode four. However, in operating mode five, because valve 124 is also closed, all refrigerant flowing throughline 142c fromevaporator 122 is directed through connectorrefrigerant line 170 and intoeconomizer cylinder module 132. - Similar to the mode above, in operating mode six, first valve 124 is closed and
third valve 172 is open. However, in contrast to above, the economizer cycle is activated by openingsecond valve 126. Since valve 124 is closed, the main refrigerant fromevaporator 122 is directed througheconomizer cylinder module 132 in addition to the economizer refrigerant flowing through economizerrefrigerant line 144b. In the final two operating modes seven and eight of Table 2, designated as full unloading,third valve 172 in connectorrefrigerant line 170 is closed. Therefore, these two operating modes are feasible in a refrigerant system without a connector line, likerefrigerant system 10 ofFIG. 1 , and were described above. Operating modes seven and eight are not common; ifrefrigerant system 110 operates in either of these modes, typically it is temporary operating mode and is used to avoid shutting downrefrigerant system 110. Either of modes seven and eight may be adjusted to mid-level unloading or even a low level unloading by only partially closing one of the valves designated as being closed in Table 2. For example, if valve 124 is partially closed in either operating mode seven or eight,system 110 may operate between a low and mid-level unloading, depending on a specific position of valve 124. -
Controller 128 regulates a position ofvalves refrigerant system 110 in an operating mode that aligns with the cooling load demands, while still operating efficiently and avoiding nuisance shutdowns. As described above in reference tocontroller 28 ofrefrigerant system 10,controller 128 controls a position ofvalves refrigerant system 110. Similar torefrigerant system 10,refrigerant system 110 may includetemperature sensors 150 and 160 for measuring, respectively, a temperature (T1) insideevaporator 122 and an ambient air temperature (AT).Refrigerant system 110 also includespressure sensors FIG. 1 . Due to a presence of connectorrefrigerant line 170,refrigerant system 110 may also includepressure sensor 159 located closer to suction inlet 134 for measuring pressure (P5).Pressure sensors valve 172 is open in order to monitor a flow of refrigerant being redirected either from economizerrefrigerant line 144b to mainrefrigerant line 142c or vice versa. The inputs tocontroller 128, as shown inFIG. 2 , may include evaporator temperature (T1) and the ambient temperature (AT), as well as pressures (P1) through (P5). It is recognized that additional sensors and inputs not shown inFIG. 2 may be included inrefrigerant system 110. - In the embodiment shown in
FIG. 2 ,refrigerant system 110 also includes variable frequency drive 129 (VFD), which is used to drive an electric motor ofcompressor 112 and vary the speed of the motor.Variable frequency drive 129 is controlled bycontroller 128. AlthoughVFD 129 is not required inrefrigerant system 110, it may be used for additional capacity control since the speed of the motor impacts the capacity ofcompressor 112. Other types of adjustable speed drives may also be used. A variable frequency drive may also be used inrefrigerant system 10 ofFIG. 1 . - Through the use of
valves refrigerant line 170,refrigerant system 110 provides superior flexibility during unloading, as well as the feasibility to achieve a greater cooling capacity when the economizer module is not being used. In the exemplary embodiment shown inFIG. 2 ,refrigerant system 110 includes bothvalves 124 and 126 in combination with connectorrefrigerant line 170 andvalve 172. In alternative embodiments, valve 124 orvalve 126 may be eliminated. - In the embodiments shown in
FIGS. 1 and2 ,economizer module FIG. 3 is an alternative example in whicheconomizer module 218 is a flash tank. Inrefrigerant systems economizer module 218 ofFIG. 3 , the single refrigerant stream from the high pressure heat exchanger passes throughexpansion device 219, where it is partially expanded to an intermediate pressure and temperature. As such, the refrigerant enteringflash tank 218 is usually in a two-phase thermodynamic state. Insideflash tank 218, phase separation occurs and refrigerant vapor exitsflash tank 218 through economizerrefrigerant line 242, at which point it travels to the economizer cylinder module (not shown). Liquid refrigerant exitsflash tank 218 throughrefrigerant line 244 and passes through expansion or
floatflow control device 221 before traveling to the evaporator (not shown). In those embodiments using a float flow control device, floatflow control device 221 is configured to open when a liquid level in the flash tank reaches a predetermined level or provide a certain restriction to a refrigerant flow to maintain a desired refrigerant level. The refrigerant exitingflash tank 218 throughrefrigerant line 244 has low vapor and high liquid content, which enhances cooling capacity in the evaporator. - The refrigerant system and operating method described herein may easily be implemented into existing refrigerant systems. The refrigerant systems may include supermarket refrigerant systems, container refrigerant systems, truck/trailer refrigerant systems, rooftop air conditioning and heat pump refrigerant systems, and residential air conditioning refrigerant systems. The valves may be installed in existing refrigerant lines, and in some cases, a connector refrigerant line may also be added between the economizer refrigerant line and the main refrigerant line. The valves and connector refrigerant line described herein may also be incorporated into the design of new refrigerant systems.
- Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the invention as defined by the claims.
Claims (9)
- A refrigerant system (110) comprising:a high pressure heat exchanger (114) configured to absorb heat from refrigerant as the refrigerant passes through the high pressure heat exchanger;an economizer module (118) configured to receive a first refrigerant stream (142a) and a second refrigerant stream (144a) derived from the refrigerant exiting the high pressure heat exchanger;an evaporator (122) configured to evaporate the first refrigerant stream;a first refrigerant line (142c) extending from the evaporator and configured to receive the first refrigerant stream;a second refrigerant line (144b) extending from the economizer module and configured to receive the second refrigerant stream; characterized bya reciprocating compressor (112) comprising:a main cylinder module (130) having a first inlet (134) connected to the first refrigerant line and configured to receive the first refrigerant stream, direct the first refrigerant stream through the main cylinder module and output the first refrigerant stream from the compressor via a first outlet (138); andan economizer cylinder module (132) having a second inlet (136) connected to the second refrigerant line and configured to receive the second refrigerant stream, direct the second refrigerant stream through the economizer cylinder module and output the second refrigerant stream from the compressor via a second outlet (140) separate from the first outlet; anda controller (128) for controlling flow of at least one of the first refrigerant stream and the second refrigerant stream;a first valve (124) in the first refrigerant line between the evaporator and the reciprocating compressor, to control flow of the first refrigerant stream into the reciprocating compressor;a second valve (126) in the second refrigerant line between the economizer module and the reciprocating compressor, to control flow of the second refrigerant stream into the reciprocating compressor;a connector refrigerant line (170) between the first refrigerant line (142c) and the second refrigerant line (144b) and configured to perform at least one of bypassing the first refrigerant stream (142c) into the economizer cylinder module (132) and bypassing the second refrigerant stream (144b) into the main cylinder module (130); anda valve (172) in the connector refrigerant line to control at least one of the bypass of the first refrigerant stream into the economizer cylinder module and the bypass of the second refrigerant stream into the main cylinder module;wherein the valve in the connector refrigerant line is located downstream of the valve (126) in the second refrigerant line (144b) and upstream of the valve (124) in the first refrigerant line (142c).
- The refrigerant system of claim 1 wherein the controller is configured to at least partially close the valve in the second refrigerant line and at least partially open the valve in the connector refrigerant line such that at least a portion of the first refrigerant stream flows through the second refrigerant line and through the economizer cylinder module.
- The refrigerant system of claim 1 wherein the controller is configured to at least partially close the valve in the first refrigerant line such that the first refrigerant stream flows through the second refrigerant line and through the economizer cylinder module.
- The refrigerant system of claim 1 wherein the controller is configured to at least partially open the valves in the first and second refrigerant lines and at least partially open the valve in the connector refrigerant line such that a portion of the second refrigerant stream flows through the first refrigerant line and through the main cylinder module.
- A method of operating a refrigerant system (110) according to claim 1 configured to provide cooling using a refrigerant and including a high pressure heat exchanger (114), an economizer module (118), an evaporator (122), and a reciprocating compressor (112) having a main cylinder module (130) with a first inlet (134) and a first outlet (138) and an economizer cylinder module (132) with a second inlet (136) and a second outlet (140), wherein the main cylinder module and the economizer cylinder module have separate inlet and outlet streams, wherein the refrigerant system comprises:a first refrigerant line (142c) connecting the evaporator to the first inlet of the main cylinder module of the reciprocating compressor; anda second refrigerant line (144b) connecting the economizer module to the second inlet of the economizer cylinder module;a connector refrigerant line (170) between the first refrigerant line and the second refrigerant line;a valve (172) in the connector refrigerant line;a first valve (124) in the first refrigerant line; anda second valve (126) in the second refrigerant line, wherein the valve in the connector refrigerant line is located downstream of the second valve and upstream of the first valve, the method comprising:flowing the refrigerant through the high pressure heat exchanger, the economizer module, the evaporator, and at least one of the main cylinder module and the economizer cylinder module, wherein the refrigerant exiting the economizer module is in a main refrigerant stream (142b) and an economizer refrigerant stream (144b), and the main refrigerant stream flows through the evaporator;controlling a flow of the refrigerant into the main cylinder module of the reciprocating compressor at least in part as a function of an operating mode of the refrigerant system; andcontrolling a flow of refrigerant into the economizer cylinder module of the reciprocating compressor at least in part as a function of the operating mode;wherein controlling a flow of the refrigerant into the main cylinder module includes:preventing the main refrigerant stream (142c) exiting the evaporator from entering the main cylinder module; anddirecting the main refrigerant stream exiting the evaporator through the economizer cylinder module.
- The method of claim 5 wherein the operating mode is a function of at least one of an ambient air temperature (AT; 160), a set point air temperature (SPT; 162), a pressure (P1; P3; P5; 152; 156; 159) at an inlet of the reciprocating compressor, and a pressure (P2; P4; 154; 158) at an outlet of the reciprocating compressor.
- The method of claim 5 wherein controlling a flow of the refrigerant into the economizer cylinder module includes preventing the economizer refrigerant stream exiting the economizer module from entering the economizer cylinder module.
- The method of claim 7 further comprising:
directing at least a portion of the main refrigerant stream exiting the evaporator through the economizer cylinder module. - The method of claim 7 further comprising:
directing the economizer refrigerant stream exiting the economizer module through the main cylinder module.
Applications Claiming Priority (2)
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US8700808P | 2008-08-07 | 2008-08-07 | |
PCT/US2009/052995 WO2010017384A2 (en) | 2008-08-07 | 2009-08-06 | Improved operation of a refrigerant system |
Publications (3)
Publication Number | Publication Date |
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EP2321593A2 EP2321593A2 (en) | 2011-05-18 |
EP2321593A4 EP2321593A4 (en) | 2014-05-28 |
EP2321593B1 true EP2321593B1 (en) | 2019-06-19 |
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EP09805559.3A Not-in-force EP2321593B1 (en) | 2008-08-07 | 2009-08-06 | Improved operation of a refrigerant system |
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US (1) | US20110138827A1 (en) |
EP (1) | EP2321593B1 (en) |
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JP2012233676A (en) * | 2011-04-21 | 2012-11-29 | Denso Corp | Heat pump cycle |
US8876650B2 (en) | 2012-03-30 | 2014-11-04 | Hamilton Sundstrand Corporation | Aircraft accessory drive multiple speed transmission |
CN103471275B (en) * | 2013-08-30 | 2017-12-19 | 青岛海信日立空调系统有限公司 | Enhanced vapor injection air-conditioning circulating system and its control method |
US9581985B2 (en) | 2014-02-21 | 2017-02-28 | Johnson Controls Technology Company | Systems and methods for auto-commissioning and self-diagnostics |
KR102240070B1 (en) * | 2014-03-20 | 2021-04-13 | 엘지전자 주식회사 | Air Conditioner and Controlling method for the same |
US9835347B2 (en) | 2014-12-08 | 2017-12-05 | Johnson Controls Technology Company | State-based control in an air handling unit |
DE102017115623A1 (en) | 2016-07-13 | 2018-01-18 | Trane International Inc. | Variable economizer injection position |
Citations (1)
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US20060037336A1 (en) * | 2004-08-20 | 2006-02-23 | Bush James W | Compressor loading control |
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US4947655A (en) * | 1984-01-11 | 1990-08-14 | Copeland Corporation | Refrigeration system |
JPH09267629A (en) * | 1996-04-03 | 1997-10-14 | Toyota Autom Loom Works Ltd | Car air conditioner |
US6047556A (en) | 1997-12-08 | 2000-04-11 | Carrier Corporation | Pulsed flow for capacity control |
JP4658347B2 (en) * | 2001-01-31 | 2011-03-23 | 三菱重工業株式会社 | Supercritical vapor compression refrigeration cycle |
US6718781B2 (en) * | 2001-07-11 | 2004-04-13 | Thermo King Corporation | Refrigeration unit apparatus and method |
US7353660B2 (en) * | 2004-09-13 | 2008-04-08 | Carrier Corporation | Multi-temperature cooling system with unloading |
US7478539B2 (en) * | 2005-06-24 | 2009-01-20 | Hussmann Corporation | Two-stage linear compressor |
-
2009
- 2009-08-06 EP EP09805559.3A patent/EP2321593B1/en not_active Not-in-force
- 2009-08-06 US US13/057,959 patent/US20110138827A1/en not_active Abandoned
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US20060037336A1 (en) * | 2004-08-20 | 2006-02-23 | Bush James W | Compressor loading control |
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WO2010017384A2 (en) | 2010-02-11 |
EP2321593A2 (en) | 2011-05-18 |
WO2010017384A3 (en) | 2010-05-14 |
EP2321593A4 (en) | 2014-05-28 |
US20110138827A1 (en) | 2011-06-16 |
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