Hybrid Water Chiller

Berg’s Hybrid Water Chiller is the ideal solution for industrial customers that want to lower their electrical operating costs. The Hybrid Chiller provides industrial refrigeration and mechanical cooling during hot weather and 100% free cooling during cooler weather, automatically and without compromising production capacity.

  • Features and Benefits
  • Technical Information
  • System Payback
Hybrid Water Chiller

In a standard industrial water cooled cooling system, chilled water loops cooled by mechanical refrigeration operate continuously.  Using free cooling, refrigeration compressors can be turned off during cooler months, enabling the outside air to provide system cooling.  Once ambient temperatures increase, the compressor reactivates to provide the necessary cooling. Berg’s Hybrid Chiller includes all the necessary monitoring and controls, so the management of free and mechanical cooling is invisible to the operator.

Features

Skid Based Design – The Hybrid Chiller is mounted on a rugged steel frame that is designed and manufactured based on the specific project’s needs.  Berg’s skid based design ensures lower overall project capital cost, reduced installation time and minimal operation disruption, shorter time from project kick-off to completion, and ease of maintenance over its operating life.

PLC Driven Control – Berg’s System Manager optimises system performance to ensure seamless blending of active and mechanical cooling throughout the year that is hassle free to operators.

Factory Tested – Quality assurance testing is completed under design conditions before delivery, ensuring fewer issues during start-up and commissioning.

Redundancy – Hybrid Chillers can be designed with independent refrigeration circuits that can provide any required level of redundancy for compressors, fan motors, and when built as a packaged chiller also include standby pumping.  Your chiller plant can continue to run safely until components can be serviced and maintained during a planned shutdown.

Technical Specifications

Capacity

  • Compressor (HP) 20 – 120 or more
  • Cooling capacity (Refrigeration tons) 15 to 300 or more

Compressor Options

Semi Hermetic Compressor (WS)

  • Semi-hermetic reciprocating compressor
  • Suction gas cooled motor
  • Suction and discharge stop valve
  • Step capacity control
  • Crankcase heater with current sensing relay
  • Suction and discharge pressure transmitter
  • High pressure switch
  • Hot gas capacity control

Open Type Compressor (WO)

  • Suction and discharge stop valve
  • Step capacity control
  • Drive coupling and C-flange adaptor/coupling guard
  • Suction and discharge pressure transmitter
  • Discharge high temperature cut-out
  • High pressure switch
  • Oil flow switch
  • Oil separator with 230 V / Single phase / 50 Hz heater
  • Oil heater current relay
  • TEFC motor certified for hazardous environments
  • Hot gas capacity control

Scroll Compressor (WZ)

  • Suction gas cooled motor
  • Suction and discharge stop valve
  • High pressure switch
  • Crankcase heater with current sensing relay
  • Hot gas capacity control

Screw Compressor  (WQ)

  • Suction gas cooled motor
  • Suction and discharge stop valve
  • Slide valve capacity control
  • Integral oil separator with heater and current sensing relay
  • Crankcase heater with current sensing relay
  • Suction and discharge pressure transmitter
  • High pressure switch
  • Hot gas capacity control

Evaporator

  • High efficiency copper brazed stainless steel plate construction
  • designed and constructed in accordance with ASME code
  • High efficiency shell and tube construction
  • Carbon steel shell (water side)
  • Copper tube with inner fin (refrigerant side)
  • Vessel designed and constructed in accordance with ASME code

*other materials of are construction available upon request

Water-Cooled Condenser

  • Heavy construction while maintaining maximum heat transfer
  • Steel shell on refrigerant side
  • Copper tubing with outer fin on water side
  • Removable heads for cleaning

Stainless Steel Tank

  • Baffled Stainless Steel type 304 Reservoir, 11 gauge
  • Reinforcement bands
  • Removable stainless steel cover
  • Overflow connection
  • Bottom drain connection with shut‑off valve
  • Automatic float operated water make‑up valve
  • Thermometer with well
  • Spare well opening
  • Closed cell flexible insulation nominal ½” thick applied to bottom and sides of tank

Centrifugal Pump Assembly

  • Evaporator pumps circulate water from the hot well to the chiller and back to the cold well.  This provides a constant flow and pressure for stable operation, maximum efficiency and safety.
  • Process pumps circulate water from the cold well to the process and back to hot well.  This flow may fluctuate without affecting the flow through the chiller.
  • Optional combined standby pump, complete with valved header assembly is capable of acting as either the chiller or process pump if necessary to prevent any unnecessary shut-downs due to an operating pump fault.
  • Dedicated standby also available

Pump assembly includes:

  • Close coupled TEFC motor
  • non-overloading impeller
  • Cast iron volute
  • Brass shaft sleeve
  • Mechanical seal
  • Suction shut‑off valve
  • Discharge flow/shut‑off valve
  • Discharge check valve
  • Discharge pressure gauge

Reservoir Mixing Tank and Frame

  • Frame manufactured from heavy gauge structured steel tube with welded construction.
  • Tank models manufactured from heavy gauge stainless steel.
  • Tank cover manufactured from stainless steel and supplied in sections for ease of removal and access ( Covers are optional ).
  • All tanks have baffled compartments if required.
  • Make-up float valve.
  • Tanks are structurally supported around top and sides as required.

Fluid Cooler

  • Available as either dry or adiabatic for added cooling capacity
  • Heavy duty construction with maximum heat transfer
  • Seamless copper tube mechanically expanded into the aluminium fins making permanent metal-to‑metal contact
  • All galvanized construction for outdoor operation
  • Self-contained controller for fan cycling to maintain set point.
  • Coils are manufactured using seamless, deoxidized, heavy wall, smooth copper tubes

Electrical

  • 460 / 575 / 230 / 380 Volts        60 / 50 Hz
  • 120 / 240 Volt single phase control voltage
  • Microprocessor controller
  • Operating and fail lights
  • UL or CSA approved components

Central Control Electrical Panel

A custom electrical control panel allows one point hookup and may include:

  • HMI (Human Interface Device) touchscreens
  • PLC (Programmable Logic Control)
  • SCADA (Supervisory Control And Data Acquisition) communication systems
  • 24/7 alarm reporting to beepers or cell phones

Safety Controls

Tested under load conditions prior to shipment
All safety controls are factory set and checked

  • Freeze-up controls
  • High and low refrigerant pressure controls
  • Compressor motor overload protection
  • Tank low-level cutout (glycol units)
  • Oil pressure safety control
  • Refrigerant pressure relief valve

All pump starters, fuses, disconnect, control voltage transformer, run and fail lights, are housed in a common NEMA rated panel.

Central Thermostat Control System

This system is used to control the chiller units in a multiple central chilling system. The temperature controller is located at the Berg tank and senses the process water temperature. The process water temperature is maintained by cycling the chiller units.

The Hybrid Chiller reduces operating costs due to energy, municipal water usage, and chemical treatment savings.   The financial return on investment is unique to each specific application, however, we have provided systems that resulted in payback in less than two years to data centres, welding and stamping plants, laser cooling systems, die Casting, food and beverage and plastics plants that mold with engineered plastics.

In general, payback and ROI is dependent upon three main variables:

  • Process Load – The higher the process cooling water temperature your equipment can tolerate, the shorter the payback period;
  • Local Environment – The lower average outdoor air temperature throughout the year, the greater the availability of free cooling, and the shorter the payback period; and
  • Electricity Rates – The higher the cost of energy, the shorter the payback period.
Custom Engineered

Berg engineers work with you to custom design the hybrid chiller that will meet your economic and functional needs.

24/7 Technical & Service Support

Berg is available to you 24/7 for technical and service support.

Energy Efficient

All of Berg’s hybrid chillers come equipped with high system efficiency features.