Industrial Water Cooled Chiller Packages

Water Cooled Chiller Packages

Berg Chilling Systems’ industrial water cooled chiller packages have a choice of semi-hermetic refrigeration compressors, scroll refrigeration compressors or screw refrigeration compressors with a double pump tank mounted with the chiller module, plus the advantage of being able to reclaim waste heat. All Berg water chiller systems are fully tested under actual load conditions before being shipped.

Features and Benefits
Technical Information
Layout Pictorial & Specifications

Water Cooled Chiller Packages

Berg water cooled industrial refrigeration packages are used where:

Cooling tower water is available
Integral pumping is required
The inside air is either corrosive, extremely dusty or hot
Supplemental heating is of no benefit
The plant is air conditioned

These self-contained water-cooled industrial process cooling systems include both a water chiller and a double pump tank system for a complete industrial cooling solution.

This water cooled chiller comes pre-piped and pre-wired and requires a minimum of installation effort and occupies a small amount of floor space.

Berg Chilling Systems Inc. has a long history of delivering high quality and reliable industrial chiller packages for a variety of industrial and commercial applications.

Working with Berg allows you to benefit from our extensive experience acquired from hundreds of installations in all types of conditions all over the world.

Water Cooled Industrial Refrigeration Systems

Technical Specifications

Capacity

Compressor (HP) 20 or more
Cooling capacity (Refrigeration tons) 15 or more

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.

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.

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.

Industrial Process Chiller Refrigeration Basic Cycle

As the heated process fluid passes over the evaporator some of the heat contained in the fluid (process chillers use water for the medium instead of air) is absorbed into it.

The refrigerant inside the evaporator coil, originating from the condenser, has been metered causing a pressure drop of the refrigerant.

The process of the metering of the refrigerant and resulting pressure drop causes the temperature of the refrigerant to drop.

This causes the evaporator to be cooler than the air. As more warmer air passes over the evaporator coil the heat from the process fluid is absorbed into the coil and refrigerant, which is partially a liquid.

This heat transfer, from the process fluid, to the coils, to the refrigerant, causes the refrigerant to boil and turn into a vapor. The vapor leaves the evaporator coil and is pulled towards the compressor.

The vapor enters the compressor where it is compressed. This compression process raises the temperature and pressure of the refrigerant where it is discharged into the condenser coils.

Again using water being pulled through the coils, another heat exchange process occurs. This time the heat picked up from the evaporator coils is rejected to the water.

As the temperature of the refrigerant drops it once again becomes a liquid and is pumped back towards the metering device usually located near the evaporator coils where it will begin the process of absorbing heat from the evaporator all over again.