Packaged chilling systems for building air conditioning and process cooling

Abstract

Disclosed is a packaged chilling system for providing chilled water to an air conditioning system for a building that includes: a duct system; an air handling system; and a water chilling system; wherein: the duct system is in operable communication with a building that has a plurality of rooms, at least one of the rooms having a sensor for detecting the room air temperature in the room, the duct system comprising at least one supply duct for directing low temperature air from the air handling system to the building and at least one return duct for directing high temperature air from the building to the air handling system; the air handling system includes a plurality of air handling units, each air handling unit comprising an air inlet for receiving high temperature air from the building, a cooling coil that includes at least one conduit through which chilled water flows, the cooling coil having multiple passes and positioned for heat transfer contact with the high temperature air, and a fan for increasing the velocity of air in the air handling unit; the water chilling system is installed at a location proximate the building, and is operably connected to the air handling system; and the water chilling system includes a moveable support structure comprising a support base on which a plurality of water chilling system components are affixed, the components including at least one water chiller for lowering the temperature of water from a high temperature to a low temperature. This packaged chilling system may also be used to provide chilled water to industrial processes such as chemical plants, automotive plants, textile mills, paper mills, computer cooling, and factory air-conditioning.

1 - 39 . (canceled)  
   
   
       40 . A prefabricated chilling water system for building cooling or process cooling, comprising: 
 a duct system;    an air handling system; and    a water chilling system;    wherein the duct system is in operable communication with the air handling system;    wherein the duct system comprises at least one supply duct capable of directing low temperature air from the air handling system to the building cooling load or process cooling load    wherein the air handling system comprises at least one air handling unit, wherein each air handling unit comprises: 
 an air inlet for receiving high temperature air from the building cooling load or process cooling load,  
 a cooling coil comprising at least one conduit through which chilling water flows, and a fan for moving the high temperature air across the cooling coil;  
   wherein the cooling coil is positioned for heat transfer contact with the high temperature air;    wherein the water chilling system is operably connected to the cooling coil;    wherein the water chilling system comprises a moveable support structure, wherein the moveable support structure comprises a support base on which a plurality of water chilling system components are affixed prior to its shipping to a jobsite location, wherein the components comprises at least one water chiller for lowering the temperature of chilling water from a higher temperature to a lower temperature.    
   
   
       41 . The system of  claim 40 , further comprising a motor control center or starter mounted upon the support base and wherein at least one chiller motor and at least one pump motor are prewired to the motor control center such that field power wiring can be brought to a single point power connection for each voltage.  
   
   
       42 . The system of  claim 40 , further comprising an expansion tank operably connected to the chilling water system and mounted on the support base.  
   
   
       43 . The system of  claim 41 , further comprising: 
 a controls system prewired to a chiller control panel and the motor control center; and    a chilling water flow switch prepiped to each water chiller and wired to safety interlocks.    
   
   
       44 . The system of  claim 40 , further comprising a weatherproof enclosure or building with access doors or removable panels for maintenance or personnel access to the water chilling components.  
   
   
       45 . The system of  claim 40  further comprising a refrigerant gas monitor operably connected to an alarm and an exhaust fan, wherein the alarm and the exhaust fan are activated when a refrigerant level reaches a predetermined setpoint as measured by the refrigerant gas monitor.  
   
   
       46 . The system of  claim 40 , wherein an annualized chilling water production cost is minimized and the chilled water is sold on a metered basis.  
   
   
       47 . The system of  claim 40 , wherein the chilling water comprises at least one additive to reduce a freezing point of the chilling water.  
   
   
       48 . The system of  claim 47 , wherein the additive comprises sodium nitrate.  
   
   
       49 . The system of  claim 47 , wherein the additive comprises potassium formate.  
   
   
       50 . The system of  claim 40 , in which the duct system further comprises a plurality of ducts, wherein each duct leads to individual rooms or process loads.  
   
   
       51 . The system of  claim 40 , wherein at least one water chiller comprises a first chiller and a second chiller, wherein the first chiller and the second chiller are arranged in series such that chilling water is capable of sequentially passing through the first chiller and the second chiller.  
   
   
       52 . The system of  claim 40  wherein the water chilling system comprises a plurality of water chillers, including a first water chiller and a second water chiller, wherein the system is configured such that chilling water is capable of passing sequentially through each of the water chillers, wherein the chilling water is chilled to a first temperature after passing through the first water chiller and wherein the chilling water is chilled to a second temperature after passing through the second water chiller.  
   
   
       53 . The system of  claim 40 , wherein some of the chilling water provides cooling for industrial and petrochemical processes such as polyethylene and polypropylene production, internet load centers, computers, manufacturing facilities such as microprocessor manufacturing, paper mills, automotive manufacturing, textiles, or factory air conditioning.  
   
   
       54 . The system of  claim 40 , wherein the system comprises at least one moveable structure, where all key mechanical and electrical components are mounted prior to shipment to the jobsite that are required for providing circulating chilled water, hot water, or steam.  
   
   
       55 . The system of  claim 40 , wherein at least some of the chilling system components are pre-assembled on the moveable support structure and are affixed to the support base before the chilling water system is installed at the jobsite location.  
   
   
       56 . The system of  claim 40 , wherein the support base comprises a frame that includes a plurality of steel I-beams on which a metal plate is affixed.  
   
   
       57 . The system of  claim 40 , wherein the chilling water system further comprises a housing removably affixed to the moveable substructure, wherein the housing is sized and configured to enclose the plurality of components.  
   
   
       58 . The system of  claim 40 , wherein the chilling water system is assembled before it is shipped to the jobsite location, such that the assembled chilling water system comprises at least two compressors and at least two evaporators, wherein the evaporators are capable of operating at different temperatures and refrigerant pressures to achieve a sequential chilling of the chilling water passing through the evaporators.  
   
   
       59 . The system of  claim 40 , wherein the chilling water system is assembled before it is installed at the jobsite location, such that the assembled water chilling system comprises: 
 at least two chillers having at least two compressors and at least two evaporators configured to operate with chilled water in series so that the evaporators are at sequentially lower temperatures and refrigerant pressures to achieve at least two stages of sequential chilling of the circulating chilled water;    at least two condensers;    at least one chilled water pump;    at least one isolation valve; and    at least one motor starter.    
   
   
       60 . The system of  claim 40 , further comprising: 
 a chilling water temperature sensor operably connected to chilling water passing through the chiller; and    a controller responsive to the water temperature sensor capable of adjusting either the temperature or the flowrate of the chilling water.    
   
   
       61 . The system of  claim 40 , further comprising a water temperature control system operably connected to each water chiller capable of adjusting the temperature of the chilling water passing through the at least one water chiller.  
   
   
       62 . The system of  claim 61 , further comprising a prewired control system, wherein the control system is prewired to the water temperature control system and is configured to stop and start the water chillers, and wherein the chilled water pumps and the condenser water pumps provide a predetermined leaving chilling water temperature and flowrate.  
   
   
       63 . The system of  claim 40 , further comprising a chilled water thermal energy water storage tank that is operably connected to the water chiller.  
   
   
       64 . The system of  claim 58 , wherein at least two condensers comprise a first condenser and a second condenser, wherein condenser water passes through the second condenser prior to passing through the first condenser and wherein the chilling water passes through the first evaporator prior to passing through the second evaporator, resulting in a differential refrigerant head pressure of the second compressor which is less than about 20% of a differential refrigerant head pressure of the first compressor.  
   
   
       65 . The system of  claim 40 , further comprising a cooling tower.  
   
   
       66 . The system of  claim 40 , further comprising a cooling tower affixed to the moveable support structure.  
   
   
       67 . The system of  claim 40 , further comprising a cooling tower, wherein 
 (a) the support base is a lower support base on which the plurality of water chilling system components are affixed; and    (b) the moveable support structure additionally includes an upper support base positioned above the lower support base upon which the cooling tower is mounted.    
   
   
       68 . The system of  claim 40 , wherein the water chilling system is assembled before it is installed at the jobsite location, such that the assembled water chilling system comprises: 
 at least one chiller;    at least one chilled water circulating pump;    at least one isolation valve;    at least one chiller motor starter;    at least one circulation pump motor starter;    at least one condenser water pump; and    at least one control system.    
   
   
       69 . The system of  claim 67  wherein the cooling tower support structure is pre-engineered to allow the cooling tower support to be used as a lifting support allowing for chiller maintenance.  
   
   
       70 . The system of  claim 40 , further comprising an air-cooled condenser or an evaporative condenser capable of providing for heat rejection to the environment  
   
   
       71 . The system of  claim 70 , whereby the air-cooled condenser or evaporative condenser is located either adjacent to or above a refrigeration unit and connected with a factory pre-fabricated piping package.  
   
   
       72 . A prefabricated chilling water system to be used to provide circulating chilled water for use on industrial or petrochemical process cooling applications comprising: 
 a moveable support structure, wherein the structure comprises a support base on which a plurality of water chilling system components are affixed prior to shipment to the jobsite, the water chilling system components including at least one water chiller for lowering the temperature of chilling water from a high temperature to a low temperature; and    a modular water chilling system, comprising at least one moveable support structure capable of being installed at the jobsite location to form a modular water chilling system, such that when each support structure is assembled, the assembled support structure contains at least one chiller, at least one chilled water circulation pump, and at least one isolation valve.    
   
   
       73 . The system of  claim 72 , wherein each moveable support structure further comprises at least one condenser water pump.  
   
   
       74 . The system of  claim 72 , wherein each movable support structure further comprises at least one prewired motor starter.  
   
   
       75 . The system of  claim 72 , wherein each movable support structure further comprises at least one control system.  
   
   
       76 . A prefabricated circulating chilled water system for building air conditioning, industrial process cooling, or factory air-conditioning in which the majority of the components necessary for a complete chilled water system are affixed on at least one structural steel base prior to shipment to the jobsite, wherein each structural base will contain at least the following components: 
 at least one water chiller having a capacity of at least about 100 tons;    at least one chilled water circulation pump;    interconnecting piping to connect each circulation pump to at least one water chiller;    chilled water inlet and outlet connections for easy connection to external field piping, and;    motor control centers which are prewired to each pump motor and chiller motor.    
   
   
       77 . A prefabricated chilling water system to be used to provide circulating chilled water for use on industrial and petrochemical processes such as polyethylene and polypropylene production, internet load centers, computers, manufacturing facilities such as microprocessor manufacturing, paper mills, automotive manufacturing, textiles and factory air conditioning, the system comprising a moveable support structure which comprises a support base on which a plurality of water chilling system components are affixed, wherein the components comprise at least one water chiller for lowering the temperature of chilling water from a high temperature to a low temperature and at least one circulating water pump.  
   
   
       78 . The system of  claim 76 , wherein the prefabricated chilling water system comprises: 
 at least two chillers having at least two compressors and at least two evaporators configured to operate with the chilled water in series so that the evaporators are at sequentially lower temperatures and refrigerant pressures to achieve at least two stages of sequential chilling of the circulating chilled water;    at least two condensers; and    at least one chilled water pump.    
   
   
       79 . The system of  claim 78 , wherein the at least two condensers are configured to operate with the condenser water in series so that the condensers are at sequentially higher temperatures and refrigerant pressures to achieve at least two stages of sequential heat rejection of the circulating condenser water.