Patent Grant
11656012
This disclosure relates generally to a cooling system.
Cooling systems may cycle a refrigerant (e.g., carbon dioxide refrigerant) to cool various spaces.
Cooling systems may cycle a refrigerant (e.g., carbon dioxide refrigerant) to cool various spaces. These systems typically include a compressor to compress refrigerant and a high side heat exchanger that removes heat from the compressed refrigerant. When the compressor compresses the refrigerant, oil that coats certain components of the compressor may mix with and be discharged with the refrigerant.
When these systems are installed in tall buildings (e.g., high-rises), the high side heat exchanger may be installed on the roof of the building while the compressor is installed on a lower floor of the building. As a result, a significant vertical separation may exist between the compressor and the high side heat exchanger. If refrigerant from the compressor were directed to the high side heat exchanger, the oil that mixed with the refrigerant discharged by the compressor may not be able to overcome the vertical separation and, as a result, the oil may flow backwards to the compressor. To avoid this oil return issue, conventional systems use a separate water cooling system that cycles water that absorbs heat from the refrigerant discharged by the compressor. The water is then pumped to the high side heat exchanger on the roof so that the absorbed heat can be removed. The cooled refrigerant is cycled back to the rest of the cooling system, bypassing the high side heat exchanger. The water cooling system, however, increases the overall energy consumption, size, and cost of the cooling system.
This disclosure contemplates an unconventional cooling system that uses P-traps to address the oil return issues that result from a vertical separation between the compressor and the high side heat exchanger. Generally, the vertical piping that carries the refrigerant from the compressor to the high side heat exchanger includes P-traps installed at various heights to capture oil in the refrigerant and to prevent that oil from flowing back to the compressor. As oil collects in the P-traps, the refrigerant begins to push the oil upwards until the oil reaches the high side heat exchanger. Multiple piping of different sizes may be used depending on a discharge pressure of the compressor. When the discharge pressure is higher, a larger piping may be used direct the oil and refrigerant to the high side heat exchanger. Certain embodiments of the cooling system are described below.
According to an embodiment, a system includes a high side heat exchanger, a flash tank, a first low side heat exchanger, a second low side heat exchanger, a first compressor, a second compressor, first piping, second piping, a first valve, and a second valve. The high side heat exchanger removes heat from a refrigerant. The flash tank stores the refrigerant. The first low side heat exchanger uses the refrigerant to cool a space proximate the first low side heat exchanger. The second low side heat exchanger uses the refrigerant to cool a space proximate the second low side heat exchanger. The first compressor compresses refrigerant from the first low side heat exchanger. The second compressor compresses refrigerant from the second low side heat exchanger and the first compressor. The high side heat exchanger is positioned vertically above the second compressor. The first piping directs refrigerant from the second compressor to the high side heat exchanger. The first piping includes a first p-trap positioned vertically above the second compressor and vertically below the high side heat exchanger and a second p-trap positioned vertically above the first p-trap and vertically below the high side heat exchanger. The second piping directs refrigerant from the second compressor to the high side heat exchanger. The second piping is larger than the first piping. The second piping includes a third p-trap positioned vertically above the second compressor and vertically below the high side heat exchanger and a fourth p-trap positioned vertically above the first p-trap and vertically below the high side heat exchanger. The first valve controls a flow of refrigerant and oil from the second compressor to the first piping. The second valve controls a flow of refrigerant and oil from the second compressor to the second piping.
According to another embodiment, a method includes removing, by a high side heat exchanger, heat from a refrigerant and storing, by a flash tank, the refrigerant. The method also includes using, by a first low side heat exchanger, the refrigerant to cool a space proximate the first low side heat exchanger and using, by a second low side heat exchanger, the refrigerant to cool a space proximate the second low side heat exchanger. The method further includes compressing, by a first compressor, refrigerant from the first low side heat exchanger and compressing, by a second compressor, refrigerant from the second low side heat exchanger and the first compressor. The high side heat exchanger is positioned vertically above the second compressor. The method also includes directing, by first piping, refrigerant from the second compressor to the high side heat exchanger. The first piping includes a first p-trap positioned vertically above the second compressor and vertically below the high side heat exchanger and a second p-trap positioned vertically above the first p-trap and vertically below the high side heat exchanger. The method further includes directing, by second piping, refrigerant from the second compressor to the high side heat exchanger. The second piping is larger than the first piping. The second piping includes a third p-trap positioned vertically above the second compressor and vertically below the high side heat exchanger and a fourth p-trap positioned vertically above the first p-trap and vertically below the high side heat exchanger. The method also includes controlling, by a first valve, a flow of refrigerant and oil from the second compressor to the first piping and controlling, by a second valve, a flow of refrigerant and oil from the second compressor to the second piping.
According to yet another embodiment, a system includes a high side heat exchanger, a flash tank, a first low side heat exchanger, a second low side heat exchanger, a first compressor, a second compressor, first piping, second piping, and a valve. The high side heat exchanger removes heat from a refrigerant. The flash tank stores the refrigerant. The first low side heat exchanger uses the refrigerant to cool a space proximate the first low side heat exchanger. The second low side heat exchanger uses the refrigerant to cool a space proximate the second low side heat exchanger. The first compressor compresses refrigerant from the first low side heat exchanger. The second compressor compresses refrigerant from the second low side heat exchanger and the first compressor. The high side heat exchanger is positioned vertically above the second compressor. The first piping directs refrigerant from the second compressor to the high side heat exchanger. The first piping includes a first p-trap positioned vertically above the second compressor and vertically below the high side heat exchanger and a second p-trap positioned vertically above the first p-trap and vertically below the high side heat exchanger. The second piping directs refrigerant from the second compressor to the high side heat exchanger. The second piping is larger than the first piping. The second piping includes a third p-trap positioned vertically above the second compressor and vertically below the high side heat exchanger and a fourth p-trap positioned vertically above the first p-trap and vertically below the high side heat exchanger. The valve controls a flow of refrigerant and oil from the second compressor to the second piping.
Certain embodiments provide one or more technical advantages. For example, an embodiment uses P-traps to prevent oil from flowing back to a compressor when there is a vertical separation between the compressor and a high side heat exchanger. As another example, an embodiment reduces energy consumption, size, and cost relative to a cooling system that uses a separate water cooling system to overcome a vertical separation between a compressor and a high side heat exchanger. Certain embodiments may include none, some, or all of the above technical advantages. One or more other technical advantages may be readily apparent to one skilled in the art from the figures, descriptions, and claims included herein.
For a more complete understanding of the present disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
Embodiments of the present disclosure and its advantages are best understood by referring to
Cooling systems may cycle a refrigerant (e.g., carbon dioxide refrigerant) to cool various spaces. These systems typically include a compressor to compress refrigerant and a high side heat exchanger that removes heat from the compressed refrigerant. When the compressor compresses the refrigerant, oil that coats certain components of the compressor may mix with and be discharged with the refrigerant.
When these systems are installed in tall buildings (e.g., high-rises), the high side heat exchanger may be installed on the roof of the building while the compressor is installed on a lower floor of the building. As a result, a significant vertical separation may exist between the compressor and the high side heat exchanger. If refrigerant from the compressor were directed to the high side heat exchanger, the oil that mixed with the refrigerant discharged by the compressor may not be able to overcome the vertical separation and, as a result, the oil may flow backwards to the compressor. To avoid this oil return issue, conventional systems use a separate water cooling system that cycles water that absorbs heat from the refrigerant discharged by the compressor. The water is then pumped to the high side heat exchanger on the roof so that the absorbed heat can be removed. The cooled refrigerant is cycled back to the rest of the cooling system, bypassing the high side heat exchanger. The water cooling system, however, increases the overall energy consumption, size, and cost of the cooling system.
This disclosure contemplates an unconventional cooling system that uses P-traps to address the oil return issues that result from a vertical separation between the compressor and the high side heat exchanger. Generally, the vertical piping that carries the refrigerant from the compressor to the high side heat exchanger includes P-traps installed at various heights to capture oil in the refrigerant and to prevent that oil from flowing back to the compressor. As oil collects in the P-traps, the refrigerant begins to push the oil upwards until the oil reaches the high side heat exchanger. Multiple piping of different sizes may be used depending on a discharge pressure of the compressor. When the discharge pressure is higher, a larger piping may be used direct the oil and refrigerant to the high side heat exchanger. In this manner, the P-traps prevent oil from flowing back to the compressor when there is a vertical separation between the compressor and the high side heat exchanger. Additionally, the cooling system reduces energy consumption, size, and cost relative to a cooling system that uses a separate water cooling system to overcome the vertical separation between the compressor and the high side heat exchanger. The cooling system will be described using
High side heat exchanger 102 removes heat from a refrigerant. When heat is removed from the refrigerant, the refrigerant is cooled. High side heat exchanger 102 may be operated as a condenser and/or a gas cooler. When operating as a condenser, high side heat exchanger 102 cools the refrigerant such that the state of the refrigerant changes from a gas to a liquid. When operating as a gas cooler, high side heat exchanger 102 cools gaseous refrigerant and the refrigerant remains a gas. In certain configurations, high side heat exchanger 102 is positioned such that heat removed from the refrigerant may be discharged into the air. For example, high side heat exchanger 102 may be positioned on a rooftop so that heat removed from the refrigerant may be discharged into the air. This disclosure contemplates any suitable refrigerant (e.g., carbon dioxide) being used in any of the disclosed cooling systems.
Flash tank 104 stores refrigerant received from high side heat exchanger 102. This disclosure contemplates flash tank 104 storing refrigerant in any state such as, for example, a liquid state and/or a gaseous state. Refrigerant leaving flash tank 104 is fed to low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108. In some embodiments, a flash gas and/or a gaseous refrigerant is released from flash tank 104. By releasing flash gas, the pressure within flash tank 104 may be reduced.
System 100 includes a low temperature portion and a medium temperature portion. The low temperature portion operates at a lower temperature than the medium temperature portion. In some refrigeration systems, the low temperature portion may be a freezer system and the medium temperature system may be a regular refrigeration system. In a grocery store setting, the low temperature portion may include freezers used to hold frozen foods, and the medium temperature portion may include refrigerated shelves used to hold produce. Refrigerant flows from flash tank 104 to both the low temperature and medium temperature portions of the refrigeration system. For example, the refrigerant flows to low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108.
When the refrigerant reaches low temperature low side heat exchanger 106 or medium temperature low side heat exchanger 108, the refrigerant removes heat from the air around low temperature low side heat exchanger 106 or medium temperature low side heat exchanger 108. For example, the refrigerant cools metallic components (e.g., metallic coils, plates, and/or tubes) of low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108 as the refrigerant passes through low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108. These metallic components may then cool the air around them. The cooled air may then be circulated such as, for example, by a fan to cool a space such as, for example, a freezer and/or a refrigerated shelf. As refrigerant passes through low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108, the refrigerant may change from a liquid state to a gaseous state as it absorbs heat. Any number of low temperature low side heat exchangers 106 and medium temperature low side heat exchangers 108 may be included in any of the disclosed cooling systems.
Refrigerant flows from low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108 to compressors 110 and 112. The disclosed cooling systems may include any number of low temperature compressors 110 and medium temperature compressors 112. Both the low temperature compressor 110 and medium temperature compressor 112 compress refrigerant to increase the pressure of the refrigerant. As a result, the heat in the refrigerant may become concentrated and the refrigerant may become a high-pressure gas. Low temperature compressor 110 compresses refrigerant from low temperature low side heat exchanger 106 and sends the compressed refrigerant to medium temperature compressor 112. Medium temperature compressor 112 compresses a mixture of the refrigerant from low temperature compressor 110 and medium temperature low side heat exchanger 108. When the compressors 110 and 112 compress the refrigerant, oil that coats certain components of compressors 110 and 112 may mix with and be discharged with the refrigerant.
Valve 114 controls a flow of flash gas from flash tank 104. When valve 114 is closed, flash tank 104 may not discharge flash gas through valve 114. When valve 114 is opened, flash tank 104 may discharge flash gas through valve 114. In this manner, valve 114 may also control an internal pressure of flash tank 104. Valve 114 directs flash gas to medium temperature compressor 112. Medium temperature compressor 112 compresses the flash gas along with refrigerant from low temperature compressor 110 and medium temperature low side heat exchanger 108.
This disclosure contemplates an unconventional cooling system that uses P-traps to address the oil return issues that result from a vertical separation between the compressor 112 and the high side heat exchanger 102. Generally, the vertical piping that carries the refrigerant from the compressor 112 to the high side heat exchanger 102 includes P-traps installed at various heights to capture oil in the refrigerant and to prevent that oil from flowing back to the compressor 112. As oil collects in the P-traps, the refrigerant begins to push the oil upwards until the oil reaches the high side heat exchanger 102. Multiple piping of different sizes may be used depending on a discharge pressure of the compressor 112. When the discharge pressure is higher, a larger piping may be used direct the oil and refrigerant to the high side heat exchanger 102. In this manner, the P-traps prevent oil from flowing back to the compressor 112 when there is a vertical separation between the compressor 112 and the high side heat exchanger 102. Additionally, the cooling system reduces energy consumption, size, and cost relative to a cooling system that uses a separate water cooling system 124 to overcome the vertical separation between the compressor 112 and the high side heat exchanger 102. Embodiments of the cooling system are described below using
Several components of system 200A operate similarly as they did in system 100. For example, high side heat exchanger 102 removes heat from a refrigerant. Flash tank 104 stores the refrigerant. Low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108 use refrigerant to cool spaces proximate low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108. Low temperature compressor 110 compresses refrigerant from low temperature low side heat exchanger 106. Medium temperature compressor 112 compresses refrigerant from low temperature compressor 110, medium temperature low side heat exchanger 108, and flash tank 104. Valve 114 controls the flow of refrigerant, as a flash gas, from flash tank 104 to medium temperature compressor 112.
Piping 202A and 202B direct refrigerant from medium temperature compressor 112 to high side heat exchanger 102. The structure of piping 202A and 202B allows piping 202A and 202B to carry refrigerant up the vertical separation to high side heat exchanger 102 without allowing oil to flow back to medium temperature compressor 112. Although system 200A is illustrated with only two piping 202A and 202B, system 200A (and any system described herein) may include any suitable number of piping (e.g., three, four, five, etc.).
As seen in
Refrigerant flowing from medium temperature compressor 112 to high side heat exchanger 102 through one of piping 202A and 202B will flow through P-traps 204A-C or P-traps 204D-F enroute to high side heat exchanger 102. As the refrigerant, which is a vapor, flows through piping 202A or 202B, oil in the refrigerant may begin to flow back towards medium temperature compressor 112. P-traps 204A-F collect the oil before the oil reaches medium temperature compressor 112. As a result, P-traps 204A-F prevent oil from flowing back to medium temperature compressor 112. As more refrigerant is sent through piping 202A or 202B, more oil collects in P-traps 204A-F.
As more oil collects in P-traps 204A-F, the refrigerant flowing through piping 202A or 202B will begin pushing the oil in these P-traps 204A-F upwards until the oil reaches the next P-trap 204 and/or until the oil reaches high side heat exchanger 102. For example, as refrigerant flows through piping 202A, oil will begin collecting in P-trap 204A. As the level of oil in P-trap 204A increases, the refrigerant in piping 202A will begin pushing that oil upwards until that oil reaches and is collected by P-trap 204B. As the level of oil in P-trap 204B increases, the refrigerant in piping 202A will begin pushing that oil upwards. This process continues until that oil reaches and is collected by P-trap 204C. As the level of oil in P-trap 204C increases the refrigerant in piping 202A will begin pushing that oil upwards until that oil reaches high side heat exchanger 102. In this manner, oil is kept flowing in system 200A in the same direction as the refrigerant.
Valves 206A and 206B control a flow of refrigerant and/or oil through piping 202A and 202B, respectively. When valve 206A is open, valve 206A allows refrigerant and/or oil to flow through piping 202A. When valve 206A is closed, valve 206A prevents refrigerant and/or oil from flowing through piping 202A. Similarly, when valve 206B is open, valve 206B allows refrigerant and/or oil to flow through piping 202B. When valve 206B is closed, valve 206B prevents refrigerant and/or oil from flowing through piping 202B.
In certain embodiments, piping 202A and 202B may be different sizes. For example, piping 202A may be ⅞ of an inch in diameter and piping 202B may be 1 and ⅛ inches in diameter. The smaller size of piping 202A may result in refrigerant and/or oil flowing through piping 202A to maintain a higher velocity and experience a smaller pressure drop than refrigerant and/or oil flowing through piping 202B. Valves 206A and 206B can be controlled to send refrigerant and/or oil from compressor 112 through differently sized piping 202A and 202B depending on the discharge pressure and/or capacity of compressor 112. For example, sensor 208 may be a pressure sensor that detects a discharge pressure and/or capacity of compressor 112. When the discharge pressure and/or capacity is below a first threshold (e.g., 40%), valve 206A may be opened and valve 206B may be closed such that refrigerant and/or oil from compressor 112 is directed through the smaller piping 202A. In this manner, the smaller piping 202A is used to maintain sufficient velocity and pressure to push oil up piping 202A when the discharge pressure and/or capacity of compressor 112 is low. When the discharge pressure and/or capacity of compressor 112 is between the first threshold (e.g., 40%) and a second threshold (e.g., 70%) that is higher than the first threshold, valve 206A may be closed and valve 206B may be open such that refrigerant and/or oil from compressor 112 is directed through larger piping 202B. In this manner, the larger piping 202B is used when the discharge pressure and/or capacity of compressor 112 are high enough such that the refrigerant discharged from compressor 112 can push oil up piping 202B. When the discharge pressure and/or capacity of compressor 112 is above the second threshold (e.g., 70%), both valves 206A and 206B may be open such that refrigerant and/or oil from compressor 112 is directed through both piping 202A and 202B. In this manner, both piping 202A and 202B are used when the discharge pressure and/or capacity of compressor 112 necessitates additional piping 202 to handle the refrigerant discharge of compressor 112.
Several components of system 200B operate similarly as they did in system 200A. High side heat exchanger 102 removes heat from a refrigerant. Flash tank 104 stores the refrigerant. Low temperature low side heat exchangers 106 and medium temperature low side heat exchanger 108 use refrigerant to cool spaces proximate low temperature low side heat exchanger 106 and medium temperature low side heat exchanger 108. Low temperature compressor 110 compresses refrigerant from low temperature low side heat exchanger 106. Medium temperature compressor 112 compresses refrigerant from low temperature compressor 110, medium temperature low side heat exchanger 108, and flash tank 104. Valve 114 controls the flow of refrigerant, as a flash gas, from flash tank 104 to medium temperature compressor 112. Piping 202A and 202B direct refrigerant from medium temperature compressor 112 to high side heat exchanger 102. P-traps 204A-F collect oil and prevent that oil from flowing back to medium temperature compressor 112. Valve 206B controls a flow of oil and/or refrigerant through piping 202B. Sensor 208 is a pressure sensor that detects a discharge pressure of medium temperature compressor 112.
As discussed above, in system 200B, piping 202A and 202B are the same size. Additionally, valve 206A is removed such that refrigerant and/or oil from compressor 112 is always directed at least through piping 202A. Similar to system 200A, valve 206B may open or closed depending on a discharge pressure and/or capacity of compressor 112 detected by sensor 208. For example, when the discharge pressure and/or capacity falls below a threshold (e.g., 60%), valve 206B is closed such that refrigerant and/or oil from compressor 112 is directed through piping 202A but not piping 202B. In this manner, only one piping 202A is used when the discharge pressure and/or capacity of compressor 112 is lower. When the discharge pressure and/or capacity exceeds the threshold (e.g., 60%), valve 206B is opened such that refrigerant and/or oil from compressor 112 is directed through both piping 202A and piping 202B. In this manner, the amount of available piping 202 effectively doubles when the discharge pressure and/or capacity of compressor 112 is higher.
In step 302, high side heat exchanger 102 removes heat from a refrigerant. Flash tank 104 stores the refrigerant in step 304. In step 306, low temperature low side heat exchanger 106 uses the refrigerant to cool a space. In step 308, medium temperature low side heat exchanger 108 uses the refrigerant to cool a space. Low temperature compressor 110 compresses the refrigerant from low temperature low side heat exchanger 106 in step 310. In step 312, medium temperature compressor 112 compresses the refrigerant from low temperature compressor 110, medium temperature low side heat exchanger 108, and flash tank 104. In step 314, sensor 208 detects a discharge pressure of medium temperature compressor 112.
In step 316, it is determined whether the detected discharge pressure exceeds a first threshold. If the discharge pressure does not exceed the first threshold, then a first valve 206A opens in step 318, a second valve 206B closes in step 320, and piping 202A directs refrigerant to high side heat exchanger 102 in step 322. If the discharge pressure does exceed the first threshold, then it is determined in step 324 whether the discharge pressure exceeds a second threshold that is higher than the first threshold. If the discharge pressure does not exceed the second threshold, then the second valve 206B opens in step 326, the first valve 206A closes in step 328, and piping 202B directs refrigerant to high side heat exchanger 102 in step 330. If the discharge pressure exceeds the second threshold, then the second valve 206B is opened in step 332, the first valve 206A is opened in step 334, and piping 202A and 202B direct refrigerant to the high side heat exchanger 102 in step 336.
Modifications, additions, or omissions may be made to method 300 depicted in
Modifications, additions, or omissions may be made to the systems and apparatuses described herein without departing from the scope of the disclosure. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components. Additionally, operations of the systems and apparatuses may be performed using any suitable logic comprising software, hardware, and/or other logic. As used in this document, “each” refers to each member of a set or each member of a subset of a set.
This disclosure may refer to a refrigerant being from a particular component of a system (e.g., the refrigerant from the medium temperature compressor, the refrigerant from the low temperature compressor, the refrigerant from the flash tank, etc.). When such terminology is used, this disclosure is not limiting the described refrigerant to being directly from the particular component. This disclosure contemplates refrigerant being from a particular component (e.g., the low temperature low side heat exchanger) even though there may be other intervening components between the particular component and the destination of the refrigerant. For example, the medium temperature compressor receives a refrigerant from the low temperature low side heat exchanger even though there is a low temperature compressor between the low temperature low side heat exchanger and the medium temperature compressor.
Although the present disclosure includes several embodiments, a myriad of changes, variations, alterations, transformations, and modifications may be suggested to one skilled in the art, and it is intended that the present disclosure encompass such changes, variations, alterations, transformations, and modifications as fall within the scope of the appended claims.
This application is a continuation of U.S. patent application Ser. No. 16/782,618 filed Feb. 5, 2020, by Shitong Zha, and entitled “COOLING SYSTEM WITH VERTICAL ALIGNMENT,” which is incorporated herein by reference.
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| Child | 17471517 | US |
