HVAC&R SYSTEM WITH CHILLER AND FREE COOLING

Information

  • Patent Application
  • 20250230957
  • Publication Number
    20250230957
  • Date Filed
    January 09, 2025
    6 months ago
  • Date Published
    July 17, 2025
    13 days ago
Abstract
A heating, ventilation, air conditioning, and/or refrigeration (HVAC&R) system includes a vapor compression loop configured to receive a working fluid, an additional fluid loop configured to selectively bias an additional fluid to a condenser of the vapor compression loop and an evaporator of the vapor compression loop, and an air-cooled heat exchanger disposed on the additional fluid loop and configured to selectively cool the additional fluid.
Description
BACKGROUND

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.


This application relates generally to heating, ventilating, air conditioning, and/or refrigeration (HVAC&R) systems employing a vapor compression assembly (or “chiller assembly”) and an additional fluid assembly including an air-cooled heat exchanger.


Certain HVAC&R systems, such as chillers, employ a vapor compression assembly. Vapor compression assemblies utilize a working fluid (e.g., a refrigerant) that changes phases between vapor, liquid, and combinations thereof in response to exposure to different temperatures and pressures within components of the vapor compression assembly. The vapor compression assembly may include an evaporator configured to place the working fluid in a heat exchange relationship with, for example, a conditioning or process fluid (e.g., water), such that the working fluid absorbs heat from the process fluid. The process fluid, cooled by the working fluid, may then be directed towards a conditioned environment, such as a data center, serviced by the HVAC&R system. The process fluid may be passed through downstream equipment, such as air handlers, to condition other fluids, such as air directed into the conditioned environment. A condenser of the vapor compression assembly may be employed to receive the working fluid and condense the working fluid into liquid phase. A compressor of the vapor compression assembly may be employed to bias the working fluid through the vapor compression assembly (e.g., by increasing a pressure of the working fluid).


In certain traditional HVAC&R systems employing a vapor compression assembly, a free cooling assembly or mode may also be employed. For example, a cooling fluid (e.g., water, glycol, or a mixture thereof) associated with the free cooling assembly may be employed to cool various fluids associated with the HVAC&R system, such as the working fluid in the condenser of the vapor compression assembly. Further, a cooling tower (or other cooling source) may be employed in the free cooling assembly to reduce a temperature of the process fluid via ambient air. In this way, the free cooling assembly may leverage a relatively low ambient air temperature for providing cooling and reducing a load on the vapor compression assembly.


In traditional systems, operation of the free cooling assembly may be activated during certain conditions, such as when ambient air temperature is relatively low. When the ambient air temperature is relatively low, the HVAC&R system may be configured to operate, via the free cooling assembly, at an adequate cooling capacity without powering the compressor and/or while reducing a reliance on the compressor (or other components) of the vapor compression assembly. However, in traditional HVAC&R systems utilizing vapor compression and free cooling assemblies, technical constraints may require that reliance on the vapor compression assembly be prioritized over reliance on the free cooling assembly. That is, in traditional HVAC&R systems, cooling may rely heavily on the vapor compression assembly, which requires a relatively large refrigerant charge in the vapor compression assembly and contributes to energy inefficiencies of the HVAC&R system. Further, in traditional HVAC&R systems utilizing vapor compression and free cooling assemblies, three or more fluid loops may be employed, which requires a large quantity of componentry and controls. Accordingly, it is now recognized that improved HVAC&R systems are desired.


SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.


In an embodiment of the present disclosure, a heating, ventilation, air conditioning, and/or refrigeration (HVAC&R) system includes a vapor compression loop configured to receive a working fluid, an additional fluid loop configured to selectively bias an additional fluid to a condenser of the vapor compression loop and an evaporator of the vapor compression loop, and an air-cooled heat exchanger disposed on the additional fluid loop and configured to selectively cool the additional fluid.


In another embodiment of the present disclosure, a method of operating a heating, ventilation, air conditioning, and/or refrigeration (HVAC&R) system includes biasing a working fluid through a vapor compression loop, selectively biasing an additional fluid through an additional fluid loop to a condenser of the vapor compression loop and an evaporator of the vapor compression loop, and cooling the additional fluid via an air-cooled heat exchanger of the additional fluid loop.


In another embodiment of the present disclosure, a heating, ventilation, air conditioning, and/or refrigeration (HVAC&R) system includes a vapor compression loop configured to receive a working fluid, a process load heat exchanger, and an additional fluid loop comprising an air-cooled heat exchanger, wherein the additional fluid loop is configured to circulate an additional fluid through the process load heat exchanger and selectively bias the additional fluid to the air-cooled heat exchanger and one or more components of the vapor compression loop.





BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:



FIG. 1 is a schematic view of a heating, ventilating, air conditioning, and/or refrigeration (HVAC&R) system employing a vapor compression assembly (or chiller assembly) and an additional fluid loop interfaced with the vapor compression assembly, in accordance with an aspect of the present disclosure; and



FIG. 2 is a process flow diagram illustrating a method of controlling a heating, ventilating, air conditioning, and/or refrigeration (HVAC&R) system employing a vapor compression assembly (or chiller assembly) and an additional fluid loop interfaced with the vapor compression assembly, in accordance with an aspect of the present disclosure.





DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.


When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.


Embodiments of the present disclosure relate to a heating, ventilating, air conditioning, and/or refrigeration (HVAC&R) system utilizing a vapor compression assembly and free cooling features. The vapor compression assembly includes a vapor compression loop (referred to in certain instances of the present disclosure as a working fluid loop) that circulates a working fluid (e.g., refrigerant) through an evaporator, a compressor, and a condenser. The compressor may operate to compress (e.g., increase a pressure of) the working fluid in certain conditions, thereby biasing the working fluid through the vapor compression loop. The evaporator may be employed to cool a process or conditioning fluid (e.g., water, glycol, or a mixture thereof), referred to in the present disclosure as an “additional fluid” separate from the working fluid, of an additional fluid loop by absorbing heat from the additional fluid into the working fluid in certain conditions. The condenser may be employed to remove heat from the working fluid, for example, via heat exchange with the additional fluid of the additional fluid loop.


In this way, a common loop (i.e., the additional fluid loop) is employed for interfacing the additional fluid with the condenser of the vapor compression loop and the evaporator of the vapor compression loop. However, various features of presently disclosed embodiments, such as valves and pumps, are employed to control flows of the additional fluid through various portions of the additional fluid loop. As an example, such features may be employed to block the additional fluid of the additional fluid loop from the condenser of the vapor compression loop, block the additional fluid of the additional fluid loop from the evaporator of the vapor compression loop, or both. Additionally or alternatively, such features may be employed to control a first amount (or flow rate) of the additional fluid that interfaces with the evaporator and a second amount of the additional fluid that bypasses the evaporator.


An air-cooled heat exchanger disposed in an external environment and corresponding to the additional fluid loop also may be employed to cool the additional fluid. The air-cooled heat exchanger may include one or more fans, such as a single fan servicing a V-shaped coil assembly and operable at variable speeds. In certain conditions, the HVAC&R system may be operated in a free cooling only mode in which the air-cooled heat exchanger is sufficient for cooling the additional fluid to provide a target conditioning of a load (e.g., without the vapor compression assembly). In other conditions, the HVAC&R system may be operated in one or more hybrid cooling modes in which the vapor compression assembly and the air-cooled heat exchanger are employed to cool the additional fluid to provide the target conditioning of the load. Multiple hybrid cooling modes, which differ from each other based on varying loads on the air-cooled heat exchanger and the vapor compression assembly, may be possible. In still other conditions, the HVAC&R system may be operated in a vapor compression (or “chiller”) mode. The above-described flow control features (e.g., valves and pumps) may be controlled to enable these various operating modes of the HVAC&R system, which will be described in greater detail with reference to the drawings.


In general, presently disclosed systems and methods enable conditioning (e.g., cooling) with a heavier reliance on free cooling and a reduced reliance on vapor compression compared to certain traditional embodiments. In doing so, a necessary refrigerant charge of the vapor compression assembly may be reduced relative to certain traditional embodiments, due at least in part to the use of compact condensers instead of larger volume air cooled condensers, and an energy efficiency of the HVAC&R system may be improved relative to certain traditional embodiments, due at least in part to the lower air resistance of a single air-cooled heat exchanger and intelligent speed control of the air-cooled heat exchanger fan and the cooling fluid pump. Further, presently disclosed systems and methods may employ fewer fluid loops than certain traditional configurations (e.g., only two fluid loops, such as the vapor compression loop and the additional fluid loop), which may reduce a part count and/or control complexity relative to traditional embodiments, among other technical benefits. These and other features are described in detail below with reference to the drawings.



FIG. 1 is a schematic view of an embodiment of an HVAC&R system 1010 employing a vapor compression assembly 1012 (or chiller assembly), an additional fluid assembly 1014 (or process or conditioning fluid assembly), and control features configured to modulate a reliance on the vapor compression assembly 1012 and various aspects associated with the additional fluid assembly 1014. In general, the HVAC&R system 1010 is employed to condition (e.g., cool) a conditioning or process fluid, referred to below as an additional fluid 1016, of a conditioning or process fluid loop, referred to below as an additional fluid loop 1018. In this way, the cooled additional fluid 1016 is directed toward a process load heat exchanger 1020 (e.g., a load, a terminal unit, or some other heat exchanger associated with a load) via the additional fluid loop 1018 such that the additional fluid 1016 conditions (e.g., cools) the load (e.g., via the process load heat exchanger 1020). These and other aspects of presently disclosed embodiments are described in detail below.


The vapor compression assembly 1012 includes, for example, a vapor compression loop 1022 (referred to in certain instances of the present disclosure as a working fluid loop) that routes a working fluid 1024 (e.g., a refrigerant, such as R-123, R-514A, R-1224 yd, R-1233zd, R-134a, R-1234ze, R-1234yf, R-1311, R-32, R-410A, R-744, R-717, R-290, or others) through various components of the vapor compression assembly 1012. For example, the vapor compression loop 1022 may include (or route the working fluid 1024 through) a compressor 1028, a condenser 1026, an expansion valve 1032, and an evaporator 1030 of the vapor compression assembly 1012. The compressor 1028 may operate to bias the working fluid 1024 through the vapor compression loop 1022 (e.g., by increasing a pressure of the working fluid 1024) in certain conditions. The evaporator 1030 may operate to cool the additional fluid 1016 of the additional fluid loop 1018 in certain conditions. The expansion valve 1032 may operate to reduce a pressure of the working fluid 1024 between the condenser 1026 and the evaporator 1030. The condenser 1026 may operate to remove heat from the working fluid 1024 in certain conditions via fluid-to-liquid cooling in which heat is transferred from the working fluid 1024 to the additional fluid 1016.


In certain operating and/or ambient conditions, the additional fluid loop 1018 of the additional fluid assembly 1014 is configured to cool the additional fluid 1016, for example, after the additional fluid 1016 is circulated through the condenser 1026 via an air-cooled heat exchanger 1038 including at least one fan 1039 (e.g., a single fan servicing a V-shaped coil assembly), although condenser bypass features are also possible and will be described in more detail with reference to other control componentry. When the additional fluid 1016 is circulated through the condenser 1026, the additional fluid 1016 absorbs heat from the working fluid 1024 corresponding to the vapor compression assembly 1012, causing the working fluid 1024 to condense prior to delivery of the working fluid 1024 to the expansion valve 1032. At least some of said heat absorbed by the additional fluid 1016 is rejected to environment when the additional fluid 1016 is routed from the condenser 1026 through the air-cooled heat exchanger 1038. Indeed, the air-cooled heat exchanger 1038 may be positioned in an external environment such that the fan(s) 1039 can generate a cool ambient air flow for cooling the additional fluid 1016. In certain ambient and/or operating conditions, the additional fluid loop 1018 of the additional fluid assembly 1014 may then route the additional fluid 1016 toward and through the evaporator 1030 of the vapor compression loop 1022, where the working fluid 1024 absorbs heat from the additional fluid 1016 to further cool the additional fluid 1016 prior to deliver of the additional fluid 1016 to, for example, the process load heat exchanger 1020.


Depending on ambient conditions and/or operating conditions of the HVAC&R system 1010, a reliance on the vapor compression assembly 1012 and/or a reliance on free cooling features (e.g., the air-cooled heat exchanger 1038) of the additional fluid assembly 1014 may be modulated to ensure adequate cooling and reduce energy consumption of the HVAC&R system 1010 relative to traditional embodiments. For example, a first valve 1040 on the additional fluid loop 1018 is disposed at a first location downstream from the process load heat exchanger 1020 (e.g., between the process load heat exchanger 1020 and the air-cooled heat exchanger 1038) in FIG. 1. The first valve 1040 may be controlled to a first setting that enables a flow of the additional fluid 1016 to the condenser 1026 and/or the air-cooled heat exchanger 1038, and a second setting that blocks the flow of the additional fluid 1016 from the condenser 1026 and/or the air-cooled heat exchanger 1038 (e.g., such that the additional fluid 1016 is directed instead toward the evaporator 1030 and/or the process load heat exchanger 1020). While the additional fluid loop 1018 is illustrated as extending from the first valve 1040 and overlapping with the air-cooled heat exchanger 1038 upstream of, for example, the condenser 1026, it should be understood that the additional fluid loop 1018 may not bias the additional fluid 1016 through the air-cooled heat exchanger 1038 until after the additional fluid 1016 is circulated through the condenser 1026 or bypasses the condenser 1026 via bypass componentry described in greater detail below.


With the first valve 1040 controlled to the first setting, the additional fluid 1016 is directed by the additional fluid loop 1018 toward (and, in certain ambient and/or operating conditions, through) the condenser 1026 of the vapor compression assembly 1012. For example, a second valve 1042 and a third valve 1043 may be controlled such that the additional fluid 1016 is directed through the condenser 1026 or such that the additional fluid 1016 is directed through a bypass line 1044 that causes the additional fluid 1016 to bypass the condenser 1026. For example, the bypass line 1044 is coupled to an additional fluid loop condenser inlet segment 1046 and an additional fluid loop condenser outlet segment 1048, with the third valve 1043 being disposed in the bypass line 1044. The second valve 1042 may be controllable to a first setting that enables the additional fluid 1016 to pass therethrough and to the condenser 1026, and a second setting that blocks the additional fluid 1016 from passing therethrough toward the condenser 1026. The third valve 1043 is controllable to a first setting that enables the additional fluid 1016 to pass therethrough and through the bypass line 1044, and a second setting that blocks the additional fluid 1016 from passing therethrough and through the bypass line 1044. In certain ambient and/or operating conditions, the second valve 1042 may be controlled to the first setting and the third valve 1043 may be controlled to the second setting, such that the additional fluid 1016 is passed to the condenser 1026 and not through the bypass line 1044. In certain other ambient and/or operating conditions, the second valve 1042 may be controlled to the second setting and the third valve 1043 may be controlled to the first setting, such that the additional fluid 1016 is passed through the bypass line 1044 and not the condenser 1026. In FIG. 1, the second valve 1042 is disposed at a second location downstream from the first location of the first valve 1040 and upstream of a condenser inlet 1051 to the condenser 1026 (e.g., where the additional fluid loop condenser inlet segment 1046 fluidly coupled to and/or extends into the condenser inlet 1051). Further, the third valve 1043 is disposed at a third location in the bypass line 1044 in FIG. 1, as previously described.


After passing through the condenser 1026 and/or the bypass line 1044, the additional fluid 1016 may be routed by the additional fluid loop 1018 of the additional fluid assembly 1014 through an inlet 1055 of the air-cooled heat exchanger 1038 and toward a first pump 1047 disposed on the additional fluid loop 1018. That is, the air-cooled heat exchanger 1038 may be configured to cool the additional fluid 1016 (e.g., via the fan 1039) after the additional fluid 1016 passes through the condenser 1026 or the third valve 1043. A setting of the first pump 1047 (e.g., a speed setting of the first pump) may be a function of expected process load (i.e., at the process load heat exchanger 1020) and/or ambient dry bulb temperature. A fourth valve 1049 disposed at a fourth location in a return loop line 1050 of the additional fluid loop 1018 may be actuated between a first setting that enables a flow of the additional fluid 1016 through the return loop line 1050 and back to the condenser 1026, or a second setting that blocks the flow of the additional fluid 1016 through the return loop line 1050. That is, the return loop line 1050 is positioned in FIG. 1 to bias the additional fluid 1016, while the fourth valve 1049 is in the first setting (e.g., an open position), from an outlet 1053 of the air-cooled heat exchanger 1038 toward the condenser inlet 1051 of the condenser 1026.


With the fourth valve 1049 in the second setting, the additional fluid 1016 is routed (e.g., biased, circulated) toward the evaporator 1030 and/or the process load heat exchanger 1020. For example, a fifth valve 1052 may be actuated between a first setting that enables a flow of the additional fluid 1016 therethrough and toward the evaporator 1030, and a second setting that blocks the flow of the additional fluid 1016 (e.g., instead causing the additional fluid 1016 to flow toward the process load heat exchanger 1020). With the fifth valve 1052 in the first setting, the additional fluid 1016 is directed toward at least one sixth valve 1054 (e.g., e.g., control valve, modulating three-way valve), where the at least one sixth valve 1054 in FIG. 1 is disposed at a sixth location upstream of the evaporator 1030 and downstream from a fifth location of the fifth valve 1052. The at least one sixth valve 1054 may be controllable to a variety of settings that modulates an amount of the additional fluid 1016 directed to the evaporator 1030 and/or an amount of the additional fluid 1016 that recirculates to the evaporator 1030 via a recirculation segment 1056 coupled to an additional fluid loop evaporator inlet segment 1058 and an additional fluid loop evaporator outlet segment 1060. That is, the control valve 1054 may be controlled to one or more settings that enables at least a portion (e.g., controllable portion) of the additional fluid 1016 to flow upwardly through the recirculation segment 1056 and back into the evaporator 1030.


Further, a second pump 1062 disposed between the control valve 1054 and the evaporator 1030 may be controlled to ensure a fixed or constant flow rate of the additional fluid 1016 through the evaporator 1030 (e.g., when operation of the vapor compression assembly 1012 is required). When operation of the vapor compression assembly 1012 is required, the working fluid 1024 in the evaporator 1030 absorbs heat from the additional fluid 1016 in the evaporator 1030, which is subsequently routed by the additional fluid loop 1018 toward the process load heat exchanger 1020 (e.g., for cooling a load). In some embodiments, a third pump 1064 is positioned upstream of the process load heat exchanger 1020 and is operated to control a flow of the additional fluid 1016 to the process load heat exchanger 1020.


As previously described, various components may be controlled to change various aspects of the HVAC&R system 1010 in response to operating and/or ambient conditions. For example, a sensor assembly 1066 including one or more sensors may be employed to detect the operating and/or ambient conditions, and a controller assembly 1068 (e.g., including one or more controllers) may control various aspects of the HVAC&R system 1010 based on sensor feedback received from the sensor assembly 1066. The sensor assembly 1066 may be configured to detect, for example, a dry bulb ambient temperature, a wet bulb ambient temperature, a condenser inlet temperature of the additional fluid 1016 and/or the working fluid 1024, a condenser outlet temperature of the additional fluid 1016 and/or the working fluid 1024, an evaporator inlet temperature of the additional fluid 1016 and/or the working fluid 1024, an evaporator outlet temperature of the additional fluid 1016 and/or the working fluid 1024, a temperature of the additional fluid 1016 at (or upstream of) an inlet to the process load heat exchanger 1020, a temperature of the additional fluid 1016 at (or downstream of) the process load heat exchanger 1020, any other temperature associated with the additional fluid 1016 at any location of the additional fluid loop 1018, any other temperature associated with the working fluid 1024 at any location of the vapor compression loop 1022, etc.


The controller assembly 1068 may include memory circuitry 1070 (e.g., one or more memories) configured to store instructions thereon that, when executed by processing circuitry 1072 (e.g., one or more processors) of the controller assembly 1068, cause the processing circuitry 1072 to perform various functions. For example, the processing circuitry 1072 may control various components of the HVAC&R system 1010 based on the sensor feedback received from the one or more sensors of the sensor assembly 1066. In some embodiments, control of such componentry may be based at least in part on the sensor feedback, parameters determined by way of the sensor feedback (e.g., temperature ranges across the evaporator, across the condenser, etc.), and/or other conditions. In some embodiments, the controller assembly 1068 determines a desirable mode of the HVAC&R system 1010 based on the sensor feedback.


For example, in a free cooling only mode (e.g., which excludes work done by the vapor compression assembly 1012), the controller assembly 1068 may control the first valve 1040 and the third valve 1043 to a first setting (e.g., open setting), and the second valve 1042, the fourth valve 1049, and the fifth valve 1052 to a second setting (e.g., closed setting). In this way, the additional fluid 1016 is biased through the air-cooled heat exchanger 1038, but does not interface with the condenser 1026 and does not interface with the evaporator 1030. Further, the controller assembly 1068 may control the fan 1039 of the air-cooled heat exchanger 1038 to a desirable (e.g., target) setting to facilitate a target cooling of the additional fluid 1016, and shut off the compressor 1028. Selection of the free cooling only mode may be based on the sensor feedback from the sensor assembly 1066, as previously described, and/or in response to determining (e.g., based on the sensor feedback) that the air-cooled heat exchanger 1038 can handle the required load of the process load heat exchanger 1020. The speed of the fan 1039 of the air-cooled heat exchanger 1038 may be controlled to meet a specified process load heat exchanger inlet temperature (e.g., of the additional fluid 1016).


Further, in a hybrid cooling mode, the controller assembly 1068 may control the first valve 1040, the second valve 1042, and the fifth valve 1052 to a first setting (e.g., open setting), and the third valve 1043 and the fourth valve 1049 to a second setting (e.g., closed setting). In this way, the additional fluid 1016 is biased through both the condenser 1026 and the air-cooled heat exchanger 1038 and interfaces with the evaporator 1030 of the vapor compression assembly 1012. Further, the controller assembly 1068 may control the fan 1039 of the air-cooled heat exchanger 1038 to a 100% speed, and the compressor 1028 of the vapor compression assembly 1012 to a desirable (e.g., target) setting to facilitate a target cooling of the additional fluid 1016. Selection of the hybrid cooling mode may be based on the sensor feedback from the sensor assembly 1066, as previously described, and/or in response to determining (e.g., based on the sensor feedback) that the outlet temperature of the additional fluid 1016 from the air-cooled heat exchanger 1038 is below the outlet temperature of the additional fluid 1016 from the process load heat exchanger 1020 and above the inlet temperature of the additional fluid 1016 to the process load heat exchanger 1020 even when the fan 1039 is operated at 100% (or maximum) speed. In this way, in the hybrid cooling mode(s), the load of the process load heat exchanger 1020 is handled by a combination of the vapor compression assembly 1012 and the air-cooled heat exchanger 1038.


It should be noted that multiple hybrid cooling modes may be employed (e.g., where each hybrid cooling mode relies on the vapor compression assembly 1012, such as the compressor 1028 of the vapor compression assembly 1012, to varying degrees for handling the process load). Further, the fan speed of the fan 1039 may be modulated down in the hybrid cooling mode(s) once the chiller capacity reaches its minimum operating level to hold a specified condenser entering temperature, and until the fan speed falls below a threshold percentage, at which point the controller assembly 1068 may initiate the free cooling only mode.


Further still, in a vapor compression (or chiller) mode, the controller assembly 1068 may control the second valve 1042, the fourth valve 1049, and the fifth valve 1052 to a first setting (e.g. open setting), and the first valve 1040 and the third valve 1043 to a second setting (e.g., closed setting). In this way, a heat load of the process load heat exchanger 1020 is handled entirely by the vapor compression assembly 1012 (or chiller). The vapor compression (or chiller) mode may be selected when the vapor compression assembly 1012 is in operation and the outlet temperature of the additional fluid 1016 from the air-cooled heat exchanger 1038 is equal to or above the outlet temperature of the additional fluid 1016 from the process load heat exchanger 1020. While the vapor compression assembly 1012 (or chiller) is running at or above its minimum capacity, the fan 1039 of the air-cooled heat exchange 1038 may be controlled at 100%. Once the chiller capacity reaches its minimum operating level, the speed of the fan 1039 is modulated down to hold a specified condenser entering temperature of the additional fluid 1016, and until a determination is made that the HVAC&R system 1010 can revert to hybrid cooling mode.


It should be noted that the locations of the various valves 1040, 1042, 1043, 1049, 1052, 1054 illustrated in FIG. 1 and described in detail above are exemplary and that other locations and/or implementations for at least some of the valves 1040, 1042, 1043, 1049, 1052, 1054 are also possible. For example, the additional fluid loop 1018 may include a first branch circuit 1074 that interfaces with the air-cooled heat exchanger 1038 and/or the condenser 1026 and a second branch circuit 1076 that interfaces with the evaporator 1030, as shown. A connecting conduit 1078 enables a flow of the additional fluid 1016 in at least some operating modes from the first branch circuit 1074 toward the second branch circuit 1076, and a connection assembly 1080 (e.g., including conduits, the third pump 1064, and the process load heat exchanger 1020) enables a flow of the additional fluid 1016 in at least some operating modes from the second branch circuit 1076 through the process load heat exchanger 1020 and then toward the first branch circuit 1074. While the first valve 1040 is disposed at or adjacent to an inlet 1082 to the first branch circuit 1074 (e.g., downstream from the process load heat exchanger 1020 and upstream of the air-cooled heat exchanger 1038 relative to the flow of the additional fluid 1016) in FIG. 1, in another embodiment, the first valve 1040 may be disposed at another location, such as alternate location 1083 at or adjacent to an outlet 1084 of the first branch circuit 1074 (e.g., positioned downstream from the first pump 1047). That is, whether the first valve 1040 positioned as shown in FIG. 1 or at the alternate location 1082, the first valve 1040 is controllable to selectively enable or disable active flow of the additional fluid 1016 through the first branch circuit 1074.


Additionally or alternatively, while the fifth valve 1052 is disposed at or adjacent to an inlet 1086 to the second branch circuit 1076 (e.g., upstream from the at least one sixth valve 1054 relative to the flow of the additional fluid 1016) in FIG. 1, in another embodiment, the fifth valve 1052 may be disposed at another location, such as an alternate location 1087 at or adjacent to an outlet 1088 of the second branch circuit 1076 (e.g., positioned downstream from the evaporator 1030 and/or between the evaporator 1030 and the third pump 1064). That is, whether the fifth valve 1052 is positioned as shown in FIG. 1 or at the alternate location 1087, the second valve 1052 is controllable to selectively enable or disable active flow of the additional fluid 1016 through the second branch circuit 1076.


Further, as previously described, the at least one sixth valve 1054 (e.g., control valve, three-way modulating valve) may be controllable to a variety of settings that modulates an amount of the additional fluid 1016 flowing into the second branch circuit 1076 directed toward the evaporator 1030 and/or an amount of the additional fluid 1016 that recirculates to the evaporator 1030. That is, the at least one sixth valve 1054 may enable a mixing of the additional fluid 1016 coming off the evaporator 1030 with the additional fluid 1016 flowing into the second branch circuit 1076 from the connecting conduit 1078 and toward the evaporator 1030. In another implementation, the at least one sixth valve 1054 may include, for example, two valves, such as a sixth mixing valve and an additional sixth mixing valve, which are controllable for the same or similar purposes noted above, namely, mixing the additional fluid 1016 coming off the evaporator 1030 with the additional fluid 1016 flowing into the second branch circuit 1076 from the connecting conduit 1078 and toward the evaporator 1030.



FIG. 2 is a process flow diagram illustrating an embodiment of a method 2000 of operating an HVAC&R system, such as the HVAC&R system of FIG. 1, employing a vapor compression assembly (or chiller assembly) and an additional fluid loop interfaced with the vapor compression assembly. In the illustrated embodiment, the method 2000 includes interfacing (block 2002) a vapor compression loop configured to circulate a working fluid with an additional fluid loop configured to circulate an additional fluid, where the additional fluid loop is configured to bias the additional fluid to a process load heat exchanger (e.g., load heat exchanger) for conditioning a load. For example, as previously described, the additional fluid loop may interface with both a condenser and an evaporator of the vapor compression loop. Heat exchange relationships between the working fluid and the additional fluid may be selectively established at the condenser and the evaporator based on various ambient and/or operating conditions and corresponding modes of the HVAC&R system.


The method 2000 also includes controlling (block 2004) a plurality of valves and/or pumps to initiate a free cooling only mode based on first ambient and/or operating conditions to cool the additional fluid, where the cooled additional fluid is biased to the process load heat exchanger. Detailed discussion of the free cooling only mode and corresponding controls can be found above with reference to FIG. 1. In general, in the free cooling only mode, the additional fluid bypasses the condenser and the evaporator and is cooled by the air-cooled heat exchanger to a sufficient degree that the requirements of the process load heat exchanger can be met.


The method 2000 also includes controlling (block 2006) the plurality of valves and/or pumps to initiate a hybrid cooling mode based on second ambient and/or operating conditions (e.g., different than the first ambient and/or operating conditions) to cool the additional fluid, where the cooled additional fluid is biased to the process load heat exchanger. Detailed discussion of the hybrid cooling mode(s) and corresponding controls can be found above with reference to FIG. 1. In general, in the hybrid cooling mode(s), a combination of the vapor compression loop and the air-cooled heat exchanger are relied upon for meeting the requirements of the process load heat exchanger.


The method 2000 also includes controlling (block 2008) the plurality of valves and/or pumps to initiate a vapor compression cooling mode based on third ambient and/or operating conditions (e.g., different than the first and second ambient and/or operating conditions) to cool the additional fluid, where the cooled additional fluid is biased to the process load heat exchanger. Detailed discussion of the vapor compression cooling mode and corresponding controls can be found above with reference to FIG. 1. In general, in the vapor compression cooling mode, the vapor compression loop is relied upon for meeting the requirements of the process load heat exchanger. Control of the valves and/or the pumps at block 2004, 2006, and/or 2008 may be based, for example, on sensor feedback from a sensor configured to detect an ambient or operating condition, as previously described with respect to FIG. 1.


In general, presently disclosed systems and methods are configured to provide adequate cooling to one or more loads associated with an HVAC&R system, while improving energy efficiency over traditional embodiments, reducing refrigerant charge for vapor compression over traditional embodiments, reducing an amount of fluid loops and/or control complexity thereof over traditional embodiments, and the like.


While only certain features of present embodiments have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes that fall within the true spirit of the disclosure. Further, it should be understood that certain elements of the disclosed embodiments may be combined or exchanged with one another.


The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims
  • 1. A heating, ventilation, air conditioning, and/or refrigeration (HVAC&R) system, comprising: a vapor compression loop configured to receive a working fluid;an additional fluid loop configured to selectively bias an additional fluid to a condenser of the vapor compression loop and an evaporator of the vapor compression loop; andan air-cooled heat exchanger disposed on the additional fluid loop and configured to selectively cool the additional fluid.
  • 2. The HVAC&R system of claim 1, wherein the additional fluid loop is configured to circulate the additional fluid to a process load heat exchanger.
  • 3. The HVAC&R system of claim 1, comprising a valve disposed on the additional fluid loop between a process load heat exchanger and a condenser inlet to the condenser, the air-cooled heat exchanger, or both, wherein the valve is configured to be actuated between: a first setting that enables a flow of the additional fluid from the process load heat exchanger to the condenser, the air-cooled heat exchanger, or both; anda second setting that blocks the flow of the additional fluid from the process load heat exchanger to the condenser, the air-cooled heat exchanger, or both.
  • 4. The HVAC&R system of claim 1, comprising a valve disposed on the additional fluid loop upstream of a condenser inlet to the condenser, wherein the valve is configured to be actuated between: a first setting that enables a flow of the additional fluid; anda second setting that blocks the flow of the additional fluid.
  • 5. The HVAC&R system of claim 4, comprising an additional valve disposed on a bypass line extending between an additional fluid loop condenser inlet segment and an additional fluid loop condenser outlet segment, wherein the additional valve is configured to be actuated between: an open setting when the valve is actuated to the first setting; anda closed setting when the valve is actuated to the second setting.
  • 6. The HVAC&R system of claim 1, comprising a valve disposed on a return loop line downstream from the air-cooled heat exchanger relative to a flow of the additional fluid, wherein the valve is configured to be actuated between: a first setting configured to direct the additional fluid back to the air-cooled heat exchanger; anda second setting configured to direct the additional fluid toward the evaporator, a process load heat exchanger, or both.
  • 7. The HVAC&R system of claim 1, comprising: a first pump configured to control a first flow of the additional fluid through the air-cooled heat exchanger;a second pump configured to control a second flow of the additional fluid toward a process load heat exchanger; anda third pump configured to control a third flow of the additional fluid toward an evaporator disposed on the vapor compression loop.
  • 8. The HVAC&R system of claim 1, comprising a control valve controllable between two or more settings to: control a first amount of the additional fluid directed toward the evaporator; andcontrol a second amount of the additional fluid recirculated to the evaporator.
  • 9. The HVAC&R system of claim 1, comprising: at least one sensor configured to detect at least one ambient or operating condition; anda controller configured to control at least one valve of the additional fluid loop based on sensor feedback received from the at least one sensor.
  • 10. The HVAC&R system of claim 9, wherein the additional fluid loop comprises a first branch circuit interfacing with the condenser, the air-cooled heat exchanger, or both, wherein the additional fluid loop comprises a second branch circuit interfacing with the evaporator, and wherein the at least one valve comprises: a first valve disposed on the first branch circuit at or adjacent to an inlet or an outlet of the first branch circuit;a second valve disposed on the first branch circuit adjacent to a condenser inlet to the condenser;a third valve disposed on a bypass line of the first branch circuit, wherein the bypass line extends between an additional fluid loop condenser inlet segment and an additional fluid loop condenser outlet segment of the first branch circuit;a fourth valve disposed on a return loop line of the first branch circuit, wherein the return loop line extends between an outlet of the air-cooled heat exchanger and the condenser inlet;a fifth valve disposed on the second branch circuit at or adjacent to an inlet or an outlet of the second branch circuit; andat least one sixth valve disposed adjacent to an additional fluid loop evaporator inlet segment of the second branch circuit.
  • 11. The HVAC&R system of claim 9, wherein the additional fluid loop comprises a first branch circuit interfacing with the condenser, the air-cooled heat exchanger, or both, wherein the additional fluid loop comprises a second branch circuit interfacing with the evaporator, and wherein the at least one valve comprises: a first valve disposed on the first branch circuit at or adjacent to an inlet or an outlet of the first branch circuit;a second valve disposed on the first branch circuit adjacent to a condenser inlet to the condenser;a third valve disposed on a bypass line of the first branch circuit, wherein the bypass line extends between an additional fluid loop condenser inlet segment and an additional fluid loop condenser outlet segment of the first branch circuit;a fourth valve disposed on a return loop line of the first branch circuit, wherein the return loop line extends between an outlet of the air-cooled heat exchanger and the condenser inlet;a fifth valve disposed on the second branch circuit at or adjacent to an inlet or an outlet of the second branch circuit; orat least one sixth valve disposed adjacent to an additional fluid loop evaporator inlet segment of the second branch circuit.
  • 12. A method of operating a heating, ventilation, air conditioning, and/or refrigeration (HVAC&R) system, comprising: biasing a working fluid through a vapor compression loop;selectively biasing an additional fluid through an additional fluid loop to a condenser of the vapor compression loop and an evaporator of the vapor compression loop; andcooling the additional fluid via an air-cooled heat exchanger of the additional fluid loop.
  • 13. The method of claim 12, comprising: biasing the additional fluid through the additional fluid loop to a process load heat exchanger; andcontrolling a valve disposed on the additional fluid loop between the process load heat exchanger and a condenser inlet to the condenser, the air-cooled heat exchanger, or both between: a first setting that enables a flow of the additional fluid from the process load heat exchanger to the condenser, the air-cooled heat exchanger, or both; anda second setting that blocks the flow of the additional fluid from the process load heat exchanger to the condenser, the air-cooled heat exchanger, or both.
  • 14. The method of claim 12, comprising: controlling a valve disposed on the additional fluid loop upstream of a condenser inlet to the condenser between a first setting that enables a flow of the additional fluid and a second setting that blocks the flow of the additional fluid; andcontrolling an additional valve disposed on a bypass line extending between an additional fluid loop condenser inlet segment and an additional fluid loop condenser outlet segment between an open setting when the valve is actuated to the first setting and a closed setting when the valve is actuated to the second setting.
  • 15. The method of claim 12, comprising controlling a valve disposed on a return loop line downstream from the air-cooled heat exchanger relative to a flow of the additional fluid between: a first setting configured to direct the additional fluid back to a condenser inlet to the condenser; anda second setting configured to direct the additional fluid toward the evaporator, a process load heat exchanger, or both.
  • 16. The method of claim 15, comprising controlling a control valve between two or more settings to: control a first amount of the additional fluid directed toward the evaporator; andcontrol a second amount of the additional fluid recirculated to the evaporator.
  • 17. The method of claim 12, comprising controlling, based on sensor feedback indicative of at least one ambient or operating condition, at least one valve of the additional fluid loop, wherein the additional fluid loop comprises a first branch circuit interfacing with the condenser, the air-cooled heat exchanger, or both, wherein the additional fluid loop comprises a second branch circuit interfacing with the evaporator, and wherein the at least one valve of the additional fluid loop comprises at least one of: a first valve disposed on the first branch circuit at or adjacent to an inlet or an outlet of the first branch circuit;a second valve disposed on the first branch circuit adjacent to a condenser inlet to the condenser;a third valve disposed on a bypass line of the first branch circuit, wherein the bypass line extends between an additional fluid loop condenser inlet segment and an additional fluid loop condenser outlet segment of the first branch circuit;a fourth valve disposed on a return loop line of the first branch circuit, wherein the return loop line extends between an outlet of the air-cooled heat exchanger and the condenser inlet;a fifth valve disposed on the second branch circuit at or adjacent to an inlet or an outlet of the second branch circuit; orat least one sixth valve disposed adjacent to an additional fluid loop evaporator inlet segment of the second branch circuit.
  • 18. A heating, ventilation, air conditioning, and/or refrigeration (HVAC&R) system, comprising: a vapor compression loop configured to receive a working fluid;a process load heat exchanger; andan additional fluid loop comprising an air-cooled heat exchanger, wherein the additional fluid loop is configured to circulate an additional fluid through the process load heat exchanger and selectively bias the additional fluid to the air-cooled heat exchanger and one or more components of the vapor compression loop.
  • 19. The HVAC&R system of claim 18, wherein the one or more components comprise a condenser, an evaporator, or both.
  • 20. The HVAC&R system of claim 18, comprising: a first branch circuit of the additional fluid loop, wherein the first branch circuit interfaces with the air-cooled heat exchanger, a condenser of the vapor compression loop, or both;a second branch circuit of the additional fluid loop, wherein the second branch circuit interfaces with an evaporator of the vapor compression loop;a sensor configured to detect at least one ambient or operating condition; anda controller configured to control, based on sensor feedback from the sensor, at least one valve of the additional fluid loop, wherein the at least one valve of the additional fluid loop comprises at least one of: a first valve disposed on the first branch circuit at or adjacent to an inlet or an outlet of the first branch circuit;a second valve disposed on the first branch circuit adjacent to a condenser inlet to the condenser;a third valve disposed on a bypass line of the first branch circuit, wherein the bypass line extends between an additional fluid loop condenser inlet segment and an additional fluid loop condenser outlet segment;a fourth valve disposed on a return loop line of the first branch circuit, wherein the return loop line extends between an outlet of the air-cooled heat exchanger and the condenser inlet;a fifth valve disposed on the second branch circuit at or adjacent to an inlet or an outlet of the second branch circuit; ora sixth valve disposed adjacent to an additional fluid loop evaporator inlet segment of the second branch circuit.
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from and the benefit of U.S. Provisional Application Ser. No. 63/619,985, entitled “HVAC&R SYSTEM WITH CHILLER AND FREE COOLING,” filed Jan. 11, 2024, which is hereby incorporated by reference in its entirety for all purposes.

Provisional Applications (1)
Number Date Country
63619985 Jan 2024 US