Energy Saving Design Of The Performance Test Facility For Air-cooled Water Chilling And Heat Pump Package Cover Upto 500RT

Up to now, there were thousands of air conditioning manufactures in China. Performance test as the part of the air conditioning manufacturing is the largest energy consumption process in the whole manufacturing process. So, how to reduce the energy consumption in the performance testing process is the key point to reduce the energy consumption throughout the industry.In this paper, an analysis on the design methods of the traditional performance test facility was made. The categories of the energy consumption of the testing facility was classified, and the energy waste because of the heating or cooling input and output from the test facility at different position at the same time was figured out. The key points of energy saving were summarized. A series of theoretical and design calculations were made regarding air-cooled chiller(heat pump) performance test facility invested by the Trane Company. The energy saving design method was vivificated by the experimental and certification of the test facility. The design method will be a guide for the other similar testing facilities.The main research and results include:(1) An energy consumption analysis of the regular performance test facility was made. The energy consumption was classified as: the power input for the tested chiller, the energy input to the test facility in order for maintaining the constant temperature and the stable cycled water flow rate, and the energy input to the test facility for maintaining the constant temperature and humidity of the testing room. Where, the energy consumed in cycled water temperature and the tested room environment are contrary at any time, no matter the tested chiller running at the cooling mode or at the heating mode. That means the energy used in the tested room aims for heating, then the energy of used in the cycled water will be for cooling. Thus, there is a chance to offset the energy from the energy transfer and conservation law if there is welldesigned system.(2) The energy consumption of the regular performance test facility was estimated by theoretical calculation. It is figured out the energy consumption will be up to 2.59 times the cooling capacity of the tested chiller when the performance test facility running for the performance test.(3) The concept of the energy saving design of the performance test facility was introduced systematically. The details of the control methods and the implementation of the newly designed performance test facility include the following sections, namely, the temperature and flow rate control of the cycled water flow; the temperature control of the testing room; the humidity control of the testing room, and the temperature control of the mixed water tank.(4) The optimized design of the testing room airflow, which meets the demand of the testing room temperature vectors and the velocity vectors, was completed using CFD method. The calculation and design of the main parts, like the air handling unit, the piping system, the auxiliary chiller, the condensing unit, the steam system, the cooling tower, the water pumps and the plate heat exchanger were completed. The data measurement system for the temperature, humidity, power, flow rate, and the data processing and recording software were completed.(5) A study on the energy consumption of the new designed performance test facility was completed. The energy consumption of the new designed performance test facility is around 1.12 times the cooling capacity of the tested chiller. An experiment was conducted with on the AHRI and GMPI qualified party witness followed on the guidance of AHRI 100% load and 25% load. The theoretical calculation result was verified by the experimental result. The energy saving design of the performance test facility is proved success with the verification of test and the theoretical results.