FIELD
[0001] This disclosure generally relates to heating-cooling systems used in heating, ventilation,
air conditioning, and refrigeration (HVACR) systems. More particularly, this disclosure
relates cooling-heating units in such heating-cooling systems.
Background
[0002] Heating, ventilation, air conditioning, and refrigeration (HVACR) systems can be
used to provide heating and/or cooling. In some systems, the HVACR can include a one
or more cooling-heating units that provide both heating and cooling. A cooling-heating
unit includes a refrigerant circuit that provides heating to a first fluid and cooling
to a second fluid. The cooling-heating unit includes a compressor that compresses
refrigerant in the refrigerant circuit. A compressor can be compressor configured
to operate at part loads (e.g., partial capacity), and the conditioning provided by
the cooling-heating unit can be adjusted by adjusting the load/capacity of its compressor.
Summary
[0003] In an embodiment, a heating-cooling system includes a heating flow path for a first
process fluid, a cooling flow path for a second process fluid, and cooling-heating
units each fluidly connected to the heating flow path and to the cooling flow path.
Each of the cooling-heating units includes a refrigerant circuit with a compressor,
an expander, a condenser for heating the first process fluid, and an evaporator for
cooling the second process fluid. The cooling-heating units include one or more primary
cooling-heating units and one or more secondary cooling-heating units. The one or
more primary cooling-heating units and the one or more secondary cooling-heating units
being fluidly connected to the heating flow path such that when active, heating load
is prioritized to the one or more primary cooling-heating units over the one or more
secondary cooling-heating units.
[0004] In an embodiment, a method is directed to controlling a heating-cooling system. The
heating-cooling system includes a heating flow path for a first process fluid, a cooling
flow path for a second process fluid, and cooling-heating units that are each fluidly
connected to the heating flow path and to the cooling flow path. The cooling-heating
units including one or more primary cooling-heating units and one or more secondary
cooling-heating unit. The method includes selectively operating the heating-cooling
system in a plurality of modes that include a first mode, a second mode, and a third
mode. Operating the heating-cooling system in the first mode includes one or more
of the secondary cooling-heating units each heating the first process fluid and cooling
the second process fluid. The one or more primary cooling-heating units are inactive
in the first mode. Operating the heating-cooling system in the second mode includes
one or more of the primary cooling-heating units each heating the first process fluid
and cooling the second process fluid. The secondary cooling-heating units are inactive
in the second mode. Operating the heating-cooling system in the third mode includes
at least one of the one or more secondary cooling-heating units and at least one of
the one or more primary cooling-heating units each heating the first process fluid
and cooling the second process fluid. The at least one of the one or more primary
cooling-heating units operating at or about maximum conditioning capacity in the third
mode.
Drawings
[0005]
Figure 1 is schematic diagram of an embodiment of a cooling-heating unit for a heating,
ventilation, air conditioning, and refrigeration (HVACR) system.
Figure 2 is a schematic diagram of an embodiment of a heating-cooling system in a
HVACR system.
Figure 3 is a schematic diagram of an embodiment of a heating-cooling system.
Figure 4A is a schematic diagram of the heating-cooling system in Figure 3 operating
in a first mode, according to an embodiment.
Figure 4A is a schematic diagram of the heating-cooling system in Figure 3 operating
in a first mode, according to an embodiment.
Figure 4B is a schematic diagram of the heating-cooling system in Figure 3 operating
in a second mode, according to an embodiment.
Figure 4C is a schematic diagram of the heating-cooling system in Figure 3 operating
in a third mode, according to an embodiment.
Figure 5 is a block flow diagram of an embodiment of a method of controlling a heating-cooling
system.
[0006] Like numbers represent like features.
Detailed Description
[0007] An HVACR system can be used to cool or heat one or more conditioned spaces. An HVACR
system can also be used to provide hot and/or cooled fluid (e.g., hot water, cooled
water, or the like). A HVACR system may provide cooled fluid (e.g., for conditioning
one or more conditioned spaces, or the like) and heated fluid (e.g., hot water for
use in a building, or the like). A HVACR system may utilize a heating-cooling system
with a refrigerant in a circuit to heat a first process fluid (e.g., air, water, or
the like) and to cool a second process fluid (e.g., air, water, chiller liquid, or
the like). For example, the cooled heated fluid in some instances may be used to heat
air supplied to/in the conditioned space(s), may be used to provide hot water in a
building, or to provide heating to other fluids in a building. For example, the cooled
process fluid (e.g., a chiller liquid) can then be used to cool air supplied to/in
the conditioned space(s), or the like.
[0008] In some HVACR systems, the HVAC system can include a plurality cooling-heating units
with each unit including refrigerant circuit that heats the first process fluid and
cools the second process fluid. In conventional systems, the amount of the load shifting
between the cooling-heating units is significantly limited due to physical operating
limits of the components of the system and complex control logic is necessary for
even achieve the limited load shifting. In chiller systems and heat pump systems,
the degree of unloading of compressors is limited relative to other types of systems
(e.g., comfort cooling HVACR applications, and the like) Utilizing a larger number
of smaller capacity units to allow for larger unloading results in lower efficiency
and increased costs (e.g., increased maintenance cost, increased initial cost).
[0009] Embodiments disclosed herein are directed to HVACR systems and methods of operating
HVACR systems in which the cooling-heating units are sized and fluidly connected to
allow for easier load shifting without complex control algorithms while maintaining
efficiency.
[0010] Figure 1 is a schematic diagram of an embodiment of a cooling-heating unit 1 in a
heating, ventilation, air conditioning, and refrigeration (HVACR) system. The cooling-heating
unit 1 includes a refrigerant circuit 5. The cooling-heating unit 1 utilizes a compression-expansion
cycle of refrigerant in the refrigeration circuit 5 to provide heating and cooling,
as discussed below.
[0011] The refrigeration circuit 5 includes a compressor 10, a condenser 20, an expansion
device 30, and an evaporator 40. In an embodiment, the refrigeration circuit 5 can
be modified to include additional components. For example, the refrigeration circuit
5 in an embodiment can include an economizer heat exchanger, one or more flow control
devices, a receiver tank, a dryer, a suction-liquid heat exchanger, or the like. The
components of the refrigerant circuit 5 are fluidly connected.
[0012] Short dashed lines are provided in the Figures to indicate fluid flows through some
components (e.g., compressor 10, condenser 20, evaporator 40) for clarity, and should
be understood as not specifying a specific route within each component. Long dash
lines are provided in the Figures to indicate features that may be different in an
embodiment, and should not be considered as indicating necessary or required features.
Dashed-dotted lines are used in the Figures to indicate communications between different
components/features (e.g., controller 290 in Figure 3 controlling/operating different
components, sensing via different sensors, and the like of the system). Said communications
may include one or more of, for example (but not limited to), electrical communications,
fiber-optic communications, wireless communications, electro-mechanical communications,
pneumatic communications, or the like.
[0013] The refrigeration circuit 5 applies known principles of gas compression and heat
transfer. The refrigeration circuit 5 of the cooling-heating unit 1 is configured
to heat a first process fluid PF
1 and to cool a second process fluid PF
2. As shown in Figure 1, the cooling-heating unit 1 heats a flow of the first process
fluid PF
1 and cools a flow of the second process fluid PF
2. In an embodiment, a process fluid is a liquid (e.g., water, glycol, a water and
glycol mixture, chiller liquid, and the like). For example, the first process fluid
is a first liquid and the second process fluid is a second liquid. The first process
fluid PF
1 and the second process fluid PF
2 can the same type of fluid (e.g., the first process fluid and the second process
fluid both being water) or can be different types of fluids (e.g., first process fluid
being a chiller liquid and the second process fluid being water, or the like).
[0014] During the operation of the refrigeration circuit 5, a working fluid (e.g., containing
refrigerant, refrigerant mixture, or the like) flows into the compressor 10 from the
evaporator 40 in a gaseous state at a relatively lower pressure. The compressor 10
compresses the gas into a high pressure state, which also heats the gas. After being
compressed, the relatively higher pressure and higher temperature gas flows from the
compressor 10 to the condenser 20. In addition to the working fluid flowing through
the condenser 20, the first process fluid PF
1 also separately flows through the condenser 20. The first process fluid absorbs heat
from the working fluid as the first process fluid PF
1 flows through the condenser 20, which cools the working fluid as it flows through
the condenser. The working fluid condenses to liquid and then flows into the expansion
device 30. The expansion device 30 allows the working fluid to expand, which converts
the working fluid to a vapor or mixed vapor and liquid state. An "expansion device"
as described herein may also be referred to as an expander. In an embodiment, the
expander may be an expansion valve, expansion plate, expansion vessel, orifice, or
the like, or other such types of expansion mechanisms. It should be appreciated that
the expander may be any type of expander used in the field for expanding a working
fluid to cause the gaseous working fluid to decrease in pressure and temperature.
[0015] The relatively lower temperature, vapor/liquid working fluid then flows from the
expansion device 30 into the evaporator 40. The second process fluid PF
2 also flows through the evaporator 40. The working fluid absorbs heat from the second
process fluid PF
2 as it flows through the evaporator 40, which cools the second process fluid PF
2 as it flows through the evaporator 40. As the working fluid absorbs heat, the liquid
working fluid evaporates to vapor. The working fluid then returns to the compressor
10 from the evaporator 40.
[0016] The cooling-heating unit 1 is configured to provide both heating and cooling simultaneously
(e.g., heating to the first process fluid PF
1 and cooling to the second process fluid PF
2). In different modes, the cooling-heating unit 1 may operate based on providing a
target/desired amount of heating to the first process fluid PF
1 (e.g., a heating mode) or based on provided a target/desired amount of cooling to
the second process fluid PF
2 (e.g., a cooled). A "cooling-heating unit" may also be referred to as a chiller-heating
unit or a refrigeration-heating unit. In some embodiments, the cooling-heating unit
may be referred to as a chiller-heating unit when the unit is configured to cool a
liquid (e.g., process fluid PF
2 is a chiller liquid/water, or the like).
[0017] Figure 2 is a schematic view of an embodiment of a heating, ventilation, air conditioning,
and refrigeration (HVACR) system 100. The HVACR system 100 is configured to provide
both heating and cooling. The HVACR system 100 is configured to heat a first process
fluid PF
1 and cool a second process fluid PF
2. The HVACR system 100 includes a plurality of cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 for heating the first process fluid PF
1 and cooling the second process fluid PF
2.
[0018] The HVACR system 100 utilizes the first process fluid PF
1 to provide heating (e.g., in a building, heating load 102) and utilizes the second
process fluid PF
2 to provide cooling (e.g., in a building, cooling load 104). The first process fluid
PF
1 can be for a heating load 102 of the HVACR system 100 and the second process fluid
PF2 may be for a cooling load 104 of the HVACR system 100. For example, the heating
load 102 may be the heating demand for a building conditioned by the HVACR system
100, and the cooling load 102 can be cooling for said building. In an embodiment,
heating load 102 may include, but is not limited to, heating of conditioned space(s)
(e.g., heating load 102 including heat exchanger(s)/radiator(s) that heat air in/for
conditioned space(s)), hot water, or the like). In an embodiment, cooling load 104
may include, but is not limited to, cooling of conditioned space(s) (e.g., cooling
load 104 including heat exchanger(s)/radiator(s) that cool air in/for the conditioned
space(s)), electronic(s) cooling, cold water, or the like). In an embodiment, the
cooling load 104 may include a heat source (e.g., a geothermal source system, or the
like) utilized to provide heating of the heating load (e.g., the heat source via the
second process fluid PF
2 is used to provide heat to the first process fluid PF
1). In an embodiment, the heating load 102 may include a heat sink (e.g., a ambient
outdoor heat exchanger, or the like) utilized to remove/reject heat from the cooling
load (e.g., the heat sink via the first process fluid PF
1 being used to remove/reject heat from the second process fluid PF
2).
[0019] As shown in Figure 2, the HVACR system 100 includes a heating-cooling system 101
that heats the first process fluid PF
1 and cools the second process fluid PF
2. The heating-cooling system receives the first process fluid PF
1 at inlet temperature T
H-I (e.g., a return temperature, a hot-side return temperature, or the like) and is configured
to heat the first process fluid from the inlet temperature T
H-I to an outlet temperature T
H-O. For example, the outlet (hot-side) temperature T
H-O can be a target temperature for the (heated) first process fluid PF
1 supplied by the heating-cooling system 101 for use in the HVACR system 100 (e.g.,
a predetermined target temperature, or the like). For example, the outlet (cold-side)
temperature Tc-o can be a target temperature for the (cooled) second process fluid
PF
2 supplied by the heating-cooling system 101 for use in the HVACR system 100 (e.g.,
a predetermined target temperature, or the like).
[0020] The heating-cooling system 101 receives the second process fluid PF
2 at an inlet temperature T
C-I (e.g., a return temperature, a cold-side return temperature, or the like) and is
configured to cool the second process fluid PF
2 from the inlet temperature Tc-i (e.g., a return temperature) to an outlet cold-side
temperature T
C-I. For example, the outlet (cold-side) temperature can be a target temperature for
the (cooled) second process fluid PF
2 supplied by the heating-cooling system 101 for use in the HVACR system 100 (e.g.,
a predetermined target temperature, or the like).
[0021] The heating-cooling system 101 of the HVACR system 100 includes the cooling-heating
units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3. Each of the cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 can have features as described for the cooling-heating unit 1 in Figure 1. For example,
each cooling-heating unit CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 includes a respective refrigerant circuit (not shown) (e.g., refrigerant circuit
5 of cooling-heating unit 1 in Figure 1) with a compressor 110A, 110B, 110C, 110D,
110E (e.g., compressor 10 in Figure 1), a condenser (not shown) (e.g., condenser 20
in Figure 1), an expander (not shown) (e.g., expander 30 in Figure 1), and an evaporator
(not shown) (e.g., evaporator 40 in Figure 1).
[0022] For easier understanding, Figure 2 illustrates the heating-cooling system 101 in
which all of the cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3, the supplemental heating unit(s) 120, and supplemental cooling unit(s) 125 are active
(e.g., arrows/flow directions are based on all the units being active). As described
below, the activation of the cooling-heating units and the supplemental conditioning
units 120, 125 is based on the heating/cooling demand of the heating-cooling system
101 (e.g., amount of heating/cooling for the process fluids PF
1, PF
2). In many instances, one or more of the cooling-heating units and the conditioning
units will be shutdown/inactive. It should also be understood that the heating-cooling
system 101 may include additional features than those shown in Figure 2. The heating-cooling
system 101 in embodiments may include, for example (but is not limited to), one or
more additional pump(s), control valve(s), holding tank(s), sensor(s), or the like.
[0023] The first process fluid PF
1 and the second process fluid PF
2 flow through one or more of the cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3. In each active cooling-heating unit, the active cooling-heating unit both heats
the first process fluid PF
1 flowing therethrough and cools the second process fluid PF
2 flowing therethrough. For example, the first process fluid PF
1 is heated in the respective condenser (not shown) (e.g., condenser 20 in Figure 1)
of each active cooling-heating unit, and the second process fluid PF
2 is cooled in the respective condenser (not shown) (e.g., evaporator 40 in Figure
1) of each active cooling-heating unit.
[0024] The cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 in the heating-cooling system 101 include one or more primary cooling-heating units
CH
P1, CH
P2 and one or more secondary cooling-heating units CH
S1, CH
S2, CHss. In the illustrated embodiment, the heating-cooling system 101 includes two
primary cooling-heating units CH
P1, CH
P2 and three secondary cooling-heating units CH
S1, CH
S2, CH
S3. However, it should be appreciated the heating-cooling system 101 in another embodiment
may be a different number of primary cooling-heating units and a different number
of secondary cooling-heating units. In an embodiment, the HVACR system 100 may include
a plurality of primary chill-heating units CH
P1, CH
P2 and/or a plurality of secondary cooling-heating units CH
S1, CH
S2, CH
S3.
[0025] The primary cooling-heating units CH
P1, CH
P2 each have a larger conditioning (e.g., heating capacity and/or cooling capacity)
than the secondary cooling-heating units CH
S1, CH
S2, CH
S3, respectively. For example, the compressor 110A, 110B in each of the primary cooling-heating
units CH
P1, CH
P2 has a larger capacity than the compressors 110C, 110D, 110D in the secondary cooling-heating
units CH
S1, CH
S2, CH
S3, respectively. The compressors 110A, 110B in the primary cooling-heating units CH
P1, CH
P2 may be referred to as primary compressors, and the compressors 110C, 110D, 110D in
the secondary cooling-heating units CH
S1, CH
S2, CH
S3 may be referred to as secondary compressors.
[0026] The primary cooling-heating units CH
P1, CH
P2 each have a maximum conditioning capacity and a minimum conditioning capacity. A
maximum conditioning capacity is the amount of conditioning provided by a cooling-heating
unit CH
P1, CH
P2 when operating at or about 100% (e.g., when operating the compressor 110A, 110B of
said cooling-heating at its maximum load). For example, the maximum conditioning capacity
of a cooling-heating unit may be less than 100% of the compressor capacity (e.g.,
about 100%) to avoid operating at maximum conditions/speeds that helps avoid damage
to the compressor. The compressors 110A, 110B of at least the primary cooling-heating
units CH
P1, CH
P2 can operate at partial loads and have a (predetermined) minimum load. A minimum conditioning
load is the amount of conditioning provided a cooling-heating unit when operating
at the (predetermined) minimum load of its compressor. The maximum conditioning capacity
and the minimum conditioning capacity for a cooling-heating unit may be predetermined
amounts based on the configuration each cooling-heating unit (e.g., size of the refrigerant
circuit, size of the compressor, type of compressor, and the like).
[0027] The minimum conditioning capacity can be predetermined based on a predetermined minimum
load for the compressor of the respective cooling-heating units. For example, the
predetermined minimum load of a compressor is the minimum partial capacity for stably
operating the compressor (e.g., preventing surge, stall, etc. of the compressor, preventing
substantially lower efficiency, or the like). The minimum partial may be predetermined
based on, for example, previous testing of the compressor, previous testing of the
same model or a similar model of compressor, computational modeling of the compressor,
of the like. In an embodiment, the compressors 110A, 110B in each of the primary cooling-heating
units CH
P1, CH
P2 have a minimum load that is greater than the minimum load of the compressors 1 10C,
110D, 110D in the secondary cooling-heating units CH
S1, CH
S2, CH
S3, respectively. In an embodiment, the compressors 110A, 110B in the primary cooling-heating
units may be configured to operate with a higher efficiency than the compressors 110C,
110D, 110D in the secondary cooling-heating units CH
S1, CH
S2, CH
S3, respectively.
[0028] In an embodiment, each of the primary cooling-heating unit(s) CH
P1, CH
P2 has a respective minimum conditioning capacity of at or greater than 60% of its maximum
conditioning capacity (e.g., each primary compressor 110A, 110B has a (predetermined)
minimum load of at or greater than 60% of the maximum load of the compressor 110A,
110B). In an embodiment, each of the primary cooling-heating unit(s) CH
P1, CH
P2 has a respective minimum conditioning capacity of at or greater than 70% of its maximum
conditioning capacity (e.g., each primary compressor 110A, 110B has a (predetermined)
minimum load of at or greater than 70% of the maximum load of the compressor 110A,
110B). In an embodiment, each of the primary cooling-heating unit(s) CH
P1, CH
P2 has a respective minimum conditioning capacity of at or greater than 75% of its maximum
conditioning capacity (e.g., each primary compressor 110A, 110B has a (predetermined)
minimum load of at or greater than 75% of the maximum load of the compressor 110A,
110B).
[0029] The primary cooling-heating unit(s) CH
P1, CH
P2 in the heating-cooling system 101 have a conditioning load range. The conditioning
load range is the range in the amount of conditioning that can be provided by the
primary cooling-heating unit(s) CH
P1, CH
P2 based on the minimum conditioning capacity(s) of the primary cooling-heating unit(s)
CH
P1, CH
P2. In one non-limiting example, the two cooling-heating unit CH
P1 CH
P2 in the illustrated embodiment may each have a minimum conditioning capacity of 70%
and the same maximum conditioning capacity, and the conditioning load range of the
two primary cooling-heating units CH
P1, CH
P2 is the amount of conditioning provided by 70 - 100% and 140 - 200% of the maximum
conditioning capacity.
[0030] In some instances, the heating/cooling to be provided to the process fluids PF
1, PF
2 by the heating-cooling system 101 (e.g., amount of heating to heat the first process
fluid PF
1 to its target temperature, amount of cooling to cool the second process fluid PF
2 to its target temperature) is outside the conditioning load range of the primary
cooling-heating unit(s) CH
P1, CH
P2. For example, when a conditioning load (e.g., amount of heating for heating the first
process fluid PF
1 to its target temperature) is less than a minimum conditioning capacity of the primary
cooling-heating units CH
P1, CH
P2 (e.g., a heating load being 35% of a maximum conditioning capacity of the primary
cooling-heating unit(s) that have a minimum conditioning capacity of greater than
60% of maximum conditioning capacity). For example, when a conditioning load is above
the minimum conditioning capacity but outside the conditioning load range of the primary
cooling-heating unit(s) CH
P1, CH
P2 (e.g., a heating load is 110% of a maximum conditioning capacity of a single primary
cooling-heating unit CH
P1, CH
P2, and the primary cooling-heating units each have a minimum conditioning load of at
or greater than 60% of maximum conditioning capacity).
[0031] The secondary cooling-heating unit(s) CH
S1, CH
S2, CH
S3 are provided to provide conditioning to meet conditioning loads that are outside
the conditioning load range of the primary cooling-heating unit(s) CH
P1, CH
P2.
[0032] In an embodiment, the secondary cooling-heating unit(s) CH
S1, CH
S2, CH
S3 can be configured to provide less than the minimum conditioning capacity of the primary
cooling-heating unit(s) CH
P1, CH
P2. The secondary cooling-heating unit(s) CH
S1, CH
S2, CH
S3 may be configured to cover a range from a lowest desired conditioning load (e.g.,
a minimum temperature difference of the process fluids PF
1, PF
2 that activates the cooling/heating of the process fluids PF
1, PF
2 by the cooling-heating unit(s) CH
P1, CH
P2, CH
S1, CH
S2, CH
S3). In one non-limiting example, the primary cooling-heating units CH
P1, CH
P2 each have a minimum conditioning capacity of 70% of maximum, and the lowest desired
conditioning load is 25% of the maximum conditioning load, and the secondary cooling-heating
unit(s) CH
S1, CH
S2, CH
S3 are configured to provide conditioning load equal to at or about 25% - 69% of the
maximum conditioning load.
[0033] In an embodiment, the secondary cooling-heating unit(s) CH
S1, CH
S2, CH
S3 may be a type configured to have greater capacity adjustability than the primary
cooling-heating unit(s) CH
P1, CH
P2 (e.g., to have a broader range of partial capacity). The secondary cooling-heating
unit(s) CH
S1, CH
S2, CH
S3 can each have a minimum conditioning capacity that is lower than the minimum conditioning
capacity of the primary cooling-heating unit(s) CH
P1, CH
P2. For example, the secondary cooling-heating unit(s) CH
S1, CH
S2, CH
S3 may have compressor(s) 110C, 110D, 110E with a lower minimum load than the compressors
110A, 110B of the primary cooling-heating unit(s) CH
P1, CH
P2. In one example, the primary cooling-heating unit(s) CH
P1, CH
P2 may be centrifugal compressors (e.g., to provide a large/base conditioning load at
a relatively higher efficiency) and the secondary cooling-heating unit(s) CH
S1, CH
S2, CH
S3 can be rotary compressors (e.g., screw compressor, or the like) that have relatively
more adjustable capacity and/or a smaller partial capacity/minimum load.
[0034] In an embodiment, the plurality and size of the secondary cooling-heating unit(s)
CH
S1, CH
S2, CH
S3 provided in the heating-cooling system may provide load adjustability. In such an
embodiment, the secondary cooling-heating units CH
S1, CH
S2, CH
S3 may each have a similar minimum conditioning capacity as the primary cooling-heating
unit(s) CH
P1, CH
P2, and are provided in number to provide conditioning load adjustability. For example,
the secondary cooling-heating units CH
S1, CH
S2, CH
S3 can include three units as shown in Figure 2, and each unit can be sized to have
a significantly smaller maximum conditioning capacity relative to the primary cooling-heating
unit(s) CH
P1, CH
P2. In one non-limiting example, the heating-cooling system 101 may include three secondary
cooling-heating units that each have a maximum conditioning capacity that is 15% of
a maximum conditioning capacity of one primary cooling-heating unit and have a minimum
conditioning capacity of 50% of their maximum conditioning capacity. In such embodiments,
the relatively larger number of relatively smaller capacity secondary cooling-heating
units can be utilized to provide relatively broader conditioning capacity range.
[0035] The heating-cooling system 101 may also include one or more supplemental heating
unit(s) 120 for heating the first process fluid PF
1 and one or more supplemental cooling unit(s) 125 for cooling the second process fluid
PF
2. The supplemental heating unit(s) 120 and the supplemental cooling unit(s) 125 are
configured to provide supplemental heating to the first process fluid PF
1 and/or supplemental cooling to cool second process fluid PF
2. In the illustrated embodiment, the supplemental conditioning units 120, 125 provide
conditioning at an intermediate point. In other embodiment, the supplemental unit(s)
120, 125 may be provided at different locations in the system 101 (e.g., provide conditioning
of the process fluid prior to flowing through the cooling-heating units, provide conditioning
of the entire stream of process fluid.
[0036] When operating in a heating mode, cooling by the cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 may be less than the target cooling for the second process fluid PF
2 (e.g., to cool the second process fluid PF
2 from T
C-I to the target outlet temperature), and further increasing the capacity of the cooling-heating
units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 results in over-heating of the first process fluid PF
1. The supplemental cooling unit(s) 125 are configured to provide cooling to the second
process fluid PF
2 such that the heating-cooling system provides the target cooling to the second process
fluid PF
2. The supplemental cooling unit(s) 125 may include, for example, air heat exchanger
unit (e.g., cools the second process fluid PF
2 utilizing air, cools the second process fluid PF
2 utilizing an intermediate fluid cooled by air, or the like). In some embodiments,
the supplemental cooling unit(s) 125 may operate to decrease the amount of cooling
for the cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 to meet the cooling demand (e.g., supplemental cooling unit(s) cooling to ambient
air temperature using ambient air cooling, to a lower temperature via geothermal cooling,
or the like).
[0037] When operating in a cooling mode, heating by the cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 may be less than the target heating for the first process fluid PF
1 (e.g., to cool the first process fluid PF
1 from T
H-I to the target outlet temperature). The supplemental heating unit(s) 120 are configured
to provide heating to the first process fluid PF
1 such that the heating-cooling system 101 provides the target heating to the first
process fluid PF
1. The supplemental heating unit(s) 120 may include, for example, convention heater(s),
boiler(s), geothermal heater(s), or the like. In an embodiment, the supplemental heating
unit(s) 120 may decrease the amount of heating for the cooling-heating units CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 to meet the heating demand (e.g., supplemental heating unit(s) heating using geothermal
heat, using convection heating via sunlight, or the like).
[0038] Figure 3 shows a schematic view of an embodiment of a heating-cooling system 200.
The heating-cooling system 200 may be employed in an HVACR system. The heating-cooling
system 101 is a heating and cooling system configured to heat a first process fluid
PF
1 and to cool a second process fluid PF
2. For example, the heating-cooling system 201 in an embodiment may be the heating-cooling
system 101 of the HVACR system 100 in Figure 2.
[0039] The heating-cooling system 200 includes cooling-heating units 210A, 210B, 210C, 210D
that are each configured to heat the first process fluid PF
1 and to cool the second process fluid PF
2, during operation. The cooling-heating units 210A, 210B, 210C, 210D in the heating-cooling
system 200 can have features as previously discussed for the cooling-heating units
CH
P1, CH
P2, CH
S1, CH
S2, CH
S3 in Figure 2. For example, as shown in Figure 3, each cooling-heating unit 210A, 210B,
210C, 210D includes a respective refrigerant circuit with a compressor 212A, 212B,
212C, 212D; a condenser 214A, 214B, 214C, 214D; an expander 218A, 218D; and an evaporator
216A, 216B, 216C, 216D. The heating-cooling system 200 includes primary cooling-heating
units 210A, 210B and secondary cooling-heating unit(s) 210B, 210C, as similarly discussed
in for the heating-cooling system 101 in Figure 2.
[0040] The heating-cooling system 200 also includes one or more supplemental heating units
280 for providing supplemental heating of the first process fluid PF
1 and one or more supplemental cooling units 282 to provide supplemental cooling of
the second process fluid PF
2. The supplemental heating unit(s) 280 and the supplemental cooling unit(s) 282 can
have features as similarly discussed for the supplemental heating unit(s) 120 and
the supplemental cooling units 125, respectively, in Figure 2.
[0041] The heating-cooling system 200 includes a heating flow path 202A with an inlet 204A
and an outlet 206A. The first process fluid PF
1 is heated as it flows through the heating flow path 202A (e.g., as the first process
fluid PF
1 flows from the inlet 204A to the outlet 206A). The first process fluid PF
1 (to be heated) is received through the inlet 204A, is heated by the heating-cooling
system 200, and the heated first process fluid PF
1 is discharged from the outlet 204B. In an embodiment, the inlet 204A and outlet 206A
may be part of a circuit (e.g., a hot water circuit, heating circuit, or the like),
such that the outlet 206A connects back to the inlet 204A (e.g., with one or more
heat exchangers disposed there-between). For example, the inlet 204A is a return inlet
in which the first process fluid PF
1 after providing heat (and being cooled thereby) returns to the heating flow path
202A to be re-heated. In an embodiment, the heated first process fluid PF
1 may be used (e.g., for cleaning, or the like), and fresh first process fluid PF
1 may be received at the inlet 204A.
[0042] The cooling-heating units (CHUs) 210A, 210B, 210C, 210D include one or more (first)
inlet(s) 240, 244 that connect to the heating flow path 202A and one or more (first)
outlets 242, 246 that connect to the heating flow path 202A. The CHUs receive the
first process fluid PF
1 from the heating flow path 202A via the (first) inlet(s) 240, 244 and discharge the
first process fluid PF
1 (after being heated) into the heating flow path 202A via the (first) outlet(s) 242,
246. In the illustrated embodiment, the primary CHUs 210A, 210B have a single (first)
inlet 240 and a single outlet 242 that connect to the primary CHUs 210A, 210B in parallel.
In another embodiment, the primary CHUs 210A, 210B may each have a respective inlet
and outlet connected to the heating flow path 202A. Similarly, the secondary CHUs
210A, 210B in an embodiment may have a single inlet and/or a single outlet (e.g.,
connected in parallel, as shown in Figure 3) or may each have a respective inlet and
a respective outlet connecting to the heating flow path 202A.
[0043] The inlet(s) 240 of the primary CHUs 210A, 210B connect to the heating flow path
202A upstream of the outlet(s) 242 of the primary CHUs 210A, 210B. The inlet(s) 240
of the primary CHUs 210A, 210B connects to the heating flow path 202A upstream of
the inlet(s) 244 of the secondary CHUs 210C, 210D. For example, the inlet(s) 240 of
the primary CHUs 210A, 210B is closer to the inlet 204A of the heating flow path 202A
than the inlet(s) 244 of the secondary CHUs 210C, 210D are to the inlet 204A of the
heating flow path 202A. The outlet(s) 242 of the primary CHUs 210A, 210B connect to
the cooling flow path 202B upstream of the inlet(s) 244 of the secondary CHUs 210A,
210B. When one or more primary CHUs 210A, 210B is operating and one or more of the
secondary CHUs 210C, 210D is operating, secondary CHUs 210D, 210C may receive at least
a portion of first process fluid PF
1 heated by the primary CHUs 210A, 210B. The outlet(s) 246 of the secondary CHUs 210C,
210D connects to the heating flow path 202A downstream of the outlet(s) 242 of the
primary CHUs 210A, 210B and downstream of the inlet(s) 244 of the secondary CHUs 210A,
210B.
[0044] The heating-cooling system 200 includes a cooling flow path 202B with an inlet 204B
and an outlet 206B. The second process fluid PF
2 is cooled as it flows through the cooling flow path 202B (e.g., as the second process
fluid PF
2 flows from the inlet 204B to the outlet 206B). The second process fluid PF
2 (to be cooled) is received through the inlet 204B, is cooled by the heating-cooling
system 200, and the cooled second process fluid PF
2 is discharged from the outlet 204B. In an embodiment, the inlet 204A and outlet 206B
may be part of a circuit (e.g., a chiller circuit, a cooling circuit, or the like),
such that the outlet 206B connects back to the inlet 206B (e.g., with one or more
heat exchangers disposed there-between). For example, the inlet 206B is a return inlet
in which the second process fluid PF
2 after providing cooling (and being heated thereby) returns to the cooling flow path
202B to be re-cooled.
[0045] The CHUs 210A, 210B, 210C, 210D include one or more (second) inlet(s) 250, 254 that
connect to the cooling flow path 202B and one or more (second) outlets 252, 256 that
connect to the cooling flow path 202B. The CHUs 210A, 210B, 210C, 210D receive the
second process fluid PF
2 from the cooling flow path 202B via the (second) inlet(s) 250, 254 and discharge
the second process fluid PF
2 (after being cooled) into the cooling flow path 202B via the (second) outlet(s) 252,
256. In the illustrated embodiment, the primary CHUs 210A, 210B have a single (second)
inlet 250 and a single (second) outlet 252 that connect to the primary CHUs 210A,
210B in parallel. In another embodiment, the primary CHUs 210A, 210B may each have
a respective inlet and outlet connected to the cooling flow path 202B. Similarly,
the secondary CHUs 210A, 210B in an embodiment may have a single inlet and/or a single
outlet (e.g., connected in parallel, as shown in Figure 3) or may each have a respective
inlet and a respective outlet connecting to the cooling flow path 202B.
[0046] The inlet(s) 250 of the primary CHUs 210A, 210B connect to the cooling flow path
202B upstream of the outlet(s) 252 of the primary CHUs 210A, 210B. The inlet(s) 250
of the primary CHUs 210A, 210B connect to the cooling flow path 202B upstream of the
inlet(s) 254 of the secondary CHUs 210C, 210D. The outlet(s) 252 of the primary CHUs
210A, 210B connects to the cooling flow path 202B upstream of the inlet(s) 254 of
the secondary CHUs 210A, 210B. This allows for the primary CHUs 210A, 210B to have
load priority over the secondary CHUs 210C, 210D. When one or more primary CHUs 210A,
210B is operating and one or more of the secondary CHUs 210C, 210D is operating, secondary
CHUs 210D, 210C may receive at least a portion of second process fluid PF
2 heated by the primary CHUs 210A, 210B. The outlet(s) 256 of the secondary CHUs 210C,
210D connects to the cooling flow path 202B downstream of the outlet(s) 252 of the
primary CHUs 210A, 210B and downstream of the inlet(s) 254 of the secondary CHUs 210A,
210B.
[0047] In an embodiment, the heating-cooling system 200 may include one or more tertiary
CHUs (not shown). In such an embodiment, (first) inlet(s) of the tertiary CHU(s) can
connect to the heating flow path 202A between the (first) outlet(s) 242 of the primary
CHU(s) and upstream of the outlet(s) 246 of the secondary CHU(s) (e.g., downstream
of the outlet(s) 242 and upstream of the outlet(s) 246). In such an embodiment, (second)
inlet(s) of the tertiary CHU(s) can connect to the cooling flow path 202B between
the (second) outlet(s) 252 of the primary CHU(s) and upstream of the outlet(s) 256
of the secondary CHU(s) (e.g., downstream of the outlet(s) 252 and upstream of the
outlet(s) 256).
[0048] With respect to each flow path 202A, 202B, it should be appreciated that the term
"upstream" can refer to being connected/located closer to the inlet 204A, 204B of
said flow path and the term "downstream" can refer to being connected/located closer
to the outlet 206A, 206B of said flow path.
[0049] The heating-cooling system 200 includes a controller 290 for controlling the heating-cooling
system 200. In an embodiment, the controller 190 may be a controller of the HVACR
system of the heating-cooling system 200 (e.g., controller of the HVACR system 100
in Figure 2). The controller 290 is configured to control operation of the CHUs 210A,
210B, 210C, 210D. For example, the controller 290 can activate or shutdown each of
the CHUs 210A, 210B, 210C, 210D. The heating-cooling system 200 can include one or
more flow control devices for controlling the flow of the process fluids PF
1, PF
2 to/through each of the CHUs 210A, 210B, 210C, 210D. For example, the heating-cooling
system 200 may include valves 232A-D, 234A-D and/or pumps 230A, 230B, 231A, 231B for
directing/controlling flow of the process fluids PF
1, PF
2 to/through each of the CHUs 210A, 210B, 210C, 210D. For example, when a second primary
CHU 232B is inactive (i.e., shutdown), the heating-cooling system 200 can close valve
232B to block flow of the first process fluid PF
1 into the primary CHU 232B and close valve 234B to block flow of the second process
fluid PF
2 into the primary CHU 232B. It should be appreciated that the heating-cooling system
200 in other embodiments may have flow control devices in different configurations/locations
than shown in Figure 3. Specific operation of the heating-cooling system 200 is discussed
in more detail below.
[0050] The heating-cooling system 200 may include one or more sensors (e.g., temperature
sensor, flow sensor, or the like) for detecting one or more properties of the process
fluids. The controller 290 may sense property/properties of the process fluid using
the sensor(s). As shown in Figure 3, the heating cooling system 200 may include a
temperature sensor 292A for detecting the inlet temperature T
H-I of the first process fluid PF
1 and a temperature sensor 292B for detecting the inlet temperature TC-I of the second
process fluid PF
2. It should be appreciated that the heating system 200 may include additional sensors
than shown in Figure 3 (e.g., temperature sensor(s) for detecting the outlet temperature(s),
unit discharge temperature(s), or the like of the process fluids, temperature sensor(s)
for detecting a temperature of conditioned space(s), or the like).
[0051] The primary CHUs 210A, 210B and the secondary CHUs 210C, 210D are arranged/connected
to the flow paths 202A, 202B (e.g., to the heating flow path 202A, to the cooling
flow path 202B, to each of the flow paths 202A, 202B) such that the conditioning load
(e.g., heating load, cooling load) is prioritized to active primary CHUs 210A, 210B
over the secondary CHUs 210C, 210D. For example, when operating one or more of the
primary CHUs 210A, 210B and one or more of the secondary CHUs 210C, 210B, the one
or more primary CHUs 210A operate at full load/capacity, while the one or more the
secondary CHUs 210C, 210B operate at partial or fully capacity load/capacity to meet
the conditioning demand.
[0052] In one example, a heating demand for a heating-cooling system 200 is less than a
minimum conditioning capacity of the primary CHUs 210A, 210B (e.g., heating demand
is less than a minimum conditioning capacity of the primary CHU 210A, heating demand
is less than a minimum conditioning capacity of the primary CHU 210B, and the like).
The heating-cooling system 200 is configured to operate one or more of the secondary
CHUs 210C, 210D to provide said heating demand.
[0053] Figure 4A shows a schematic view of the heating-cooling system 200 in Figure 3 operating
in a first mode, according to an embodiment. The heating-cooling system 200 operating
in the first mode is also indicated as "200A". The heating-cooling system 200 heats
a flow
fH-I of the first process fluid P
F1 from an inlet temperature T
H-I to an outlet temperature T
H-O (e.g., the target/desired temperature for the first process fluid PF
1), and cools a flow
fC-I of the second process fluid PF
2 from an inlet temperature T
C-I to an outlet temperature Tc-o (e.g., the target/desired temperature for the first
process fluid PF
1). In the first mode, the heating-cooling system 200 operates one secondary CHU 210C
to meet said heating demand (and the cooling demand).
[0054] For the first mode, the heating-cooling system 200 is configured to operate the one
or more flow control devices to direct each of the process fluids PF
1, PF
2 through the secondary CHU 210C. As shown in Figure 4A, valves 232A, 234A, 234A, 234B,
232D, 234D for flow of process fluids PF
1, PF
2 into the shutdown CHUs 210A, 210B, 210D are closed, valves 232C, 234C for flow of
process fluids PF
1, PF
2 through the active CHU 210C are open. Pump 231A is active and supplies the first
process fluid PF
1 to/through the active CHU 210C, and pump 231B is active and supplies the second process
fluid PF
2 through the active CHU 210C.
[0055] In the first mode, the CHU 210C is active and the other CHUs 210A, 210B, 210D are
shutdown. The active CHU 210C heats the first process fluid PF
1 flowing through the CHU 210C (e.g., flowing through the condenser of the CHU 210C)
and cools the second process fluid PF
2 (separately) flowing through the CHU 210C (e.g., flowing through the evaporator of
the CHU 210C). For example, the secondary CHU 210C may be operating at 55% of its
maximum conditioning capacity in the first mode (e.g., the compressor 212C of the
CHU 210C operating at 55% of its maximum load). In an embodiment, the supplemental
heating unit(s) 280 and the supplemental cooling unit(s) 282 can be inactive, as shown
in the illustrated embodiment. Table 1 is provided below that provides non-limiting
exemplary flowrates and temperatures for the heating-cooling system 200A in Figure
4.
Table 1 - CHU 210C Active
PF1 Temps. & Flowrates |
PF2 Temps. & Flowrates |
|
TH-I = 110°F |
|
TC-I = 56°F |
TH-O = T246 = T202A-1 = 125°F |
TC-O = T256 = T202B-1 = 42°F |
|
T244 = 112.5°F |
|
T254 = 54.6°F |
|
fH-I = fH-O = 50 gpm |
|
fC-I = fC-O = 45 gpm |
|
f244 = 60 gpm |
|
f254 = 50 gpm |
|
f202A-1 = 10 gpm |
|
f202B-1 = 5 gpm |
^ gpm = gallons per minute |
[0056] As shown in Figure 4A, a portion of the conditioned first working fluid PF
1 discharged from the CHU 210C may cycle back into the CHU 210C (e.g., flow
f202A-1 of the first working fluid PF
1 in the heating flow path 202A). For example, a temperature T
244 of the first process fluid PF
1 entering the CHU 210C is an intermediate temperature between the first process fluid
inlet temperature T
H-I and the first process fluid outlet temperature T
H-O of the heating flow path 202A (e.g., T
H-I < T
244 < T
H-O). As shown in Figure 4A, a portion of the conditioned second working fluid PF
2 discharged from the CHU 210C may cycle back into the CHU 210C (e.g., flow
f202B-1 of the second working fluid PF
2 in the cooling flow path 202B). For example, a temperature T
254 of the second process fluid PF
2 entering the CHU 210C is an intermediate temperature between the second process fluid
inlet temperature Tc-i and the second process fluid outlet temperature Tc-o of the
cooling flow path 202B (e.g., T
C-I > T
254 > T
C-O).
[0057] In another example, a heating demand for the heating-cooling system 200 is within
the conditioning load range of the primary CHUs 210A, 210B (e.g., heating demand is
greater than a minimum conditioning capacity of the primary CHU 210A, heating demand
not between the maximum conditioning capacity of one primary CHU 210A and a combination
of the minimum conditioning capacity of multiple primary CHUs 210A, 210B, and the
like). The heating-cooling system 200 can operate one or more of the primary CHUs
210A, 210B to provide said heating demand.
[0058] Figure 4B shows a schematic view of the heating-cooling system 200 in Figure 3 operating
in a second mode, according to an embodiment. The heating-cooling system 200 operating
in the second mode is also indicated as "200B". The heating-cooling system 200B heats
a flow
fH-I* of the first process fluid PF
1 from an inlet temperature T
H-I* to an outlet temperature T
H-O* (e.g., the target/desired temperature for the first process fluid PF
1), and cools a flow
fC-I* of the second process fluid PF
2 from an inlet temperature T
C-I* to an outlet temperature T
C-O* (e.g., the target/desired temperature for the first process fluid PF
1). In the second mode, the heating-cooling system 200B operates one primary CHU 210A
to meet said heating demand (and the cooling demand).
[0059] For the second mode, the heating-cooling system 200B is configured to operate the
one or more flow control devices to direct each of the process fluids PF
1, PF
2 through the primary CHU 210A. As shown in Figure 4B, valves 232B, 232C, 232D, 234B,
234C, 234D for flow of process fluids PF
1, PF
2 into the shutdown CHUs 210B, 210C, 210D are closed, valves 232A, 234A for flow of
process fluids PF
1, PF
2 through the active (primary) CHU 210A are open. Pump 230A is active and supplies
the first process fluid PF
1 to/through the active CHU 210A, and pump 230B is active and supplies the second process
fluid PF
2 through the active CHU 210A.
[0060] In the second mode, the CHU 210A is active and the other CHUs 210B, 210C, 210D are
shutdown. In another embodiment of the second mode, one or more of the other primary
CHUs (e.g., CHU 210B in Figure 4B) may also be active (e.g., when the heating demand
is within the conditioning load range of a combination of multiple primary CHUs 210A,
210B). The active CHU 210A heats the first process fluid PF
1 flowing through the CHU 210A (e.g., flowing through the condenser 214A of the CHU
210A) and cools the second process fluid PF
2 (separately) flowing through the CHU 210A (e.g., flowing through the evaporator 216A
of the CHU 210A). For example, the primary CHU 210A may be operating at 85% of its
maximum conditioning capacity in the second mode (e.g., the compressor 212A of the
CHU 210A operating at 85% of its maximum load). In an embodiment, the supplemental
heating unit(s) 280 and the supplemental cooling unit(s) 282 can be inactive, as shown
in the illustrated embodiment. Table 2 is provided below that provides non-limiting
exemplary flowrates and temperatures for the heating-cooling system 200B in Figure
4.
Table 2 - CHU 210A Active
PF1 Temps. & Flowrates |
PF2 Temps. & Flowrates |
|
TH-I* = 110°F |
|
TC-I* = 56°F |
TH-O* = T242* = T202A* = 125°F |
TC-O = T252 = T202B = 42°F |
|
T240* = 108°F |
|
T250* = 53.2°F |
|
fH-I* = fH-O* = 100 gpm |
|
fC-I = fC-O = 80 gpm |
|
f240* = 120 gpm |
|
f250 = 100 gpm |
|
f202A* = 20 gpm |
|
f202B = 20 gpm |
[0061] As shown in Figure 4B, a portion of the conditioned first working fluid PF
1 discharged from the CHU 210A may cycle back into the CHU 210A (e.g., flow
f202A* of the first working fluid PF
1 in the heating flow path 202A). For example, a temperature T
240* of the first process fluid PF
1 entering the CHU 210A is an intermediate temperature between the first process fluid
inlet temperature T
H-I* and the first process fluid outlet temperature T
H-O* of the heating flow path 202A (e.g., T
H-I* < T
240* < T
H-O*). As shown in Figure 4B, a portion of the conditioned second working fluid PF
2 discharged from the CHU 210A may cycle back into the CHU 210A (e.g., flow
f202B* of the second working fluid PF
2 in the cooling flow path 202B). For example, a temperature T
250* of the second process fluid PF
2 entering the CHU 210A is an intermediate temperature between the second process fluid
inlet temperature T
C-I* and the second process fluid outlet temperature T
C-O* of the cooling flow path 202B (e.g., T
C-I* > T
254* > T
C-O*).
[0062] In another example, a heating demand for the heating-cooling system 200 is above
the minimum conditioning capacity for the primary CHUs 210A, 210B and is outside the
conditioning load range of the primary CHUs 210A, 210B (e.g., heating demand is greater
than a minimum conditioning capacity of the primary CHU 210A and is outside the combined
load conditioning range of both CHUs 210A, 210B). The heating-cooling system 200 can
operate one or more of the primary CHUs 210A, 210B and one or more of the secondary
CHUs 210C, 210D to provide said heating demand.
[0063] Figure 4C shows a schematic view of the heating-cooling system 200 in Figure 3 operating
in a third mode, according to an embodiment. The heating-cooling system 200 operating
in the second mode is also indicated as "200C". The heating-cooling system 200C heats
a flow
fH-I+ of the first process fluid PF
1 from an inlet temperature T
H-I+ to an outlet temperature T
H-O+ (e.g., the target/desired temperature for the first process fluid PF
1), and cools a flow
fC-I+ of the second process fluid PF
2 from an inlet temperature T
C-I+ to an outlet temperature T
C-O+ (e.g., the target/desired temperature for the first process fluid PF
1). In the illustrated embodiment of the third mode, the heating-cooling system 200C
operates one primary CHU 210A and one secondary CHU 210D to meet said heating demand
(and part of the cooling demand).
[0064] For the third mode, the heating-cooling system 200C is configured to operate the
one or more flow control devices to direct each of the process fluids PF
1, PF
2 through the primary CHU 210A and the secondary CHU 210D. As shown in Figure 4C, valves
232B, 232C, 234B, 234C, for flow of process fluids PF
1, PF
2 into the shutdown CHUs 210B, 210C are closed, and valves 232A, 234A, 232D, 234D for
flow of process fluids PF
1, PF
2 through the active (primary and secondary) CHUs 210A, 210D are open. Pumps 230A,
231A are active and supply the first process fluid PF
1 to/through each of the active CHUs 210A, 210D, and pumps 230B, 231B are active and
supply the second process fluid PF
2 through each of the active CHUs 210A.
[0065] Table 3 is provided below that provides non-limiting exemplary flowrates and temperatures
for the heating-cooling system 200C in Figure 4C.
Table 3 - CHU 210A & CHU 210D Active
PF1 Temps. & Flowrates |
PF2 Temps. & Flowrates |
TH-I+ = T202A-1+ = T240+ = 110°F |
TC-I+ = T202B-1+ = T202B-2+ = T250+ = T254+ 56°F |
TH-O+ = T242+ = T246 = T202A-2+ = T202A-3 = 125°F |
T252 = T256 = 42°F |
T244+ = 116.8°F |
T202B-3+ = 44.3°F |
fH-I+ = fH-O+ = 150 gpm |
T202B-4+ = 43.6°F |
f240+ = 120 gpm |
TC-O+ = 42°F |
f244+ = 55 gpm |
fH-I+ = fH-O+ = 170 gpm |
f202A-1+ = 30 gpm |
f250+ = 100 gpm |
f202A-2+ = 25 gpm |
f254+ = 50 gpm |
f202A-3+ = 95 gpm |
f202B-1+ = 70 gpm |
|
f202B-2+ = 20 gpm |
|
f202B-3+ = 120 gpm |
^GPM = gallons per minute |
[0066] The active CHUs 210A, 210D heat the first process fluid PF
1 flowing through the CHUs 210A, 210D. The primary CHU 210A heats a flow
f240+ of the first process fluid PF
1 (e.g., a portion of the first process fluid PF
1 flowing through the condenser 214A of the CHU 210A), and the secondary CHU 210D heats
a different flow
f240+ of the first process fluid PF
1 (e.g., a portion of the first process fluid PF
1 flowing through the condenser of the CHU 210D). The flow
f240+ is a first portion of inlet flow
fH-I+ of the heating flow path 202A. A flow
f202-A+ in the heating flow path 202A is a (different) second portion of the inlet flow
fH-I+. The primary CHU 210A heats a flow
f240+ of the first process fluid PF
1 (e.g., a portion of the first process fluid PF
1 flowing through the condenser 214A of the CHU 210A), and the secondary CHU 210D heats
a different flow
f240+ of the first process fluid PF
1 (e.g., a portion of the first process fluid PF
1 flowing through the condenser of the CHU 210D).
[0067] As shown in Figure 4C, the flow
f244+ of the first process fluid PF
1 flowing to/through the secondary CHU 210D is a mixture of the second portion of the
inlet flow
fH-I+ (e.g., flow
f202A-1) and the first process fluid PF
1 discharged from the primary CHU 210A (e.g., a portion of the flow
f202-A+ of heated first process fluid PF
1 discharged from the outlet 242 of the primary CHU 210A). For example, a temperature
T
240+ of the first process fluid PF
1 entering the secondary CHU 210D is an intermediate temperature between the first
process fluid inlet temperature T
H-I+ and the first process fluid outlet temperature T
H-O+ of the heating flow path 202A (e.g., T
H-I+ < T
240+ < T
H-O+). A portion of the first process fluid PF
1 heated by the secondary CHU 210D is the first process fluid heated in the primary
PF
1. For example, for the first process fluid PF
1 flowing through the heating flow path 202A in the third mode, a first part is heated
by the primary CHUs 210A, 210B (e.g., heated only by the primary CHU 210A, flow
f202A-3+), a second part is heated by the secondary CHUs (e.g., heated only by the CHU 210D,
flow
f202A-1+), and a third part is heated by both the primary CHUs 210A, 210B and the secondary
CHUs 210C, 210D (e.g., heated in series by the primary CHU 210A and then the secondary
CHU 210D, flow
f202A-1+).
[0068] The active CHUs 210A, 210D also cool the second process fluid PF
2 flowing through the CHUs 210A, 210D. The primary CHU 210A cools a flow
f250+ of the second process fluid PF
2 (e.g., a portion of the second process fluid PF
2 flowing through the evaporator 216A of the CHU 210A), and the secondary CHU 210D
cools a different flow
f254+ of the second process fluid PF
2 (e.g., a portion of the second process fluid PF
2 flowing through the condenser of the CHU 210D). The flow
f250+ is a first portion of inlet flow
fH-I+ of the heating flow path 202A. A flow
f202-A+ in the heating flow path 202A is a (different) second portion of the inlet flow
fH-I+.
[0069] As shown in Figure 4C, none of the second process fluid PF
2 heated in the CHUs 210A, 210D cycles back through another one of the CHUs (e.g.,
none of the second process fluid PF
2 passes through the CHUs multiple times as it flows from the inlet 204B to the outlet
206B, flow
f202B-2+ is not in a reverse direction of the cooling flow path 202B). In this embodiment,
the CHUs 210A, 210B do not provide the cooling demand for the second process fluid
PF
2 (e.g., the second process fluid PF
2 after passing through the CHUs 210A, 210B is not at the target/desired temperature,
T
202B-4+ temperature of flow
f202B-4+ is not the target/desired temperature). In the illustrated embodiment, the CHUs 210A,
210B provide the heating demand to the first process fluid PF
1, which results in the CHUs 210A being unable to fully provide the cooling demand
for the second process fluid PF
2. For example, the temperature T
202B-4+ of flow
f202B-4+ of the second process fluid PF
2 in the cooling flow path 202B after passing through the CHUs 204 is different from
a discharge temperature T
252+, T
256+ of the active CHUs 210A, 210B (e.g., T
252+ > T
202B-4+, T
252+ > T
202B-4+) and from the desired/target temperature of the second process fluid PF
2.
[0070] For example, increasing the cooling provided by the CHUs 210A, 210B in Figure 4C
to meet the cooling demand would result in overheating of the first process fluid
PF
1. As shown in Figure 4C, the one or more supplemental cooling unit(s) 282 operates
to provide supplemental cooling of the second process fluid PF
2, such that the heating-cooling system 200C meets the cooling demand (e.g., the second
process fluid outlet temperature T
C-O+ is at the target/desired temperature).
[0071] In the third mode, the primary CHU 210A and secondary CHU 210D are active, and the
other secondary other CHUs 210B, 210C are shutdown. In another embodiment of the third
mode, multiple primary CHUs (e.g., CHU 210B in Figure 4B) and/or multiple secondary
CHUs (e.g., CHU 210C) may be active (e.g., as needed to meet a heating demand).
[0072] For example, in the third mode, the primary CHU 210A may be operating at 100% of
its maximum conditioning capacity (e.g., the compressor 212A of the CHU 210A operating
at its maximum load), and the secondary CHU 210D may be operating at 55% of its maximum
conditioning capacity (e.g., the compressor of the CHU 210D operating at its maximum
load). The progressive configuration of the heating circuit 200 is configured such
that in the third mode, each active primary CHUs 210A, 210B operates at its maximum
conditioning capacity (e.g., the compressor of the CHU 210D operating at its maximum
load). When at least one secondary CHU is active, any/all active primary CHUs are
configured to be operating at their maximum conditioning capacity.
[0073] The operation of the heating-cooling system 200 in Figures 4A - 4C (e.g., selection
of active CHUs, the capacity for the active CHUs, and like) is discussed above with
respect to providing the heating demand for the first process fluid PF
1. For example, this can result in the active CHUs not providing cooling to meet the
cooling demand for the second process fluid PF
2. In another embodiment, the operation of the heating-cooling system 200 may be controlled
based on the cooling demand. In such an embodiment, the supplemental heating unit(s)
280 may operate to provide supplemental heating of the first process fluid PF
1 such that the heating-cooling system 200 meets the heating demand.
[0074] Figure 5 shows a block flow diagram of an embodiment of a method 1000 of controlling
a heating-cooling system. In some embodiments, the method 1000 may be used to control
the heating-cooling system 101 in Figure 2 or to operate the heating-cooling system
200 in Figure 3. For example, the method 1000 may be employed by a controller (not
shown) of the heating-cooling system 101 in Figure 2 or by the controller 290 of the
heating-cooling system 200 in Figure 3. The heating-cooling system operates to simultaneously
provide heating to a first process fluid (e.g., first process fluid PF
1) and cooling a second process fluid (e.g., first process fluid PF
1). The method 1000 can start at 1010.
[0075] At 1010, a conditioning demand for a first process fluid and/or a second process
fluid. In an embodiment, the conditioning demand determined at 1010 can include determining
a heating demand for the first process fluid 1012 and/or determining a cooling demand
for the second process fluid. For example, the heating demand corresponds with an
amount of heat to increase the first process fluid from an inlet temperature (e.g.,
inlet temperature T
H-I, inlet temperature T
H-I*, inlet temperature T
H-I+) to the target/desired temperature for the first process fluid PF
1. For example, the cooling demand corresponds with an amount of heat to increase the
second process fluid from an inlet temperature (e.g., inlet temperature Tc-i, inlet
temperature T
C-I*, inlet temperature T
C-I+) to the target/desired temperature for the second process fluid PF
2. The method 1000 then proceeds to 1020.
[0076] At 1020, the heating-cooling system is selectively operated in a plurality of operating
modes. Selective operation of the heating-cooling system refers to separate operation
of the heating-cooling system in each of the operating modes at different times. In
the illustrated embodiment, the plurality of operating modes includes a first mode,
a second mode, and a third mode. For example, the selective operation at 1020 may
be based on the determined conditioning demand at 1010 (e.g., determined heating demand
at 1012, determined cooling demand at 1014). The selective operation at 1020 may be
configured to operating the heating-cooling system in a present operation mode based
on the determined conditioning demand.
[0077] The selective operation of the heating-cooling system at 1020 includes operating
the heating-cooling system in a first mode at 1030A (e.g., heating-cooling system
200A in Figure 4A), operating the heating-cooling system in a second mode at 1030B
(e.g., heating-cooling system 200B in Figure 4B), and operating the heating-cooling
system in a third mode at 1030C (e.g., heating-cooling system 200C in Figure 4C).
The heating-cooling system includes one or more primary CHUs (e.g., primary CHU CH
P1, primary CHU CH
P1, primary CHU 210A, primary CHU 210B) and one or more secondary CHUs (e.g., secondary
CHU CH
S1, secondary CHU CH
S2, secondary CHU CHss, secondary CHU 210C, secondary CHU 210D). For example, the different
modes 1030A, 1030B, 1030C utilize different one/sets of the CHUs in the heating-cooling
system.
[0078] In the heating-cooling system operating in the first mode at 1030A, the primary CHU(s)
in the heating-cooling system are shutdown 1032A and one or more of the secondary
CHU(s) in the heating-cooling system are active 1034A. In the first mode 1030A, each
of the active secondary CHU(s) are both heating the first process fluid and cooling
of the second process fluid. For example, the first mode 1030A is selected in response
to the conditioning demand (e.g., the heating demand, the cooling demand) being below
a minimum conditioning capacity for the primary CHU(s). The secondary CHU(s) operating
in the first mode 1030A to meet the conditioning demand (e.g., to meet the heating
demand and/or to meet the cooling demand).
[0079] In the heating-cooling system operating in the second mode at 1030B, one or more
of the primary CHU(s) in the heating-cooling system are active 1032B and the secondary
CHU(s) in the heating-cooling system are shutdown 1034B. In the second mode 1030B,
the active primary CHU(s) are each both heating the first process fluid and cooling
of the second process fluid. For example, the second mode 1030B is selected in response
to the conditioning demand (e.g., the heating demand, the cooling demand) being in
a conditioning load range of the primary CHU(s). The primary CHU(s) operating in the
second mode 1030B to meet the conditioning demand (e.g., to meet the heating demand
and/or to meet the cooling demand).
[0080] In the heating-cooling system operating in the second mode at 1030C, one or more
of the primary CHU(s) in the heating-cooling system are active 1032C and one or more
of the secondary CHU(s) in the heating-cooling system are active 1034C. In the third
mode 1030C, the active primary CHU(s) and the active secondary CHU(s) are each both
heating the first process fluid and cooling of the second process fluid. For example,
the third mode 1030C is selected in response to the conditioning demand (e.g., the
heating demand, the cooling demand) being above the minimum conditioning capacity
of the primary CHU(s) and outside the conditioning load range of the primary CHU(s).
The active primary CHU(s) and the active secondary CHU(s) operating in the third mode
1030C to meet the conditioning demand (e.g., to meet the heating demand and/or to
meet the cooling demand).
[0081] In an embodiment, one or more supplemental conditioning unit(s) in the heating-cooling
system may be active to provide supplemental heating of the first process fluid and/or
to provide supplemental cooling of the second process fluid. The supplemental cooling
can be used when the CHU(s) operating to meet the heating demand for the first process
fluid results in the cooling of the second process fluid by the CHU(s) being insufficient
(e.g., not meeting the cooling demand). The supplemental heating can be used when
the CHU(s) operating to meet the cooling demand for the second process fluid results
in the heating of the first process fluid by the CHU(s) being insufficient (e.g.,
not meeting the heating demand). In some embodiments, the supplemental heating and/or
cooling by the supplemental conditioning unit(s) may also be provided to lower the
amount of heating and/or the amount of cooling provided by the CHU(s) to meet the
conditioning demand for the process fluids. In such an embodiment, the supplemental
conditioning unit(s) may provide supplemental heating and/or cooling in the first
mode 1030A and/or the second mode 1030B.
[0082] It should be appreciated that the method 1000 may be modified based on the cooling-heating
unit 1 in Figure 1, the HVACR system 100 in Figure 2, and/or the heating-cooling system
200 in Figures 3 - 4C as shown and/or described above. For example, the method 1000
in an embodiment may be modified to include features for operating the refrigerant
circuit in each of the active CHUs based on the cooling-heating unit 1 in Figure 1.
Aspects:
[0083]
Aspect 1. A heating-cooling system, comprising:
a heating flow path for a first process fluid,
a cooling flow path for a second process fluid,
cooling-heating units each fluidly connected to the heating flow path and to the cooling
flow path, each of the cooling-heating units including a refrigerant circuit with
a compressor, an expander, a condenser for heating the first process fluid, and an
evaporator for cooling the second process fluid, the cooling-heating units including:
one or more primary cooling-heating units, and
one or more secondary cooling-heating units, the one or more primary cooling-heating
units and the one or more secondary cooling-heating units being fluidly connected
to the heating flow path such that when active, a heating load is prioritized to the
one or more primary cooling-heating units over the one or more secondary cooling-heating
units.
Aspect 2. The heating-cooling system of Aspect 1, wherein one or more of:
the one or more secondary cooling-heating units have a smaller load capacity than
the primary cooling-heating units, and
the compressor in each of the one or more secondary cooling-heating units is a different
compressor type from the compressor in the primary cooling-heating units.
Aspect 3. The heating-cooling system of any one of Aspects 1-2, wherein
the one or more primary cooling-heating units are a single primary cooling-heating
unit or two or more primary cooling-heating units fluidly connected to the heating
flow path in parallel, and
the one or more secondary cooling-heating units are a single secondary cooling-heating
unit or two or more secondary cooling-heating units fluidly connected to the heating
flow path in parallel.
Aspect 4. The heating-cooling system of any one of Aspects 1-3, wherein
the one or more primary cooling-heating units are two or more primary cooling-heating
units fluidly connected to the heating flow path in parallel, and
the one or more secondary cooling-heating units are two or more of secondary cooling-heating
units fluidly connected to the cooling flow path in parallel.
Aspect 5. The heating-cooling system of any one of Aspects 1-4, wherein when operating
at least one of the one or more primary cooling-heating units, the at least one of
the one or more primary cooling-heating units operate at maximum conditioning capacity
prior to activating any of the one or more secondary cooling-heating units.
Aspect 6. The heating-cooling system of any one of Aspects 1-5, wherein
the one or more primary cooling-heating units have an inlet and an outlet each fluidly
connected to the heating flow path, and
the one or more secondary cooling-heating units have an inlet that fluidly connects
to the heating flow path between the inlet and the outlet of the one or more primary
cooling-heating units.
Aspect 7. The heating-cooling system of any one of Aspects 1 - 6, wherein the one
or more secondary cooling-heating units have an outlet fluidly connecting to the heating
flow path, and the outlet of the one or more primary cooling-heating units fluidly
connect to the heating flow path between the inlet and the outlet of the one or more
secondary cooling-heating units.
Aspect 8. The heating-cooling system of any one of Aspects 1 - 7, further comprising:
a controller for the heating-cooling system, the controller configured to selectively
operate the heating-cooling system in each of a plurality of modes that include:
a first mode in which the one or more primary chill-heating units are shutdown and
at least one of the one or more secondary cooling-heating units is active,
a second mode in which the one or more secondary cooling-heating units are shutdown
and at least one of the one or more primary cooling-heating units is active, and
a third mode in which at least one of the one or more secondary cooling-heating units
is active and at least one of the one or more primary cooling-heating units is active.
Aspect 9. The heating-cooling system of Aspect 8, wherein the controller is configured
to selectively operate the heating-cooling system in each of a plurality of modes
based on one or more of a heating demand for the first process fluid and a cooling
demand for the second process fluid.
Aspect 10. The heating-cooling system of any one of Aspects 8 and 9, wherein the controller
is configured to selectively operate the heating-cooling system in:
the first mode in response to a conditioning demand for the first process fluid or
the second process fluid being less than a minimum conditioning capacity of the one
or more primary cooling-heating units,
the second mode in response to the conditioning demand for the first process fluid
of the second process fluid being within a load capacity range of the one or more
primary cooling-heating units, and
the third mode in response to the conditioning demand for the first process fluid
of the second process fluid being greater than the minimum conditioning capacity of
the one or more primary cooling-heating units and outside the load capacity range
of the one or more primary cooling-heating units.
Aspect 11. The heating-cooling system of any one of Aspects 1 - 10, further comprising
one or more of:
one or more supplemental heating units fluidly connected to the heating flow path,
the one or more supplemental heating units configured to provide supplemental heating
of the first process fluid; and
one or more supplemental cooling units fluidly connected to the cooling flow path,
the one or more supplemental cooling units configured to provide supplemental cooling
of the second process fluid.
Aspect 12. A method of controlling a heating-cooling system, the heating-cooling system
including a heating flow path for a first process fluid, a cooling flow path for a
second process fluid, and cooling-heating units that are each fluidly connected to
the heating flow path and to the cooling flow path, the cooling-heating units including
one or more primary cooling-heating units and one or more secondary cooling-heating
units, the method comprising:
selectively operating the heating-cooling system in a plurality of modes including:
a first mode, wherein operating the heating-cooling system in a first mode includes
one or more of the secondary cooling-heating units each heating the first process
fluid and cooling the second process fluid,
a second mode, wherein operating in the second mode includes one or more of the primary
cooling-heating units each heating the first process fluid and cooling the second
process fluid,
a third mode, wherein operating in the third mode includes one or more of the secondary
cooling-heating units and one or more of the primary cooling-heating units each heating
the first process fluid and cooling the second process fluid, wherein the one or more
of the primary cooling-heating units operating at or about maximum conditioning capacity
in the third mode.
Aspect 13. The method of Aspect 12, wherein the one or more primary cooling-heating
units are shutdown in the first mode, and the secondary cooling-heating units are
shutdown in the second mode.
Aspect 14. The method of any one of Aspects 12 - 13, wherein the selectively operating
of the heating-cooling system in the plurality of modes is based on a conditioning
demand for one or more of the first process fluid and the second process fluid.
Aspect 15. The method of any one of Aspects 12 - 14, wherein the conditioning demand
includes one or more of a heating demand for the first process fluid and a cooling
demand for the second process fluid.
Aspect 16. The method of any one of Aspects 12 - 15, wherein
the selective operation of the heating-cooling system includes:
selecting the operating of the heating-cooling system in the first mode, in response
to a conditioning demand exceeding a minimum conditioning capacity of the one or more
primary cooling-heating units,
selecting the operating of the heating-cooling system in the second mode, in response
to the conditioning demand being within the conditioning load range of the one or
more primary cooling-heating units; and
selecting the operating of the heating-cooling system in the third mode, in response
to a conditioning demand exceeding the minimum conditioning capacity and being outside
the conditioning load range of the of the one or more primary cooling-heating units.
Aspect 17. The method of any one of Aspects 12 - 16, wherein the operation of heating-cooling
system in the third mode includes one or more of:
heating, with one or more supplemental heating units of the heating-cooling system,
the first process fluid, and
cooling, with one or more supplemental cooling units of the heating-cooling system,
the second process fluid.
Aspect 18. A heating, ventilation, air conditioning, and refrigeration system comprising:
the heating-cooling system of any one of Aspects 1 - 12.
Aspect 19. A heating, ventilation, air conditioning, and refrigeration system of Aspect
18, wherein the second process fluid is utilized to cool a conditioned space.
Aspect 20. The heating, ventilation, air conditioning, and refrigeration system of
any one of Aspect 8, 9 or 10, wherein, in the third mode, the controller is arranged
to operate the one or more primary cooling-heating units at full load/capacity and
the one or more the secondary cooling-heating units at partial or fully capacity load/capacity
to meet the conditioning demand
[0084] The terminology used herein is intended to describe particular embodiments and is
not intended to be limiting. The terms "a," "an," and "the" include the plural forms
as well, unless clearly indicated otherwise. The terms "comprises" and/or "comprising,"
when used in this Specification, specify the presence of the stated features, integers,
steps, operations, elements, and/or components, but do not preclude the presence or
addition of one or more other features, integers, steps, operations, elements, and/or
components. In an embodiment, "connected" and "connecting" as described herein can
refer to being "directly connected" and "directly connecting", and/or "fluidly connected"
and "fluidly connecting" as described herein can refer to being "directly fluidly
connected" and "directly fluidly connected".
[0085] With regard to the preceding description, it is to be understood that changes may
be made in detail, especially in matters of the construction materials employed and
the shape, size, and arrangement of parts without departing from the scope of the
present disclosure. This Specification and the embodiments described are exemplary
only, with the true scope and spirit of the disclosure being indicated by the claims
that follow.