Expansion Check of existing plant

[rize1159]

Dear All,
We have an existing refrigeration capacity of 1000KW and now we want to upgrade it to 3000KW with addition of similar compressor. Following are the component data for existing components and components being added.
1- Refrigerant: Ammonia
2- Required Process cooling water temperature: 0-2C
3- GEA V1400 compressor 01 existing; Two more compressors to be added.
4- Condensers: Evaporative condenser 1200KW (wetbulb 28C/conden. Temp 37C/Evaporation Temp: -4C) Same condensers to be added making total 3 condensers
5- HP receiver size: 500mm x 1200mm vertical (will remain same)
6- LP Receiver Size: 1200mm x 3500mm horizontal (will remain same)
7- Expansion Valve: ICS type hand expansion valve (will remain same)
8- Evaporator: Gravity feed 3000KW PHE (03 meter below LP Rec.)
9- Ice water tank size is 20000 liters
10- Piping, we know its OK for pressure drops
My questions are:
1- Are HP & LP receivers of sufficient capacity?
2- How can I check capacity of expansion valve to handle extra flow?
3- Although evaporator is of 3000KW, will it generate sufficient vapors for working of 3 compressors? How can I check?
3-Ice water tank capacity is oK or we need to increase its size? What is criteria of its sizing? How to check for its working for peak conditions?
Regards
Rize

[RANGER1]

Dear All,
We have an existing refrigeration capacity of 1000KW and now we want to upgrade it to 3000KW with addition of similar compressor. Following are the component data for existing components and components being added.
1- Refrigerant: Ammonia
2- Required Process cooling water temperature: 0-2C
3- GEA V1400 compressor 01 existing; Two more compressors to be added.
4- Condensers: Evaporative condenser 1200KW (wetbulb 28C/conden. Temp 37C/Evaporation Temp: -4C) Same condensers to be added making total 3 condensers
5- HP receiver size: 500mm x 1200mm vertical (will remain same)
6- LP Receiver Size: 1200mm x 3500mm horizontal (will remain same)
7- Expansion Valve: ICS type hand expansion valve (will remain same)
8- Evaporator: Gravity feed 3000KW PHE (03 meter below LP Rec.)
9- Ice water tank size is 20000 liters
10- Piping, we know its OK for pressure drops
My questions are:
1- Are HP & LP receivers of sufficient capacity?
2- How can I check capacity of expansion valve to handle extra flow?
3- Although evaporator is of 3000KW, will it generate sufficient vapors for working of 3 compressors? How can I check?
3-Ice water tank capacity is oK or we need to increase its size? What is criteria of its sizing? How to check for its working for peak conditions?
Regards
Rize

Rize,
I think you need to hire a refrigeration company to engineer system fully.
Here are links to some information.

Danfoss ICS 65
Reg valve 40B
https://www.danfoss.com/en/service-and-support/downloads/dcs/coolselector-2/

Vessel might be a bit okay, as see dimmensions
850tons 3000kw, 1500 diameter x 3250mm HSDD-60-128 20degF

https://www.johnsoncontrols.com/-/media/jci/be/united-states/refrigeration/industrial-refrigeration/files/be_spec_dual_horiz_surge_drum.pdf?la=en&hash=02EF22696BFE23C982E70FEB66FEC3CC9775DBF7

0 to 2deg water can be dangerous for instant freeze up if power failure.

Condensers maybe go a bit bigger, as you add motor power input on top of load.
Also fouling, deterioration of condensers, as well as a pull down if water hotter.

[rize1159]

Ranger1, thank you for your valuable input. We have already have a refrigeration company contracted. They say system seems OK. But previously, we have relied on someone with similar words. Now We have getting temperature of 10C to process whenever we have some electrical power changeover. Thats why we are trying to make a check by our-self.
BTW ice water is a glycol mixture by 10%. so no worries of icing. But what about storage tank volume? 20K liters is enough or we need to add. Tank hot return water is 11C & primary ice water circuit is 2C.
Our few persons are saying, Condensers are small. They are of opinion that it should be 1600KW as per formula given by RJ Dossat Principals of Refrigeration. (Compressor refrigeration capacity plus motor power multiplied by factor)

[AKI]

I am totally agree with Ranger,If you have reserved with local company that made calculation then you must others worldwide.

regards
Aki

[AKI]

And if you go to calculate condenser then you right,compressor capacity,motor power, (capacity of oil cooler),plus factor.

regards
Aki