Oil-free liquid chiller

• US 20010037651A1
• Filed: 07/11/2001
• Published: 11/08/2001
• Est. Priority Date: 10/09/1998
• Status: Active Grant

• Current Assignee: Trane International Inc. (Trane Technologies plc)
• Original Assignee: Arthur L. Butterworth, David H. Eber, Todd R. Vandeleest
• Inventors: Vandeleest, Todd R., Butterworth, Arthur L., Eber, David H.
• Granted Patent: US 6,564,560 B2
• Time in Patent Office: Days
• US Class Current: 62/193
• CPC Class Codes: F04D 25/06 the pump being electrically driven F04D25/08 takes precedence
• CPC Class Codes: F04D 29/023 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/059 Roller bearings
• CPC Class Codes: F04D 29/063 specially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/5806 Cooling the drive system
• CPC Class Codes: F05D 2300/20 Oxide or non-oxide ceramics
• CPC Class Codes: F05D 2300/2283 of silicon
• CPC Class Codes: F05D 2300/501 Elasticity
• CPC Class Codes: F05D 2300/5021 Expansivity
• CPC Class Codes: F05D 2300/522 Density
• CPC Class Codes: F16C 2360/44 Centrifugal pumps in general F04D
• CPC Class Codes: F16C 2380/26 Dynamo-electric machines or combinations therewith, e.g. electro-motors and generators in general H02K
• CPC Class Codes: F16C 33/6659 Details of supply of the liquid to the bearing, e.g. passages or nozzles
• CPC Class Codes: F16C 33/6692 Liquids other than oil, e.g. water, refrigerants, liquid metal
• CPC Class Codes: F25B 31/002 Lubrication
• CPC Class Codes: F25B 31/006 Cooling of compressor or motor
• CPC Class Codes: F25B 31/008 by injecting a liquid
• CPC Class Codes: F25B 49/025 Motor control arrangements
• CPC Class Codes: H02K 7/083 radially supporting the rotary shaft at both ends of the rotor H02K7/086, H02K7/09 take precedence
• CPC Class Codes: H02K 9/20 wherein the cooling medium vaporises within the machine casing
• CPC Class Codes: Y10S 62/02 : Refrigerant pumps

Abstract

A refrigeration chiller employs a centrifugal compressor the impellers of which are mounted on a shaft which is itself mounted for rotation using rolling element bearings lubricated only by the refrigerant which constitutes the working fluid of the chiller system. Apparatus is taught for providing liquid refrigerant to (1.) the bearings immediately upon chiller start-up, during chiller operation and during a coastdown period subsequent to shutdown of the chiller and (2.) the drive motor of the chiller'"'"'s compressor for motor cooling purposes. By use of a variable speed-driven motor to drive the compressor, optimized part load chiller performance is achieved in a chiller which does not require or employ an oil-based lubrication system.

Claims

1. A liquid chiller comprising:

a condenser, said condenser condensing refrigerant gas to the liquid state when said chiller is in operation;

a metering device, said metering device receiving refrigerant from said condenser and reducing the pressure thereof;

an evaporator, said evaporator receiving refrigerant from said metering device and causing liquid refrigerant to evaporate when said chiller is in operation;

a compressor, said compressor receiving refrigerant from said evaporator and delivering refrigerant in the gaseous state to said condenser when said chiller is in operation, said compressor having a shaft, at least one compressive element being mounted on said shaft, said shaft being rotatably supported by at least one bearing, said at least one bearing being a rolling element bearing, the rolling elements of said bearing being fabricated from a non-metallic material, said at least one bearing being lubricated by refrigerant and in the absence of oil; and

a source location for liquid refrigerant, discrete from said evaporator and condenser, from which liquid refrigerant is supplied to said at least one bearing.

2. The chiller according to

claim 1

wherein said chiller is a centrifugal chiller, wherein said non-metallic bearing material is a ceramic material, wherein said compressive element is an impeller and wherein the refrigerant used to lubricate said at least one bearing is primarily in the liquid state.

3. The chiller according to

claim 2

wherein said source location is a reservoir for refrigerant.

4. The chiller according to

claim 3

wherein said reservoir contains refrigerant in the liquid state both during chiller operation and for a period of time subsequent to shutdown of said chiller, the amount of such liquid refrigerant in said reservoir being sufficient to ensure the delivery of adequate liquid refrigerant, for lubrication purposes, to said at least one bearing both while said chiller is in operation and while said shaft on which said at least one impeller is mounted coasts to a stop after said chiller is shutdown.

5. The chiller according to

claim 4

wherein said reservoir is replenished with liquid refrigerant sourced out of said condenser when said chiller is in operation, said reservoir being isolated from said condenser and the pressure drop that occurs therein when said chiller shuts down.

6. The chiller according to

claim 4

further comprising a pump, said pump capable of pumping saturated liquid refrigerant to said reservoir without causing a significant portion of said refrigerant to flash to gas in the pumping process.

7. The chiller according to

claim 4

wherein subsequent to shutdown of said chiller and prior to its next startup, said reservoir is provided liquid refrigerant supplied from said evaporator while said chiller is shutdown so that said reservoir contains liquid refrigerant to provide for the lubrication of said at least one bearing when said shaft next starts rotating.

8. The chiller according to

claim 4

further comprising a motor, the rotor of said motor being mounted on said shaft of said compressor, wherein said condenser supplies liquid refrigerant to said reservoir for bearing lubrication purposes and to said motor for purposes of cooling said motor when said compressor is in operation.

9. The chiller according to

claim 8

further comprising a variable speed drive for said motor and wherein said condenser supplies liquid refrigerant to said variable speed drive in order to cool said drive when said compressor is in operation.

10. The chiller according to

claim 9

wherein refrigerant used for motor cooling, bearing lubrication and motor drive cooling is returned to said condenser.

11. The chiller according to

claim 4

further comprising a refrigerant sump said sump being in flow communication with said reservoir and said evaporator, said sump being provided liquid refrigerant from said evaporator when said chiller is shutdown and being the location from which liquid refrigerant is initially provided liquid refrigerant for bearing lubrication purposes when said chiller starts up.

12. The chiller according to

claim 2

further comprising a refrigerant sump, liquid refrigerant being delivered to said sump from said evaporator while said chiller is shutdown.

13. The chiller according to

claim 12

wherein said source location is a reservoir for refrigerant, said reservoir being in selective flow communication with said sump, said sump being the location from which liquid refrigerant is initially provided to said reservoir for bearing lubrication purposes when said chiller starts up.

14. The chiller according to

claim 13

wherein said sump is isolated from said evaporator when said chiller starts up.

15. The chiller according to

claim 14

further comprising means for delivering liquid refrigerant to said reservoir so as to replenish the supply of liquid refrigerant available for bearing lubrication purposes therein while said chiller is in operation.

16. The chiller according to

claim 15

wherein said means for delivering liquid refrigerant initially delivers liquid refrigerant from said sump to said reservoir as said chiller starts up and subsequently delivers liquid refrigerant from said condenser to said reservoir.

17. The chiller according to

claim 16

wherein said means for delivering liquid refrigerant is a pump, said pump being in flow communication with and disposed (i) upstream of said reservoir and (ii) downstream of both said condenser and said sump.

18. The chiller according to

claim 13

further comprising means for isolating said reservoir upon shutdown of said chiller so as to retain a residual pressure therein for a period of time after chiller shutdown, said residual pressure being the driving force by which liquid refrigerant in said reservoir at the time of chiller shutdown is driven to said at least one bearing so as to provide for the lubrication thereof while said shaft coasts to a stop.

19. The chiller according to

claim 13

wherein said chiller further comprises a motor and a pump, said pump pumping liquid refrigerant from said sump to both said reservoir and said motor when said chiller starts up and from said condenser to both said reservoir and said motor when said chiller is in operation, liquid refrigerant pumped to said reservoir by said pump being used to lubricate said at least one bearing and liquid refrigerant pumped to said motor by said pump being used to cool said motor.

20. The chiller according to

claim 2

further comprising a motor for driving said compressor and means for delivering liquid refrigerant to both said source location for bearing lubrication purposes and to said motor for motor cooling purposes while said chiller is in operation.

21. The chiller according to

claim 20

further comprising a variable speed drive, said motor being an induction motor capable of being driven at variable speeds substantially higher than 3600 RPM in order for said chiller to operate at its maximum capacity.

22. The chiller according to

claim 20

wherein liquid refrigerant is delivered from said condenser to said source location for bearing lubrication purposes and to said motor for motor cooling purposes while said chiller is in operation and from a location other than said condenser when said chiller starts up and until such time as liquid refrigerant comes to be available for such purposes from said condenser.

23. The chiller according to

claim 20

wherein refrigerant used for bearing lubrication and motor cooling purposes is returned to said condenser after such uses.

24. The chiller according to

claim 20

further comprising a pump, said pump pumping liquid refrigerant to said source location and to said motor both during start-up and during normal operation of said chiller.

25. The chiller according to

claim 20

further comprising a reservoir, a pump and a sump, said reservoir being said source location for liquid refrigerant for bearing lubrication purposes, said pump pumping liquid refrigerant from said sump to both said reservoir and said motor when said chiller initially starts up and said pump pumping liquid refrigerant from said condenser to both said reservoir and said motor subsequent to start-up of said chiller when liquid refrigerant comes to be available in said condenser for such purposes.

26. The chiller according to

claim 20

further comprising an economizer, refrigerant used for cooling said motor and the refrigerant used for lubricating said at least one bearing being delivered to said economizer subsequent to such uses.

27. The chiller according to

claim 20

further comprising a drive for said motor and means for delivering liquid refrigerant to said motor drive for purposes of cooling heat generating components therein.

28. The chiller according to

claim 27

wherein refrigerant used for bearing lubrication purposes, for motor cooling purposes and for motor drive cooling purposes is returned to said condenser.

29. The chiller according to

claim 27

further comprising an economizer, refrigerant used for cooling said motor and said motor drive being returned to said economizer.

30. The chiller according to

claim 2

wherein said source location is a reservoir, said reservoir being continuously replenished with liquid refrigerant when said chiller is operating and replenishment being discontinued when said chiller shuts down, said reservoir containing sufficient liquid refrigerant, when said chiller shuts down, to provide for the lubrication of said at least one bearing as said shaft coasts to a stop.

31. The chiller according to

claim 30

wherein said reservoir is initially replenished with liquid refrigerant sourced from said evaporator during each chiller start-up, the initial replenishment liquid refrigerant being sourced from said evaporator and stored in a location other than said evaporator after each chiller shutdown.

32. The chiller according to

claim 31

wherein said reservoir is isolated from the pressure drop which occurs in said condenser when said chiller shuts down so that sufficient pressure is maintained in said reservoir, subsequent to chiller shutdown, to drive liquid refrigerant contained therein to said at least one bearing while said shaft coasts to a stop.

33. The chiller according to

claim 32

wherein said location in which refrigerant sourced from said evaporator is stored subsequent to shutdown of said chiller is a sump, said sump being isolated from said evaporator prior to the next start-up of said chiller.

34. The chiller according to

claim 33

further comprising a compressor drive motor, a housing and a conduit, said motor being disposed in said housing and said conduit communicating liquid refrigerant sourced from said condenser to the interior of said housing and into contact with said motor when said chiller is in operation so as to cool said motor.

35. The chiller according to

claim 34

wherein refrigerant used to cool said motor and refrigerant used to lubricate said at least one bearing is returned to said condenser subsequent to said uses.

36. The chiller according to

claim 2

further comprising means for delivering liquid refrigerant sourced from one of said evaporator and said condenser to said source location while said chiller is in operation.

37. The chiller according to

claim 36

wherein said means for delivering refrigerant from one of said condenser and said evaporator comprises a pump.

38. The chiller according to

claim 37

wherein said source location is a reservoir for liquid refrigerant, liquid refrigerant in said reservoir being the refrigerant by which said at least one bearing is lubricated.

39. The chiller according to

claim 38

further comprising a sump, said sump being the location from which said reservoir is replenished with liquid refrigerant during chiller start-up, said pump pumping liquid refrigerant from said sump to said reservoir during chiller start-up and from said condenser to said reservoir when said chiller is in operation.

40. The chiller according to

claim 38

wherein refrigerant used for bearing lubrication purposes is returned to said condenser subsequent to such use.

41. The chiller according to

claim 38

wherein the rate of flow of liquid refrigerant from said reservoir to said at least one bearing is such that at least 80% of the liquid refrigerant delivered to said at least one bearing for bearing lubrication purposes remains in the liquid state subsequent to having been used to lubricate said at least one bearing.

42. The chiller according to

claim 38

wherein said pump has an impeller, a motor and a shaft, said pump shaft being mounted for rotation in a pump bearing, said pump bearing having rolling elements fabricated from a ceramic material, said pump motor being cooled and said pump bearing being lubricated by liquid refrigerant, said pump impeller pumping liquid refrigerant from said sump to said reservoir as said chiller starts up and from said condenser to said reservoir when said chiller is in operation.

43. The chiller according to

claim 38

further comprising means for isolating said reservoir from the pressure drop that occurs in said condenser when said chiller shuts down so that sufficient pressure is maintained in said reservoir to drive liquid refrigerant from said reservoir to said at least one bearing while said shaft on which said at least one impeller is mounted coasts to a stop.

44. The chiller according to

claim 37

further comprising a motor for driving said compressor and a drive for said motor, said pump pumping liquid refrigerant to said motor and to said drive for purposes of cooling said motor and said drive.

45. The chiller according to

claim 44

wherein refrigerant used to lubricate said at least one bearing and to cool said motor and said drive is returned to said condenser.

46. A centrifugal chiller comprising:

a condenser, said condenser condensing refrigerant gas to the liquid state when said chiller is in operation;

a metering device, said metering device receiving refrigerant from said condenser and reducing the pressure thereof;

an evaporator, said evaporator receiving refrigerant from said metering device and causing liquid refrigerant to evaporate when said chiller is in operation;

a compressor, said compressor receiving refrigerant from said evaporator and delivering refrigerant in the gaseous state to said condenser when said chiller is in operation, said compressor having a shaft and a motor, at least one impeller and the rotor of said motor being mounted on said shaft, said shaft being rotatably supported by at least one bearing of other than the magnetic, hydrostatic or hydrodynamic type, said bearing having rolling elements and being lubricated exclusively by refrigerant, the rolling elements of said bearing having a lower density, a higher modulus of elasticity and being less sensitive to thermal expansion than rolling elements fabricated from steel;

a reservoir, said reservoir being the location from which refrigerant is supplied to said at least one bearing for the lubrication thereof; and

means for replenishing the liquid refrigerant in said reservoir when said chiller is in operation.

47. The centrifugal chiller according to

claim 46

wherein the rolling elements of said bearings are fabricated from a ceramic material and wherein said reservoir is isolated from said condenser when said chiller shuts down, isolation of said reservoir at chiller shutdown causing sufficient pressure to be retained in said reservoir to drive liquid refrigerant from said reservoir to said at least one bearing as said shaft coasts to a stop, and wherein said means for replenishing said reservoir with liquid refrigerant comprises a pump, said pump pumping liquid refrigerant from said condenser to said reservoir subsequent to start-up of said chiller.

48. The chiller according to

claim 47

further comprising a sump, said sump being in selective flow communication with said evaporator and being replenished with liquid refrigerant therefrom during periods when said chiller is shutdown, said sump being isolated from said evaporator when said chiller next starts up, said pump pumping liquid refrigerant from said sump to said reservoir when said chiller initially starts up and from said condenser to said reservoir when said chiller is in operation.

49. The chiller according to

claim 48

wherein said pump pumps liquid refrigerant to said motor, for purposes of cooling said motor, when said chiller is in operation.

50. The chiller according to

claim 49

wherein refrigerant used to lubricate said at least one bearing and refrigerant used to cool said motor is returned to said condenser subsequent to having lubricated said at least one bearing and having cooled said motor.

51. The centrifugal chiller according to

claim 50

wherein said motor is an induction motor and further comprising a variable speed drive, said variable speed drive driving said motor over a predetermined range of speeds, the highest of such speeds being substantially higher than 3600 RPM.

52. The chiller according to

claim 47

wherein refrigerant used for purposes of lubricating said at least one bearing is returned to said condenser subsequent to such use.

53. The chiller according to

claim 47

wherein said pump pumps liquid refrigerant both to said reservoir and to said motor, refrigerant pumped to said reservoir being used for bearing lubrication purposes and refrigerant pumped to said motor being used for motor cooling purposes when said chiller is in operation.

54. The centrifugal chiller according to

claim 47

wherein at least 80% of the liquid refrigerant delivered to said at least one bearing for bearing lubrication purposes remains in the liquid state subsequent to such use.

55. The chiller according to

claim 47

wherein said condenser is in flow communication with said reservoir and wherein said means for replenishing said reservoir with liquid refrigerant constitutes condenser pressure.

56. The chiller according to

claim 47

wherein said pump pumps liquid refrigerant from said condenser to said compressor drive motor for purposes of cooling said motor.

57. The chiller according to

claim 56

further comprising a drive for said motor, said pump pumping liquid refrigerant from said condenser to said drive for purposes of cooling heat generating components in said drive.

58. The chiller according to

claim 57

wherein refrigerant used to lubricate said at least one bearing, cool said compressor drive motor and cool said motor drive is returned to said condenser.

59. An oil-free bearing lubrication and motor cooling system in a centrifugal chiller comprising:

a condenser, said condenser condensing refrigerant gas to the liquid state when said chiller is in operation;

a metering device, said metering device receiving refrigerant from said condenser and reducing the pressure thereof;

an evaporator, said evaporator receiving refrigerant from said metering device and causing liquid refrigerant to vaporize when said chiller is in operation;

a motor housing;

a motor;

a compressor, said compressor having a shaft, at least one impeller and the rotor of said motor being mounted on said shaft, said shaft being rotatably supported by at least one bearing, said at least one bearing being a rolling element bearing, at least one component of said rolling element bearing being fabricated from a ceramic material, said bearing being lubricated by refrigerant in the absence of oil and said motor being cooled by refrigerant; and

means for delivering liquid refrigerant both to said at least one bearing for lubrication thereof in the absence of oil and to said motor for motor cooling purposes.

60. The bearing lubrication and motor cooling system of

claim 59

further comprising a reservoir for liquid refrigerant, said means for delivering liquid refrigerant delivering liquid refrigerant to said motor and to said reservoir, said at least one bearing being lubricated by liquid refrigerant which is first delivered to said reservoir and is then directed to said at least one bearing.

61. The bearing lubrication and motor cooling system according to

claim 60

wherein refrigerant used to lubricate said at least one bearing and refrigerant used to cool said motor is returned, subsequent to such uses, to said condenser.

62. The bearing lubrication and motor cooling system according to

claim 60

wherein said chiller further comprises an economizer and wherein refrigerant used to lubricate said at least one bearing and refrigerant used to cool said motor is delivered to said economizer subsequent to such uses.

63. The bearing lubrication and motor cooling system according to

claim 60

wherein at least 80% of the liquid refrigerant delivered to said at least one bearing is returned therefrom in the liquid state subsequent to such use.

64. The bearing lubrication and motor cooling system according to

claim 60

wherein said centrifugal chiller further comprises a pump and a refrigerant sump, said sump being in selective flow communication with said evaporator, said sump filling with liquid refrigerant sourced from said evaporator subsequent to shutdown of said chiller and said sump being isolated from said evaporator subsequent to being filled with liquid refrigerant therefrom prior to the next start-up of said chiller, said pump pumping liquid refrigerant from said sump to said at least one bearing and to said motor as said chiller initially starts up and said pump pumping liquid refrigerant from said condenser to said at least one bearing and to said motor when liquid refrigerant comes to be available in said condenser subsequent to chiller start-up.

65. The system according to

claim 64

further comprising means for isolating said reservoir from the pressure drop that occurs in said condenser when said chiller shuts down and wherein liquid refrigerant used to lubricate said at least one bearing and to cool said motor is returned to said condenser subsequent to such uses.

66. The system according to

claim 60

further comprising means for metering liquid refrigerant to said motor at a first flow rate during the start-up of said chiller and at a second and higher flow rate when the shaft of said chiller has achieved operational speeds and the load on said chiller exceeds a predetermined load.

67. The system according to

claim 66

wherein the flow rate of liquid refrigerant to said motor is reduced when the load on said chiller falls below said predetermined load.

68. The system according to

claim 60

wherein said motor is cooled by liquid refrigerant which is first delivered to said reservoir and is then directed to said motor.

69. The system according to

claim 61

further comprising a drive for said motor, said means for delivering liquid refrigerant both to said at least one bearing and to said motor also delivering liquid refrigerant to said drive for purposes of cooling heat generating components therein.

70. A method of operating a centrifugal refrigeration chiller having a condenser and an evaporator comprising the steps of:

mounting an impeller on a shaft;

mounting said shaft for rotation in a bearing, said bearing being a rolling element bearing, the rolling elements of said bearing being fabricated from a ceramic material;

providing a source location for liquid refrigerant which is discrete from said condenser and said evaporator, said source location containing liquid refrigerant for purposes of lubricating said bearing both when said chiller is operating and for a period of time subsequent to shutdown of said chiller during which said shaft coasts to a stop in said bearing; and

delivering liquid refrigerant, in the absence of oil, from said source location to said bearing both while said chiller is in operation and as said shaft coasts to a stop subsequent to chiller shutdown.

71. The method according to

claim 70

comprising the further steps of defining a reservoir in said chiller, said reservoir being said source location for liquid refrigerant;

and, replenishing said reservoir with liquid refrigerant sourced from said condenser when said chiller is in operation.

72. The method according to

claim 71

comprising the further step of isolating said reservoir from the occurrence of a pressure drop upstream thereof so as to maintain a residual pressure in said reservoir capable of driving liquid refrigerant contained therein to said bearing when such pressure drop occurs.

73. The method according to

claim 72

comprising the further step of pumping liquid refrigerant to said reservoir from said condenser while said chiller is in operation.

74. The method according to

claim 73

comprising the further steps of defining a sump for liquid refrigerant in said chiller;

providing said sump with liquid refrigerant from said evaporator while said chiller is shut down;

isolating said sump from said evaporator prior to the next startup of said chiller; and

, initially delivering liquid refrigerant from said sump to said reservoir as said chiller next starts up.

75. The method according to

claim 74

comprising the further step of pumping liquid refrigerant to said reservoir from said sump as said chiller starts up.

76. The method according to

claim 75

wherein the pumping of liquid refrigerant to said reservoir is accomplished by means of a pump and comprising the further step of lubricating the bearings of said pump with liquid refrigerant in the absence of oil.

77. The method according to

claim 71

comprising the further step of permitting said shaft to rotate in said bearing for a period of time when said chiller initially starts up, without the delivery of liquid refrigerant to the bearing for bearing lubrication purposes.

78. The method according to

claim 71

comprising the further step of returning liquid refrigerant, delivered from said source location to said bearing in said delivering step, from said bearing to said condenser.

79. The method according to

claim 71

wherein said delivering step includes the step of flowing liquid refrigerant from said reservoir to said bearing at a rate sufficiently high to ensure that at least 80% of the liquid refrigerant delivered to said bearing for purposes of lubricating said bearing remains in the liquid state subsequent to having lubricated said bearing.

80. The method according to

claim 70

comprising the further step of mounting the rotor of a variable speed motor on said shaft.

81. The method according to

claim 80

comprising the further step of delivering liquid refrigerant to said motor for purposes of cooling said motor when said chiller is in operation.

82. The method according to

claim 81

comprising the further step of defining a reservoir in said chiller, said reservoir being the source of liquid refrigerant used to lubricate said bearing;

and, replenishing said reservoir with liquid refrigerant while said chiller is in operation.

83. The method according to

claim 82

comprising the further step of delivering liquid refrigerant to the drive by which said motor is driven for purposes of cooling heat generating components therein.

84. The method according to

claim 83

comprising the further step of returning refrigerant used to cool said motor and said drive to said condenser.

85. The method according to

claim 82

comprising the further steps of defining a sump in said chiller;

providing said sump with liquid refrigerant from said evaporator when said chiller is shutdown; and

, isolating said sump from said evaporator prior to startup of said chiller.

86. The method according to

claim 85

comprising the further step of pumping liquid refrigerant from said sump to both said reservoir and said motor as said chiller starts up and from said condenser to both said reservoir and said motor while said chiller is in operation.

87. The method according to

claim 86

comprising the further steps of isolating said reservoir from both said condenser and said sump when said chiller shuts down so that a residual pressure is trapped in said reservoir;

and, driving liquid refrigerant contained in said reservoir to said bearing as said shaft coasts to a stop using said residual pressure.

88. A method for lubricating a rolling element bearing in and for cooling the drive motor of a centrifugal refrigeration chiller having a condenser and an evaporator where the rolling elements of the bearing are fabricated from a ceramic material comprising the steps of:

mounting at least one impeller and the rotor of the drive motor on a shaft;

supporting the shaft for rotation in the rolling element bearing;

delivering liquid refrigerant, in the absence of oil, to the rolling element bearing for purposes of lubricating the bearing; and

delivering liquid refrigerant to the drive motor for purposes of cooling the motor when the chiller is in operation.

89. The method according to

claim 88

comprising the further steps of defining a reservoir discrete from the condenser and evaporator of the chiller, liquid refrigerant first being delivered to the reservoir prior to being delivered to the bearing for bearing lubrication purposes;

and replenishing the reservoir with liquid refrigerant while the chiller is in operation.

90. The method according to

claim 89

comprising the further step of returning liquid refrigerant used to lubricate the bearing and liquid refrigerant used to cool the motor to the chiller condenser subsequent to such uses.

91. The method according to

claim 89

comprising the further step of isolating the reservoir from a drop in pressure of predetermined magnitude occurring upstream thereof so as to retain pressure in the reservoir subsequent to the occurrence of such pressure drop;

and, driving liquid refrigerant from the reservoir to the bearing, using said retained pressure, for a predetermined period of time subsequent to such a drop in pressure.

92. The method according to

claim 89

wherein said replenishing step comprises the step of pumping liquid refrigerant, using a pump, to the reservoir and further comprising the step of lubricating a bearing of the pump with liquid refrigerant.

93. The method according to

claim 89

wherein said replenishing step includes the steps of pumping liquid refrigerant from the chiller condenser to the reservoir when the chiller is in normal operation and pumping liquid refrigerant from a location other than the chiller condenser and other than the chiller evaporator to the reservoir when the chiller initially starts up after a period of being shutdown.

94. The method according to

claim 89

wherein both the liquid refrigerant delivered to the bearing and the liquid refrigerant delivered to the motor in said steps of delivering liquid refrigerant to the bearing and delivering liquid refrigerant to the motor is delivered to the bearing and to the motor from the reservoir.

95. The method according to

claim 89

wherein the step of delivering liquid refrigerant to the motor includes the steps of delivering liquid refrigerant to the motor at a first flow rate when the chiller first starts up;

and, delivering liquid refrigerant to the motor at a second flow rate, greater than the first flow rate, when the chiller is in normal operation and is operating at a capacity greater than a predetermined capacity.

96. The method according to

claim 89

comprising the further steps of storing liquid refrigerant, while the chiller is shutdown, in a location discrete from the evaporator and said condenser and wherein liquid refrigerant initially delivered to the bearing and initially delivered to the motor when the chiller starts up is sourced from the discrete location.

97. The method according to

claim 89

wherein said replenishing step includes the step of employing condenser pressure to drive liquid refrigerant from the condenser to the reservoir.

98. The method according to

claim 89

wherein said step of delivering liquid refrigerant to the bearing includes the step of delaying the delivery of liquid refrigerant to the bearing until such time as liquid refrigerant is available in the condenser to be delivered from the condenser to the reservoir.

99. The method according to

claim 89

comprising the further steps of discontinuing the replenishment of the reservoir with liquid refrigerant when the chiller shuts down;

and, continuing the delivery of liquid refrigerant to the bearing from the reservoir after said chiller shuts down for so long as the shaft rotates in the bearing.

100. The method according to

claim 89

comprising the further step of varying the rotational speed of the drive motor in accordance with the load on the chiller.

101. The method according to

claim 100

comprising the further step of delivering liquid refrigerant to the drive by which the rotational speed of the drive motor is varied so as to cool heat generating components therein.

102. The method according to

claim 89

comprising the further step of permitting the shaft to rotate in the bearing for a period of time when the chiller initially starts up without the delivery of liquid refrigerant to the bearing for bearing lubrication purposes.

103. A liquid chiller comprising:

a condenser, said condenser condensing liquid refrigerant to the liquid state when said chiller is in operation;

a metering device, said metering device receiving refrigerant from said condenser;

an evaporator, said evaporator receiving refrigerant from said metering device;

a compressor, said compressor receiving refrigerant gas from said evaporator and delivering refrigerant gas to said condenser when said chiller is in operation, said compressor having a shaft, said shaft being rotatably supported by at least one bearing; and

pump apparatus, said pump apparatus being connected to draw refrigerant from both said condenser and said evaporator and pumping liquid refrigerant from at least one of said condenser and said evaporator for the purpose of lubricating said at least one compressor bearing.

104. The liquid chiller according to

claim 103

wherein the liquid refrigerant output of said pump apparatus is, at any given time, sourced from the one of said condenser and said evaporator where the liquid refrigerant, if available, is available at a higher pressure.

105. The liquid chiller according to

claim 104

wherein said at least one compressor bearing is a rolling element bearing and wherein the rolling elements of said at least one compressor bearing are fabricated from a ceramic material.

106. The liquid chiller according to

claim 105

wherein said pump apparatus includes a first pumping mechanism and a second pumping mechanism, said first pumping mechanism being configured to pump liquid refrigerant from said condenser and said second pumping mechanism being configured to pump liquid refrigerant from said evaporator.

107. The liquid chiller according to

claim 106

wherein said first pumping mechanism and said second pumping mechanism are commonly driven by a single motor.

108. The liquid chiller according to

claim 106

further comprising a check valve arrangement for preventing the flow of the output of said first pumping mechanism to said second pumping mechanism and for preventing the flow of the output of said second pumping mechanism to said first pumping mechanism.

109. The liquid chiller according to

claim 106

further comprising a path into which the output of said first pumping mechanism flows;

a path into which the output of said second pumping mechanism flows, the path into which the output of said first pumping mechanism flows and the path into which the output of said second pumping mechanism flows converging into a single flow path; and

means for preventing the flow of the output of the one of said first and said second pumping mechanisms which is at lower pressure into said single flow path.

110. The liquid chiller according to

claim 103

wherein said pump apparatus includes a shaft, said shaft being mounted for rotation in at least one bearing, said at least one pump bearing being lubricated by the liquid refrigerant pumped by said pump apparatus.

111. The liquid chiller according to

claim 103

further comprising a reservoir and wherein the output of said pump apparatus is delivered to said reservoir, said reservoir supplying liquid refrigerant to lubricate said at least one compressor bearing.

112. The liquid chiller according to

claim 111

further comprising apparatus for isolating said reservoir from the output of said pump apparatus when the output pressure of said pump apparatus drops below a predetermined pressure whereby sufficient pressure is maintained in said reservoir, subsequent to said drop in pump output pressure, to ensure the delivery of liquid refrigerant from said reservoir to said at least one compressor bearing for a predetermined period of time.

113. The liquid chiller according to

claim 103

further comprising a motor, said motor driving said compressor, said pump mechanism additionally pumping liquid refrigerant to said motor so as to cool said motor.

114. The liquid chiller according to

claim 113

further comprising a motor drive, said motor drive driving said motor at variable speeds, said pump mechanism additionally pumping liquid refrigerant to said drive so as to cool heat generating components therein.

115. The liquid chiller according to

claim 105

wherein liquid refrigerant delivered to said at least one compressor bearing is returned therefrom to said condenser.

116. A liquid chiller comprising:

a compressor;

a motor for driving said compressor;

a condenser, said condenser receiving compressed refrigerant gas from said compressor;

a metering device, said metering device receiving refrigerant from said condenser;

an evaporator, said evaporator receiving refrigerant from said metering device; and

a pump, said pump being connected to draw refrigerant from both said condenser and said evaporator and to deliver liquid refrigerant from at least one of said condenser and said evaporator to said motor for purposes of cooling said motor.

117. The liquid chiller according to

claim 116

wherein the liquid refrigerant delivered to said motor by said pump is sourced from the one of said condenser and said evaporator where liquid refrigerant, if available, is available at a higher pressure.

118. The liquid chiller according to

claim 116

wherein liquid refrigerant delivered to said motor by said pump is returned therefrom to said condenser.

119. The liquid chiller according to

claim 116

wherein said compressor includes a shaft, said shaft being rotatably supported by at least one bearing, said at least one bearing being a rolling element bearing the rolling elements of which are fabricated from a ceramic material and wherein the output of said pump, in addition to being directed to said motor for motor cooling purposes, is directed to said at least one bearing for bearing lubrication purposes.

120. The liquid chiller according to

claim 116

further comprising a drive for driving said motor at variable speeds, said pump additionally delivering liquid refrigerant to said drive so as to cool heat generating components therein.

121. A method of lubricating a bearing in a refrigeration chiller comprising the steps of:

connecting pump apparatus to pump liquid refrigerant from both the condenser and the evaporator of said chiller;

controlling the output of said pump apparatus so that the liquid refrigerant pumped thereby is from the one of said condenser and said evaporator where liquid refrigerant is available and is at higher pressure; and

delivering at least a portion of liquid refrigerant output of said pump apparatus to said bearing so as to lubricate said bearing.

122. The method according to

claim 121

comprising the further step of returning liquid refrigerant delivered to said bearing to said condenser.

123. The method according to

claim 122

wherein said delivering step includes the step of directing liquid refrigerant into a reservoir prior to its delivery to said bearing.

124. The step according to

claim 123

comprising the further step of isolating said reservoir from said pump apparatus upon the occurrence of a predetermined drop in pressure upstream of said reservoir so as to maintain sufficient pressure in said reservoir to cause the delivery of liquid refrigerant from said reservoir to said at least one bearing for a predetermined period of time subsequent to said drop in pressure.

125. The method according to

claim 121

comprising the further step of lubricating the bearings of said pump apparatus with liquid refrigerant pumped thereby.

126. The method according to

claim 121

wherein said refrigeration chiller has a motor and wherein said method comprises the further step of additionally delivering liquid refrigerant pumped by said pump apparatus to said motor so as to cool said motor.

127. The method according to

claim 126

wherein said motor is a variable speed motor which is driven by a drive and comprising the further step of additionally delivering liquid refrigerant pumped by said pump to said drive so as to cool heat generating components therein.

128. The method according to

claim 127

comprising the further step of returning refrigerant used to lubricate said bearing, cool said motor and cool said drive to said condenser.

129. A method of cooling a motor in a refrigeration chiller comprising the steps of:

connecting pump apparatus to pump liquid refrigerant from both the condenser and the evaporator of said chiller;

controlling the output of said pump apparatus so that the liquid refrigerant pumped thereby is from the one of said condenser and said evaporator where liquid refrigerant is available and is at higher pressure; and

delivering at least a portion of liquid refrigerant output of said pump apparatus to said motor so as to cool said motor.

130. The method according to

claim 129

comprising the further step of returning liquid refrigerant delivered to said motor for motor cooling purposes to said condenser.

131. The method according to

claim 129

comprising the further step of lubricating the bearings of said pump apparatus with liquid refrigerant pumped thereby.

132. The method according to

claim 129

wherein said refrigeration chiller has a bearing and further comprising the step of delivering at least a portion of the liquid refrigerant output of said pump to said chiller bearing so as to lubricate said bearing.

133. The method according to

claim 129

comprising the steps of driving said motor at variable speeds and delivering at least a portion of the liquid refrigerant output of said pump to the drive by which said motor is driven at variable speeds so as to cool heat generating components of said drive.