Hydraulics and CPC

Technical Seminar
Hydraulics & Chiller Sequencing
Gaëtan Michielsen
21 October 2008
In Chilled Water System
Design ...
“Everything should be made

as simple as possible, but
no simpler.”
Albert Einstein
‹#› Hydraulics & Chiller Sequencing

Today's Agenda
1) Hydraulic Fundamentals
– Basic formulas
– Mixing
– Pipe Sizing
– Balancing
– Pumps: Parallel / Serial
2) Different Hydraulic Arrangements

– Non Decoupled Constant flow
– Non Decoupled Variable flow
– Decoupled Constant Flow
– Decoupled Variable Flow
– Decoupling line sizing
– Chillers in Series
– Variable Primary Flow
– Water Content / Buffer tanks / Expansion tanks
– Ice Storage
– Cooling Towers
3) Chiller Plant Management

– Chiller Sequencing
– Load / Unload
– Rotations
– Failure recovery
– Tower Optimisation
4) Wrap-up


 Water has nearly infinite compressive strength.

 Water has almost no tensile strength.
 Water always flows from a point of higher pressure to
a point of lower pressure.
 All water flowing into a “T” must flow out of it.
 Water does not flow simultaneously in two opposite
directions in the same pipe.
 Water does not flow through closed valves.
 Water cannot read the arrows painted on pipes.

Basic Concepts
• To achieve the desired conditioning:

load and the source has to be equal
• Better the balance

Better the quality
• True either at
full and partial load

• Basic formulas
• Mixing
• Pipe Sizing
• Balancing
• Pumps: Parallel / Serial

Basic Formulas
• Capacity
kW capacity = 4.186 * l/s * K
1000 kW = 4.186 * 47.8 l/s * 5 K
• Reduction of capacity
– reduction of temperature DT .  constant volume application
– reduction of flow  variable volume application
– change of both  as in a terminal device
500 kW = 4.186 * 47.8 l/s * 2.5 K

500 kW = 4.186 * 23.9 l/s * 5 K
500 kW = 4.186 * 17.1 l/s * 7 K

Basic Formulas
• Pump
kW pump = l/s * kPa .
eff pump * eff motor * 1000
12.5 kW = 47.8 l/s * 200 kPa .

85% eff pump * 90% eff motor * 1000
• Pump laws
l/s pump proportional to rpm
kPapump proportional to rpm²
kW pump proportional to rpm³
• Reduction of speed 100% to 50%  “ 0.5”

– reduction of flow 47.8 l/s * 0.5  23.9 l/s
– reduction2 of kPa 200 kPa * 0.5²  50 kPa
– reduction3 of kW 12.5 kW * 0.5³  1.6 kW
Basic Formulas
• Pump
kW pump = l/s * kPa .
eff pump * eff motor * 1000
12.5 kW = 47.8 l/s * 200 kPa .
85% eff pump * 90% eff motor * 1000
• Pump laws
l/s pump a rpm
kPa pump a rpm2
kW pump a rpm3
• Reduction of speed 100%  50%
– reduction of flow 47.8 l/s 23.9 l/s 50%
– reduction2 of kPa 200 kPa 50 kPa 25%
– reduction3 of kW 12.5 kW 1.6 kW 13%

Basic Formulas
Mixing
Flow1 10 l/s
Temp1 6°C
Flow2 5 l/s
Temp2 12°C
Flow3 15 l/s = 10 l/s + 5 l/s

Temp3 8°C = 10 l/s * 6°C + 5 l/s * 12°C
10 l/s + 5 l/s
Flow3 = Flow1 + Flow2

Temp3 = Flow1 * Temp1 + Flow2 * Temp2
Flow1 + Flow2

Part Load in Terminals
100% Load 100% Flow 36% Flow 50% Load
7°C 7°C
27°C 13°C 23°C 15.5°C
12°C 14°C

Water Flow in Terminals
2-way valve 36% 100% 36% 3-way valve
7°C 7°C
14°C 100%64% 7°C 14°C

9.5°C
‹#›Whatever
Hydraulicsthe control
& Chiller  terminal
Sequencing sees the same -reduced- water flow
Terminal Control Options
• 2-way modulating valve
– Variable water flow (pump energy savings)
– (almost) Constant system return-water temperature
– Reduced installation cost
– Requires a System Bypass
• 3-way modulating valve

– Constant water flow
– Variable system return-water temperature
– Pump Energy Same at All Loads
– Flow Balance Critical
– Higher installation cost

Example:
For a constant flow system

with 3-way valves
LOAD, % LOAD, kw RETURN T° SUPPLY T° ΔT

100 1000 12 7 5
80 800 11 7 4
60 600 10 7 3
40 400 9 7 2
20 200 8 7 1
0 0 7 7 0

• Basic formulas
• Mixing
• Pipe Sizing
• Balancing

Pipe Systems Design
 Two major concerns:
• Size the pipe (e.g. from charts & tables)
• Determine the flow-pressure relationship
 By analyzing the system, e.g. finding out pump pressure
 By using manual or computer-based methods
 Calculations for pipelines or pipe networks

• Can be very complicated for branches & loops
• Basic parameters: pipe diameter, length, friction factor, roughness,
velocity, pressure drop

Pipe Sizing
 While the moving water overcomes the resistance there is
pressure drop
 L   rV 
2
Dp  f *   *  
D  2 
Dp = energy loss through friction
f = friction factor
L = pipe length
D = pipe diameter
V = fluid velocity
r = fluid density

Pipe Sizing
• The pressure drop is quadratic function of the speed
• Longer the length, larger the pressure drop
• Narrower the diameter, larger the pressure drop
• Larger the density, larger the pressure drop
• Smoother the pipe surface, smaller the pressure drop
 Pressure drop and noise is a function of the flow speed

 Speed ranges set by economics & acoustics

Pipe Sizing
Speed
 Volume [m³] = surface [m²] * length [m]
 Speed [m/s] = distance [m] / time unit [s]
 Flow [m3/s] = volume [m3] / time [s]
 Flow [m³/s] = surface [m²] * speed [m/s]
Speed [m/s] = flow [m³/s] / surface [m²]

Pipe Sizing
Speed Limits Pressure Drop Limits
 Usual figures:  Usual figures:
• Larger pipes, • Larger pipes,

long distance over 50 mm diameter,
2.5 ~ 3 m/s long distance
• Branches
0.3 ~ 1.5 m/s 400 ~ 500 Pa / m
• Variable flow systems
up to 5 m/s

• Basic formulas
• Mixing
• Pipe Sizing
• Balancing

Balancing
Typical complaints with balancing problems
 Some rooms never reach the desired temperatures,
particularly after load changes
 Room temperatures keep swinging, particularly at low and
medium loads, even though the terminals have sophisticated
controllers
 Although the rated power of the production units may be
sufficient, design power can’t be transmitted
 Un-favored circuits must wait for full flow until the
temperature sensors closes the favored circuits
 Many terminals only receive the desired temperature at
midday, some not until late afternoon, some
Particularly during start-up
after weekend or night set back

Balancing
Some consequences of bad balancing

• Incorrect flows prevent controllers from doing their job
• The flow goes on the "easy way"
• Controllers can control efficiently only close to the
design flows conditions

Balancing
Energy cost
Heating Cooling
Energy Waste by Unbalance
• When the system is not properly
balanced, tenant satisfaction is
achieved by over heating/cooling
• The energy cost rises radically

with every degree of over
tempering

Balancing
What Can Influence Balancing?
Even the best-designed and best-built plants can suffer from
hidden operational problems:
– Clogged filters or valves,
– Terminal units replaced,
– Damaged pipe,
– Shut-off valve half open.
Measure differential pressure, flow and temperature and you will

find the cause!
Service and maintenance has an important role!

• Basic formulas
• Mixing
• Pipe Sizing
• Balancing
• Pumps: Selection / Parallel / Serial

Pumps
Indoor coils
Are the “Heart of the system”
• Deliver media
• Lift against pressure
• Convert mechanical work
to energy (static and dynamic)
• Can overcome the system total pressure P1
• Meets the minimum net positive suction head System
requirements (no surge at the inlet) pump
• Maintains the dynamic pressure head at P0
components
• Multiple pumps are used for redundancy
• Can be constant or variable flow
Note: The major portion of the generated heat Chiller / Boiler
by the pump is absorbed by the system water!

Pump Selection
System
curve
• Where is our operating
point?
• System resistance curve
• Flow rate P1
• Pressure drop
Pressure
Operating
point
P2
F2 F1
Water flow

Pump Selection  Operating Point
Total Total (3) (4) steep
Pressure (1) Pressure (1)
[kPa] [kPa]
system (2)
(2)
system
flat
Flow [l/s] Flow [l/s]

Provides high pressure at constant flow Less sensible for Flow variation
Small change in system pressure (1) - (2) is stable operation: Higher pressure
changes the flow significantly means lower flow
(3) - (4) is unstable operation: Higher pressure
means more flow (impossible to control)
‹#› Note
Hydraulics the relationship
& Chiller Sequencing between pressure and flow change
Pump Selection
• Determine the load
• Determine the temperature drop
• Determine the total flow
• Find the pressure on the most resistant circuit path
• Determine the pump type
Based on the just determined data:
• Select a pump family by the manufacturer's curves
• Select the pump by the individual pump performance curve
chart

Pump Parallel Operation
H
• total pressure will not
change
• forwarded amount of liquid is
summarized
HA
HB
QA QB 2QA 2QB Flow

Pump Parallel Operation
• The Operating Point H
travels the system
resistance curve System curve
• So in this example
Q2 = 1,4 x Q1
Q1 Q2 Q
The head pressures has to be balanced to avoid
‹#›the pumps
Hydraulics toSequencing
& Chiller work "against" each other !!!!!!!!!!!
Pump Serial Operation
H
• forwarded amount of liquid is 2HB
not changed
• total pressure will be
summarized 2HA
HB
HA
QB QA Flow

Pump Serial Operation
H System curve
• The Operating Point travels
the system resistance curve
• So in this example
H2
H2 = 1,7 x H 1
H1
Q1 Q2 Flow

Pump Sequencing
Head Pressure System Curve (Circuit resistance)
More resistance Less resistance
If Pump has constant speed : When system

100% curve changes the functioning point follows
90% the PUMP curve
80%
If Pump has variable speed : When system
70%
curve changes the functioning point follows
the SYSTEM curve
Flow

Pump Sequencing
Head Pressure System Curve (Circuit resistance)
H2 The curves shows the combination

100% between two pumps:
90% Pump 1 Constant flow
80% Pump 2 Variable flow
H1 70%
60% Flow

Pump Sequencing
Flow
Variable speed
over 30% of range
100%
If you have two pumps in parallel, and only
one variable, you will not be able to control the
The control of the flow cannot be
flow correctly and therefore you won’t make the
optimal. The variable pump needs
energy @100%
Pump1 savings your are supposed to doto with at least 70% before the
reach
50%
a variable flow solution. flow increases.
You need a frequency drive on both pumps!
Pump2 @70%
Time

2) Different Hydraulic
Arrangements

2) Different Hydraulics
• Non Decoupled Constant Flow
• Non Decoupled Variable Flow (Sequenced)
• Decoupled Constant Secondary Flow
• Decoupled Variable Secondary Flow
• Decoupling line sizing
• Chillers in Series
• Variable Primary Flow
• Out of range applications
• Water Content / Buffer tanks / Expansion tanks
• Ice storage
• Cooling towers

Non Decoupled Constant Flow
(bağımsız sabit akış)
Pump
3-way
valves

(bağımsız sabit akış)
Chiller: Start/Stop/Set point
Supply temp
(Besleme Sıcaklığı)
Constant Pump
Return temp
(Dönüş Sıcaklığı)
3-way
valves Change chiller set point
to control the load
(Yükü kontrol etmek için,chiller
ayar noktasını değiştirin)

CHILLER #1
CW RETURN CW SUPPLY
T° T°
CHILLER #2
LOAD
CHILLER #1 FLOW
CW RETURN SWITCH CW SUPPLY
TS1 (Akış Anahtarı)
T° T°
FLOW
TS2 SWITCH
CHILLER #2
LOAD
Minimum accessories needed
for a hydraulic system.
(hidrolik sistem için gerekli minimum aksesuarlar)

CHILLER #1 7°c 7°c
CW RETURN TS1 CW SUPPLY
T° T°
100%
ON
12°c
7°c
TS2
100%
ON
FULL LOAD (100%)
Load fluctuation CHILLER #2
(Yük Dalgalanması)
LOAD
LOAD, % RETURN T° CH1, % T° S1 CH2, % T° S2 SUPPLY T°
100 12 100 7 100 7 7

T° T°
80%
ON
11°c
7°c
TS2
80%
ON
Load fluctuation LOAD 80%
CHILLER #2
LOAD
100 12 100 7 100 7 7
80 11 80 7 80 7 7

T° T°
60%
ON
10°c
7°c
TS2
60%
ON
CHILLER #2
LOAD
100 12 100 7 100 7 7
80 11 80 7 80 7 7
60 10 60 7 60 7 7

T° T°
50%
ON
9,5°c
7°c
TS2
50%
CHILLER #2
ON
LOAD
100 12 100 7 100 7 7
80 11 80 7 80 7 7
60 10 60 7 60 7 7
50 9,5 50 7 50 7 7

T° T°
40%
ON
9°c
7°c
TS2
40%
ON
LOAD 40%
Load fluctuation CHILLER #2
LOAD
100 12 100 7 100 7 7
80 11 80 7 80 7 7
60 10 60 7 60 7 7
50 9,5 50 7 50 7 7
40 9 40 7 40 7 7

T° T°
40%
ON
9°c
7°c
TS2
40%
ON
LOAD 40%
CHILLER #2
LOAD
Less than 50% load ….
(Yük 50% ‘den daha az….)
What about turning a chiller off ?

(Chillerlerin birini kapatsak mı ?)

CW RETURN
CHILLER #1 ? ?
CW SUPPLY
TS1
T° T°
40%
OFF
ON
9°c
7°c
TS2
40%
ON
LOAD 40%
CHILLER #2
LOAD
What happens to chilled water supply
temperature ?
(Soğutulmuş besleme suyu sıcaklığına ne olur ?)

T° T°
OFF
ON
9°c
7°c
TS2
ON
LOAD 40%
CHILLER #2
LOAD
Supply temperature higher means ….
(Besleme sıcaklığının yüksek olması demek ….)
Inability to satisfy load (Yükü
karşılayamamaktır)
(designed for 7°c)

T° T°
OFF
ON
9°c
5°c
TS2
80%
ON
LOAD 40%
CHILLER #2
LOAD
How can we keep our designed
Supply temperature at 7°c ?
(Dizayn besleme sıcaklığımızı 7 °C de nasıl tutarız ?)
Change chiller #2 setpoint down to 5°c
(2 No’lu Chillerin ayar noktasını 5°c’ye düşürmek)

• Lower water supply temperature means …

• (Düşük besleme suyu sıcaklığı demek…)
– Lower evaporation pressure (Daha düşük buharlaşma basıncı demek.)

– Higher compressor work (Daha çok kompresör iş yükü demek.)
9°c condenser C
pressure
5°c F E D
CW RETURN TS2
T° expansion
device compressor
ON
A B
CHILLER #2
enthalpy
‹#› Hydraulics & Chiller RISK

Sequencing
OF FREEZING EVAPORATOR !
Chillers, set points and constant pump can be
controlled by the chiller plant control management
system.
Characteristics:
- 3-way valves  constant water flow
- Typical design for small industrial process
- Works great if cooling load is maximum all the time
- Supply temperature controlled using chiller set-points
- Reduced energy consumption
- Possible rotating of chillers (same working hours)
Risks:
- Variable chilled water supply temperature
- If load request not 100%, pump still runs 100%

Ayrılmaz Sabit Akış
Chillerler, ayar noktaları ve sabit pompa, chiller
fabrika kontrol yönetim sistemi ile kontrol edilebilir..
Özellikleri:
- 3 yollu vanalar  sabit su akışı
- Küçük endüstriyel proses için tipik tasarım
- Soğutma yükü her zaman maksimumsa işler mükemmel
- Chiller ayar noktalarını kullanarak besleme sıcaklığı kontrol edilir
- Düşürülmüş enerji tüketimi
- Chillerlerin dönüşümlü olabilmesi (aynı çalışma saatleri)
Risks:
-Değişken soğutulmuş su besleme sıcaklığı.
-Yük ihtiyacı % 100 değilse bile, pompa hala % 100 çalışır.

• Ice storage
• Cooling towers

Non Decoupled Variable Flow (Sequenced)
(bağımsız değişken akış) (Sıralı)
3-way
valves

Chiller: Start/Stop/Set point
Constant
Flow
Pumps
Supply
Temp
Return Temp
3-way
valves

CHILLER #1
TS1 CW SUPPLY
T°
TS2
CHILLER #2
CW RETURN
T°
LOAD
CHILLER #1
TS1 CW SUPPLY
T°
M
OFF OFF
ON
TS2
M
ON ON
CHILLER #2
CW RETURN
T°
LOAD
What happens at partial load if we
switch OFF one chiller with his pump?
(Bir soğutucuyu pompasıyla birlikte kapattığımızda
kısmi yüke ne olur?)

3 Way Valve Circuit
12th Floor
Distant from the production, (Üretime uzak)
LOAD high pressure drop (Yüksek basınç düşmesi)
Close to production, (Üretime yakın)

low pressure drop (Düşük basınç düşmesi)
Ground Floor
PRODUCTION
LOAD

System is balanced for nominal flow
(Sistem nominal akış için dengelenmiştir)

3 Way Valve Circuit
12th Floor
LOAD 40 l/s
By-pass : 10 l/s
50 l/s
50 l/s 30 l/s
Ground Floor
PRODUCTION
LOAD 100 l/s
By-pass : 20 l/s
System is balanced
Nominal flow = 100 l/s 100 l/s

3 Way Valve Circuit
12th Floor
? l/s
LOAD STARVING H System curve
By-pass : ?
? l/s Q1 Q2 Q
50 l/s 10 l/s
Ground Floor
PRODUCTION
LOAD
½ CAPACITY
60 l/s
By-pass : 40 l/s
Let’s suppose we have a flow of 60 l/s. 60 l/s

(60 l/s debimiz olduğunu varsayalım)

The chiller and its dedicated pump are switched on and off according
to the estimated cooling load and the outside weather conditions
In this system we get sequenced flow as per the number of chillers
running at the same time
Characteristics:
- 3-way valves
- Pump per chiller
- Typical design for small Building process
- Control based on the variation of the flow
(1 pump/chiller set or both)

• Ice storage
• Cooling towers

Decoupled Constant Secondary Flow
(Ayrıştırılmış Sabit İkincil Akış)
Larger Loads
Larger Installations
For larger installations,
pressure drop in the distribution circuits is higher as
• More piping length, curves, balancing valves, accessories
• More terminal units
• Larger terminal units (more water to handle, larger flow)
Pump are bigger resulting in too large flow to be

handle by one pump.
SOLUTION : Split production and distribution pumps

Constant
production Pump
Pumps Constant flow
(Sabit üretim pompası) (Sabit akış pompası)
Supply
Temp
Return Temp
3 ways valves

Constant
production
pumps
Pump
Supply Temp Constant flow
Return Temp
3 ways valves

50 l/s at 6°C
100% Load
50 l/s at 6°C
100 l/s at 12°C
100 l/s at 6°C
No flow
100 l/s at 6°C
100 l/s at 12°C
50 l/s at 12°C
three-way valve
50 l/s at 12°C

OFF No flow
50% Load
50 l/s at 11,5°C 50 l/s at 6°C
OFF
50 l/s at 6°C
50 l/s at 11,5°C
100 l/s at 8,5°C
100 l/s at 11,5°C
50 l/s at 11,5°C
three-way valve
50 l/s at 11,5°C

Primary-Secondary with a by-pass
Dedicated pump per chiller
By-pass flow is the difference of water flow between the 2 circuits
when not all chillers/primary pumps are running
In this case a Constant speed secondary pump is used
This is a frequently used system, but it is not the most stable in supply
temperature and certainly not the most energy efficient!
Warning: Trane does not recommend this design !
Characteristics:
- Supply temp. control only by changing the chiller set points
- The reactivity of the control is very slow because the set points have to
be changed very slowly to avoid start/stop cycling
- Max. supply temp. accuracy +/- 1.5 °C
- Waste of energy because the secondary flow pump will run 100% all
the time whatever the demand.
• Ice storage
• Cooling towers

Decoupled Variable Secondary Flow
production
pumps
pump
production
loop
distribution
loop
two-way valves
The chiller set points are constant, system control is achieved through
the variable speed pump
Constant
production
pumps Variable
pump
Supply
Temp
production
Return Temp
loop
distribution two-way valves

loop

CHILLER #1
50 l/s
PRODUCTION FLOW
CHILLER #2 EQUALS
DISTRIBUTION FLOW
50 l/s (ÜRETİM AKIŞI=DAĞITIM AKIŞI)
PRODUCTION PRODUCTION 50 l/s 50 l/s

LOAD LOAD
DISTRIBUTION BY-PASS = +/-0 l/s DISTRIBUTION
Nearly No Flow

CHILLER #1
PRODUCTION FLOW
50 l/s DIFFERENT FROM
DISTRIBUTION FLOW
(Üretim akışı, dağıtım akışından farklı.)
ON
CHILLER #2
DECOUPLED SYSTEM,
50 l/s
NO PUMP IN SERIE
(Bağımsız sistem, Seri bağlantıda olan pompa yok)
ON
PRODUCTION PRODUCTION
50 l/s 25 l/s
LOAD LOAD
DISTRIBUTION BY-PASS = 25 l/s DISTRIBUTION
Variable
speed drive
ΔP

Varying Distribution Flow (Değişen Dağıtım Akışı)
Variable-speed control Riding the system curve
(Değişken hız kontrolü)
LOAD
head pressure
ΔP
Variable
speed drive
pressure
difference 0 percent flow 100

CHILLER #1
50 l/s Load decreases (Yük azalır)

Distribution flow decreases (Dağıtım akışı azalır)
ON
By-pass flow increases (Baypas akışı artar)
CHILLER #2
By-pass flow not used by the
50 l/s distribution circuit = excess flow
(Baypas akışı,dağıtım devresi tarafından
kullanılmaz = aşırı akış)
ON
20 l/s 25 l/s
LOAD LOAD
DISTRIBUTION
BY-PASS = 55 l/s DISTRIBUTION
Excess Flow
Variable
speed drive
(Değişken hız ΔP
sürücüsü)

CHILLER #1
50 l/s
Excess by-pass flow > 110%
of one chiller flow
ON ,(Aşırı baypas akışı bir chillerin akışından 110% fazladır
CHILLER #2 One chiller can be turned off

(Bir Chiller kapatılabilir)
50 l/s
ON
15 l/s 20 l/s
LOAD LOAD
Excess Flow
Variable
speed drive
ΔP

CHILLER #1
0 l/s
Production flow is 50 l/s against
35 l/s needed
OFF
ON (Üretim akışı 35 l/s ihtiyaç olmasına karşın 50 l/s)
CHILLER #2
By-pass flow is 15 l/s in excess
direction
50 l/s (Aşırı yönde bypass akışı 15 l / sn'dir.)
ON
15 l/s 20 l/s
LOAD LOAD
Excess Flow
Variable
speed drive ΔP

CHILLER #1
0 l/s Load increases (Yük artar)

Distribution flow increases (Dağıtım akışı artar)
OFF
ON
By-pass flow changes direction
CHILLER #2 and increases (Baypas akışı yön değiştirir ve artar)
50 l/s By-pass flow not produced = deficit
flow (baypas akışı yok = açık akış)
ON
30 l/s 35 l/s
LOAD LOAD
Deficit Flow
Variable
speed drive
ΔP

Here we have variable speed secondary pumps (instead of constant speed)
and we have 2-way valves on the equipment (instead of 3-way valves)
Measuring the direction of water flow and the amount in by-pass gives a
correct indication of when to add or subtract a chiller
Characteristics:
- 2-way valves
- Good design for all type of cooling processes
- Control based on the variation of the flow
- Best solution for temperature accuracy
- Best solution for energy saving
- Variable speed pump controlled from differential pressure in secondary
circuit
- Chillers and pumps sequenced by Bypass flow or Water temperatures
Risks:
- Too low flow in distribution equipment
- Poor heat exchange functionality
• Ice storage
• Cooling towers

By-Pass
Sensing Deficit Flow
PRODUCTION
PRODUCTION CHWR CHWS PRODUCTION
DISTRIBUTION DISTRIBUTION
Deficit Flow
CW SUPPLY
T°
DISTRIBUTION
Load is increasing
Distribution Flow is increasing
We have a deficit flow in the by-pass
The temperature sensor to see effect of Deficit Flow will be placed

By-Pass
Sensing Excess Flow
CW RETURN
T° PRODUCTION
PRODUCTION CHWR CHWS PRODUCTION
DISTRIBUTION DISTRIBUTION
Excess Flow
DISTRIBUTION
Load is decreasing
Distribution Flow is decreasing
We have an Excess flow in the by-pass
The temperature sensor to see effect of Excess Flow will be placed

By-Pass
PRODUCTION
• When deficit flow appears

– Seen by Temperature sensor
 ADD A CHILLER Deficit Flow
DISTRIBUTION
• Excess flow > 110% to 115% of the flow

of the chiller to be turned off PRODUCTION
– Seen by Temperature Δt
Sensors
OR
Excess Flow
– Seen by Flow sensor device
 SUBTRACT A CHILLER DISTRIBUTION

By-Pass Sizing
• Bypass sized for 110 to 115 percent of the largest

chiller’s designed flow rate AND for minimum
security flow of all chillers (in case distribution flow
breakdown)
• Minimum length of 5 to 10 pipe diameters is
recommended to prevent random mixing of the
supply
• Minimal pressure drop in bypass pipe
– No obstruction (valves or other)

• Ice storage
• Cooling towers

Chillers in Series

Chillers in Series
• Advantages
– Constant chilled-water supply temperature
– Constant water flow within system and chillers
• Issues
– Addition of Pressure Drop
– High flow
• Fix:
– Selection of low pressure drop heat exchangers
– Best apply with high delta T system
• Limitation:
– (More) Complex control
– More complex piping (valves, pipes) for the maintenance or an
emergency- redondant chiller

Chillers in Series
• Summary
– Can generate more capacity than parallel chillers
 At a better EER
– Allows to preferentially load a chiller
 Heat Recovery Unit
– Allows for large water temperature rise/drop
 Reduced water flow  Reduced pump input

• Ice storage
• Cooling towers

Variable Primary Flow

Prefer manifold pumps:

VPF is a method for balancing production and
Variable-
UCP2
UCP2
distribution flows by making them equal
Speed
Drive
UCP2
UCP2
Flow
S UPP LY
Meter Production
DE MAND Air Handling Units
Bypass Line
Distribution
Control Valves
System variation of the primary/secondary flow

system is a ‘Highly Specialized’ design

VPF Key Principles
• Just as in the primary-secondary system, VPF systems respond
to load changes by modulating flow
• In a VPF system, water flow varies throughout the entire system,

i.e. also through the evaporator of each operating chiller as
well as through the cooling coils
• VPF system elements:

- Two-way control valves on coils
- Check (or isolation) valves on chillers
- A bypass line with a control valve is mandatory
- Smallest VPF Chiller = 300 kW

• Prerequisite:
– Chillers must handle variable evaporator flow
– System-level controls must limit the rate-of-flow change
– System must include a controlled bypass
• Advantages
– One set of (variable volume) pumps
 Savings in first cost, space, operation
– Bypass
 Sized on (largest chiller minimum flow)
 Could be located in the plant room or in the distribution loop
• Issues:
– Adequate time to design and commission controls
– Operator must understand the system

VPF system – can only be used when…
• Load demand is variable
• Chillers with adaptive controls
– Operator understands plant operation
VPF system - benefits

• Reduced pumping costs
• Reduced piping costs
• Reduced electrical costs

• Ice storage
• Cooling towers

Out of Range Applications
• Flow out of Range
chiller 15 L/s at 7.0°C
15 L/s at 13.0°C
5 L/s at 7.0°C
5 L/s at 25.0°C
Industrial Process
(375 kW)
• Flow out of Range
15 L/s at 13.0°C
5 L/s at 7.0°C
5 L/s at 25.0°C
Industrial Process
(375 kW)

• Flow and Temperature out of Range
15 L/s at 13.0°C
5 L/s at 20.0°C
5 L/s at 38.0°C
Industrial Process
(375 kW)

• Flow and Temperature out of Range
2.9 L/s at 7.0°C

15 L/s at 13.0°C
5 L/s at 20.0°C
2.9 L/s at 38.0°C
5 L/s at 38.0°C
Industrial Process
(375 kW)

• Ice storage
• Cooling towers

Water Content
• To estimate the minimum water content
on a system, we can use the following
Rule of Thumb relationship between
Cooling capacity & Evaporator water flow:
Flow (6°/12°) [l/s] = cooling kW / 25

Water Content
• Loop time is the time required for chilled water to make one round trip in
the distribution system.
• Depending on the type of chiller control the required loop time can vary
between 1..3..5 minutes.

Water Content
• Practically the 3 minutes is a good guess, i.e.:

Minimum Water Content [l] = Flowrate [l/s] * 180 s
• We have seen that:

Flow (6°/12°) [l/s] = cooling kW / 25
• Therefore:
Min. Water [l] = Cooling capacity [kW] * 7,2 [l/kW]
 For example: a chiller has 250kW cooling capacity,at 6°/12°C
the flow is roughly 10 l/s = 600 l/min = 0.6 m3/min
 with 3 minutes loop time the ideal water content minimum is around 1.8 m3

Buffer Tanks THE PURPOSE OF
Chiller THE STORAGE
TANK IS TO STORE
A CERTAIN
AMOUNT OF
WATER TO
Pump SATISFY THE
Load DEMAND DURING
THE STOP TIME
Buffer
Tank OF THE CHILLER.
The buffer tank has to be on the return to allow

warmer water capacity to the chiller in case of small
loads. It also allows the CONTROLLER time to adapt
to the load.

Buffer Tanks
• Is an extension of the system volume,

to enlarge the water content
• It should have a mixing function
• Can be used as hydraulic by-pass
• Thermally well insulated

Buffer Tanks
WHAT DOES AFFECT TANK SIZE?
• Minimum Load
• Number of cooling steps
• Anti-recycle timers
• Control Dead-Band
• Installation Water content
• Allowed temp. fluctuation

Buffer Tanks
• Available Energy Qty in Tank:
– Q = M x C x DT
• Required Time to reach a given DT:
– t = (M x C x DT)/Load
• So:
– DT = (Load x t) / (M x C)
or
– M = (Load x t) / (DT x C)

Buffer Tanks
EXAMPLE
• Chilled Water Temp.: 12/7°C Entering Leaving
• 2 compressors
• Cooling Cap. at Full load: 85 kW
• Minimum building Load 20 kW
• Anti-Recycle Timer: 10 min
• Control Dead Band: 4°C
• Total Volume of water Loop: 400 l (Pipes + Tank)

Buffer Tanks
EXAMPLE
• Water Temp. in the tank when chiller stops:
– (Chilled Water setpoint) - (Dead band/2) + (DT at 50% Load)
– 7°C - 2 + 2.5 = 7.5°C
• Average Anti-recycle timer:
– ART(for 1 compressor) / (Nbr of compressors)
– 10 / 2 = 5 min = 300 s
• Water temp. rise in tank 5 min Later:
– DT= (300 x 20)/(400 x 4.18) = 3.6°C
– 7.5°C + 3.6°C = 11.1°C  This is to much
Normally + 2°C is excepted as maximum.
So we calculate M with these 2°C raise.
M = 20 x 300 / 2 x 4,18  717,7 l Must be total Content

Buffer Tanks
What would be the reason to add a tank in
the installation ?
Is it correctly placed for this purpose ?
What are the parameters that influence
sizing of the tank ?
LOAD
LOAD
M
TANK

Buffer Tanks
• Adding a tank protect chiller from short-cycling
– If the water volume (content) of the installation is not sufficient
– If Load is likely to vary quickly
• Tank should be placed after loads to absorb loads variations
(temporize loads variations). Tank is named “buffer tank”
• Parameters for sizing (volume) are
– Anti-short cycling time
– Minimum capacity of the chiller (before turning off)
– Water volume of installation
– Authorized variation of Temperature (chilled water set point
deadband)

Expansion Tanks
Water Expansion
• As temperature changes water expands or shrinks
• Expansion Tank has to be selected according to the water content and
temperature range of the system
Temperature [°C] 30 40 50 60 70 80 90
Expansion [%] 0.4 0.75 1.17 1.67 2.24 2.86 3.55

Expansion Tanks
Accommodates the volume change caused by temperature
change
• Open-tank
tank open to atmosphere
•A diaphragm tank
flexible membrane

Expansion Tanks
Diaphragm tank
Connector
– flexible membrane
Polypropylene liner
Reservoir
Butyl diaphragm
Nitrogen cushion
Nitrogen charge valve

Expansion Tanks
Thermal function:
• The water which occupies 1 m3 @ 10°C
occupies 1,044 m3 @ 80°C
• Need space for 44 litres of water
Hydraulic function:
• System pressure reference point

• Ice storage
• Cooling towers

Ice Storage Tank
Example are Calmac tanks

Ice Storage
pump chiller
cooling heat-transfer
coil fluid
ice storage
tanks

Ice Storage
ice VFD
ice storage
pu tanks
mp
cooling
coil with bypass
two-way pipe
control valve
load
pump
VFD
water-cooled chiller
chiller pump

Ice Storage
ice VFD
ice storage
pump tanks
cooling
coil
off-peak
chiller
off-peak load ice chiller
pump pump chiller pump
VFD VFD

Ice Storage
Intermediate Heat Exchanger ice storage
tanks
heat
exchanger
cooling
coil
ice
load valve
pump
chiller
pumps
VFD
existing ice-making ice

chillers chiller pump

Ice Storage
100
75
cooling load, % of design
50
Building Cooling Load Profile
25
0
midnight 6 a.m. noon 6 p.m. midnight

Ice Storage
100
75
off peak on peak off peak
50
On-Peak and Off-Peak Periods

25
0

Ice Storage
100
75
On-Peak Cooling with Ice
50
make melt
ice ice
25
0

Ice Storage
100
75
On-Peak Cooling with Chiller and Ice
melt
ice
50
make
ice
25
chiller
0

Ice Storage
100
75
melt melt
ice ice
50
make make
25 ice ice
chiller chiller
0
midnight 6 a.m. noon 6 p.m. midnight midnight 6 a.m. noon 6 p.m. midnight
Peak shaving Load shifting

The melt of Ice is used to The melt of the Ice is used
reduced the electrical peak to reduce the electrical
consumption when the consumption on peaks
demand of electricity when the electricity
in the building is high. is very expensive

Ice Storage
Downsizing the Chiller
100
chiller melt
capacity ice
75
chiller
capacity
50
chiller
make chiller
25 ice
0
midnight 6 a.m. noon 6 p.m. midnight midnight 6 a.m. noon 6 p.m. midnight
Full-sized chiller Downsized chiller

Ice Storage
Potential Benefits
• Lower utility costs
– Lower on-peak electrical consumption (kWh)
– Lower on-peak electrical demand (kW)
• Smaller equipment size
– Smaller chiller
– Smaller electrical service (A)
• Reduced installed cost
– May qualify for utility rebates or other incentives

Ice Storage
Cooling-only chiller Ice-making chiller
– Increases or – Operates at
decreases capacity maximum capacity
in response to while in
changing cooling ice-making mode
load – Operates until
– Controlled to entering-fluid
maintain leaving- temperature drops
fluid temperature at below lower limit
setpoint

Ice Storage
Combining tactical and strategic control
Overlapping Operating Modes
operating mode start time end time
chiller only 6 a.m. noon
ice only noon 8 p.m.
chiller and ice noon 8 p.m.
chiller only 8 p.m. midnight
freeze and cool 8 p.m. midnight
freeze midnight 6 a.m.
off when building or ice-making loads
are not present
• Ice storage
• Cooling towers

Cooling Towers
• Generally, water cooled chillers use cool
(e.g. 15 to 30°C) water to condense refrigerant.
• This cool water may come from

– Cooling tower
– Lake or river
– Ground water
– Geothermal loop
– Dry Cooler

Cooling Towers
Condenser water
system
cooling tower
condenser

Cooling Towers
Chiller – Tower Interaction
• Tower determines return condenser water
temperature
• Chiller determines required heat rejection rate of
tower
• Condenser water warms in proportion to heat
rejection and condenser water flow rate
• Condenser pressure rises with condenser
temperature
• Compressor work increases as
condenser pressure rises

Cooling Towers
• Heat transfer device, often tower-like, in which

atmospheric air cools warm water, generally by direct
contact (evaporation).

Cooling Towers
propeller fan
sprays
louvers
outdoor fill
air
sump
to from
condenser cold water hot water condenser

Cooling Towers
Cooling Tower Types
Open-Circuit Closed Circuit

Cooling Towers
Definitions
• Wet Bulb
• Range
– Difference between tower entering and leaving water
temperatures
• Approach
– Difference between ambient
wet bulb temp and tower
leaving water temp
• Flow rate

Cooling Towers
Performance Factors
• Interferences
• Position/Orientation
 Restrictions
 Air recirculation
 Obstacles
 Piping positioning
• Recirculation
 Space
 Winds
 Air velocity
 Plume (fogging)

Dry Cooler
• A dry cooler is a forced convection air-cooled fluid
cooler.
• Air is forced over a finned coil which contains the
working fluid such as water or water & glycol mix.

Dry Cooler Principle
from condenser to condenser

 In a dry cooler, there is no direct contact between
atmospheric air & condenser water!
Dry Cooler
PROs CONs
• Cost similar to evaporative cooling • Higher leaving water temperature
tower
• High electrical consumption due to the
• No water consumption numerous fans
• No sanitary risk of Legionnaires’ • High noise level because of higher
disease airflow rate
• No need of chemical water treatment • Necessity to add glycol to water to
avoid freezing of installation
• No plume
• Important ground surface
• Easy maintenance, even if finned coils
must be regularly cleaned to keep
efficiency

Cooling Towers
Capacity Control
• Lowest possible leaving water temp
= ambient wet bulb + approach
• Maintain tower leaving water setpoint

by modulating airflow, using:
– Fan control
 Cycling (On/Off)
 Two-speed fans
 Variable speed drives
 More economical to modulate multiple fans
than have one at full speed
– Modulating dampers

Dry Coolers
Some examples of free-cooling with dry-coolers in combination with
water-cooled chiller and air-cooled chiller.
Example 1: Water-Cooled chillers, decoupled variable secondary

flow at the condenser side and decoupled

Example 1: 100% Mechanical Cooling
n + 1 scenario:
• One chiller running
• One chiller stand by
• Free cooling off
• Four dry coolers running
• One dry cooler stand by
• Chiller has the best COP
• No extra pressure drops are created
 Save pump energy
All dry coolers could be running if

wanted, to optimize efficiency.
Optimal functioning in full load

and part load is guaranteed by the
Chiller Plant Control:
Sequencing of chillers, ...
Example 1: Simultaneous Mechanical
Cooling and Free-Cooling
• Free Cooling circuit opens

• One chiller running
• One chiller stand by
• Five dry coolers are running
to maximize the free cooling capacity.
Optimal functioning is guaranteed by the

Chiller Plant Control:
Free Cooling and Chiller working together
‹#› Hydraulics & Chiller Sequencing ...

Example 1: 100% Free-Cooling
• Chillers off
• Free cooling on
• Five dry coolers are running.
When very low ambient temperatures,
the dry coolers also go into part load.
Optimal functioning is guaranteed by

the Chiller Plant Control

Example 2: Free-Cooling System set-up
with Air Cooled Chillers
‹#› Only example – Temperatures are not right

3) Chiller Plant Control
• Chiller Sequencing
• Load / Unload
• Rotations
• Failure Recovery
• Tower Optimisation

Chiller Plant
Automation
System Cooling
Loads
Remember:
Without controls, it’s not a system.

Chiller Plant Control is more than

turning chillers On and Off.

• What are the requirements:

– Reliable chilled water flow
– Operating cost (energy
efficiency)
– Operator safety
– Environmental awareness
– Reduce maintenance cost

Key Issues for Chiller Plant Control
• Load determination
– When to add or subtract a chiller?
• Capacity matching
– Number of running chillers required?
• Rotation
CHILLER
– Which SEQUENCING
chiller leads?
• ChillerWhich
setpointchiller to turn on or off?
control
– What is the setpoint strategy?
• Failure recovery
– What happens after a chiller failure?
• Operator interface
– How to communicate with the operator?

Chiller Plant Control
Load Chiller
Determination Sequencing

Chiller Sequencing
• Turning on an additional chiller

• Turning off a chiller
• Which chiller to turn on or off?

Chiller Sequencing
Load Determination
• When to add or subtract a chiller ?
– Look at the building needs
 Match plant capacity to building(s) load.

– Said another way...
 Run as few chillers as possible at optimal efficiency

Chiller Sequencing
• Which chiller to turn on or off?
– Turn the right chiller on!
• Decision taken according to the following criteria:

– Load determination
– Capacity matching
– Rotation
– Chiller setpoint control
– Failure recovery

Chiller Sequencing
Load Determination
• Applies to Constant or Variable Flow systems
• Add logic
– Based on Supply Temp & Chilled Water Setpoint
– Operator editable delay times and dead bands
• Subtract logic
– Based on:
 Supply/Return water temperatures & Chiller capacities
 or Bypass Flow (for large systems) & Chiller flows
– Operator editable delay times and dead bands
• Custom
– Adaptable to suit customer specific algorithm requirements

Chiller Sequencing
Add Example
Add timer starts Chiller is added
6.5°
1.5° Add temp

Add timer dead band
reset 5°
Add delay
time (10 mn)
Chilled water supply temp System supply
set point
Parameters

Chiller Sequencing
Temperature Based Logic
• Preferred method for:
– Non-decoupled systems (constant flow) and
– Decoupled systems (variable flow) up to 4 chillers
• Based on supply & return chilled water temp
• Simple to setup and to understand
• Add logic:
– Based on error from
chilled water system
supply setpoint
• Subtract logic:
– Based on system Delta T
Chiller Sequencing
Subtract Example
(Temperature)
Chilled water delta temp
5°
Chiller is
Subtract timer starts
subtracted
Design delta temp 3°
Subtract timer reset

Subtract temp dead
band 0°
Subtract delay
time (20 minutes)
Parameters

Chiller Sequencing
Bypass Flow Based Logic
• Recommended for larger systems, i.e. decoupled systems
with more than 4 chillers
• Much more accurate than temperature based logic
• Add logic based on deficit flow
• Subtract logic based on excess flow
• Two sensing methods:
– Direct flow
– Indirect flow

Chiller Sequencing
Bypass Flow – Direct Flow Sensing
• Flow measured with any type of flow meter
• Common problems when using flow meters:
– Accuracy + regular calibration required
– Cost Production
• Add a chiller
– Deficit flow
(based on error from chilled Load
water system supply setpoint )
• Subtract a chiller Production
– Excess flow > 110% of the flow
of the chiller to be turned off
E.g.: Chiller flow = 30 L/s, Load
Turn it off when excess flow = 33 L/s

Chiller Sequencing
Subtract Example (Flow)
Subtract flow threshold Chiller is
Subtract timer starts Subtracted
70 l/s
60 l/s
Subtract timer reset
By-pass Pipe
flow ???????
Subtract delay
time (20 mn)
Parameters

Chiller Sequencing
Capacity Matching
• What is the necessary number of running chillers
required?
• Purpose:
– Reduce operating cost by turning on and off the appropriate
chillers when needed
• Dependent on chiller types and sizes available
• Linked to the chillers rotation priority sequence!

Chiller Sequencing
Capacity MatchingChillers On vs. Load
100% 2600
Chiller 1 (1000)
80% 2080 Chiller 2 (1600)
% Building Load
60% 1560
40% 1040
20% 520
kW
0%
Chiller Stages

Chiller Sequencing
Capacity MatchingChillers On vs. Load
78% 5800
Chiller 5 (1600) Peak
Chiller 4 (1600) Base
65% 4800 Chiller 3 (1600) Normal 2
% Building Load
Chiller 2 (1600) Normal 1

57% 4200 Chiller 1 (1000) Swing
43% 3200
38% 2800
21% 1600
kW
0%
Chiller Stages (7400 kW Load)

Chiller Sequencing
Swing example
UCP2 UCP2
UCP2
200 Ton Chiller 500 Ton Chiller (Normal500 Ton Chiller (Normal
(Swing) - 1) - 2)
0 200 500 700 1000 1200

Building Load (Tons)
The small chiller is used to match the flow capacity.

• Load / Unload / Soft Start
• Rotations

Load / Unload / Soft Start
• What is the chiller startup sequence?
– Start the chilled water pump
– Wait for a chilled water flow confirmation
– Chiller is enabled
– Wait for chiller status confirmation

• What is the purpose of unloading operating chillers before

starting an additional chiller?
– Remember: before you start a chiller you typically start a pump
or open a valve!
– This results in:
 A flow transient through the chillers
 Operational disturbance.
 In the worst case it can result in a chiller getting locked out

on low evaporator temp!

Unload at start
• Avoids electrical consumption peaks

when you start a new chiller
• Avoids flow discontinuities
In Variable Primary Flow Systems, this function is

necessary in order to prevent freezing the evaporator

• When do we need a soft start ?

– System soft loading is sometimes required during
system hot starts,
– Prevent more chillers than are actually required to
meet the load.

Soft Start Example
System chilled water
supply temperature
Chiller plant
enabled in the 16°
soft start mode
Chiller plant
transitions from 10° Soft start dead band
soft start mode to
normal mode
7.5°
System supply
1.5° Add temp dead band set point
6°

Soft Load gives time to the first chiller to reach the setpoint temperature
when the complete plant starts with warm water temperature
System chilled water
supply temperature
Chiller plant
enabled in the 16°
soft start mode
Chiller plant
Soft Loading prevents a peak
transitions from in electric
10° Soft start dead band
consumption that would happen if
soft start mode
to normal mode
all chillers were started at the same time 7,5°
System supply
1,5° Add temp dead band set point
6°

• Summary:
– Soft Start
 Prevents excess capacity on “warm” starts
 Pull down the system smoothly
 Don’t “machine gun” chillers on and off
– Unload before start

 Ride out flow transients during pump control
 Variable flow / multiple pump systems
 Low supply water temperatures (1 to 3°C)

Ambient Lockout
Automatically disable the chiller plant when the outside air
temperature drops below the ambient lockout setpoint.
12°C
2°C
10°C

• Rotations

Rotations
• Which chiller leads?

– Look at the chillers priority order
• Factors influencing the rotation decision:

– Chiller plant design,
– Relative chiller age,
– Relative chiller efficiency,
– Customer preference.

Rotations
• Action based on either (for normal sequencing only!):

– Selected rotation type
– Calendar
– Other system inputs
– Run time
– Manual operator action

Rotations
• Normal rotation type:
equal-capacity chillers

Rotations
• Example of a special rotation type:
small electric
chiller large electric
chiller
absorption
chiller

• Rotations

Failure Recovery
• Maintain flow of chilled water
• Keep it simple
– Lock out failed equipment
– Turn on the next chiller in the sequence
– Turn on Back-up Pump
• Notify the operator
• Allow the operator to intervene

• Rotations

Tower optimization
Condenser temperature
100
Chiller 27°C
Power (% of KW)
80 23°C
19°C
60
40
20
0
0 20 40 60 80 100
Load (%of kW)
Compressor Power Input increases by 2.5% to 3% approx

when Cond. Leaving Water Temperature increases by 1°C
– Compressor Power Input is function of
Condenser Leaving Water Temperature and Load
‹#› Coldest Water is better for the compressor

Tower optimization
Cooling Tower Air
Flow Rate
– Cooling Tower Performances depend on
Warm Water
 Approach Temperature
 Range
Range
 Water Flow Rate
 Air Flow Rate
Cold Water
Temperature
Water
Approach Flow Rate
Ambient Wet Bulb

Coldest Water is obtained at reduced Approach
 at the maximum airflow

Coldest Water is harder for the cooling tower
Tower optimization
- The condensing pressure is the refrigerant pressure in the
chiller compressor
- The more you decrease this pressure the less energy the chiller
will use
The target is to find the optimal
tower set point so that
energy used by the chillers AND
the towers is the lowest possible
-To reduce this pressure, the condenser water temperature
needs to be lowered
- To lower the condenser temperature, the tower setpoint needs

to be decreased, and therefore the tower will use more energy

Tower optimization
Chiller kW +
Towers kW Optimizing
200 kW
1 100 kW
23°C WB
160 kW
550 kW
120 kW 19°C WB
80 kW 300 kW
15°C WB
40 kW
15°C 20°C 25°C 30°C 35°C

Leaving Condenser water set point

4) Wrap-UP
Best Practices in System Design
Multiple chillers system are more common than

single chiller systems for the same reason that most
commercial airplanes have more than one engine.
Balance of reliability and cost.
Selection of the optimum coil size and type from

the wide variety available is important for proper
system performance (Terminal units)

4) Wrap-UP
Best Practice – Temperature Sensor
• Temperature sensor requires good installation for accurate
temperature, sensor up to central axis of the tube
• Sensors need to be calibrated all together
• Sensors of same type for a common regulation
• Proper positioning to see deficit (supply) and excess flow
(return)
Don’t take Temperature Sensor value for granted.

Check the right positioning and calibration.

4) Wrap-UP
Best Practice – Check Valve
• Check-valve should be correctly placed into the system
• Selection is important. Take into account additional pressure
drop for this device
Compare arrow on the check valve

with desired flow in the circuit

4) Wrap-UP
Best Practice – Flow Switch
• Flow switch placed downstream each chiller
• Direct connection to chiller regulation (safety shutdown if insufficient
flow)
• Paddle of the flow switch need to be adjusted to piping diameter
• Adjust reactivity of flow switch
Check flow direction

same as
designed flow
Flow
Free movement of the paddle

4) Wrap-UP
Best Practice – Pump Selection
• Some pumps have different speed settings
• It does not replace design calculations
pressure
efficiency
rpm
volume

4) Wrap-UP
Best Practice – Pump Selection
Operating
System curve
point
Pressure
• What if the desired P1
operation point is
between two curves?
• Go below! Go to left! P2
– Lower first cost
– Lower operating cost
– Avoid over pumping
Q2 Q1 Water flow

Thank you for your participation and interest.
The whole team is entirely at you disposal for further questions and remarks.
We hope that TRANE is a trusted partner for you, now and in the future.


Hydraulics and CPC

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Hydraulics and CPC

Caricato da

Copyright:

Formati disponibili

Technical Seminar

Hydraulics & Chiller Sequencing

“Everything should be made

‹#› Hydraulics & Chiller Sequencing

2) Different Hydraulic Arrangements

3) Chiller Plant Management

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

 Water has nearly infinite compressive strength.

‹#› Hydraulics & Chiller Sequencing

• To achieve the desired conditioning:

• Better the balance

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

– reduction of flow  variable volume application

– change of both  as in a terminal device

500 kW = 4.186 * 47.8 l/s * 2.5 K

‹#› Hydraulics & Chiller Sequencing

12.5 kW = 47.8 l/s * 200 kPa .

• Reduction of speed 100% to 50%  “ 0.5”

‹#› Hydraulics & Chiller Sequencing

Flow3 15 l/s = 10 l/s + 5 l/s

Flow3 = Flow1 + Flow2

‹#› Hydraulics & Chiller Sequencing

27°C 13°C 23°C 15.5°C

‹#› Hydraulics & Chiller Sequencing

14°C 100%64% 7°C 14°C

• 3-way modulating valve

‹#› Hydraulics & Chiller Sequencing

For a constant flow system

LOAD, % LOAD, kw RETURN T° SUPPLY T° ΔT

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

 Calculations for pipelines or pipe networks

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

 Pressure drop and noise is a function of the flow speed

‹#› Hydraulics & Chiller Sequencing

 Speed [m/s] = distance [m] / time unit [s]

 Flow [m3/s] = volume [m3] / time [s]

 Flow [m³/s] = surface [m²] * speed [m/s]

Speed [m/s] = flow [m³/s] / surface [m²]

‹#› Hydraulics & Chiller Sequencing

Speed Limits Pressure Drop Limits

 Usual figures:  Usual figures:

• Larger pipes, • Larger pipes,

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

Some consequences of bad balancing

‹#› Hydraulics & Chiller Sequencing

• The energy cost rises radically

‹#› Hydraulics & Chiller Sequencing

Measure differential pressure, flow and temperature and you will

Service and maintenance has an important role!

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

‹#› Hydraulics & Chiller Sequencing

Flow [l/s] Flow [l/s]

‹#› Hydraulics & Chiller Sequencing

QA QB 2QA 2QB Flow