Chilled Water Systems

Chilled-Water Systems
A Trane Air Conditioning Clinic
ACES Training K Y Yow

23 Jan 2015
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

period one
Types of Water Chillers

Driving Sources
compressor-driven heat-driven

Compressor Types
scroll
reciprocating
helical-rotary centrifugal
Condenser Types
air-cooled
water-cooled

Air-Cooled or Water-Cooled
water-cooled
air-cooled
0 tons 500 tons 1,000 tons 1,500 tons 2,000 tons 2,500 tons 3,000 tons
[0 kW] [1,759 kW] [3,517 kW] [5,276 kW] [7,034 kW] [8,793 kW] [10,551 kW]
chiller capacity

air-cooled or water-cooled
Comparison
air-cooled water-cooled
 Lower maintenance  Greater energy efficiency
 Packaged system  Longer equipment life
 Better low-ambient
operation
ASHRAE/IESNA Standard 90.1–2013
 Energy standard
 Building design and
materials
 Minimum equipment
efficiencies
 HVAC system design

ASHRAE Standard 15–2004
 Safety standard for
refrigerating systems
 Mechanical equipment
room
 Refrigerant monitors
 Alarms
 Mechanical ventilation
 Pressure-relief piping

equipment certification standards
AHRI Standard 550/590
 Purpose
 Establish definitions, testing,
and rating requirements
 Scope
 Factory designed and
prefabricated water chillers
 Vapor-compression
refrigeration
 Air-cooled and water-cooled
condensing

period two
Chilled-Water System Design

Chilled-Water System Components
cooling tower
cooling coil
chiller
pumps
Chilled-Water System
air-cooled
chiller
coil
pump
control
valve

Load-Terminal Control Options
 Three-way
modulating valve
 Two-way
modulating valve
 Face-and-bypass
dampers

Three-Way Valve Control
airflow
three-way bypass
modulating pipe
valve

Two-Way Valve Control
airflow
two-way
modulating valve

Face-and-Bypass Damper Control
bypass
damper
airflow
face
damper
Load-Terminal Control Options
 Three-way modulating valve
 Constant water flow
 Variable return-water temperature
 Two-way modulating valve
 Variable water flow (pump energy savings)
 Constant return-water temperature
 Face-and-bypass dampers
 Constant water flow
 Variable return-water temperature
 Enhanced dehumidification capability with “wild” coils
Chiller Evaporator Flow
 Constant flow is most
common
 Variable flow is
possible
 Can reduce energy
consumption
 Use only with evaporator
advanced chiller and
system controls

Single-Chiller System
air-cooled
chiller
coil
pump
© American Standard Inc. 2001

three-way valve Air Conditioning Clinic TRG-TRC016-EN
Multiple-Chiller Systems
 Redundancy
 Part-load efficiency

chillers piped in parallel
Single Pump
54°F
[12.2°C]
off
42°F 48°F
[5.6°C] [8.9°C]
on
54°F
[12.2°C]

Dedicated Pumps
off
42°F
[5.6°C]
on
54°F
[12.2°C] 60% to 70%
of system flow
coil starved for flow

Dedicated Pumps
2 pumps
1 pump
head pressure
system
curve
65% 100%
percent flow
Chillers Piped in Series
electric
chiller
absorption
chiller
three-way valve

chillers piped in series
Equal Set Points
set point = 42°F [5.6°C] set point = 42°F [5.6°C]
42°F
48°F [5.6°C]
[8.9°C]
54°F
[12.2°C]

chillers piped in series
Staggered Set Points
set point = 48°F [8.9°C] set point = 42°F [5.6°C]
42°F
48°F [5.6°C]
[8.9°C]
52°F
[11.1°C]

Primary-Secondary Configuration
production
pumps
distribution
pump
production
loop
distribution
loop

two-way valve Air Conditioning Clinic TRG-TRC016-EN
Primary-Secondary System Rules
 The bypass pipe should be free of restrictions
 Sized for minimal pressure drop
 Avoid random mixing of supply- and return-water
streams
 No check valve

Production Loop
production
pumps
supply
tee
return
tee
Manifolded Production Pumps
production
pumps
isolation
valves

Distribution Loop
supply
tee
distribution
pump
return
tee
two-way valve
 Load terminals should use two-way
modulating control valves

Varying Distribution Flow
B
pump
curve
head pressure
A
pressure 0 50 100
difference percent flow
variable-speed control riding the pump curve
Multiple Distribution Pumps
distribution
pumps
return
from loads
supply
to loads Air Conditioning Clinic TRG-TRC016-EN
Multiple Distribution Pumps
distribution
pumps
return
from loads
A
B
supply
C to loads
B C
A
Tertiary Pumping
distribution
pump
tertiary
pump
two-way
valve
bleed line
Distribution Loop Characteristics
 Reduced pump
energy use
 Distribution loop
sized for system
diversity
 Higher return-water
temperatures

 Load terminals should use two-way
modulating control valves
 All chillers should be selected for the same
leaving chilled-water temperature and T

System Operation
supply
tee
production
loop
distribution
loop
return
tee

Deficit Flow
1,000 gpm at 42°F
[63 L/s at 5.6°C]
1,000 gpm at 56°F

[63 L/s at 13.3°C] 1,200 gpm at 44.3°F
[76 L/s at 6.8°C]
1,200 gpm at 56°F

© American Standard Inc. 2001 [76 L/s at 13.3°C] Air Conditioning Clinic TRG-TRC016-EN
Excess Flow
2,000 gpm at 42°F
[126 L/s at 5.6°C]
2,000 gpm at 54.6°F

[126 L/s at 12.6°C] 1,800 gpm at 42°F
[114 L/s at 5.6°C]
1,800 gpm at 56°F

© American Standard Inc. 2001 [114 L/s at 13.3°C] Air Conditioning Clinic TRG-TRC016-EN
Control of Primary-Secondary System
condition response
deficit flow for start another

specified period of chiller and pump
time
excess flow greater turn off next chiller

than 110% to 115% of and pump
next pump to turn off
neither do nothing
Types of Fluid Flow Meters
 Pressure-based
 Pitot tube
 Venturi
 Orifice plate
 Differential pressure
 Turbine and impeller
 Vortex
 Magnetic
 Ultrasonic
Temperature-Based Calculations
supply
tee
system-level
controller
return
tee

period three
System Variations

Electric Utility Deregulation
0.30
price of electricity, $/kWh
0.20
0.10
San Diego, CA
2000 May June July August September
Fuel Choice Options
absorption
thermal storage
power
indirectly-coupled,
gas-engine
chillers
control interface
Chiller Efficiency Improvements
0.9 8.0
COP
chiller efficiency (kW/ton)
chiller efficiency (COP)

0.8 7.0
0.7 6.0
0.6 5.0
kW/ton
0.5 4.0
1970 1980 1990 2000

year
Greater Focus on System Efficiency

Trend Toward Lower Flow Rates
electric-driven chiller yesterday today
evaporator 2.4 gpm/ton 1.5 gpm/ton

flow rate [0.043 L/s/kW] [0.027 L/s/kW]
leaving 44°F 41°F

chilled-water [6.7°C] [5°C]
temperature
condenser 3.0 gpm/ton 2.0 gpm/ton

flow rate [0.054 L/s/kW] [0.036 L/s/kW]
entering 85°F 85°F

condenser-water [29.4°C] [29.4°C]
temperature
Low-Flow Systems
750,000
annual energy consumption, kWh
600,000
chiller
450,000
300,000
150,000 pumps
cooling tower fans
0
base case low flow
Variable-Primary-Flow Systems
variable-flow
pumps
check
valves
control
valve
two-way
valve
optional bypass
with three-way valve
Critical VPF System Requirements
 Chillers must handle variable evaporator flow
 System must include a bypass
 System-level controls must limit the rate-of-
flow change
 Adequate time to design and commission
controls
 Operator must understand the system

Preferential Chiller Loading
distribution
pump
equally
loaded
absorption
chiller
preferentially
loaded

Sidestream Configuration
distribution
pump
heat-recovery
chiller

Heat-Recovery Chiller
heat-recovery
condenser
standard
condenser
evaporator

Heat-Recovery Chiller Options
heat-recovery auxiliary
(dual) condenser condenser heat pump
 Second, full-  Second, smaller-  No extra
size condenser size condenser condenser
 Large heating  Preheating loads  Large base-heating
loads  Moderate
loads or continuous
 High hot-water hot-water operation
temperatures temperatures  Highhot-water
 Controlled  Uncontrolled
temperatures
 Controlled
 Degrades  Improves chiller
chiller efficiency efficiency  Good heating
efficiency
Heat-Recovery Chiller Efficiency
cooling heat-recovery
chiller type mode mode
cooling-only 0.57 kW/ton not
centrifugal chiller [6.2 COP] applicable
heat-recovery 0.60 kW/ton 0.69 kW/ton

centrifugal chiller [5.9 COP] [5.1 COP]
cooling mode conditions:

• evaporator T = 44°F to 54°F [6.7°C to 12.2°C]
• condenser T = 85°F to 95°F [29.4°C to 35.0°C]
heat-recovery mode conditions:
• evaporator T = 44°F to 54°F [6.7°C to 12.2°C]
• condenser T = 85°F to 105°F [29.4°C to 40.6°C]
Control of a Heat-Recovery Chiller
120
percent maximum pressure differential
100 A
B
unloading with
80
constant leaving hot-
C water temperature
unloading with
constant entering hot-
60 water temperature
0 50 100
percent load Air Conditioning Clinic TRG-TRC016-EN
Asymmetric Design
 Different chiller
capacities 10,000
annual operating hours

 Different chiller 8,000
efficiencies
6,000 lag
chiller
4,000
2,000 lead
chiller
0
50% / 50% 60% / 40%
chiller split
Swing Chiller
equal-capacity
large chillers
small-capacity
“swing” chiller

Swing Chiller
100
swing chiller
80
percent cooling load
swing chiller
60
chiller 2
40
20
swing chiller chiller 1
0
chiller sequence
“Free” Cooling
 Airside economizer
 Waterside economizer
 Strainer cycle
 Plate-and-frame heat exchanger
 Refrigerant migration

waterside economizer
Plate-and-Frame Heat Exchanger
distribution
pump
plate-and-frame
heat exchanger Air Conditioning Clinic TRG-TRC016-EN
waterside economizer
Refrigerant Migration
from
compressor
condenser
shutoff
valve
vapor
to migration
compressor
shutoff
valve evaporator
liquid
flow
Application Outside Range of Chiller
240 gpm at 45°F
air-cooled [15 L/s at 7.2°C]
chiller
240 gpm at 56.7°F

[15 L/s at 13.7°C]
80 gpm at 45°F
[5 L/s at 7.2°C]
80 gpm at 80°F
[5 L/s at 26.7°C]
process load

period four
Chiller-Plant Control

Chiller Controls
 Start–stop
 Chilled-water
temperature
control
 Monitor and
protect
 Adapt to
unusual
conditions

Key Issues for Chiller-Plant Control
 When to turn a chiller on or off
 Which chiller to turn on or off
 How to recover from an equipment failure
 How to optimize system efficiency
 How to communicate with the operator

Chiller Sequencing
 Turning on an additional chiller
 Turning off a chiller
 Which chiller to turn on or off?

load indicators
Temperature
supply-water
temperature
return-water
temperature
chiller-plant
controller

load indicators
Flow
flow
meter
chiller-plant
controller

load indicators
Capacity
supply-water
temperature
flow
meter
return-water
temperature
chiller-plant
controller

Chiller Rotation
equal-capacity chillers

Chiller Rotation
small electric
chiller large electric
chiller
absorption
chiller

Heat Recovery
standard
electric chillers
preferentially-loaded
heat-recovery
chiller
Variable-Primary-Flow Systems
variable-flow
pumps
check
valves
control
valve
two-way
valve
optional bypass
with three-way valve
System Failure Recovery
 Maintain flow of chilled water
 Keep it simple
 Lock out failed equipment
 Turn on the next chiller in the sequence
 Notify the operator
 Allow the operator to intervene

Contingency Planning
piping
stubouts
electrical
connections
System Timers
 Load-confirmation timer
 Avoids transient conditions
 Staging-interval timer
 Allows time for the system to
respond to turning a chiller on
 Minimum-cycle timer
 Prevents excessive cycling

Unload Before Start
2 pumps
1 pump
head pressure
system
curve
system flow rate 610 gpm 870 gpm

[38.5 L/s] [54.9 L/s] Air Conditioning Clinic TRG-TRC016-EN
Soft Loading
80°F
[26.7°C]
soft loading
supply-water temperature
(one chiller)
60°F
[15.6°C]
set point
40°F
[4.4°C] two chillers
0 30 60
© American Standard Inc. 2001 operating time, minutes Air Conditioning Clinic TRG-TRC016-EN
constant-volume pumping system
Chilled-Water Set Point Control
54°F
off [12.2°C]
37°F 45.5°F
[2.8°C] [7.5°C]
on
54°F
[12.2°C]
lowering operating
chiller set point
helps regain control
System Optimization
 Chiller
 Decrease condenser-water temperature
 Increase chilled-water temperature
 Chilled-water pump (variable-flow system)
 Increase chilled-water T
 Cooling tower
 Increase condenser-water temperature
 Condenser-water pump (variable-flow system)
 Increase condenser-water T
Chilled Water Reset
 Pros  Cons
 Reduces chiller energy  Increases pump energy
 Can work in constant- in variable-flow systems
flow systems  Can cause loss of
space humidity control
 Complicates chiller
sequencing control

Condenser-Water Temperature
300,000
annual energy consumption, kWh
cooling
tower
200,000
chiller
100,000
85°F 70°F 55°F optimal

[29.4°C] [21.1°C] [12.8°C] control
© American Standard Inc. 2001 condenser-water temperature set point Air Conditioning Clinic TRG-TRC016-EN
Control of Condensing Pressure
condenser
control
panel
evaporator

Operator Training and Support

Operator Interface

chiller operating log
ASHRAE Guideline 3
 Chilled-water inlet and outlet  Compressor-refrigerant suction
temperatures and pressures and discharge temperatures
 Chilled water flow  Oil pressures, temperature, and
 Evaporator-refrigerant levels
temperature and pressures  Refrigerant level
 Evaporator approach  Vibration levels
temperature
 Condenser-water inlet and  Addition of refrigerant or oil
outlet temperatures and
pressures
 Condenser water flow
 Condenser-refrigerant
temperature and pressures
 Condenser approach
temperature
period five
Review

Review—Period One
 Vapor-compression
water chillers
 Air-cooled versus water-
cooled
 Absorption water
chillers
 Equipment rating
standards
 ASHRAE/IESNA
Standard 90.1-2013

Review—Period Two
 Load-terminal control
 Three-way valve
 Two-way valve
 Face-and-bypass
dampers
 Parallel configuration
 Series configuration
 Primary-secondary
configuration primary-secondary system
Review—Period Three
 Hybrid systems
 Low-flow systems
 Variable-primary-flow systems
 Preferential loading
 Heat recovery
 Asymmetric design
 “Free” (reduced-energy) cooling
 Application of a chiller outside its normal
operating range
Review—Period Four
 Chiller sequencing
 Failure recovery
 Contingency
planning
 System tuning
 System optimization
 Operator interface

Chilled Water Systems

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Chilled-Water Systems

A Trane Air Conditioning Clinic

ACES Training K Y Yow

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

coil starved for flow

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

1,000 gpm at 56°F

1,200 gpm at 56°F

2,000 gpm at 54.6°F

1,800 gpm at 56°F

deficit flow for start another

excess flow greater turn off next chiller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

chiller efficiency (COP)

1970 1980 1990 2000

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

evaporator 2.4 gpm/ton 1.5 gpm/ton

leaving 44°F 41°F

condenser 3.0 gpm/ton 2.0 gpm/ton

entering 85°F 85°F

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

heat-recovery 0.60 kW/ton 0.69 kW/ton

cooling mode conditions:

annual operating hours

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

240 gpm at 56.7°F

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN