Large Chilled Water System

This presentation is being brought to you
by:
ASHRAE India Chapter and Xylem, Inc.
Large Chilled Water System

Design Seminar
Presented by:
Larry Konopacz, Manager of Training & Education
Bell & Gossett Little Red Schoolhouse
Saturday, September 21, 2013
Large Chilled Water System Design Seminar

The Production Loop
Chilled Water Sources

Chillers
Cooling towers
Free-Cooling &
Waterside Economizer
Thermal Storage
Water Source Heat Pumps
Whats a Ton?
I Ton Ice =
2000 LB;
1LB Ice =
144 Btu;
1 Ton ice =
288,000 Btu
Rule of 24
12,000 Btu/h = 500 x gpm x tF = 1 ton
gpm/ton = 12,000/(500 x tF)
= 24/tF
What Types of Chillers

are Available?
Compressor
Centrifugal
Rotary screw
Reciprocating
Absorption
Condenser
Evaporator
Refrigeration Cycle
Expansion Device
Hot Water
Liquid Flow
Vapor Flow
Condenser
Water Pump
Compressor
Motor
Load
Evaporator
Low Pressure Zone
Cool Water
High Pressure Zone
Condenser
Cooling
Tower
Supply
Water
Return
Water
Chilled
Water
Pump
Where is What Used?

Large chilled water plants - centrifugal
Mid-range size - rotary screw
Smaller chilled water applications reciprocating
Inexpensive source of steam or other
energy source - absorption
Combinations of the above
Chiller Piping - Evaporator Side

C
Chiller 2
Chiller 1
Return
Common Pipe
Supply
Typical Piping Method

Chiller 3
Chiller 2
Triple
Duty
Chiller 1
Supply
Triple
Duty
Common
Pipe
Return
Adding Pump Redundancy

Chiller 2
Triple
Duty
Chiller 1
Supply
Triple
Duty
Common
Pipe
Return
Headered Primary Pumps

Actuated Control Valve
Chiller 3
Chiller 2
Piped for
Standby
Pumps
Supply
Triple
Duty
Chiller 1
Common
Pipe
Triple
Duty
Return
Chiller Piping - Condenser Side

Cooling
SRS
Towers
SRS
SRS
Pumps
Triple Duty
Condenser
Condenser
Condenser
Multi-celled Cooling Tower

Condenser
Condenser
Condenser
Multi-cell Cooling Tower
Triple
Duty
SRS
Standby Pump
Tower Equalization
Cooling Towers
Equalization
Line
Condenser
Condenser
SRS
Triple Duty
Condenser
Cooling Tower Piping Practices

Fill all sections of pipe to purge air.
Size piping at a minimum of 2 fps to
move free air bubbles to tower.
All piping installed below system purge
level.
Condenser Water Piping Above Grade

System Purge Level
SRS
Overhead Piping Concerns
Piping manifolds can result in low velocities.

Low velocity will allow air to be released.
Air trapped in piping increases head required.
Piping installed above purge level compounds
problem.
Unpurged areas are potential sources of
problems when pumps are turned on.
Elevated Suction Piping Concerns
Condenser water pump difficult to purge.

At start-up a manual air vent may be required.
During operation air will again accumulate.
Automatic air vent may not work.
If above the basin fill level, the result is
cavitation.
Improper Piping Above Basin Level

System Purge Level
Basin Fill Level
Multi-tower System, Properly Piped

System Purge Level
SRS
Tower Piping Observations

At part load reduced velocities in headers may
allow air to be released.
Idle pumps will accumulate air that should be
released prior to starting the pump.
Tower basins should be elevated to ensure
positive pressure under all flow conditions.
Pump casings should be fitted with automatic
air vents.
Condenser Head Pressure Control

With centrifugal chillers a minimum supply
water temperature is needed to:
Maintain optimum efficiency
Maintain a minimum pressure differential
between condenser and evaporator
Prevent pressure imbalance
Hermetic Compressor Guidelines
Condenser water temperature > 75 F.

Establish 75 F within 15 minutes.
N/O condenser water throttling valve.
Three-way bypass valve can be used.
Constant condenser water flow.
Water temperature control through fan
modulation, or other methods.
Open Compressor Guidelines
Condenser water temperature > 55 F.

Three-way bypass valve can be used.
Constant condenser water flow.
Water temperature control through fan
modulation, or other methods.
Cooling Towers
Air in
Air out
Water In
Water out
Induced Draft, Counter-flow Tower

Air Out
Water in
Air in
Water out
Air in
Forced Draft, Cross-flow Tower

Air Out
Air in
Air in
Water out
Water in
Dynamic Relationship of Load,

Approach, and Range
Temperature
Range
(R F)
Approach
(F)
Wet bulb F
Heat Load = L x R
L lb/min of water
Load
L lb/min of water
Hot water F
Cold water F
Water Flow
Tower Size Relationships

Variables:
Heat Load (Varies Directly)
Range (Varies Inversely)
Approach (Varies Inversely)
Wet-bulb Temperature (Varies Inversely)
Varying any of these variables will affect
the size of the tower.
Types of Free-Cooling
(Waterside Economizer)
Air Out
Water in
Air in
Air in
Water out
Earth Contact
Evaporative
Earth Contact Characteristics

Usually indirect.
Cooling medium and load separated by heat
exchanger.
Stable temperatures.
Water temperature limitations.
Water treatment and pumping costs.
Environmental concerns.
Heat Exchangers
How do they work?

Thin plates are stamped with
a unique chevron pattern and
assembled in a frame
Four holes punched in the
plate corners form a
continuous tunnel which acts
as a distribution manifold for
the inlet and outlet of each
fluid
How do they work?

Each plate has a gasket that
confines the fluid to the port
or to the heat transfer area of
the plate
Units are built to order with a
standard 150 psi ASME Code
stamped design or to custom
designs
Earth Contact - Summer Cycle
C
O
N
D
TOWER
E
V
A
P
GPX
H
E
A
T
E
X
C
H
LOAD
Triple Duty
Sediment Removal
Separator
Triple Duty
Earth Contact - Winter Cycle
C
O
N
D
TOWER
E
V
A
P
GPX
H
E
A
T
E
X
C
H
LOAD
Triple Duty
Sediment Removal
Separator
Triple Duty
Evaporative Characteristics
Heat rejection device (tower) exists.
As temperature declines, opportunity
arises.
Higher sensible vs. latent loads
Leaving water temperature approaches
42 F.
Freeze protection may be required.
Freeze Protection
Sump heaters.
Close temperature control.
Accurate water level control.
Prevention of moist air recirculation.
External piping freeze protection.
Evaporative Cooling - Direct
C
O
N
D
TOWER
E
V
A
P
LOAD
Triple Duty
Sediment Removal
Separator
Single Tower, Summer Cycle
Triple Duty
Evaporative Cooling - Direct
NOT RECOMMENDED
C
O
N
D
TOWER
E
V
A
P
Triple Duty
Sediment Removal
Separator
* Alternate location of SRS, depending on

system conditions
Single Tower, Winter Cycle
LOAD
Triple Duty
Evaporative Cooling - Indirect
C
O
N
D
TOWER
E
V
A
P
GPX
H
E
A
T
E
X
C
H
LOAD
Triple Duty
Sediment Removal
Separator
Single Tower/GPX, Summer Cycle
Triple Duty
Evaporative Cooling - Indirect
C
O
N
D
TOWER
E
V
A
P
GPX
H
E
A
T
E
X
C
H
LOAD
Triple Duty
Sediment Removal
Separator
Single Tower/GPX, Winter Cycle
Triple Duty
Temperature Cross and Approach

TEMP.
DEG. F
57= T1
CH. WATER
52= t2
7F TEMPERATURE
CROSS
45= T2
COND. WATER
3F COOLING
APPROACH
42= t1
EXCHANGER
LENGTH
Heat Transfer Area vs Approach

COND. WATER
EWT LWT FLOW
CH. WATER
EWT LWT FLOW
LMTD
DEG F
AREA EXCH.
SQ.FT. MODEL
COST
INDEX
42
52
1000
57
45
834
3.92
1390
GPX807
1.00
42
52
1000
58
46
834
4.93
1135
GPX807
0.85
42
52
1000
59
47
834
5.94
975
GPX807
0.76
Temperatures are in F
Flow is in USGPM
Heat exchanger selection based on max pressure drop of 7 psi

10/3.92=2.55
Approach = 3F
10/4.93=2.03
Approach = 4F
10/5.94=1.69
Approach = 5F
Production Source - Thermal Storage
Application Criteria
Economics
Storage Media
Storage Technologies
System Configurations
Application Criteria
High maximum load.

Significant premium for peak demand.
Incentives.
Limited space available.
Limited electrical capacity.
Back-up or redundancy required.
Storage Media
Chilled Water
Ice Harvesting
External/Internal Ice Melt
Stratified Chilled Water System

T
Load
Variable volume
distribution
pump
Warm
Vent
Storage
Pressure sustaining
and check valve
Cool
Constant volume
primary pump
Chiller
Temperature Stratification
Top 0
Depth of tank, ft
-5
-10
Thermocline
-15
Bottom -20
30
40
50
60
Temperature, F
70
Use of Pressure Sustaining Valves

Load
Distribution
pump
Primary
pump
Chiller
Transfer
Pump
Direction
control
valves
Vent
Warm
Pressure sustaining
and check valve
Storage
Cool
Constant volume
primary pump
Incorporating Heat Exchangers

Load T
Variable volume
secondary
pump
Heat
Exchanger
Variable volume
primary
pump
Warm
Vent
Storage
Cool
Constant volume
primary pump
Pressure sustaining
and check valve
Chiller
Ice Harvesting System

Section Section Section Section
1
3
4
2
Ice harvester
chiller
Load
Ice water
Chilled water
pump
recirculation
pump
External Melt Ice Storage
Discharging Mode
Charging Mode
Encapsulated Ice Storage

Charge and Discharge Modes
Charging Mode
Discharging Mode
Ice
Cold glycol
Ice
Warm glycol
Water
Full Storage Strategy

Chiller on
Charging
Storage
Charging
Storage
Chiller off
Tons
Cooling load
(met by storage)
Chiller meets load directly
Time of Day
Partial Storage - Load Leveling

Charging
Storage
Cooling load
(met by storage)
Tons
Chiller runs continuously

Cooling load
(met by chiller)
Time of Day
Charging
Storage
Partial Storage - Demand Limiting

Reduced on-peak demand
Charging
Storage
(met by storage)
Tons
Cooling load
(met by chiller)
Time of Day
Charging
Storage
Production Source - Water Source Heatpumps
Growing market segment

System temperature range 40 - 90 F
Energy added below 40 F (heat)
Heat removed above 90 F (cooling
tower)
Heat Pump Cycles - Water Source

Supply
System Water
Return
Air Coil
Water Coil
Air Coil
Water Coil
(Evaporator)
(Condenser)
(Condenser)
(Evaporator)
Cool
Air
Warm
Air
Compressor
Reversing
Valve
Capillary
Air Conditioner Cooling
Refrigerant
Loop
Compressor
Reversing
Valve
Capillary
Air Conditioner Heating
Design Considerations
Use slow closing two-way valves for
each zone
Good system balance required
Use staged c/s or v/s pumps
Use with cooling towers and GPX
Use with closed circuit cooling towers
Heat Pump-Water Source Schematic

Compression
Tank
Cooling
Tower
Water Source
Heat Pump
Buffer
Tank
( Optional )
Gasketed
Plate Heat
Exchanger
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Heat Pump-Water Source Schematic

Closed Circuit Cooler
Heat Rejecter
Water Source
Heat Pump
Buffer
Tank
( Optional )
Compression
Tank
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Water Source
Heat Pump
Comments?
Questions?
Observations?

Variable Volume Distribution
Variable flow through coil

Constant flow through system
Variable flow through coil

Variable flow through system
Three Way Valve
Two Way Valve
Three-Way Valve Systems
Low return temperatures

Balance problems
Increased flow at part load
Extra chillers to provide flow at low t
Chillers operate at high kW/ton
C
H
I
L
L
E
R
Two-Way Valve System with

Chiller Bypass
C
H
I
L
L
E
R
A Problem
We want:
a. variable volume, to save pumping
costs at part load,
b. constant flow through the chiller to
protect it.
A Solution
a. constant flow primary system for the chillers
b. variable flow secondary system for the load
Primary-Secondary Terms
Supply
Primary Loop
Production
Secondary Loop
Distribution
C
H
I
L
L
E
R
C
H
I
L
L
E
R
C
H
I
L
L
E
R
Primary-Secondary
Common Pipe
Return
Fundamental Idea
Secondary
Pump
Primary
Pump
Tee
A
Tee
B
Low pressure drop in the common pipe
Primary-Secondary Pumping
The idea is based on:
Conservation of Mass
Conservation of Energy
Law of the Tee: Diversion

50 GPM
100 GPM
50 GPM
Law of the Tee: Mixing

100 GPM
60 GPM
40 GPM
No Secondary Flow
Secondary
Pump
Off
A
100 GPM @ 45F
Primary
Pump
100 GPM @ 45F
100 GPM @ 45F
Primary = Secondary
100 GPM @ 45F
100 GPM @ 55F
Pump On
A
100 GPM @ 45F
B
0 GPM
100 GPM @ 55F
Primary > Secondary
50 GPM @ 45F
50 GPM @ 55F
Pump On
Mixing at Tee B
100 GPM @ 45F
100 GPM @ 50F

50 GPM @ 45F
Primary < Secondary
200 GPM @ 55F
200 GPM @ 50F
Pump
On
100 GPM @ 45F

Mixing at Tee A
100 GPM @ 55F

100 GPM @55F
Control Valve in Secondary
Two-way Valve
Primary-Secondary Pumping
Supply
Primary Loop
Production
Secondary Loop
Distribution
C
H
I
L
L
E
R
C
H
I
L
L
E
R
C
H
I
L
L
E
R
Primary-Secondary
Common
Return
Common Pipe Design Criteria

Use the flow of the largest chiller
Chiller staging at half of this flow is
common
Head loss in common <1 1/2 ft

Distribution pipe size is often used where
reductions would be inconvenient
Three pipe diameters between tees

Excessive length increases total head loss
Low velocities in system piping
Design of the Common Pipe

Secondary
Constant Speed
Pumps
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
Common
Return
10 dia.
Common Pipe Configurations
Secondary System Curve

Control Valves
Closing
H1
H2
Control Valves
Opening
H3
Head
Flow
F1
F2
F3
Typical System
Distribution
Production
45F
To Loads
Chiller 1, on
Chiller 2, off
Secondary Pumps
1500 gpm each
Common
1500 gpm
each
From Loads
Production = Distribution
CHWS Temp
45oF
1500
1500
Chiller 2, off
Chiller 1, on
Secondary
Pumps
1500
Common -- No Flow
0
1500
1500
ECW Temp
55oF
CHWR Temp
55oF
Distribution > Production

CHWS Temp
47.5oF
2000
1500
Chiller 2, off
Chiller 1, on
Secondary
Pumps
2000
Mixing (1500 @ 45) + (500 @ 55)
Common -- 500
1500
2000
ECW Temp
55oF
CHWR Temp
55oF
Check Valve in Common?

Supply
>1500 GPM
>1500 GPM
@ 47.5oF
Chiller 1, on
Chiller 2, off
0 GPM
Be Careful!
Common
Return
>1500 GPM
>1500 GPM
@ 55oF
What can we do?

Supply
Linear
Function
Step
Function
Chiller 1
Chiller 2
Chiller 3
Primary/Secondary
Common
Distribution
Production
Return
Typical Load Profile

30
25
% Time
20
15
10
5
0
0-10
30-40
60-70
% Load
90-100
Multiple Chillers
Chiller 1
Chiller 2
80
% Load
60
40
20
1
25
50
2
75
% Time
100
Chiller 1, 40%
Chiller 2, 60%
100
What else can we do?

Reset Supply Temperature
Lower chiller set point when mixing occurs to
maintain a constant temperature to the system.
Allows us to mix colder water and maintain supply
temperature to secondary. (coils)
Expect increases in cost of chiller operation at

lower set point: 1-3% per degree of reset.
Adds to control complexity.
Delays start of the next chiller.
Production > Distribution

P/S Chiller Bridge - Front Loaded Common
(Flow in GPM)
CHWS Temp
45oF
3000
Chiller1, on
Chiller 2, on
Secondary
Pumps
2100
Common -- 900
1500
Mixing (2100 @ 55) + (900 @ 45)

1500
2100
ECW Temp
52oF
CHWR Temp
55oF
Loading a Chiller
A chiller is a heat transfer device. Like
most equipment, it is most efficient at
full load.
To load a chiller means:
Supply it with its rated flow of water
Insure that water is warm enough to permit
removal of rated Btu without freezing the
water
Chiller Performance Curve

1.1
1.0
KW per Ton
0.9
0.8
0.7
0.6
0.5
10 20
30
40 50 60 70
Percent Load
80 90 100
Typical Load Profile

30
25
% Time
20
15
10
5
0
0-10
30-40
60-70
% Load
90-100
60/40 Chiller Split to Help Minimize

Low Part Load Operation
Chiller 1
Chiller 2
80
% Load
60
40
20
1
25
50
2
75
% Time
100
Chiller 1, 40%
Chiller 2, 60%
100
Three Unequally Sized Chillers

Chiller 1 or Chiller 2
and
Chiller 3
and
Chiller 2
80
60
% Load
40
Chiller 3
20
Chiller 1
or
Chiller 2
25
50
75
100
% Time
Chiller 1, 40%
Chiller 1
Chiller 2, 40%
Chiller 3, 60%
100
Approaching Flow = Load
% Load
Time
Applying a Variable Speed Chiller

100
Ch 1
75
% Flow
Ch 1
Ch 2
50
Ch 1
Ch 2
Ch 3
Ch 3
Ch 4
25
Ch 2
Ch 1
25
50
75
% Load
100
Back Loaded Common

To Loads
Chiller 1
Chiller 2
Chiller 3
Common
From loads
Production = Distribution
CHWS Temp
45oF
1500
1500
Chiller 1, on
Chiller 2, off
Common
0 Flow
Secondary
Pumps
1500
1500
1500
CHWR Temp
55oF
Distribution > Production

CHWS Temp
47.5oF
Mixing (1500 @ 45) + (500 @ 55)
500
Chiller 1, on
Chiller 2, off
Common
500 gpm
Secondary
Pumps
1500
2000
1500
2000
500
CHWR Temp
55oF
Production > Distribution

CHWS Temp
45oF
900
1500
Chiller 1, on
Chiller 2, on
Common
900
600
1500 GPM
@ 49oF
900 GPM
@ 45oF
Secondary
Pumps
1500
2100
1500 GPM
@ 55oF
600 GPM
@ 55oF
Mixing (900 @ 45) + (600 @ 55)
2100
CHWR Temp
55oF
Maximize Free Cooling

Secondary
Pumps
PrimarySecondary
Common
Supply
Free Cooling
Chiller 2
Chiller 3
Pump
Controller
Return
Primary-Secondary System
Secondary
Pumps
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
PrimarySecondary
Common
Return
Pump Horsepower Comparison

150
Constant Flow Primary Pumps, only

125
BHP
100
75
Secondary Pumps +
50
Primary Pumps = V/V

25
25
50
75
Design Coil Flow

%
100
2012 ASHRAE Handbook - HVAC Systems and Equipment, p 44.11
Constant vs Variable Volume

150
140
Constant Flow, C/S Pump

(3 Way Valve)
C/S Pump
(2 Way Valve)
130
120
Base
Design
HP %
Pump Over-headed by 150%
110
100

(3 Way Valve)
90
Pump Head Matched

to System @
Design Flow
80
70
60
% Full Load 50
(Design) HP 40
30
20
10
0
10 20 30 40 50 60 70 80 90 100
% Flow
Impact of Piping Length and Overheading

350
300
250
c/s @ 1.0
Yearly Operating Cost x $1000
c/s @ 1.25
200
c/s @ 1.50
c/s @ 2.0
150
100
50
0
0
1000
2000
3000
4000
5000
Pipe Length, Feet
6000
7000
8000
9000
Always Size the Pump to the System!

But...
Uncertainties
Coils
Control valves
Primary data
Lead times
Dealing With an Overheaded Pump

Throttle at the discharge valve
Limits on the valve
Flow balance & trim pump impeller

Required by ASHRAE/IES 90.1
Additional Concerns
Pump Protection at minimum flow
Chiller Staging and De-staging
instrumentation.
Pump Protection
Minimum recommended flow from ESP Plus = 900 gpm
Bypass Options
1. Establish a minimum flow equal to or greater than
the minimum required to protect the pump.
2. Install a bypass at the end of the mains with a
balance valve to set minimum flow.
3. Install a bypass at ends of zones.
4. In retrofits, leave a three way valve at the end of the
system.
5. Use P or flow sensing to open pump bypass only
when needed.
6. V/S pumps are not as big a problem because of
lower head at reduced flow.
System Bypass Options

3
Secondary
Constant Speed
Pumps
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
6
Primary
Secondary
Common
Return
Chiller Staging Instrumentation

Production
TS-S
TP-S
FS
FP
To Loads
Chiller 1, on
Chiller 2, off
Secondary/Pumps
Distribution
Common
TP-R
TS-R
From Loads
Common Pipe Flow Indication

Distribution
Production
To Loads
Flow Switches
Chiller 1
Chiller 2
Secondary/Pumps
Common
From Loads
Comments?
Questions?
Observations?
Large Chilled Water Design Seminar

Variable Speed Pumping
Why variable speed?

1. When should I use it?
2. How does it work?
3. What about variable primary flow?
Typical operating load profile

30%
20%
15%
5%
2%
3%
15%
5%
3%
2%
Bell & Gossett 70V

1970s
Adjustable Frequency Drives

Rectifier section
converts AC to DC
several varieties available
Inverter section
forms a synthetic sine wave
several varieties available
maintains a controlled frequency/voltage ratio
Requires an automatic control system

Adds to the initial cost of the system
Affinity Laws
1. Capacity varies as the RPM change ratio:
FLOW 2 = FLOW 1 ( SPEED2 / SPEED 1)
2. Head varies as the square of the RPM change ratio:
HEAD 2 = HEAD 1 (SPEED 2 / SPEED 1)
3. Brake horsepower varies as the cube of the RPM change ratio:

BHP 2 = BHP 1 (SPEED 2 / SPEED 1)
Affinity Laws for Centrifugal Pumps

100
Percent
90
80
Flow
70
Head
60
Horsepower
50
40
30
20
10
0
0
10
20
30
40
50
60
70
Flow/Speed, Percent
80
90
100
Theoretical Savings
120
110
Pump Curves
100
90%
100% Speed
110
100
Design
90
90
80%
80
Head
70
70
70%
60
50
60
50
60%
40
HP Draw
50%
30
40%
30
Head
20
BHP
10 30%
0
0 10 20
40
Flow
30 40
50
60
70 80
% Design Flow
10
0
90 100
% BHP
% Head
80
20
120
Required Differential Pressure
P Sensor/Transmitter
25 Ft. Head
System Curve
& V/S Control System
110
25 FT Differential Head
Maintained Across Load
(Set Point)
80
60
Overall
system curve
40
Distribution
piping head
loss curve
20
0
200
400
600
800
1000 1200 1400
Flow
Set Point
Pump TDH
Head
100
1600
Effect of Constant* Set Point

110
As the valve closes,

the pump slows down
100
80
Pump TDH
Head
Set point,
25 FT
Control curve
60
Overall system curve
40
Distribution
piping head
loss curve
20
0
0
200
400
600
800
1000
1200
1400
1600
Flow
*Whats Constant?
Pump
Initial Speed
Control Curve
B
Head, H
(feet)
Pipe, Fitting
Friction Loss
Flow, Q
(gpm)
Q2 Q1
Decrease in Heat Load Results in Troom < T set point

Causes Two Way Valves to Throttle Flow
Pump
Curve
Speed 1
B
Speed 2
Control Curve
A
Head, H
(feet)
Pipe, Fitting
Friction Loss
Flow, Q
(gpm)
Q3 Q2
Q1
Decrease in Pump Speed Reduces Flow, Reduces Error
Control Curve
Speed 1
Head
(ft)
Final Speed
Pipe, Fitting
Friction Loss
Flow, Q
(gpm)
Q4
Q1
System Operation on Control Curve at Lower Speed
Variable vs Constant Head Loss

Constant Head Loss
Variable Head Loss
Supply
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Pump
Controller
Adjustable Freqy. Drives
Return
Variable Head Loss Ratio

C/S, Constant Flow System
Base 100
Pump Head Matched to

System at Design Flow
90
80
Percent Design BHP
C/S, Variable Flow
V/S, 0% Variable Hd Loss, 100% Constant Hd
70
60
50
40
30
20
10
0
10
20 30 40
50 60 70 80 90
% Flow
100
Variable Head Ratio w/

Overheading
(3 Way Valve)
150
140
C/S Pump
(2 Way Valve)
130
120
Base
Design
HP %
Pump OHeaded by 150%
110
100
(3 Way Valve)
90
Pump HD Matched
to System @
Design Flow
80
70
60
% Full Load
(Design) HP
50
* 25/75 Means:
25 % Variable HD Loss
75 % Constant HD Loss
40
30
20
10
0
10
20
30 40
50 60
70 80 90
100
V/S Curves
120
50 %
110
60 % 70 %
80 % 85 % % Efficiency
85 %
80 %
100
100 %
90
Head, Feet
80
90 %
70
% Speed Curves
80 %
60
50
70 %
40
Constant
Efficiency
Curve
60 %
30
50%
20
40 %
30 %
10
0
100 200
300 400
500
GPM
600
700 800
900 1000
Efficiency Changes
50 %
120
60 %
110
70 % 80 %
% Efficiency
85 %
85 %
80 %
100
100 %
90
Head, Feet
80
90 %
70
% Speed Curves
80 %
60
50
70 %
40
Constant
Efficiency
Curve
60 %
30
50%
20
40 %
10
0
30 %
0
100 200
300 400
GPM
500
600
700
800
900 1000
Minimum Drive Speed

50 %
120
60 %
110
% Efficiency
70 % 80 %
85 %
85 %
80 %
100
100 %
90
Head, Feet
80
90 %
70
% Speed Curves
80 %
60
50
70 %
40
Constant
Efficiency
Curve
60 %
30
50%
20
40 %
10
0
30 %
0
100 200
300 400
GPM
500
600
700
800
900 1000
Multiple Pump System Staging

Constant Differential Head Loss
Variable Head Loss
Supply
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Pump
Controller
Return
Parallel V/S Operation
Pump 1
Pumps 1 & 2
Control Curve
1770 RPM
1450 RPM
1150 RPM
600 RPM
900 RPM
Pumps 1, 2 & 3
Variable Speed Pumping Equipment

3f , 60 Hz Power
(Control Agent)
Set Point
(Input Signal)
Technologic
Pump
Controller
Feedback
Signal
Sensor/
Transmitter
Set Point
+/- error
Adjustable
Frequency
Drive
(Controlled Device)
3f, Variable Frequency

Variable Voltage
Controlled
Variable
System
The Controlled Variable Determines the Type of Sensor
Pressure
Differential
Pressure
4-20
ma
signal
Temperature
Differential
Temperature
Flow
Pump
Controller
3f , 60 Hz Power
(Control Agent)
Set Point
(Input Signal)
Technologic
Pump
Controller
Feedback
Signal
Sensor/
Transmitter
Set Point
+/- error
Adjustable
Frequency
Drive
(Controlled Device)

Variable Voltage
Controlled
Variable
System
Technologic Pump
Controller
Controls pumps and drives
Accept set point, analyze sensor input
PID function
Pump staging
Pump alternation
Recognize and react to component failure
Provide message display
Central management system link
Safeguard system
PID Control
Eliminates offset from set point

Allows for timely speed change
Handles large, sudden disturbances
Prevents oscillation and over-damping
3f , 60 Hz Power
(Control Agent)
Set Point
(Input Signal)
Technologic
Pump
Controller
Feedback
Signal
Sensor/
Transmitter
Set Point
+/- error
Adjustable
Frequency
Drive
(Controlled Device)

Variable Voltage
Controlled
Variable
System
Adjustable Frequency Drive

Constant
Voltage &
Frequency
Power
Rectifier
Section
Direct
Current
Inverter
Section
Some important issues:

Rectifier and Inverter Design
Drive Efficiency
RFI and EMI Noise
Audible Noise
Size and Cost
Manual drive bypass
Variable
Voltage &
Frequency
Power
Pump
Motor
Typical Efficiency Range

Variable Speed Drives
120
Efficiency, %
100
60
Currently Available
AFDs
Typical Older AFDs
40
Other Types
80
20
0
0
20
40
60
Design Speed, %
80
100
Pump and Motor
The Pump
Minimum Flow
Minimum Speed
Inverter Duty
Motors
Motor Couplers
Maintaining Minimum Flow

120
100 % Speed
110
100
90
Head
80
70
60
30% Speed
50
40
30
20
10
0
10
20
30
40
50
% Flow
60
70
80
90
100
EPDM couplers on variable-speed pumps
Failed Hytrel Coupler from a Variable

Speed Pump
Variable Flow
Through
The Evaporator
Primary-Secondary System
Constant Differential Head Loss
Variable Head Loss
Supply
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Pump
Controller
Return
Primary-Secondary
Common Practice.
Why?
Protection.
Nuisance shutdowns.
Freezing.
Costly downtime.
Variable Primary Flow

Flow Meter, option
DP Sensor
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DP Sensor
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DP Sensor
DP Sensor
Two-position Control Valves
Modulating
Valve
AFD
AFD
AFD
Controller
Whats different?
Primary pumps only
Flow meters or p sensors at each
chiller.
Two-position isolation valves at each
chiller
Minimum flow bypass with a modulating
control valve.
Smarter controller.
Alternative #1
Minimum Flow Bypass at Chillers

Minimum Chiller Flow
Minimum Pump flow
Ganged Pumps
FLOW
METER
SUPPLY
F
SIGNAL
TO TECH
DP
SENSOR
DP
SENSOR
DP
SENSOR
CHILLER
DP
SENSOR
CHILLER
DP
SENSOR
CHILLER
SIGNAL
TO TECH
SIGNALS
TO TECH
SIGNAL
TO TECH
SIGNALS
TO TECH
SIGNALS
TO TECH
TDV
TDV
TDV
T
NOTE:
ALL SENSOR
SIGNALS WIRED TO
TECHNOLOGIC
5500
RETURN
AFD
AFD
AFD
ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
BYPASS:
FOR SYSTEMS WITH
EXTENDED LIGHT
LOADS/WEEKEND
SHUTDOWNS. SET
BALANCE VALVE
FOR LOW FLOW TO
REDUCE THERMAL
STRATIFICATION
AND ALLOW QUICK
START UP AFTER
SHUT DOWN.
Monitoring Chiller Flow

P sensors - Technologic controller ensures the chiller
is in proper working condition by monitoring each
working chillers differential pressure. Flow through the
chiller is calculated using the values defined in the user
setup.
OR
Flow sensors - Technologic controller ensures the chiller
is in proper working condition by monitoring each
working chillers flow rate.
Technologic 5500
Initial programming is
crucial.
Must use accurate data
from the chiller
manufacturer.
Start-up coordination
should include the BMS
too.
Technologic 5500 Control Variables

1. Monitor zone differential pressure sensors,
compare actual values to the required set points.
Pump speed is modulated to maintain set point.
Pump staging will occur as required to meet set point.
Control sequence is exactly as described earlier.

2. Determine if the minimum flow requirements are
being met for all working chillers.
Prevents freeze-up or chiller low-flow trips
If chiller flow is too low, controller opens minimum flow
bypass valve in programmed increments. Size the valve
for system p.
Requests de-staging action from the chiller control
system or BMS.
Allows for operator intervention, decision making.
Required by code in some areas.
Ganged pumps allow operation of two chillers with one

pump.

3. Monitors chiller flow rate to prevent operation
above the maximum flow for the chillers and the
pumps.
Excess chiller flow generates a request to stage on an
additional chiller. Minimum flow bypass valve is closed.
Operator or BMS intervention required.
Ganged pumps allow operation of one chiller, two
pumps.
Optional system flow meter provides end-of-curve
protection for the pumps
Alternative #2
Bypass at End of System
Minimum chiller flow
Minimum pump flow
Ganged Pumps
FLOW
METER
SUPPLY
F
SIGNAL
TO TECH
DP
SENSOR
DP
SENSOR
CHILLER
DP
SENSOR
CHILLER
SIGNALS
TO TECH
CHILLER
DP
SENSOR
SIGNAL
TO TECH
SIGNALS
TO TECH
DP
SENSOR
SIGNAL
TO TECH
SIGNALS
TO TECH
TDV
TDV
TDV
T
NOTE:
ALL SENSOR
SIGNALS WIRED TO
TECHNOLOGIC
5500
RETURN
AFD
AFD
AFD
ISOLATION VALVE
CHECK VALVE
Alternative #2
Minimum flow bypass valve is controlled
to protect both the pumps and the
chillers.
Pump requires >25% BEP flow
Minimum flow of largest chiller
Size the bypass valve using the zone

p.
Best for systems with extended light
loads or weekend shut-down.
Alternative #3
Primary pumps piped directly to chillers.

More common in retrofit systems.
Easier for applying un-equally sized
chillers in parallel.
FLOW
METER
SUPPLY
F
SIGNAL
TO TECH
DP
SENSOR
DP
SENSOR
CHILLER
DP
SENSOR
DP
SENSOR
CHILLER
DP
SENSOR
CHILLER
SIGNAL
TO TECH
SIGNALS
TO TECH
SIGNALS
TO TECH
TDV
SIGNAL
TO TECH
SIGNALS
TO TECH
TDV
TDV
T
NOTE:
ALL SENSOR
SIGNALS WIRED TO
TECHNOLOGIC
5500
RETURN
AFD
AFD
AFD
ISOLATION VALVE
CHECK VALVE
BYPASS:
FOR SYSTEMS WITH
EXTENDED LIGHT
LOADS/WEEKEND
SHUTDOWNS. SET
BALANCE VALVE
FOR LOW FLOW TO
REDUCE THERMAL
STRATIFICATION
AND ALLOW QUICK
START UP AFTER
SHUT DOWN.
Pump Selection
Equal size pumps.
Redundancy.
Parts.
Maintenance.
Unequal size pumps.

Control issues.
Flow issues.
Premature failure, large pump at low flow.
Chiller Selection
Equal size chillers.
Redundancy.
Parts.
Maintenance.
Unequal size chillers.

Control issues.
Flow issues
Additional equipment.
Size bypass for minimum flow of largest chiller.
Minimum building load?
Size bypass modulating valve

for system p, if its installed near the chillers
for zone p, if its out in the system.
Program the controller with the chiller p set

points for minimum and maximum chiller flow.
Verify with chiller manufacturer.
Sequence chillers based on p or temperature
sensors.
Use accurate, calibrated flow meter or p sensors
at each evaporator
Allow for operator training.
Initial
On-going
Consider this design if:

System flow can be reduced by 30%.
System can tolerate modest changes in water
temperature.
Operators are well trained.
Demonstrates a greater cost savings.
High proportion of operating hours at:
Part load.
Full load with low entering condenser water.
Turn-down Ratio
Chiller manufacturers publish 3 - 11 fps
evaporator velocity range (typically).
You may have to increase your
acceptable head loss targets, use more
pump head.
Nominal base of 7 fps desirable.
Variation of 1 to 2 fps.
Work with the manufacturer.
Rate of Change*
Maximum rate of flow change, % design flow per minute
Source
Vapor Compression
Absorption
#1
4-12
**
#2
20-30
2-5
#3
**
30
#4
**
#5
**
1.67
*Table 2-2
ARTI-21CR/611-20070-01, 2004, Bahnfleth & Peyer
** Information not provided
Do not use if:

Supply temperature is critical.
Three-way valves are used throughout.
Existing controls are old, inaccurate.
Operators are unlikely to operate the
system as designed.
Supply Water Temperature

Dependant on :
System volume.
Rate of flow change.
Application specific.
Consider thermal storage
Operator Ability
Within operators ability?.
Commercial buildings may not have well
qualified operators.
Training is mandatory.
Initial
Periodic, in view of operator turnover.
Start-Up & Shut-down

In systems that start-up and shut-down, it
may be advisable to anticipate, and
avoid, rapid changes in flow as control
valves all tend to act together.
Control system, BMS, manual
procedures.
Use slow opening/closing valves at the
chiller, 60-90 seconds.(?)
Controls Complexity
Additional controls for the chillers
Additional controls the pumps.
Pumps operate on flow, temperature, and
P.
Chiller P.
Sensor Calibration
Multiple sensors control:
Flow.
Temperature.
Delta p
Maintenance.
Calibration.
Summary
Evaluate all the options.
Read some articles:
Variable Primary Flow CHW: Potential Benefits and Application Issues
by Bahnfleth and Peyer. Pennsylvania State University, ARTI21CR/611-20070-01
Chilled Water System for University Campus by Stephen W. Duda, PE,
ASHRAE Journal May, 2006
Another tool for the toolbox.
Comments?
Questions?
Observations?

Primary-Secondary-Tertiary Pumping Systems
Primary-Secondary-Tertiary
Zone C
Zone A
Zone B
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Variable Speed Pump
Direct Pumped Zones

Zone A
Zone B
WRONG !
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DP Controller
Zone C
Constant Demand Zones

Zone A
Zone B
WRONG !
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Zone C
Hard set valve
Automatic
Flow Control
Valve
Zone C
Zone A
RIGHT !
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Zone B
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Variable Speed Pump
Three Different Buildings

A has coils selected for 44F.
B has coils selected for 45F.
C has coils selected for 46F.
Therefore, the supply water temperature
must be at least 44F for A.
But what about B and C?
can be even more useful
Zone C
Zone A
Zone B
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Optional Variable
Speed Pump
Temperature Sensor Locations

Load
Load
Load
T1
Tertiary
Zone
Pump
MV
MV
MV
T4 T1
Common
T2
T2
T3
Pumped
Chilled
Water
Supply
Circuit Setter
Chilled
Water
Return
T3
T4
Tertiary Bridge
Load
Load
Load
MV
MV
MV
T1
Tertiary
Zone
Pump
T4
Common
T2
T3
Pumped
Chilled
Water
Supply
Tertiary Bridge
Chilled
Water
Return
Temperature Sensor Locations

Load
Load
Load
T1
Tertiary
Zone
Pump
MV
MV
MV
T4 T1
Common
T2
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3
T4
ADVANTAGES
1. Permits operating at highest allowable zone temperature
2. Maximizes coil flow rate, good film coefficients
3. Maximizes flow rate through each control valve
4. Ensures good humidity control
5. Minimizes the amount of coil reheat
DISADVANTAGES
1. Temperature of return water is unknown
2. Temperature of return water to chiller may be too high
3. Will not recognize increased supply water temperature
T2 Operation
Load
T1
Tertiary
Zone
Pump
MV
Load
MV
Load
MV
T4 T1
Common
T2
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3 T4
ADVANTAGES
1. Maintains chilled water return temperature at setpoint
2. Will not overload the chiller
DISADVANTAGES
1. No control of zone supply water temperature
2. Could lose humidity control
T3 Operation
Load
Load
Load
T1
Tertiary
Zone
Pump
MV
MV
MV
T4
Common
T1
T2
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3 T4
ADVANTAGES
1. There are no perceived advantages at this location
DISADVANTAGES
1. Little, if any, valve modulation unless it is set to
close on sensing supply temperature lower than
permissible in the zone
T4 Operation
Load
Load
Load
T1
Tertiary
Zone
Pump
MV
MV
MV
T4
T1
Common
T2
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3
T4
ADVANTAGES
1. Maximizes coil flow rate
2. Ensures good humidity control
DISADVANTAGES
1. Temperature of return water is unknown
2. Temperature of return water to chiller may be too high
No single sensor location

satisfies all design criteria
SO........
Applying Zone Valve Controller

Load
Load
Load
MV
MV
MV
T1
T2
T1
Tertiary
Zone
Pump
Common
T2
T3
Pumped
Chilled
Water
Supply
Chilled
Water
Return
T3
Control Algorithm
1. Temperature control to the zone (T1 sensing).
2. If T1 is satisfied, return water temperature to the chiller
plant (T2 sensing).
3. Monitor secondary chilled water supply temperature
(T3 sensing) for temperature increase due to secondary
return water recirculation or temperature decrease due to
chiller leaving water temperature reset.
4. Reference point for automatic reset and T (T2 - T3)
control (T3 sensing).
So what?
Satisfy zone cooling requirement at the
maximum possible supply temperature
Minimize secondary flow rate
Optimize return water temperature
3-way Valve Application
Tertiary
Pump
Chiller Plant
Secondary Pumps
Tertiary
Pump
Tertiary
Pump
Problems
Bypass returns cold water to chillers,
reduces system t.
Linear valve characteristics can cause
increased flow at part load.
Balancing required in bypass pipe and
coil-to-coil.
High cost per ton at the chiller.
3-way Valve System

Load
MV
Load
MV
Load
MV
T1
T1
Common
Flow
Meter
T3
Small
By-Pass
Secondary Supply
Secondary Return
T2
T2
T3
Multi-zone Application
Zone 1
Zone 2
Zone 3
Terminal
Unit Balance
Valve
Terminal
Unit Control
Valve
Zone 4
Zone
(Tertiary)
Pump
Zone Supply
Temperature
T1
T1
Chiller Supply
Temperature
T3
Common
GPX
Flow
Meter
C
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Common
T3
]e
C
Distribution
o
(Secondary)
m
Pumps
m
o Rolairtrol
n
Return
Water
Temperature
Zone Bias
Control Valve
T2
C
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T1
Common
T3
T3
3D Valves
C
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T1
T2
T2
T2
District Cooling Application
Individual building temperature control

Static pressure isolation
Return water temperature control
Btu/hr totalization
Outdoor temperature reset
Independent operation
District Cooling Application

with GPX
Independent pressure control
HVAC fluid isolation
VPF Application
Zone 1
Zone 2
Zone 3
Terminal
Unit Balance
Valve
Terminal
Unit Control
Valve
Zone 4
Zone
(Tertiary)
Pump
Zone Supply
Temperature
T1
T1
Chiller Supply
Temperature
T3
GPX
Flow
Meter
Common
C
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Common
T3
Zone
Balance
Valve
Rolairtrol
Return
Water
Temperature
Zone Bias
Control Valve
T2
C
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T1
Common
T3
T3
3D Valves
C
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T1
T2
T2
T2
Comments?
Questions?
Observations?

Primary-Secondary Zone Pumping Systems
Primary-Secondary Zone Pumping
Zone A
C
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Zone B
Supply
Return
Zone C
Shared Piping
Zone A
C
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C
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Zone B
Supply
Shared Pipe
Return
Zone C
Shared Piping
Zone A
C
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Zone B
Supply
Shared Pipe
Return
Zone C
Present and Future Piping

1500 gpm
Flow :
Current = 3000
Future = 4500
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Zone A
1500 gpm
(1500 gpm)
Zone B
Zone C
Supply
Current = 1500
Future = 3000
Current = 0
Future = 1500
Return
Future Zone C
Zone A Requirements
(1500 gpm)
1500 gpm @ 80 (1500 gpm)
Zone A
Zone B
Zone C
4500 gpm*
A1 Supply
A2
A Zone A
Pressure drop:A to A1+B to B1
Present = 20.8
*Future = 45.2
B1
Return
B 4500 gpm*
A3
B2
B3
Zone A Calculations
Table 9-1 Zone A calculations
Zone A (A to A1 + B to B1)
Pipe Size
Pressure Drop - ft / 100 ft
Equivalent Length
(supply & return)
Pressure drop
Zone pressure drop
Total pressure drop
Future Flow @ 4500 gpm

14
2.26
Present Flow @ 3000 gpm

14
1.04
1000 ft x 2 = 2000 ft
45.2 ft
80 ft
125.2 ft
1000 ft x 2 = 2000 ft
20.8 ft
80 ft
100.8 ft
Pump Selection @ 1500 gpm
1510-6G @ 56.4 hp = 75 hp*
1510-6G @ 45.8 hp = 60 hp*
Note: 15 hp additional for future requirements

* Nominal horsepower motor for NOL pump
Zone B Requirements
(1500 gpm)
1500 gpm @ 80 1500 gpm @ 80
Zone B
Zone A
4500 gpm*
A
3000 gpm*
A1 Supply
Pressure drop: Zone B

AtoA1+ BtoB1 + A1toA2 + B1toB2
Present =20.8
9.0
*Future = 45.2
33.4 B1
B 4500 gpm*
Zone C
A2
Return
3000 gpm*
A3
B2
B3
Zone B Calculations
Table 9-2 Zone B calculations
Zone B(A1to A2+B1 to B2)
Pipe Size
Equivalent Length
(supply & return)
Pressure drop
Previous pressure drop
Zone pressure drop
Total pressure drop
Future Flow @ 3000 gpm

12
1.67

12
0.45
1000 ft x 2 = 2000 ft
33.4 ft
45.2 ft
80 ft
158.6 ft
1000 ft x 2 = 2000 ft
9.0 ft
20.8 ft
80 ft
109.8 ft
Pump Selection @ 1500 gpm
1510-6G @ 71.4 hp = 100 hp* 1510-6G @ 49.6 hp = 60 hp*
Note: 40 additional hp required for future requirements

Zone C Requirements
1500 gpm @ 80 1500 gpm @ 80
Zone B
Zone A
4500 gpm
A
1500 gpm
3000 gpm
A1 Supply
Zone C
A3
A2
Pressure drop: Zone C

AtoA1+ BtoB1 + A1toA2 + B1toB2 + A2toA3+ B2toB3
Present = 45.2 + 33.4
+ 21.4
Future = Present
B1
B 4500 gpm
1500 gpm @ 80
Return
3000 gpm
B2
B3
1500 gpm
Zone C Calculations
Zone C (A2 to A3 + B2 to B3) Future Flow @ 1500 gpm
Pipe Size
10
1.07
Equivalent Length
(supply & return)
1000 ft x 2 = 2000 ft
Pressure drop
21.4 ft
Previous pressure drop
78.6 ft
(A to A2, B to B2)
Zone pressure drop
80 ft
Total pressure drop
180.0 ft
Pump Selection @ 1500 gpm 1510-6G @ 82.7 hp = 125 hp*; Note: 50 hp more
than Zone A
Zone Pumping Summary

Summary
Zone A
Zone B
Zone C
Total
Present Requirement
Future Requirement
Duty Pump Standby Pump Duty Pump Standby Pump
1 @ 75 hp
1 @ 75 hp
1 @ 75 hp
1 @ 75 hp
1 @ 100 hp
1 @ 100 hp 1 @ 100 hp
1 @ 100 hp
1 @ 125 hp
1 @ 125 hp
2 @ 175 hp
2 @ 175 hp 3 @ 300 hp
3 @ 300 hp
4 @ 350 hp
6 @ 600 hp
Pressure Diagram - Zone Pumped

System
Zone
Pump A
Zone
Pump B
Zone
Pump C
Load
Friction
Loss
0
Friction Loss
Supply Header
Friction Loss
Return Header
Primary-Secondary Equivalent
1500 GPM
1500 GPM
3000 GPM A1 1500 GPM A2
(1500 GPM)
A3
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
AFDs
B
3000 GPM
B1
Return B2
1500 GPM
B3
P-S Calculations
Primary-Secondary pressure drop calculation:
Pipe Segment
A to A1 + B to B1
A1 to A2 + B1 to B2
A2 to A3 + B2 to B3
Zone B
Total
Pressure Drop
Present, feet
20.8
9.0
DNA
80.0
109.8
Pipe Segment
A to A1 + B to B1
A1 to A2 + B1 to B2
A2 to A3 + B2 to B3
Zone C
Total
Pressure Drop
Future, feet
45.2
33.4
21.4
80.0
180
P-S Calculations
Distribution pump selection:
Present = 3000 gpm @ 109.8 feet, increase impeller to 13.5 for future head requirements:
2 @ VSCS 8x10x17L @ 111.0 hp 125 NOL
1 @ VSCS 8x10x17L @ 111.0 hp 125 NOL, standby
Total
3 Pumps
375 NOL, Total
Future = 4500 gpm @ 180 feet:
3 @ VSCS 8x10x17L @ 114.4 hp 375 NOL
1 @ VSCS 8x10x17L @ 114.4 hp 125 NOL
Total
4 Pumps
500 NOL
Comparison
Zone Pumping
Present
350 hp
Future
600 hp
P/S Pumping
Present
375 hp
Future
500 hp
Primary-Secondary Zone
Pumping Cautions
Excessive initial horsepower
Initial equipment investment
Future considerations
Reduced Horsepower
Comments?
Questions?
Observations?

Variable Speed Sensor Selection and Location
Direct Return Piped System
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
AFDs
Return
Differential
Pressure
Sensor
Single Point Pressure Sensor

Supply
WRONG!
Chiller 1
Chiller 2
Chiller 3
Single
Point
Pressure
Sensor
AFDs
Pump
Controller
Return
Control Curve Using Single Point

Pressure Sensor
90
80
Shut-off head
Design Point
70
Constant Pressure
60
Head, FT
50
1750 RPM
(Maximum rpm)
40
30
1480 RPM
(Minimum rpm)
20
10
0
200 400
600 800
1000 1200 1400 1600
Flow, gpm
Single Point Pressure Sensor

in a CHW System
A rise in the average water temperature
results in a net expansion of the water.
This net expansion volume flows into
the compression tank, raising the
system pressure.
The pump slows down.
What if?
Zone A
Zone B
P Sensor here
Supply
C
H
I
L
L
E
R
C
H
I
L
L
E
R
C
H
I
L
L
E
R
AFDs
Pump
Controller
Return
Zone C
Sensor Across Mains At Pump

Whats the set point?
Its the greatest branch and distribution
piping head loss calculated at design
flow. In other wordsdesign head.
What will the flow be in each zone?

Determined by the zone path CV
Differential Pressure Sensor

at the Pump
90
80
Design Point
70
60
Head, FT
50
Maximum rpm
40
30
20
Minimum rpm
10
0
200 400
600 800
1000 1200 1400 1600
Flow, gpm
Variable Head Loss Ratio

C/S, Constant Flow System
Base 100
Pump Head Matched to

System at Design Flow
90
80
Percent Design BHP
C/S, Variable Flow
70
60
50
40
30
20
10
0
10
20 30 40
50 60 70 80 90
% Flow
100
Coil or Valve?
25 Head
Maximizing Variable Head Loss

Constant Head Loss
Variable Head Loss
Supply
Chiller 1
Chiller 2
Chiller 3
Pump
Controller
AFDs
Return
Differential
Pressure
Sensor
Control Area
Zone 2
20 ft
Zone 1
20 ft
DP Sensor
C
H
I
L
L
E
R
C
H
I
L
L
E
R
C
H
I
L
L
E
R
Pump
Controller
AFDs
Pressure Drops in Piping (Table 11-1)

P AB+EF
P Zone 1
20FT
20FT
P BC+DE P Zone 2
20FT
20FT
TDH = P AB + EF + BC + DE + P ZONE 2 = 60 FT
Control Area Calculation

Table 11-2 Control Area Calculation
Friction Friction P
TDH
Flow
Flow
Friction Friction P
Loss Zone 2
Zone 1 Zone 2
Loss
Loss Zone 1 Loss
BC+DE Zone 2
AB+EF Zone 1
40
20
20
20
45
0 gpm 600 gpm
5
0
25
5
20
20
30
300 gpm 300 gpm
5
5
20
0
0
20
25
600 gpm
0 gpm
5
20
20
0
0
20
20
0 gpm
0 gpm
0
0
40
20
20
20
60
600 gpm 600 gpm
20
20
What pump head is required at:

zero flow?
full flow?
less than full flow?
Control Area
60
50
40
Head, FT
30
20
Lower Limit
Upper Limit
Single Point
10
0
0
100
300
500 600 900 1100 1200

Flow, gpm
So What...?
Staging pumps in a closed loop HVAC
system by flow alone may not work
because of different head requirements
for a given flow.
Wire to water pump efficiency
calculations at part load depend heavily
on the assumptions made about the
nature and shape of the control curve.
Single Sensor, Including

Balance Valve Pressure Drop
Zone 2
20 ft
Zone 1
25 ft
B (50)
E (10)
F
What do you mean...?

The head loss across the coil and the
wide open valve in zone 1 is 25 feet at
full flow.
If thats true, then we need to add an
extra 15 feet of head loss in the balance
valve to insure adequate flow out to
Zone 2 when the Zone 1 valve is wide
open.
Set Point, Zone 1, 40 ft

Flow Zone 1
Flow Zone 2
Friction Loss
Friction Loss
Head Required
Setpoint -
AB+EF
BC+DE
Zone 2
Friction Loss
0 gpm
600 gpm
20
20
300 gpm
300 gpm
30
600 gpm
0 gpm
40
Excess head means wasted energy
Sensor Location
Zone 2
Zone 1
DP Sensor
C
H
I
L
L
E
R
C
H
I
L
L
E
R
C
H
I
L
L
E
R
Pump
Controller
AFDs
Single Sensor in Zone 2

Zone 1 requires 600 gpm at 25 ft
Flow
Zone 1
0 gpm
300 gpm
600 gpm
Flow
Zone 2
600 gpm
300 gpm
0 gpm
Friction Loss
Friction Loss
Friction Loss
AB+EF
Zone 1
BC+DE
5
5
5
0
6.25
25
20
5
0
P Zone1,
Available
40
25
20
Inadequate head for Zone 1
P Avail Friction Loss

Zone 1
40
13.75
-5
Sensor in Zone 1
Flow Zone 1
0 gpm
300 gpm
600 gpm
Flow Zone 2
600 gpm
300 gpm
0 gpm
Friction Loss
AB+EF
5
5
5
Friction Loss
BC+DE
20
5
0
Head Required
Zone 2
20
5
0
Inadequate flow in Zone 2
Setpoint Friction Loss

5
20
25
What can we do...?
In this system:
Single sensor in Zone 2 at 20 ft fails to
provide adequate flow only when
load in Zone 2 < 50% and
load in Zone 1 > 75%
Is this a predictable, recurring situation?

manual adjustment
programming
Add a second sensor
Applying Multiple Sensors

Zone A
Zone B
Supply
DP Sensors
C
H
I
L
L
E
R
C
H
I
L
L
E
R
C
H
I
L
L
E
R
AFDs
Pump
Controller
Return
Zone C
Use Multiple Sensors?

Load
Similarity
Priority
Diversity
One building or several

Redundancy
First cost vs operating cost
The Active Zone

Zone set points do not have to be the
same.
Technologic pump controller scans all
zones often, comparing process
variable to set point in each case.
Pumps are controlled to satisfy the
worst case.
What happens to the rest of the zones?
Effect of Sensor Location

Zone 1
Zone 2
A
OR
E
F
Multiple Sensors & Setpoints

Multiple sensors, set point across Zone 1, = 25 FT and setpoint across Zone 2 = 20 FT, (Table 11-6)
Flow
Flow
Friction Loss
Minimum
Friction Loss
Minimum
P
P
Zone Zone
AB+EF
Reqd
BC+DE
Reqd
Zone1
Zone 2
1
2
Available
Available
P Zone 1,
P Zone2
0
600
5
0
40
20
20
20
300
300
5
6.25
25
5
5
20
600
0
5
25
25
0
0
25
Row 1. Sensor 2 is controlling, Zone 1 is over pumped.

Row 3. Sensor 1 is controlling, Zone 2 is over pumped.
Total pump head required:
row 1 45 ft
row 2 30 ft
row 3 30 ft
Reverse Return Piped System
Supply
C
H
I
L
L
E
R
Return
Reverse Return Systems

If all the circuits are the same length,
will the pump still change speed?
Suppose a coil with a high p
requirement and another with a lower p
requirement are served by the same
reverse return piping system. OK?
If the coils are serving different sides of
the building, could we have a problem?
Tertiary Piped System
Zone A
C
H
I
L
L
E
R
Zone B
Zone C
C
H
I
L
L
E
R
Return
Zone Piped System
Zone A
C
H
I
L
L
E
R
C
H
I
L
L
E
R
Zone B
Supply
Return
Zone C
Summary
Give priority to the needs of the branch.
The rule of sensor location is simple and easy
to apply:
If you have to use a single sensor, put it across
the critical branch.
Whats the critical branch?
Its the same one that determined the pump head.
As weve seen, the analysis is more important

than the rule.
Comments?
Questions?
Observations?

Achieving Hydronic System Balance
Systems Approach
Control M
Load
Distribution
Air Management
Verification
Philosophy
Source
Systems Approach
All components work together as team
Components interact and work as well as we
understand them
A collection of mismatched components will

not perform as expected
Owner, engineer, architect, contractor, and
operators are part of the system too!
Hydronic Balancing
We worry about balance because:
Load calculations are approximate
Piping circuitry analysis is approximate
Control valve selection is approximate
Approximations will lead to underflow and
overflow situations
Results of overflow or underflow

Design Dt cannot be achieved
Supply temperature controller hunts (?)
Sequence of operation can be upset.
For example:
Published by
ASHRAE &
Hydraulic
Institute
DarcyWeisbach
Equation.
Add 15%!
What Is Balancing?
Its test, adjust & balance
Test: The system, now built, is verified in
operation to perform to the expected level.
What do we measure?
temperature, flow, pressure drop, energy
consumption.
What do we test with?

Can we test with what is installed?
Can we obtain accurate readings?
Adjust
Adjust: tested in operation, the system is
found lacking and needs fine tuning.
What level of adjustment, and for what
purpose?
Create comfort conditions
Minimize energy consumption
Prevent equipment damage
How do we adjust?
Balance
Balance is often interpreted to mean 10%
of design flow.
This generalization may or may not yield
satisfactory heat transfer required for
comfort conditions
Redefining Balance
Evaluate System Operation
If the goal is occupant comfort, then heat
transfer becomes the key concern.
We control heat transfer as a sensible
temperature control process between controller,
control valve and coil
Analysis should account for interaction of all key
components, and how they affect the rest of the
system
Balanced Hydronic Systems

All terminals receive enough flow to produce
satisfactory heat transfer (97.5% - 102.5%)
At design conditions, all terminals receive
satisfactory flow with the pump in a specified
range of operation
Under temperature control modulation to
match load, circuit flow does not exceed
design flow accuracy
Chilled Water Coil Flow vs. Heat Transfer

120%
Total
45
40
100%
80%
30
Sensible
25
60%
Latent
40%
20
15
10
20%
5
0%
0%
20%
40%
60%
80%
100%
120%
140%
% Flow
30H X 46W 10 FPI / 4 Row 30 GPM / 10T 85 DB/ 71 WB Ent 45 EWT 15 Circuits 3/8 Tube 4000 CFM Nominal 10 Ton Rating
160%
180%
0
200%
Waterside T (F)
% Heat Emission
35
Chilled Water Coil Flow vs. Emission

100
90
80
70
60
50
40
30
20
10
80%
100%
30H X 46W 10 FPI / 4 Row 30 GPM / 10T 85 DB/ 71 WB Ent 45 EWT 15 Circuits 3/8 Tube 4000 CFM Nominal 10 Ton Rating
97%
Flow Tolerance 97% Design HT

10%
15%
20%
Heating
260
240
220
200
180
160
140
120
100
80
70 16
60
50
40
0
5%
Cooling
Supply Water Temperature F
-0 / +10%
10
12
14
16
18
20
22
Suggested Flow Tolerance (%)
24
Balancing, The Obvious Answer

Maximum branch flows need to be controlled
Balancing valves are one solution
Pressure independent flow control is another
method
Systems perspective needs to be
maintained; pipe, valves, calculations.
Pressure Dependent Balancing Valve
Pressure Dependent Balancing Valve

140
Head (Feet)
120
100
80
60
40
20
0
0
50
100
150
Flow (USGPM)
200
250
Pressure Independent Flow Limiting Valve

Orifice is sized for
the design flow
Cartridge
Cartridge Operation
Flow
Flow
P1
P2
P1 is low
Cartridge Opens
P1 - P2 = Constant
P1
P2
P1 is high
Cartridge Closes
P1 - P2 = Constant

Fixed
Orifice
Flow in GPM
Control Range
Design Flow
Differential Pressure in PSI
Accuracy
Range

2 sizes available
.18 to 45.46 GPM
Externally adjustable flow limiting balance valves
Pressure Independent Control Valves

2 sizes available
.13 to 37 GPM
Externally adjustable flow limiting balance valve and

a modulating control valve
Its more than just balancing valves

Piping system decisions:
Usually have a choice between two size pipes
Varied methods of pipe head loss calculation
Have to account for safety factors, aging

Control valve selection: may not get the exact flow
coefficient you need.
Have to have a way to validate (test) and make
adjustments (branch & system)
It takes some judgment and experience.
Design Criteria For Piping

ASHRAE recommends:
Velocity
Consider:
Branch to riser pressure
drops should be 2:1 or
General 4 -10 fps
greater
Mechanical rm. 6 -15 fps
Direct return circuits in
Maximum velocity
variable speed / variable
1500 hr/yr 15 fps
flow hydronic circuits
3000 hr/yr 13 fps
require much more
6000 hr/yr 10 fps
attention to detail and
Pressure drop
control
sequence
1.0 to 4.0 ft / 100 ft.
ASHRAE 90.1-2010
CHAPTER 6
HEATING, VENTILATING, AND AIR CONDITIONING

SECTION 6.5
Prescriptive Path
TABLE 6.5.4.5 Piping System Design Maximum Flow Rate in GPM
Operating Hours/Year
<2000 Hours/Year
<2000 and <4400 Hours/Year
>4400 Hours/Year
Nominal Pipe Size, in.
Other
Variable Flow/
Variable Speed
Other
Variable Flow/
Variable Speed
Other
Variable Flow/
Variable Speed
120
180
85
130
68
110
180
270
140
210
110
170
350
530
260
400
210
320
410
620
310
470
250
370
740
1100
570
860
440
680
1200
1800
900
1400
700
1100
10
1800
2700
1300
2000
1000
1600
12
Maximum Velocity for Pipes
over 12 in. Size
2500
3800
1900
2900
1500
2300
8.5 fps
13.0 fps
6.5 fps
9.5 fps
5.0 fps
7.5 fps
Piping System Design Maximum Flow Rate

Friction Loss Rate Comparison
Friction Loss Rate
Operating
Hours/Year
<2000 and <4400

Hours/Year
<2000 Hours/Year
Nominal Pipe
Friction
Size, in.
Other Loss Rate
(GPM) (Ft/100 Ft)
120
10.01
2 1/2
180
7.26
3
350
6.55
4
5
410
2.84
6
740
3.47
1200
2.2
8
1800
1.52
10
2500
1.18
12
Variable
Friction
Speed Loss Rate
(GPM) (Ft / 100 Ft)
180
21.78
270
15.78
530
14.56
620
6.25
1100
7.44
1800
4.79
2700
3.3
3800
2.63
Other
(GPM)
85
140
260
310
570
900
1300
1900
>4400 Hours/Year
Friction
Variable
Friction
Loss Rate Speed Loss Rate
(Ft / 100 Ft) (GPM) (Ft / 100 Ft)
5.2
130
11.66
4.5
210
9.74
3.72
400
8.46
1.67
470
3.68
2.11
860
4.63
1.27
1400
2.95
0.82
2000
1.86
0.7
2900
1.57
Other
(GPM)
68
110
210
250
440
700
1000
1500
Friction
Variable
Friction
Loss Rate Speed Loss Rate
(Ft / 100 Ft) (GPM) (Ft / 100 Ft)
3.42
110
8.48
2.86
170
6.51
2.48
320
5.52
1.12
370
2.34
1.3
680
2.96
0.79
1100
1.86
0.5
1600
1.21
0.45
2300
1.01
Velocity
Operating
Hours/Year
Nominal Pipe
Size, in.
Other
(GPM)
120
2 1/2
3
180
350
4
410
5
6
740
1200
8
1800
10
2500
12
<2000 and <4400

Hours/Year
<2000 Hours/Year
Velocity
(ft/sec)
8.04
7.81
8.82
6.57
8.22
7.7
7.32
7.17
Variable
Speed
(GPM)
180
270
530
620
1100
1800
2700
3800
Velocity
(ft/sec)
12.06
11.72
13.36
9.94
12.22
11.55
10.98
10.89
Other
(GPM)
85
140
260
310
570
900
1300
1900
Velocity
(ft/sec)
5.69
6.08
6.55
4.97
6.33
5.78
5.29
5.45
Variable
Speed
(GPM)
130
210
400
470
860
1400
2000
2900
>4400 Hours/Year
Velocity
(ft/sec)
8.71
9.12
10.08
7.53
9.55
8.98
8.13
8.31
Other
(GPM)
68
110
210
250
440
700
1000
1500
Velocity
(ft/sec)
4.56
4.78
5.29
4.01
4.89
4.49
4.07
4.3
Variable
Speed
(GPM)
110
170
320
370
680
1100
1600
2300
Velocity
(ft/sec)
7.37
7.38
8.07
5.93
7.55
7.06
6.51
6.59
SYSTEM SYZER
Flow/Pressure Drop
ASHRAE 90.1 max

pipe size information
Estimated annual
energy cost based
on pipe size
Note that cost is based on a constant load it is
independent of the info in ASHRAE frame
Branch to Riser Pressure Drop Ratio

Ratio, Branch To
Distribution
4
2
1
% Design Flow
In End Circuit
95
90
80
And it falls off much more below 1:1
Branch:Riser Pressure Drop Ratio
Head
100%
Pump head constant

Improved
Distance From Pump
Branch:Riser Pressure Drop Ratio

constant
Reduced pump head
Head
100%
Distance From Pump
Issue: System Curve

When we have many paths, we have many
system curves depending upon which valves
are open.
In VS/VF systems, the pump flow changes
as the control valves modulate. The pump
speed adjusts to those changes.
A much larger system

Friction
Velocity
Loss
(FPS)
(Feet)
4.48
14.34
2.77
11.86
1.41
9.08
0.78
7.17
0.45
5.77
0.18
3.99
Flow
(USGPM)
Pipe
Size
5000
12
14
16
18
20
24
5500
14
16
18
20
24
3.33
1.7
0.94
0.54
0.22
13.04
9.99
7.89
6.35
4.39
6000
14
16
18
20
24
3.94
2.01
1.11
0.64
0.26
14.23
10.89
8.61
6.92
4.79
Reynolds
Friction
Flow Type
Number
Factor
1172764
1066660
933291
829403
743901
618839
Transition
Transition
Transition
Transition
Transition
Transition
0.014
0.0139
0.0138
0.0138
0.0138
0.0138
1173326
1026626
912343
818292
680723
Transition
Transition
Transition
Transition
Transition
0.0138
0.0137
0.0136
0.0136
0.0137
Transition
Transition
Transition
Transition
Transition
0.0137
0.0136
0.0135
0.0135
0.0136
1279992
1119949
995283
892682
742607
Balanced
Flow
Coefficient Available
CV
P
Branch
Set Point = 20 Ft
10
340
20
1000
287
28
1000
253
36
1000
229
44
1000
211
52
1000
196
60
1000
10
CV
CV
CV
e
CV
d
CV
32
Total
CV
24
4
C
16
4
D
4
A
6000@68
40
b
Branch
Flow
Branch = 20
Risers = 48
Ratio = 0.4
70.0
60.0
50.0
Head (Feet)
40.0
30.0
20.0
Inner Valves Close Head

Outer Valves CLose
System Curve
10.0
0.0
0.0
1000.0
2000.0
3000.0
4000.0
5000.0
6000
Flow (USGPM)
Q2
h2 h1 Min Control Head
Q1
2:1 BRPDR
70.0
10
10
CV
G
.83
F
60.0
Head (Feet)
50.0
.83
E
.83
D
40.0
.83
C
.83
B
30.0
20.0
Out Valves Close Head

Inner Valves Close
System Curve
0.0
1000.0
2000.0
3000.0
Flow (USGPM)
4000.0
5000.0
g
CV
1.7
CV
3.4
6000.0
.83
f
5.1
.83
e
.83
d
6.8
.83
3
CV
4
CV
c
CV
8.5
.83
b
.83
10.0
0.0
.83
A
a
6000 @ 30
Plot of Valve & Head Combinations 6000 GPM @ 30

2:1 Branch Riser Pressure Drop Ratio (BRPDR)
Variable Primary Flow System

4
VFD
6000 GPM
@88 Ft Hd
10
10
1
2
2
40
2
24
E
10
10
10
32
F
10
10
10
8
C
20
These Must Be Balanced!
0
B
10
10
10
10
16
D
Control Area for Variable Flow-Variable Speed Primary Distribution System

120.0
Valve 6 Closed
Valve 6 & 5
Closed
100.0
Valve 6,5,4,3
Closed
80.0
Valve 6,5,4
Closed
All Open
Head (Feet)
Valve 6,5,4,3,2
Closed
60.0
40.0
Valve 1 Closed
All Closed
Valve 1,2 Closed
20.0
System Curve
Inboard
Outboard
Valve 1,2,3 Closed

Valve 1,2,3,4 Closed
Valve 1,2,3,4,5 Closed
0.0
0
1000
2000
3000
4000
Flow (GPM)
5000
6000
7000
Thoughts On Selection
Coil pressure drop dominates system
controllability.
Control valve selection with = 0.5
Balancing valves: provide trim
Use as much PD as possible in control valves
Absorb the rest at the balancing valve.
Use independent flow measurement

Triple Duty Valve
Pump
Circuit Setters
Summary: Why Test & Balance?

Load calculations can be inaccurate causing
excess flow
Pipe and fitting predicted losses will vary from
actual performance
Aging factors / fouling will actually occur many years in
the future
Safety factors result in pump over-heading, improper
pump selection and over flow.
Control valve sizing is not exact.

Systems are not built as designed.
Additional Resources
Questions?
Thanks for Attending!
http://www.bellgossett.com
Resources & Tools
XylemKnowsH2o
http://mediasite.xyleminc.com
Our Representative in your area.

Large Chilled Water System

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This presentation is being brought to you

Large Chilled Water System

Large Chilled Water System Design Seminar

Chilled Water Sources

What Types of Chillers

Low Pressure Zone

High Pressure Zone

Where is What Used?

Chiller Piping - Evaporator Side

Typical Piping Method

Adding Pump Redundancy

Headered Primary Pumps

Chiller Piping - Condenser Side

Multi-celled Cooling Tower

Cooling Tower Piping Practices

Condenser Water Piping Above Grade

Overhead Piping Concerns

Piping manifolds can result in low velocities.

Elevated Suction Piping Concerns

Condenser water pump difficult to purge.

Improper Piping Above Basin Level

Basin Fill Level

Multi-tower System, Properly Piped

Tower Piping Observations

Condenser Head Pressure Control

Hermetic Compressor Guidelines

Condenser water temperature > 75 F.

Open Compressor Guidelines

Condenser water temperature > 55 F.

Induced Draft, Counter-flow Tower

Forced Draft, Cross-flow Tower

Dynamic Relationship of Load,

Tower Size Relationships

Earth Contact Characteristics

How do they work?

How do they work?

Earth Contact - Summer Cycle

Earth Contact - Winter Cycle

Evaporative Cooling - Direct

Single Tower, Summer Cycle

Evaporative Cooling - Direct

* Alternate location of SRS, depending on

Single Tower, Winter Cycle

Evaporative Cooling - Indirect

Single Tower/GPX, Summer Cycle

Evaporative Cooling - Indirect

Single Tower/GPX, Winter Cycle

Temperature Cross and Approach

Heat Transfer Area vs Approach

Heat exchanger selection based on max pressure drop of 7 psi

Production Source - Thermal Storage

High maximum load.

Stratified Chilled Water System

Use of Pressure Sustaining Valves

Incorporating Heat Exchangers

Ice Harvesting System

External Melt Ice Storage

Encapsulated Ice Storage

Full Storage Strategy

Partial Storage - Load Leveling

Chiller runs continuously

Partial Storage - Demand Limiting

Production Source - Water Source Heatpumps

Growing market segment