BCAA CADEM : 7 DIPLOMA IN MECHANICAL ENGINEERING (GREEN BUILDING TECHNOLOGY) ACMV TECHNOLOGY 2 (M2022) TOPIC THREE EQUIPMENT SELECTION (Lecturer Copy) Content 3.1 Introduction 3.2 Chiller Selection 3.3 Cooling Tower Selection 3.4 Air Handling Units 3.5 Catalogues Specific Learning Outcomes «Size and select an appropriate air-cooled chiller for a given application © Size and select an appropriate water-cooled chiller for a given application. * Size and select an appropriate cooling tower for a given application. * Identify the components of an air handling unit. "ACMV Technology 2 ~ 2010-11 Semester 1 aTjent Selection 3.1. INTRODUCTION After selecting the type of air-conditioning system to use for the project, the designer has to size and select each equipment of the system. In this topic, detailed steps of sizing and selecting the air-cooled chiller, water-cooled chiller and cooling tower would be discussed, and reference would be made to the manufacturing chart/ catalogue of the equipments. 3.2 CHILLER SELECTION 3.2.1 Types of Chiller A chiller consists of the following basic refrigerating equipments: Compressor nde Heat exchanger Evaporator aogD Flow control device Chillers can be classified by their condenser types, compressor types and motor housing type: By condenser type: > Air-cooled (no cooling tower nor condenser water required) > Water-cooled (cooling tower and condenser water required) ——— ‘ACMV Technology 2~ 2010-11 Semester 1Topic 3 - Equipment Selection error Refrigerant | CONDENSER: | Air-cooled Chiller EVAPORATOR, Y A AHU / FCU. L cuitted water Figure 3.1 Schematic Diagram of an air-cooled chiller ie __ ete — ‘Condenser water A x CONDENSER | Refrigerant Water-cooled Chiller |EVAPORATOR Y ¢ AHU /FCU L ~Chilled water Figure 3.2 Schematic Diagram of a water-cooled chiller ACM Technology 2 ~ 2010-11 Semester 4 kayTopic 3 ~ Equipment Selection By compressor type > Reciprocating > Rotary compressor > Scroll compressor > Screw compressor > Centrifugal compressor By motor housing type > Open drive > Hermetic dri > Semi-hermeticTopic 3 Equipment Selection 3.2.2 Selection Considerations 3.2.2.1 Temperature Difference (TD) of Chilled Water Entering & Leaving TD of 10°F (5.5°C) is usually used in the selection of both cooler (evaporator) and condenser. The chilled water and condenser water temperatures are usually taken as: ECHWT (Entering Chilled Water Temperature) | 54°F (12.2°C) LCHWT (Leaving Chilled Water Temperature) | 44°F (6.7°C) LCWT (Leaving Condenser Water Temperature) | 95°F (35°C) /100°F (37.8°C) ECWT (Entering Condenser Water Temperature) | 85°F (29.5°C) '90°F (32.2°C) 3.2.2.2 Fouling Factor of Chilled Water Coil The deposit of scale or other foreign material in the tubes of heat exchangers decreases the heat transfer. Thus, appropriate fouling factors must be included when selecting equipment for all water systems, so that satisfactory performance can be maintained. Even freshly cleaned equipment can usually have a quick build-up of a heat retardant film. Hence, high fouling factors can usually be expected after the equipment goes into operation. AA fouling factor of not less than 0.0005 f.°F/(Btu/h) or 0.088 mK/kW should be used even when good quality water is avallable, because some surface fouling is present from the beginning of operation. ‘ACMV Technology 2 2010-11 Semester 1 kay3.2.2.3 Flow Velocity of Chilled Water High flow velocity results in a higher U-value, thus improving heat transfer at the heat exchanger. However, high fluid velocity also increases the rate of pipe erosion, increases pressure drop across the pipe due to increased friction, and hence requires higher pumping cost. A balance has to be struck in the selection of design water velocity. Usually, a flow velocity of between 3 fps to 12 fps (or 0.92 to 3.66 m/s) can be selected. 3.2.3. Chiller Selection Basic Equations The equations can be used to determine chilled water and condenser water flowrate are given as follow: 0.239 x Cooling Capacity (kW) Chilled water flowrate (Ii ae Cooler Temp. Drop (K) 0.239 x Heat Rejection (kW) Condenser Temp. Rise (K) Condenser water flowrate (I/s) = Other useful equations are given in the formula sheet. ‘ACMV Technology 2 — 2010-11 Semester 1 35Topic 3 - Equipment Selection 3.2.4 Air-Cooled Chiller Selection Example In a certain project, the cooling load of a building is 250 RT. To meet this load, 3 nos. of identical sized chillers are required. The relevant specifications are as follows: “ ECHWT=12.2°C LCHWT=6,7°C “ Condenser EAT (Entering Air Temp.) = 33°C DB “+ Minimum fouling factor = 0.088 m2K/kW + Electrical power supply = 415V/3-ph/50 Hz Step 1 ~ Determine Level of Redundancy Required Step 2~ Determine Required Cooling Capacity Per Chiller Step 3 - Check Performance Tables for Rated Cooling Capacity & Power Input * Refer to catalogue at Appendix 3-A Step 4 - Adjust Rated Cooling Capacity & Power Input As Necessary Apply correction factor (CF) for fouling factor of 0.088 m’K/kW ‘ACM Technology 2 ~ 2010-11 Semester 1 37Topic 3 ~ Equipment Selection Step 5 — Estimate COP of chiller ‘ACMV Technology 2— 2010-11 Semester 1 aoTopic 3 - Equigment Selection Step 6 — Estimate Chilled Water Flow Rate 0.239 x Cooling Capacity (kW) Chilled water flowrate (Vs) = Cooler Temp. Drop (K) Step 7 - Estimate Cooler(Evaporator) Pressure Drop From catalogue: Step 8 - Lay Out Chillers as per Manufacturer’s Specs & Site Plan ACMV Technology 2 — 2010-11 Semester 1 3Topic 3 - Equipment Selection 3.2.5 Water-Cooled Chiller Selection Example Ina certain project, the cooling load of a building is 250 RT. To meet this load, 3 nos. of identical sized chillers are required. The relevant specifications are as follows: + ECHWT = 12.2°C LCHWT =6.7°C * LCWT=35°C = ECWT=29.4°C Minimum fouling factors = 0.088 m2K/kW. Electrical power supply = 415V/3-ph/50 Hz % * Step 1 — Determine Level of Redundancy Required Step 2 ~ Determine Required Cooling Capacity Per Chiller Step 3 - Check Performance Tables for Rated CC & PI *“* Refer to catalogue at Appendix 3-B. ‘ACMV Technology 2— 2010-11 Semester 1 woTopic 3 — Equipment Selection Step 4 — Adjust Rated CC & Pl As Necessary Apply correction factor (CF) for fouling factor of 0.088 m’K/kW Assume: CF for CC is 0.96, CF for Pl is 1.03 Step 5 — Estimate COP of chiller Step 6 — Estimate Chilled Water Flow Rate 0.239 x Cooling Capacity (kW) Chilled water fora (9 ee ron) Step 7 — Estimate Evaporator Pressure Drop 19.16 W/s = 304 gpm From catalogue: 'ACMV Technology 2— 2010-11 Semester 4 afTopic 3 - Equipment Selection Step 8 - Estimate Heat Rejection at Condenser Step 9 — Estimate Condenser Water Flow Rate and Pressure Drop 39 x Heat Rejection (kW) Condenser water flowrate (I/s) = Condenser Temp. Rise (K) Step 10 - Lay Out Chillers as per Manufacturer's Specs & Site Plan HEMV Technology 2-201011 Semester? ‘ACMV Technology 2— 2010-11 Semester 1Topic 3 — Equipment Selection 3.3 COOLING TOWER SELECTION For a water-cooled chilled water system, the cooling tower is where room heat. is being discharged to the environment. It is often neglected as it is located at a remote corner of a building. However, it has been proven that it is not an equipment that we could neglect as it could cause legionnaires’ disease, which is an acute bacterial infection of the lower respiratory tract. Figure 3.3 Cooling Tower The cooling process in the cooling tower involves heat and mass transfer. While air and condenser water come into contact at the cooling tower, air picks up heat from water. ‘ACMV Technology 2 ~ 2010-11 Semester 1 v3The objective of a cooling tower selection is typically to find a cooling tower that matches the refrigeration load or chiller capacity. The selection of cooling towers) should be based on maximum load conditions. The water flow rate, entering and leaving water temperatures are established by the condenser water requirements. Make-up water requirements would affect the storage tank sizing, and space available would affect the type of cooling tower to be selected, 3.3.1 Selection Parameters Cooling towers are selected based on a combination of some of the following parameters: a. Condenser water flow rate. Wet bulb temperature of air entering tower, two: = 27°C. Cooling tower entering water temperature, tw: (= chiller LWT) = 35°C/95°F Cooling tower leaving water temperature, tye (= chiller ECWT) = 29,4°C/85°F Range of cooling tower ie. (tw: ~ twz) Approach of cooling tower ie. (tw2 - tw1) ‘(ACMV Technology 2 — 2010-11 Semester 1 vitTopic 3 - Equipment Selection Figure 3.4 The range and approach of a cooling tower 3.3.2. Make-Up Water In the process of cooling the condenser water, there will be water loss due to: a Evaporation loss b. —Driftloss c. Blow-down loss Evaporation loss Since condenser water in the cooling tower is exposed to the atmosphere, water can be loss due to evaporation. Drift loss Droplets of water can be carried away by wind or by the fan air stream without being evaporated. This loss of water is known as drift loss. Blow-Down (Bleed-Off) loss Blow-down or bleed-off refers to the intentional discharge of water from the system. This is required as concentration of mineral solids ‘'ACMV Technology 2 2010-11 Semester 1 3BTopic 3 - Equipment Selection increases when recirculated water is continually evaporated from the cooling tower. This concentration must be controlled to reduce scale formation and corrosion problems. Make-up water is required to make up all these losses. Amount of make-up = Evaporative loss + Drift loss + Blow-down loss Normally, total make-up water requirement can be estimated to be about 2.5% of the circulating condenser water flow rate of an air- conditioning system. 3.3.3 Location of Cooling Tower ‘Some guidelines for cooling tower location are: a. For cooling tower (C/T) far from or lower than the chiller plant, pumps should be located adjacent to C/T. This Is to reduce suction piping length & NPSH problems b. For C/T located above chiller plant, the backflow of water from the condenser during tower shutdown is prevented c. CIT to be located > 5 m (measured from base) from air intakes, open windows, occupied areas, pedestrian thoroughfares, trafficable areas, areas of public access, exhaust from kitchens or other areas where nutrients transported from these systems may assist Legionella growth 4. CIT to be located away from the downwind of air intakes for the building Fon technolo 2a 2oiddi Semester AC MV Technology 2— 2010-11 Semester 7Topic 3 - Equipment Selection 3.3.4 Cooling Tower Selection Example Refer to building of 250 RT cooling load in water-cooled chiller selection example. Specifications (assume 1 tower per chiller): “> Ambient air = 33°C DB @ 27°C WB % Forchiller, LCWT=35°C = ECWT = 29.4°C + Condenser water flow rate = 23.0 Vs + Electrical power supply = 415V/3-ph/50 Hz Step 1 — Determine Range & Select Tower from Catalogue “ refer to catalogue at Appendix 3-C Condenser water temperature (IN) = 35.0 °C. Condenser water temperature (QUT) = 29.4°C. Ambient WB = 27°C Circulating water flow = 23.0 Is = 82.8m"/h Select CSKB-190 Step 2 - Estimate Make-up Water Requirements Make up water flow = 2.5% of condensing water flow = 0,025 x 23.0 = 0.575l/s ACMV Technology 2— 2010-11 Semester 4 #7Topic 3 - Equipment Selection Step 3 - Consolidate Other Relevant Data = Fan diameter = 1600 mm » Fan power supply requirements: 5.5 kW = Tower dimension: 1870 (W) x3230 (L) x 2930 (H) mm * Make-up water quantity per month (Assume full operation): 0.575 I/s x 3600 x 24 x 30 /1000 = 1490m* * Operating weight of tower: 2460 kg ‘ACMY Technology 2 ~ 2010-11 Semester 1 veTopic 3 — Equipment Selection 3.4 AIR-HANDLING UNITS AHU can be classified according to: ‘physical configuration: © horizontal = larger “footprint” ©. vertical => smaller "footprint" % fan-cooling coil configuration: © draw-through: * fan downstream of cooling coil + for lower air capacity and/or single-zone applications © blowthrough: + fan upstream of cooling coll * for higher air capacity and/or multi-zone or dual-duct applications ie Fan (Blower) Cold Figure 3.4 Draw-through AHU (single zone) aes Fan Blower) Hot ‘old Figure 3.5 Blow-through AHU (multi zone) ‘ACMV Technology. 3010-11 Semester 13.4.1. Main AHU Components © Dampers: © outdoor & return air © face & bypass, for part load control (optional) + Mixing box (or plenum) “ Electronic air cleaners or media filters: ©. pre (secondary) filters © main (primary) filters % Cooling coil + Fan (blower) ciw motor *% Silencer/attenuator (optional) RA RA damper B Belt aoe Cooling Coil | Blower _ Silencer Mane Motor ixing Box OL MA A 4 = 1 OA damper Bedplate Pre-Filter’ ; 2-Way Valve Main Filter CHWs CHWR Figure 3.7 Components of a Typical AHU ‘ACMV Technology 2 2010-11 Semester 1 20Topic 3 ~ Equipment Selection Depth 3.4.2 Coil Terminology ge, Face Area (FA) =HxW (note that face area + free area) Depth = no. of rows © 4-Tow : light duty H © 6-row: medium duty © 8-row: heavy duty Supply Ait FIOW Vex — Fin Spacing = fins per inch (fpi) © 8 fpi (316 fins/m) - 12 fpi (476 fins/m) © 10 fpi (394 fins/m)- 14 fpi (651 fins/m) * Face Velocity (FV) = VeslFA © 8 fpicoil => FVinax = 500 fpm © 10 fpi coll => FVmax = 436 fpm © 12 fpi coil => FV pax = 400 fpm 3.5 APPENDIX —- CATALOGUES Appendix 3-A Ai-Cooled Chiller Catalogue Appendix 3-B Water-Cooled Chiller Catalogue Appendix 3-C Cooling Tower Catalogue ‘ACMV Technology 2— 2010-11 Semester 1 S27