Carrier

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Series Counter Flow Chillers Control Sequence

The document explains the piping arrangement & system operation logic of chillers
arranged in series counter flow along with a standby chiller.

Chiller Plant Configuration:-

 CH-1, CH-2 & CH3 are identical variable speed screw chillers.

 CH-1 & CH-2 when operating as Series Counter flow chillers are designed to cater to
full load of the building.

 CH-3 operates in the parallel loop and acts as a STANDBY chiller.

Equipment Covered:-

 CH-1 (series counter flow LEAD chiller)

 CH-2 (series counter flow LAG chiller)

 CH-3 (STANDBY chiller) or (HEAT MACHINE option)

 Cooling towers, variable speed fans (2 working, 1 standby)

 Condenser water pumps (2 working, 1 standby)

 Evaporator water pumps (2 working, 1 standby)

 Evaporator circuit isolation valves #1 - #8

 Condenser circuit isolation valves #11 - #18

 Cooling tower isolation valves #21 - #26

 Cooling tower temperature sensors T21 – T28

 Outdoor air wet bulb temperature sensor

 Evaporator water temperature sensors T1-T8

 Condenser water temperature sensors T11-T18

 Differential Pressure Sensor Evaporator Circuit DP-1

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Valve Position Matrix

Below table highlights the position of various motorized isolation valves, for different scenarios
of chiller operation. E.g. Scenario 1 represents status of all 3 chillers - chillers 1 & 2 are
operational while chiller 3 is Off. Below chillers status, isolation valves position is shown.

Isolation Valve Table T-1

Description Scenario1 Scenario2 Scenario3 Scenario4 Scenario5 Scenario6 Scenario7
CH-1 On On Off Off On Off Off
CH-2 On Off On On Off Off Off
CH-3 Off On On Off Off On Off
Iso Valve #1 Open Open Closed Closed Open Closed Closed
Iso Valve #2 Open Open Closed Closed Open Closed Closed
Iso Valve #3 Open Closed Open Open Closed Closed Closed
Iso Valve #4 Open Closed Open Open Closed Closed Closed
Iso Valve #5 Closed Open Open Closed Closed Open Closed
Iso Valve #6 Closed Open Open Closed Closed Open Closed
Iso Valve #7 Closed Closed Open Open Closed Closed Closed
Iso Valve #8 Closed Open Closed Closed Open Closed Closed
Iso Valve #11 Open Open Closed Closed Open Closed Closed
Iso Valve #12 Open Open Closed Closed Open Closed Closed
Iso Valve #13 Open Closed Open Open Closed Closed Closed
Iso Valve #14 Open Closed Open Open Closed Closed Closed
Iso Valve #15 Closed Open Open Closed Closed Open Closed
Iso Valve #16 Closed Open Open Closed Closed Open Closed
Iso Valve #17 Closed Closed Open Open Closed Closed Closed
Iso Valve #18 Closed Open Closed Closed Open Closed Closed

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SEQUENCE OF OPERATION

Cooling Load evaluation:

Monitor common Return water temperature T8 and Common supply water temperature T7,
Cooling demand is sensed by higher return water temperature.

Start-up in Series-Counter flow mode:-

In high cooling demand situations, both CH-1 and CH-2 shall operate in series counter flow.

At the time of start, CH-1 shall be enabled to start.

In case of increasing demand, increase the speed of the CH-1 up to its maximum permissible
speed.

If the Return water temperature sensor T8, within permissible time interval, does not drop but
increases, this signals further cooling demand.

This results in the request for CH-2 to be enabled.

Change-over to Parallel mode:-

 If LEAD / LAG chillers report a FAULT feedback or internal interlock algorithms

reflect a NO-Run Permissive condition, then STANDBY chiller is requested to be
enabled.
 If CH-1 fails, then CH-2 will become the LEAD chiller and CH-3 will become LAG
chiller.
 Both CH-2 and Ch-3 shall operate in parallel mode to meet the cooling loads.
 On the other hand, if CH-2 fails, then CH-1 will remain as the LEAD chiller and CH-3
will become LAG chiller.
 Both CH-1 and Ch-3 shall operate in parallel mode to meet the cooling loads.

Under normal circumstances, when CH-1 alone is functioning, if it reports a FAULT feedback
or NO-Run permissive condition, then CH-2 shall be reassigned as LEAD chiller and enabled as
per sequence.

Now if CH-2 is not proven running within the preset time or also reports a FAULT, then Plant
Control System shall enable CH-3.

In lower cooling demand situations, if only one chiller needs to be running, then it shall be
possible to run any one chiller, i. e, CH-1 or CH-2 or CH-3

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LEAD CHILLER OPERATION

For the CH-1 to be enabled, the following pre-requisites are checked.

 One cooling tower is available.

 Its isolation valves are open.
 CH-1 condenser circuit isolation valves are open (per Table T-1).
 At least one condenser water pump is available.
 Enable the available condenser water pump.
 Confirm enabled condenser water pump is running.
 Enable the available cooling tower.
 Confirm enabled cooling tower is running.
 CH-1 evaporator circuit isolation valves are open (per Table T-1).
 At least one evaporator water pump is available.
 Enable the available evaporator water pump.
 Confirm enabled evaporator pump is running.
 Check valves shall be used to ensure that no backflow can occur through an off pump.

If all the pre-requisites are met, then the Plant Control System enables the CH-1 to start.
Once enabled to start, then CH-1 internal controls shall then confirm adequacy of minimum
evaporator and condenser flow.
 If flow cannot be confirmed, then CH-1 will communicate an appropriate ALERT to
Plant Control System.
 If flow is confirmed, then CH-1 will monitor the leaving chilled water supply
temperature using temperature sensor T1.

The compressor on CH-1 will then start, if

 the chilled water temperature is above the set point and dead band,
 start to start and stop to start timers are satisfied, and
 oil pressure verified,

The Individual controller on CH-1 shall ramp up CH-1 capacity and control to the leaving set
point. (Subject to applicable ramp schedules or demand limit functions that may be active).

If, (after the ramp up period has elapsed) the chiller is not able to control temperature T7 to the
desired set point without exceeding its adjustable %kW set point, it signals the Plant Control
System for additional capacity shall be enabled.

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LAG CHILLER OPERATION

To meet further cooling demand, if CH-2 is requested then it should be enabled, after meeting
the following prerequisites
 One additional cooling tower is available.
 Its isolation valves are open.
 CH-2 LAG chiller's condenser circuit isolation valves are open (per Table T-1).
 At least one additional condenser water pump is available.
 Enable the available additional condenser water pump.
 Confirm enabled additional condenser water pump is running.
 Enable the additional available cooling tower.
 Confirm enabled additional cooling tower is running.
 CH-2 LAG Chiller's evaporator circuit isolation valves are open (per Table T-1).
 At least one additional evaporator water pump is available.
 Enable the additional available evaporator water pump.
 Confirm enabled additional evaporator pump is running.
 Check valves shall be used to ensure that no backflow can occur through an off pump.

If all the pre-requisites are met, then Plant Control System shall enable CH-2 to start.
.
Once enabled to start, then CH-2 internal controls shall then confirm adequacy of minimum
evaporator and condenser flow.
 If flow cannot be confirmed, then CH-2 will communicate an appropriate ALERT to
Plant Control System.
 If flow is confirmed, then CH-2 will monitor the leaving chilled water supply
temperature using temperature sensor T3.

The compressor on CH-2 will then start, if

 the chilled water temperature is above the set point and dead band,
 start to start and stop to start timers are satisfied, and
 oil pressure verified,

The individual chiller control shall ramp up CH-2 capacity and control to the leaving set point.
(Subject to applicable ramp schedules or demand limit functions that may be active).

Once CH-1 and CH-2 are in operation in Series Counter flow mode, then common supply
temperature sensor T7 and common return temperature sensor T8 shall be monitored and
trended, for system stability.

Plant Room control system shall automatically start the available standby condenser and
evaporator pumps, if the duty pumps fail or cannot be proven running when called for
operation.
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SET POINT STRATEGY:-

 In Series Counter flow mode, CH-1 & CH-2 shall deliver 6.7 deg C to common supply
header which is monitored by T7.

 In Parallel mode, both operating chillers (either CH-1 & CH-3 or CH-2 & CH-3) shall
ramp up their speeds in parallel, based on the KW% set point so as to meet 6.7 deg C at
common supply header which is monitored by T7.

STANDBY CHILLER OPERATION

STANDBY chiller CH-3 is brought in to operation, if

 In series counter flow mode, either CH-1 or CH-2 reports FAULT or NO-RUN
permissive condition.
 In Normal low load condition, if CH-1 was running, reported a FAULT or NO-Run
permissive condition and CH-2 could not be enabled.
 In Normal low load condition, if CH-2 was running, reported a FAULT or NO-Run
permissive condition and CH-1 could not be enabled.
 The Plant control system chooses to operate CH-3 to allow maintenance work on CH-1
and CH-2.

If CH-3 is requested then it should be enabled, after meeting the following prerequisites
 At least one cooling tower is available.
 Its isolation valves are open.
 CH-3 chiller's condenser circuit isolation valves are open (per Table T-1).
 At least one condenser water pump is available.
 Enable the available condenser water pump.
 Confirm enabled additional condenser water pump is running.
 Enable the available cooling tower.
 Confirm enabled cooling tower is running.
 CH-3 Chiller's evaporator circuit isolation valves are open (per Table T-1).
 At least one evaporator water pump is available.
 Enable the available evaporator water pump.
 Confirm enabled evaporator pump is running.
 Check valves shall be used to ensure that no backflow can occur through an off pump.

If all the pre-requisites are met, then Plant Control System shall enable CH-3 to start.
.
Once enabled to start, then CH-3 internal controls shall then confirm adequacy of minimum
evaporator and condenser flow.
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 If flow cannot be confirmed, then CH-3

CH will communicate an appropriate ALERT to
Plant Control System.
 If flow is confirmed, then CH-3
CH 3 will monitor the leaving chilled water supply
temperature using temperature sensor T5.

The compressor on CH-3 3 will then start, if

 the chilled water temperature is above the set point and dead band,
 start to start and stop to start timers are satisfied, and
 oil pressure verified,

The individual control in the chiller shall ramp up the CH-3

CH 3 capacity and control
con to the leaving
set point. (Subject to applicable ramp schedules or demand limit functions that may be active).

Common supply temperature sensor T7 and common return temperature sensor T8 shall be
monitored and trended, for system stability.

COOLING TOWER OPERATION

T21 T23 T25

T22 T24 T26

44
Basis of Operation:-

 CT-1, CT-2
2 & CT3 are identical Cooling Towers with variable speed fans.

 Any two of the Cooling Towers are required to run, in series counter flow mode,
when CH-1 and CH-22 are required to operate.

 In parallel mode, One CT is required to run for one Chiller is running and two CTs
are required to run for 2 Chillers.

 Any CT can be assigned as Lead, Lag or Standby.

 Each Cooling tower has 2 nos. variable speed driven fans.

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 Condenser water flow rate through the CT is a constant flow rate.

Heat Rejection Load evaluation:

For the cooling towers, monitor common Entering Condenser water temperature T28 and
Common Leaving Condenser water temperature T27.

Heat rejection demand is sensed by higher Entering condenser water temperature to

Cooling Tower.

SET POINT STRATEGY:-

 At design ambient wet bulb temperature 29.4 deg C, the Leaving condenser water
temperature from the cooling tower shall be set to 35 deg C to common supply
header to CH-1+CH-2+CH-3 which is monitored by T27.

 Each CT shall deliver LWT as per set point by varying the speed of fans – ramping
up both together, subject to heat rejection load, which is measured by % actual
Temperature Difference between T27 and T28 to maximum TD.

 Plant Control manager shall vary this LWT set point based on cooler ambient wet
bulb.

At Design Ambient wet bulb = 25 deg C, Set point for LWT of CT = 30 deg C.
Maximum TD = 5 deg C
Therefore EWT of CT= 35 deg C.

At Minimum Ambient Wet bulb = 16 deg C, Set point for LWT of CT = 21 deg C.
Maximum TD = 5 deg C
Therefore EWT of CT= 26 deg C.

 Based on current LWT set point of CT, the Plant Control system shall ramp up or
ramp down the speed of both the fans together (between speed limits as per CT
manufacturers recommendation) so as to get the coldest LWT possible.

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CONDENSER WATER PUMP OPERATION:-

 Condenser water pumps are constant speed driven pumps that operate in 2 Duty + 1
standby mode.

 Any pump can be assigned LEAD, LAG or Standby.

 They pump from Common Leaving Water header from Cooling Tower to the
condensers of the Chillers CH-1, CH-2 and CH-3 in accordance with their control
regimes.

CHILLED WATER PUMP OPERATION:

 Chilled water pumps (CHP) are variable speed driven pumps of identical capacity, that
operate in 2 duty + 1 standby mode.
 Any pump can be assigned LEAD, LAG or Standby.
 Pump chilled water from the load through the evaporator and back to the load.
 When CH-1 and CH-2 operate in Series counter flow mode, any two CHPs shall run.
 In case of parallel mode, when either CH-1 and CH-3 or CH-2 and CH-3 are operating,
then any two CHPs shall run.
 The flow rate through the evaporator shall maintain the system at constant ∆T between
T7 and T8.
 Each pump shall have a minimum speed corresponding to minimum flow rate through
any one Chiller.
 In case of decreasing cooling load, the two operating CHPs shall ramp down to minimum
flow rate and then LAG chiller shall be switched off and correspondingly one CHP shall
be switched off. Then the operating CHP shall adjust its speed as per the ∆T between T7
& T8 then, subject to its maximum limit.

This example is for illustrative purposes only and should not be used or referred to as a guide for any
particular design and/or installation. This example sets forth a typical application only. Carrier makes no
representation that the application set forth in this document is suitable for any particular application or
installation. Always consult with a qualified professional engineer when designing an HVAC system

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