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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 Pumping
Supply
Primary Loop
Production
Secondary Loop
Distribution
C C C
H H H
I I I
L L L
L L L
E E E
R R 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 3
Chiller 2
Chiller 1
Pump
Controller
Common
Return
10 dia.
Common Pipe Configurations
A B
C D
Secondary System Curve
Control Valves
Closing
H1
H2 Control Valves
H3 Opening
Head
F1 F2 F3
Flow
Typical System
Distribution
Production 45F
To Loads
Chiller 1, on
Chiller 2, off
Secondary Pumps
1500 gpm each
Common
1500 gpm
each
From Loads
Check Valve in Common?
Supply
>1500 GPM
>1500 GPM
@ 47.5oF
Chiller 1, on
Chiller 2, off
0 GPM Be Careful!
Common
>1500 GPM
Return @ 55oF
>1500 GPM
What can we do?
Supply
Step Linear
Function Function
Chiller 3
Chiller 1
Chiller 2
Primary/Secondary
Common
Distribution
Production Return
Typical Load Profile
30
25
20
% Time
15
10
0
0-10 30-40 60-70 90-100
% Load
Multiple Chillers
Chiller 1
Chiller 2
Chiller 2, 60%
Chiller 1, 40%
100
80 1
% Load 60
40
1 2 2
20
25 50 75 100
% Time
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.
“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
Typical Load Profile
30
25
20
% Time
15
10
0
0-10 30-40 60-70 90-100
% Load
60/40 Chiller Split to Help Minimize
Low Part Load Operation
Chiller 1
Chiller 2
Chiller 2, 60%
Chiller 1, 40%
100
80 1
% Load 60
40
1 2 2
20
25 50 75 100
% Time
Three Unequally Sized Chillers
Chiller 1 or Chiller 2
and
Chiller 3
100
Chiller 3, 60%
Chiller 2, 40%
Chiller 1, 40%
Chiller 1
and
Chiller 2
80
60
% Load
40
Chiller 3
20
25 50 75 100
Chiller 1
or
Chiller 2 % Time
Approaching Flow = Load
% Load
Time
Primary-Secondary System
Secondary
Pumps
Supply
Chiller 3
Chiller 2
Chiller 1
Pump
Controller
Primary-
Secondary
Common
Return
Pump Horsepower Comparison
150
Constant Flow Primary Pumps, only
125
BHP 100
75
Secondary Pumps +
50
25 50 75 100
110
Base Constant Flow, C/S Pump Pump Head Matched
100
Design (3 Way Valve) to System @
90 Design Flow
HP %
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
But...
• Uncertainties
– Coils
– Control valves
– Primary data
• Lead times
Dealing With an Overheaded Pump
Secondary
Constant Speed
Supply
Pumps
2
Chiller 3
Chiller 2
Chiller 1
Pump
Controller
6 5
Primary
Secondary
Common
Return
Chiller Staging Instrumentation
TS-S FS
TP-S
ProductionChiller 1, on
FP To Loads
Chiller 2, off
Secondary/Pumps
Distribution
Common
TP-R TS-R
From Loads
Common Pipe Flow Indication
Distribution
Production
To Loads
Secondary/Pumps
Chiller 1
Chiller 2
Flow Switches
Common
From Loads
Comments?
Questions?
Observations?