Outline of presentation

•Common Chilled Water System Designs

•Heat Exchangers

•Increasing the system reliability with a VPF chilled

water system

•Fan Laws

•19XR Controller Software Versions

•Using ECAT for VPF equipment selections

Common Chilled Water
System Designs
Constant Volume Chilled Water Flow Design

3 Way valve

Chilled Water Pump

(constant speed)
Constant Volume Chilled Water Flow Design
No valve
Commonly
called a “Wild
Coil”

Chilled Water Pump

(constant speed)
Constant Volume Chilled Water Flow Design

3 Way valve

45f

50f
Temperature Differential on
the chilled water supply and
return
55f

Chilled Water Pump

(constant speed)
Capacity measurement
Constant Volume Chilled Water Flow Design
▪Constant chilled water flow required because of the three way bypass valves on
each air handler

▪Multiple chiller applications require the chillers to be in series for capacity reduction

▪Capacity measurement is with the chilled water temperature differential

Advantages to this design-

▪Ease of control

Disadvantages to this design-

▪Increased installation cost because of parallel piping required to allow for service
or isolation of one unit

▪Low fluid velocities

▪Chillers with different lift and mass flow capabilities

▪Matching or balancing the load of two chillers

Primary/Secondary Chilled Water Flow Design
(Variation)

2 Way modulating
CHW valve

Variable Flow
Secondary Chilled Check Valve in the Bridge or
Water Pump De-coupler Circuit

Constant Flow Primary

Chilled Water Pumps
Primary/Secondary Chilled Water Flow Design
(Variation)

60% Flow 52F

42F

Variable Flow
Secondary Chilled Check Valve in the Bridge or
Water Pump De-coupler Circuit

42F 42F 40% Bypass

ON

48F

ON
Constant Flow Example of 60% of
Primary Chilled Water load on each unit
Primary/Secondary Chilled Water Flow Design
(Variation)

60% Flow 52F

43F
Variable Flow
Secondary Chilled
Water Pump Check Valve in the Bridge or
De-coupler Circuit

43F 43F 0% Bypass

ON

52F

OFF
Constant Flow Primary
Example of 120% flow
Chilled Water Pumps
CHWF in one chiller
Primary/Secondary Chilled Water Flow
Design

2 Way modulating
CHW valve

Variable Flow
Secondary Chilled Bridge or De-coupler Circuit
Water Pump

Constant Flow Primary

Chilled Water Pumps
Primary/Secondary Chilled Water Flow
Design
Pressure Secondary Chilled
differential Water Return Secondary
transmitter Temperature Chilled
Water Flow
Secondary Chilled Meter
Water Supply
Temperature

Bridge or De-coupler temperature sensor

or bi-directional flow meter

Measurement devices required

for system capacity
Primary/Secondary Chilled Water Flow
Design

100% valve
position
52 deg f

42 deg f
0% flow

42 deg f
52 deg f

ON

ON Example of 100% system load

with no bypass
Primary/Secondary Chilled Water Flow Design

60% of chilled
60% valve water flow
position 52 deg f

42 deg f
40% flow

42 deg f
48 deg f

ON

ON
Example of 60% system load
with 40% bypass
Primary/Secondary Chilled Water Flow Design

55% of chilled
55% valve water flow
position 53 deg f

43 deg f
5% flow

42 deg f
50% of chilled 53 deg f
water flow
ON

Off
Example of 55% system load
with 5% negative bypass
 Accurate Control of the chillers in a
primary/secondary System requires:
-Measurement of the secondary supply temperature and water flow-

Problems:

The chilled water flow rate measured in GPM

Per ton of capacity in the secondary loop is greater than in
The primary loop. This results in operating multiple chillers
At reduced capacities to provide the necessary flow rate for
The secondary loop preventing negative flow in the bridge or
De-coupler And low temperature differentials in the secondary
loop.
Primary/Secondary Chilled Water Flow Design

▪Constant primary chilled water flow

▪Variable secondary chilled water flow

▪Capacity measurement by using secondary chilled water flow and

temperature differential at a secondary water supply temperature control
point

Advantages to this design-

▪It allows different chilled water flow rates between the primary and
secondary circuits

Disadvantages to this design-

▪Increased installation cost due to piping cost and secondary chilled
water pumps

▪Difficulty in matching the secondary chilled water flow rate to the primary
design
Original Variable Primary Chilled Water Flow
Design

2 Way modulating
CHW valve

Minimum flow bypass

The bypass is activated by a
pressure transmitter on the
chilled water supply header

Constant Speed Primary

Chilled Water Pumps
Original Variable Primary Chilled Water Flow
Design
52f
100% open

2 Way modulating Closed

CHW valve 0% flow

Minimum flow bypass

The bypass is activated by a
40psi water
pressure transmitter on the
pressure
chilled water supply header
42f
52f
ON

ON Constant Speed Example at 100%

Primary Chilled Water load
Pumps
Original Variable Primary Chilled Water Flow
Design
52f
60% flow

2 Way modulating open

CHW valve 40% flow

Minimum flow bypass

The bypass is activated by a
60psi water
pressure transmitter on the
pressure
chilled water supply header
42f
48f
ON

ON Constant Speed Example at 60%

Primary Chilled Water load
Pumps
Variable Primary Chilled Water Flow Design

2 Way modulating
CHW valve

Minimum flow bypass

Pressure differential transmitter across each chiller

evaporator to operate the minimum flow bypass

Measurement devices required to

control the chillers
Variable Primary Chilled Water Flow Design

2 Way modulating
CHW valve

Minimum flow bypass

Pressure differential transmitter across the

chilled water header to control the chilled
water pump speed

Measurement devices required to

control the chillers
Variable Primary Chilled Water Flow Design

2 Way modulating
CHW valve

Minimum flow bypass

Chilled water flow meter to measure the total

chilled water flow

Measurement devices required to

control the chillers
Variable Primary Chilled Water Flow Design

100% open
42 deg f 52 deg f

0% Open
Minimum flow bypass

42 deg f 52 deg f

CHWP’s at
100% speed
ON

ON Example of the system at full

load
Variable Primary Chilled Water Flow Design

60% open
42 deg f 0% Open 52 deg f

Minimum flow bypass

42 deg f 52 deg f

CHWP’s at
60% speed
ON

ON Example of the system at 60%

load
Variable Primary Chilled Water Flow Design

20%
42 deg f flow 5% 52 deg f

Minimum flow bypass

42 deg f 52 deg f

CHWP at
25% speed
ON

OFF Example of the system at 20%

load
Benefits of a variable primary chilled water
flow design
•Reduced first cost with the elimination of the secondary
chilled water pumps

•Reduced energy cost by the elimination of the constant

speed energy on the primary chilled water pumps

•Measurement of capacity with chilled water flow and

chilled water temperature differential

•It does not require the chillers to operate in an unloaded

condition to generate enough chilled water flow to prevent
negative water flow through the de-coupler in a primary
secondary design
Variable Primary Chilled Water Flow Design
With integrated Heat Exchanger

2 Way modulating
CHW valve

Minimum flow bypass

CW from Tower

CW to Chillers

Variable Speed Primary Chilled

Water Pumps
Benefits of a variable primary chilled water
flow design with integrated heat exchanger
•It allows the cooling tower to reduce the system load at a
greater wet bulb than if configured in a parallel
arrangement
Additional Information required with a
variable primary chilled water flow design
with integrated heat exchanger

•Identifying the minimum system load

•Identifying the minimum operating entering
condenser water operating temperature at the
minimum condenser water flow rate of 1.5ft/sec
•Requires some type of condenser water flow
control to maintain minimum condenser water flow
at 1.5ft/sec
•Identifying the condenser water flow rate and
condenser water temperature differentials at 10%
load points
 3300gpm
Condenser water 1135 tons
circuit with 55 f
entering
condenser water
and 1100 tons of
Cooling load 1650GPM
each pump
55f
2434GPM

61f

3f
825 tons Heat
Approach
Exchanger
Design

69.6f
61f

433GPM through each condenser Job Site Example

155 tons each condenser at 25% cooler load
 2200gpm
Chilled water circuit 1100 tons
with 67 f return chilled
67f
water temperature and
1100 tons of Minimum 3f
Heat
Cooling load Exchanger Approach
Design

58f

825 tons

1100GPM
55f
each pump

Job site
1100GPM through each cooler example
137 tons each cooler or 25% load on each unit
Heat
Exchangers
Condensing
94.91 F 89.70 F 84.60 F 79.55 F 75.41 F 73.34 F 71.70 F 70.72 F
Temp
Cooler Wall
54.84 F 54.87 F 54.89 F 54.91 F 54.92 F 54.92 F 54.92 F 54.93 F
Temp
Suction
54.73 F 54.78 F 54.83 F 54.87 F 54.89 F 54.88 F 54.89 F 54.90 F
Temp Minimum Refrigerant temperature
differential is 15 deg f

Condenser
8.6 deg f X 433GPM/24= 155 Tons at 25% of cooler capacity

433GPM= 1.5 ft/sec condenser water fluid velocity

69.9 deg f – 54.9 deg f= 15 deg f minimum refrigerant temperature differential

69.9 deg f (condenser refrigerant temperature) – 8.6 deg f (condenser temperature

differential) – 1 deg f (approach) = 60.3 deg f minimum entering condenser water
temperature

Cooler
3.0 deg t X 1100GPM/24= 137 tons

55 deg f LCHW/58 deg f ECHW at 1100GPM = 25% of capacity

Heat Exchangers
TWO BASIC HEAT BALANCES OCCUR IN THE HEAT
EXCHANGERS:

(1) (Cooler) HEAT GIVEN OFF BY THE FLUID TO THE REFRIGERANT AS IT PASSES
THRU THE TUBES

(2) (Condenser) THE OVERALL TRANSFER OF HEAT FROM THE REFRIGERANT IN THE
SHELL TO THE FLUID IN THE TUBES

Heat Out

Condenser
Compressor
Metering
Device Evaporator

Heat In

Heat In
 IMPACT OF FLUID VELOCITY
FLUID FLOWING THRU A TUBE FORMS A STATIC FILM
OR BOUNDARY LAYER WHICH HAS A ZERO VELOCITY
AT THE TUBE WALL. THIS FILM ACTS AS AN INSULATOR
AND HINDERS THE FLOW OF HEAT FROM THE TUBE WALL.
THE LOWER THE VELOCITY, THE THICKER THE FILM, AND
THE HIGHER THE RESISTANCE TO HEAT FLOW.

IN SELECTING A HEAT EXCHANGER, THE WATER FLUID VELOCITY

SHOULD BE KEPT BETWEEN 3 AND 12 FEET PER SECOND.
VELOCITIES LESS THAN 1.5-3FPS RESULTS IN LAMINAR FLOW
(THICK FILM LAYER BOUNDARY), WHICH CAUSES THE
APPROACH TO INCREASE DRAMATICALLY. THE HIGHER
LIMIT IS ARBITRARY AND IS BASED ON REASONABLE
PRESSURE DROP WHILE MINIMIZING TUBE EROSION.

Fluid Film Fluid

Boundary
Tube
Potential for Erosion
IN ORDER FOR EROSION TO OCCUR, AN AGENT MUST PENETRATE
THE FLUID LAYER. AGENTS THAT CAUSE TUBE DAMAGE CAN BE
CHEMICAL, MECHANICAL, OR A COMBINATION OF BOTH. CHEMICAL
AGENTS DIFFUSE THROUGH THE LIQUID TO ATTACK THE TUBE.
MECHANICAL AGENTS CAUSE DAMAGE BY THE IMPINGEMENT
OF ENTRAINED GAS BUBBLES OR SUSPENDED MATERIALS
AGAINST THE TUBE WALL.

FLUID VELOCITY IN ITSELF DOES NOT CAUSE TUBE

DAMAGE. TESTS HAVE PROVEN THAT FLUID VELOCITIES
OF 24 FPS DID NOT RESULT IN DAMAGE WITH A PURE FLUID.
Particulate

Fluid Film Fluid

Boundary
Tube
 HIGH PERFORMANCE TUBING

THE HEAT TRANSFER COEFFICIENT OF BOILING

OR CONDENSING REFRIGERANT IS SEVERAL TIMES
LESS THAN THAT OF THE WATER FLOWING THROUGH
THE TUBES. THE OUTER SURFACES OF THE TUBES ARE
USUALLY FINNED BY ROLLING GROOVES IN THE TUBES.
THE NET RESULT IS AN INCREASED SURFACE AREA OF
4-5 TIMES THE INTERNAL TUBE SURFACE AREA. THIS
ADDITONAL AREA REDUCES THE REFRIGERANT FILM
BOUNDARY ON THE OUTSIDE OF THE TUBE. THIS IS
REDUCED EVEN FURTHER BY THE 40+ FIN PER INCH
TUBES WITH THE OUTSIDE FINS BENT OVER.
The Internal Enhancements Can Operate To A Minimum
Of 1.5 Feet Of Water Fluid Velocity Per Second Without A
Laminar Flow Condition Occurring.
 *Caution*
Do not push the operating minimum flow rate
to the point of Laminar flow
Just because the tube design will prevent a laminar condition
Until you reach a water fluid velocity of 1.49 feet per second, do not
Try to operate it to 1.5 feet per second. If you start with a
10psi water pressure differential at a flow rate of 1000gpm at
6 feet per second, the flow rate can be reduced to 250gpm at
1.5 feet per second. The water pressure differential is .70psi.

Did you specify the components to measure this accurately?

At a fluid velocity of 2 feet per second and a water flow rate of

315gpm, the water pressure Differential is 1psi. The difference
In energy consumption between 25% of water flow and 31%
Is approximately 1.5% in pumping energy.
 Example of changes to a heat exchanger
with a reduction in chilled water flow
Design- Actual-
1000gpm with 20.0ft 333gpm with 2.21ft water
(8.6psi) water pressure pressure differential at
differential at 6.0ft/sec of 2.0ft/sec of water fluid
water fluid velocity velocity

Pumping Energy is
reduced by 90% with
a reduction in
Water pressure system head
differential is requirements
2.21ft or 0.9psi

The chilled water temperature differential 333gpm

is the same as the original design
Increasing the system reliability
with a VPF chilled water system
 Increasing reliability in a VPF System:

Do not select a heat exchanger with a low fluid

Velocity at the maximum chilled water flow rate in a
VPF System-

Ideal Poor Choice

Heat Heat
Exchangers Exchangers
Cooler Tube Cooler Tube
5.23 ft/s 3.23 ft/s
Vel Vel
1200.0 1200.0
Flow Rate Flow Rate
gpm gpm
Pressure 16.7 ft Pressure 10.1 ft
Drop wg Drop wg
 Increasing reliability in a VPF System:

Do not push the minimum flow rate to the point of

Laminar flow-

Design CHWF Minimum CHWF

Heat Heat
Exchangers Exchangers
Cooler Tube Cooler Tube
5.23 ft/s 2.00 ft/s
Vel Vel
1200.0 458.0
Flow Rate Flow Rate
gpm gpm
Pressure 2.43 ft
Pressure 16.7 ft
Drop wg Drop wg
Increasing system reliability in a VPF System:

Controlling the minimum water flow rate-

How are you going to maintain the minimum flow rate?

Are you Going To install a minimum flow by-pass or

specify a certain number of three Way valves to provide
the minimum flow rate?

The use of three way valves will slightly increase the pumping
Cost, but it will remove control of the minimum flow from the
Building Automation System and increase the system reliability.
Increasing system reliability in a VPF System:

Controlling the minimum water flow rate(continued)-

How are you going to maintain the minimum flow rate?

If we are going to establish a minimum flow rate, why
Not set the variable frequency drive minimum to match
The minimum water flow rate?

If the minimum flow Rate is 30% of the pump design, set the hertz
or minimum speed at 30% of the motor rating and measure the flow rate
With a flow meter or by using heat exchanger pressure differential. Identify
The frequency at which the minimum flow rate is produced and use that
For a minimum operating speed.
Increasing system reliability in a VPF System:

Maximum rate of chilled water flow change:

The chilled water “Rate of Change” for a Chiller

should not exceed --% of the design flow rate per minute.

*See two following slides for guide lines from the

Applications group
19XR/V Variable Evaporator Flow Guidelines:
1. Maintain a fluid velocity of 1.5 ft/s or greater at all times. When the fluid
velocity is below 3 ft/s, sediment begins to dropout of the fluid stream and
increases the approach across the tubes. The sediment in the tubes will be
removed when the fluid velocity is increased to greater than 3 ft/s. Constant
speed pumps should provide a fluid velocity of 3 ft/s or greater.
2. Maximum change in load is 30% per minute. For example if the full flow is
1000gpm then the max change in flow per minute is 300 gallons.

23XRV Variable Evaporator Flow Guidelines:

1. Maintain a fluid velocity of 1.5 ft/s or greater at all times. When the fluid
velocity is below 3 ft/s, sediment begins to dropout of the fluid stream and
increases the approach across the tubes. The sediment in the tubes will be
removed when the fluid velocity is increased to greater than 3 ft/s. Constant
speed pumps should provide a fluid velocity of 3 ft/s or greater.
2. Maximum change in load is 70% per minute. For example if the full flow is
1000gpm then the max change in flow per minute is 700 gallons.

30XW Variable Evaporator Flow Guidelines:

1. Maintain a fluid velocity of 1.5 ft/s or greater at all times. When the fluid
velocity is below 3 ft/s, sediment begins to dropout of the fluid stream and
increases the approach across the tubes. The sediment in the tubes will be
removed when the fluid velocity is increased to greater than 3 ft/s. Constant
speed pumps should provide a fluid velocity of 3 ft/s or greater.
2. Maximum change in load is 10% per minute. For example if the full flow is
500gpm then the max change in flow per minute is 50 gallons.
30HX Variable Evaporator Flow Guidelines:
1. Maintain a fluid velocity of 1.5 ft/s or greater at all times. When the fluid
velocity is below 3 ft/s, sediment begins to dropout of the fluid stream and
increases the approach across the tubes. The sediment in the tubes will be
removed when the fluid velocity is increased to greater than 3 ft/s. Constant
speed pumps should provide a fluid velocity of 3 ft/s or greater.
2. Maximum change in load is 10% per minute. For example if the full flow is
500gpm then the max change in flow per minute is 50 gallons.

**Please note: The % change in load per minute guidelines must

be communicated to design engineer and controls installer.

It is possible to reduce energy use by varying the flow on the evaporator, the
same logic does not always apply to condenser water flow rate reduction.
Condenser water flow should be constant unless head pressure control is
required.
Maintaining a constant ΔT through the condenser increases the amount of
energy used by the chiller at part load conditions.
Increasing system reliability in a VPF System:

Location of the minimum chilled water

flow bypass

When the unit is in 100% bypass, the total loop volume

is now from the MFB (bypass) back to the chillers or an option is the
addition of a tank to add water volume

The loop volume ideally be 3 gallons or more per ton of the

Cooling Capacity, so that should be taken into consideration
When locating the minimum chilled water flow bypass
Ideal Location Typical
Location
Increasing system reliability in a VPF System:

Oversize the Chilled Water Pump

To take advantage of tower reduction providing an increase in

capacity, if the chilled water pump is oversized, it will delay or
Eliminate the need to start a second chiller.
 Increasing system reliability in a VPF System:

The size and number of chilled water valves

The loop volume should be 3 gallons or more per ton of

Cooling Capacity. However some job sites have a small
Volume of water with a small number of chilled water valves.
In this situation, the speed of the valve movement is critical.
A slower valve opening/closing increases the chiller reliability.

CHW CHW
Return CHW Supply Return
Increasing system reliability in a VPF System:

Does the system have the instrumentation in

place to control a VPF system?

It is critical that the system have the necessary flow

meters, differential pressure sensors, and valves in the
system for proper operation. In addition, these devices
should be selected for the system requirements. The
Accuracy of the instrumentation should be factored into the
Recommended minimum/maximum water flow limits.