R4 Chiller Plant Sequence of Operation001

PNU P3-Chiller Plant Sequence of Operation 06-DEC-2012
Chiller Plant Sequence of Operation

Sequence of Operation - Chiller Plant
System Description
This project Princess Nora Bint Abdurrahman University consists of 26 Chillers and 10 Chillers for
Future expansion with two chillers in series forming a group of 13 chiller trains. Each chiller train has
one primary pump, two condenser water pumps, eighteen radiators and two expansion tanks.
The chillers are divided in two sets consisting of six and seven chiller trains in each set. Two set of
secondary chilled water pumps are provided with three and four pumps in each set respectively. Two
thermal energy storage tanks are provided. Two set of Pumps with Five pumps in each set and a set
of Nine Heat Exchangers are provided for charging and discharging the Thermal storage tanks. Two
set of makeup water pumps are provided with two pumps in each set serving chilled water and
condenser water respectively.
A set of chiller train has the following instruments connected for control and monitoring
 Supply Temperature Sensor
 Return Temperature Sensor
 Flow Meter
 Butterfly Valves
The Primary Chilled water pump has the following instrument connected for control and
monitoring
 Current Sensing Device
Each Condenser water pump has the following instrument connected for control and monitoring
 Current Sensing Device
 Butterfly Valve
 Flow Meter
 Inlet Temperature
 Outlet Temperature
Each Radiator the following instruments connected for control and monitoring
 Butterfly Valve
Each Expansion tank has the following instrument connected for monitoring
 Pressure sensor
Chiller Plant SOP R5 Page 1 of 17
Johnson Controls Inc

Each set of Secondary Chilled water pumps consists of the following instrument connected for
control and monitoring
 Pressure sensors
 Temperature Sensors
 Flow Meters
 Flow Switch
Thermal Energy Storage Tanks and consists of the following instrument connected for control
and monitoring
 Butterfly Valve
 Radar Level Sensor
 Flow Meter
 Flow Switch
TES Pumps set consists of the following instrument connected for control and monitoring
 Butterfly Valves
Heat Exchangers consists of the following instrument connected for control and monitoring
 Solenoid Equipped Flow Balancing Valves
 Pressure sensors across the Balancing Valves
 Flow Meter
 Flow Switch
 Butterfly Valve
The chiller plant is divided into two sub chiller plants as follows:
Sub Chiller Plant 1 serving Utility Tunnel:
 6 chiller trains (1, 2, 3, 4, 5, and 6 ): each chiller train consists of one primary pump (6225 GPM),
two chillers in series, two condensing water pumps (6935 GPM) and Eighteen Radiators.
 3 Secondary Pumps (13500 GPM).
Sub Chiller Plant 2 Serving Buried Site Network:
 7 chiller trains (7, 8, 9, 10, 11, 12, and 13): each chiller train consists of one primary pump (6225
GPM), two chillers, two condensing water pumps (6935 GPM) and Eighteen Radiators.
 4 Secondary Pumps (13500 GPM).

The controls are achieved with following individual controls as follows
Controller/ DDC NO Description Controls

Valve Status monitor for Chilled Water
Valve Status monitor for Chilled
DDC-7.07.0-BF-0010 supply & return line for Chiller Plant-1 &
Water supply & return line
Chiller Plant -2
Group of two chillers it's respective, primary
chilled water pump, condenser water
Chiller controller for CH-7.07.0-GR- pumps one per chiller (total 2), condenser
DDC-7.07.0-GF-0001A
01 . water chemical treatment unit 1 per circuit
(total 2), Expansion tanks 1 per chiller (total
2).
Butterfly valve monitor for CH- Monitor the position of butter fly valves for
DDC-7.07.0-GF-0001B
7.07.0-GR-01 group of two chillers
DDC-7.07.0-GF-0101C Radiator Controller for CH-7.07.0- Controls the radiator for first chiller in
DDC-7.07.0-GF-0201C GR-01 Group CH-7.07.0-GR-01
DDC-7.07.0-GF-0102C Radiator Controller for CH-7.07.0- Controls the radiator for second chiller in
DDC-7.07.0-GF-0002A
2).
DDC-7.07.0-GF-0002B
DDC-7.07.0-GF-0003A
2).
DDC-7.07.0-GF-0003B
DDC-7.07.0-GF-0004A
2).

DDC-7.07.0-GF-0004B
DDC-7.07.0-GF-0005A
2).
DDC-7.07.0-GF-0005B
DDC-7.07.0-GF-0006A
2).
DDC-7.07.0-GF-0006B
DDC-7.07.0-GF-0007A
2).
DDC-7.07.0-GF-0007B


DDC-7.07.0-GF-0008A
2).
DDC-7.07.0-GF-0008B
DDC-7.07.0-GF-0009A
2).
DDC-7.07.0-GF-0009B
DDC-7.07.0-GF-0010A
2).
DDC-7.07.0-GF-0010B
DDC-7.07.0-GF-0011A
2).


DDC-7.07.0-GF-0011B
DDC-7.07.0-GF-0012A
2).
DDC-7.07.0-GF-0012B
DDC-7.07.0-GF-0013A
2).
DDC-7.07.0-GF-0013B
Secondary Pump Sequencer Chiller Controls secondary pumps (4 Nos) for
DDC-7.07.0-GF-0001D
Plant-1 Chiller Plant-1
Controls butterfly valves at suction &
Valve Controller Secondary Pump
DDC-7.07.0-BF-0011 discharge of each secondary pump for
Chiller Plant-1
Chiller Plant-1
Controls butterfly valves at each air
Valve Controller Chilled water line
DDC-7.07.0-BF-0003 separators in chilled water line pump for
air separators Chiller Plant-1
Chiller Plant-1
Secondary Pump Sequencer Chiller Controls secondary pumps (3 Nos) for
DDC-7.07.0-GF-0002D
Plant-2 Chiller Plant-2
Controls butterfly valves at suction &
Valve Controller Secondary Pump
DDC-7.07.0-BF-0012 discharge of each secondary pump for
Chiller Plant-2
Chiller Plant-2
Controls butterfly valves at each air
Valve Controller Chilled water line
DDC-7.07.0-BF-0004 separators in chilled water line pump for
air separators Chiller Plant-2
Chiller Plant-2

Network Mains Bypass at chiller plant network beginning, linking the supply of Utility Tunnel to that
of the Buried site Network and return of Utility Tunnel to that of buried site Network will always be
Open. Both Groups of secondary pumps are connected by a bypass line installed before the them to
have balanced sharing of load from Buried site Network and return of Utility Tunnel.
Sequence of operation
Addition & Subtraction of chillers in the sequence:
Based on the building heat load the chilled water valves of the AHU & Terminal units will modulate.
The secondary chilled water pump runs to maintain the constant header pressure.
Thus based on the building heat load the total chilled water flow in the chilled water circuit & hence
in the decoupler will change, as sensed by the flow transmitter in the decoupler line.
Based on the above logic the NAE55 controller in DDC- 7.07.0-GF- 0001M2 (chiller sequencer-1) will
decide the number of chillers to be added/subtracted for chiller plant-1. The NAE55 controller in
DDC- 7.07.0-GF- 000M3 (chiller sequencer-2) will decide the number of chillers to be
added/subtracted required for chiller plant-2.
If the chilled water flow in the decoupler is reduce below the adjustable set point OR The supply
Chilled water temperature of all running chillers higher than the Supply temperature setpoint by
1 Deg C (Adjustable) the chiller sequencer will add one chiller to the sequence and Tr - Ts > ∆T,
here ∆T = 8.9O C .
If the chilled water flow in the decoupler is Increase Above the adjustable set point and
( Ts - Tr ) ≤ [ (y) x (Design ∆T) ]
Where: y = 1 - (1 ÷ # of On-line Chillers)
Ts = Common Supply chilled water temperature (CHWMS-TS0002 & CHWMS-TS0001 for First
and second plant respectively), Tr=Common return Chilled water Temperature (CHWMR-TS0001
& CHWMR-TS0002 for First and second plant respectively)
The chiller sequencer will drop one chiller from the sequence.
At any time at least one chiller will run from each chiller plant.
In addition to above if the thermal storage unit is in the charging mode the chiller sequencer will
add the number of chillers required for thermal storage systems as determined by thermal
storage tank sequencer.
Each time the chiller sequencer will add or subtract chiller based on
 The chiller with minimum/Maximum running hours.


 Chiller healthy (ready) signal from chiller controller.
Chiller Startup:
Chiller Train Modified Sequence

1. The Chiller train Enabled through Sequencer .Minimum Off time for chiller Train is 10 minutes
and minimum On time for chiller train is 10 minutes (Snapshot-1).
2. If there is no Alarm for Chiller A and Chiller B (including Chiller Common Alarm or Chiller
Mismatch Alarm), and Hi-temperature alarm is normal then MOV # 2 is commanded Open
(Snapshot-2).
MOV #2 will remain open until Primary Pump CMD/STS is ON and will close only if both
CMD/STS is OFF with a time delay of 300 sec.
3. If MOV#2 open Status is proven, all alarms (PP NF, PP Trip, PP Mismatch) are normal, Primary
Pump is in Auto and Evaporator Manual Valve is Open then Primary Pump Command will be ON
with a Delay of 40 Sec.(Snapshot-3)
Primary Pump command will be ON until either of the chiller status is ON. In event of any alarm
or any manual valve/mov#2 closing the Primary Pump command will be OFF.
4.After the Chiller train is enabled , if the MOV#11 status is proven, condenser#2 manual Valve
is open , Radiator#2 manual Valve is open and all alarms (CP2 NF,CP2 Trip, CP2 Mismatch, Chiller
B MM/CH B common Alarm, RAD2 Fault) are normal,CP2 will be commanded ON (snapshot-4).
The Condenser Pump#2 Command will remain ON until 240 sec after Chiller B Status is OFF.
5. After the Chiller train is enabled , if the MOV#7 status is proven, condenser#1 manual Valve is
open, Radiator#1 manual Valve is open and all alarms (CP1 NF,CP1 Trip, CP1 Mismatch, Chiller A
MM/CH A common Alarm, RAD1 Fault) are normal,CP2 will be commanded ON (snapshot-5).
The Condenser Pump Command #1 will remain ON until 360 sec after Chiller A Status is OFF.
6.After the CP2 Status is proven, RAD#2 manual Valve open Status is proven and All Alarms are
normal (including CP2 alarms and CH B alarms) the Radiator#2 command is ON (snapshot-6).
RAD#2 command will be on until Chiller B status is On and RAD#2 command will be Off after
delay 360 sec of Chiller B status OFF.
7. After the CP1 Status is proven, RAD#1 manual Valve open Status is proven and All Alarms are
normal (including CP1 alarms and CH A alarms) the Radiator#1 command is ON (snapshot-7).

RAD#1 command will be on until Chiller A status is On and RAD#1 command will be Off after
delay 360 sec of Chiller A status OFF.
8.When RAD#2 Status is proven, Condenser Flow is proven, Evaporator flow is proven and all
alarms are normal then Chiller B will be Command is ON (snapshot-8).
In event of any alarm in Condenser pump 2 , the chiller B will shut down immediately.RAD2
command will go OFF when the CP2 status goes OFF with a delay of 120 Sec.
In event of any alarm in Radiator 2 , the chiller B will shut down immediately.CP2 command w ill
go OFF with in 360 sec .
In event of any alarm in Chiller B , the chiller B will shut down immediately.RAD2 command will
go OFF with in 120 sec and CP2 command will go OFF with in 360 sec .
9.When RAD#1 Status is proven, Condenser Flow is proven, Evaporator flow is proven, Return
Temperature is above 10 Deg C (0.9 differential) and all alarms are normal then Chiller A will be
Command is ON (snapshot-9).
In event of any alarm in Condenser pump 1 , the chiller A will shut down immediately.RAD1
command will go OFF when the CP1 status goes OFF with a delay of 120 Sec .
In event of any alarm in Radiator 1 , the chiller A will shut down immediately.CP1 command will
go OFF with in 360 sec .
In event of any alarm in Chiller A , the chiller A will shut down immediately.RAD1 command will
go OFF with in 120 sec and CP1 command will go OFF with in 360 sec .
10.Radiator High temperature Alarm Then the chiller command will be Off and only Condenser
Pump and Radiator command will be ON (snapshot-10)

Chiller Faults
Chiller healthy bit is set off in following conditions & the alarm is generated in the BMS.
 Not receipt of open status for manual butterfly valves.
 Failure for condenser or evaporator butterfly valve status.
 Failure of radiator valve status.
 Radiator Fault/Alarm.
 Condenser Pump Fault/ Alarm or failure of status.
 Primary Pump Fault/ Alarm or failure of status.
 Low flow of condenser water flow after 30 Sec (adjustable) once the condenser pump is
started.
 Low flow of evaporator water after 30 Sec (adjusted) once the primary pump is started.
 Chiller Alarm/ Fault.
 Return Condensing water (Chiller inlet) Temperature Higher Than Return Condensing water
Temperature high limit (Adjustable)
Chiller Stop:
Chiller DDC controller will perform following sequence to stop the operating chiller
 Disable the chiller; this will stop the chiller compressor.
 Once the chiller is disabled the Primary and condenser pumps will be running until receive
off status from the Chiller, during this period the Evaporator and the condenser Valves will
be open until receive the off status from the relative pump.
 After receive off status from condenser pumps radiator fans will stop.
Load Sharing Between Two Sequencers:

If the chillers running in either of sub chiller plants does not satisfy the demand of their respective
load then a request will be sent from the deprived sequencer to the other sequencer to stage up one
more chiller.

Secondary Loop
Secondary Pumps are controlled by their dedicated PLC controller and BMS will pass the
differential pressure reference from four different locations as per the design requirement. The
four chambers are chamber # 23 in MSSH 1, chamber # 24 in MSSH 2, Chamber # 3 in Tunnel
and chamber # 40 in SSH10. These chambers are connected through their respective DDC panels
DDC-8.09.01-GF001, 8.09.03-GF0001, 8.03.0-UT0064 AND DDC-OSN-IC0026. BMS will check
reliability of individual supply and return pressure sensor of each chamber. If both sensors are
reliable then it will pass the difference of supply and return pressures to PLC. If anyone pressure
sensor is unreliable than it passes a zero value to PLC. This condition is valid for all chambers.
BMS will also calculate the average of reliable pressure sensors. If any pressure sensor of any
chamber is unreliable then it will automatically go out of calculation and average of reliable
pressure sensors will be passed to PLC. By default BMS is passing average of reliable pressure
sensors to PLC. Provision is provided for the BMS operator to select any differential pressure of
any chamber as a reference for PLC.
Thermal Storage Tanks
System Description
Thermal Energy Storage
To assist in energy savings and efficiency, Thermal Energy Storage technology is used. This
system allows chilled water to be produced at off-peak or low demand times and to then be
discharged at peak demand times.
The system consist of
 Thermal storage tanks (2 Nos.)

 Constant volume TES Pump set-1 (with 5 Pumps)
 Constant volume TES Pump set -2 (with 5 Pumps)
 Heat exchangers (9 Nos.)

All pumps & motorized valves are controlled directly by the BMS as per the operation sequence
bellow.
All other instruments as indicated in the system schematic diagram are connected to BMS for
monitoring of the system.
The electromagnetic flow meters are used to monitor the system continuous operation.
Thermal storage tank’s temperature gradient over the tank height is monitored through the
associated temperature sensors connected to BMS.
The main components of this system are:
Heat Exchangers: These are used in two modes - charging or cooling the stored water and for
cooling the water in the distribution network. Both primary and secondary flow through the
Heat Exchangers is reversed in charging and discharging modes using the installed motorized
valves.
Thermal Storage Tanks: These are used for storing the pre-cooled water for later use.
Thermal Storage Pumps: Two sets of pumps are used. One set (TES Pumps 1) circulates
stored water from the tanks through the heat exchangers for cooling and for discharging the
stored chilled water. The second set of pumps(TES Pumps 2) are used for circulating chilled
water from the distribution network through the heat exchangers for wither pre-cooling prior to
returning to the chillers or for cooling and discharge to the network.
The installed system operates in 5 modes (refer attached diagrams):
Mode 1 – TES Charging By Secondary
In this mode, chilled water produced by the main plant is circulated through the Heat
Exchangers directly by the installed Secondary CHW Pumps from the supply side of the
distribution network piping. The return water is returned to the main CHW distribution return
pipe work.
Water to be cooled is circulated from the Thermal Storage Tanks through the secondary side of
the Heat Exchangers using TES Pumps 1, cooled to 6C and returned to the TES Tanks. This is then
stored for future use.
During this mode full distribution to the main network is also available.
Refer to attached drawing and valve matrix for main valve positions.
Mode2 – TES Charging By TES Pumps

In this mode, chilled water is drawn directly from the primary CHW piping and circulated
through the heat exchangers, using TES Pump set 2, typically while the Secondary CHW
distribution pumps are off.
Water to be cooled is circulated from the Thermal Storage Tanks through the secondary side of
the Heat Exchangers using TES Pump set 1, cooled to 6C and returned to the TES Tanks. This is
then stored for future use.
MODE 3 – TES Discharge To Network
In this mode, water is drawn from the return pipe work of the CHW distribution system by TES
Pump set 2 and circulated through the Heat Exchangers. The Chilled Water stored in the TES
tanks is circulated through the primary side of the heat exchangers using TES Pumps Set 1 to
cool the chilled water down. This is then returned to the supplement or replace the existing
CHW production plant capacity. Water from the return network is distributed through the heat
exchangers, cooled and returned directly to the Secondary CHW distribution pumps.
Mode 4- TES Discharge to Chillers
In this mode water is taken from the network return and circulated through the Heat
Exchangers for pre-cooling before being returned directly to the main chiller inlet headers to
lower the water temperature prior to entering the chillers. Both TES Pumps 1 and 2 operate in
this mode.
Stand By Mode.
In this mode the main chilled water plant produces chilled water for direct distribution to the
various facilities. All pumps and heat exchangers etc. are in the OFF position and isolated from
the main CHW loops.
Sequence of Operation
The Thermal Storage System will be enabled or disabled by the operator from BMS work station.
When disabled the systems will be in Standby Mode.
When enabled the system will be in Stand By or Changing or discharging mode, as per set time
schedule or mode selected from BMS operator station.
Stand By Mode:

In standby mode chillers will run to serve the building heat load. Thermal storage system will be
isolated from chilled water loop.
TES Pump Set-1 & TES Pump Set-2 will be disabled.
For motorized butterfly valve positions refer the valve matrix in Appendix-1 & the system
schematics in Appendix-2.
Charging Mode:
During the off load conditions the Charging mode can be enabled based on time schedule or
mode selection from BMS operator station.
To enable charging mode in addition to above conditions, if the chiller plant should have spare
capacity of minimum 2 chillers after satisfying the building heat load.
In this condition any one thermal storage tank will be charged through the chiller plant.
Based on the operator selection the system will run following charging modes
Charging by Secondary Pumps:
The valves are set to the positions as mentioned in the valve matrix.
In this mode TES Pump set-1 will be enabled once the required valve status is proved open.
Based on the healthy status of the pumps & the running hours, the system will run 2 pumps in
the group & 3 pumps will act as stand by pump.
If the status of any of the pump fails the alarm will be generated in BMS & faulty pump will be
replaced by standby pump in the sequence.
Charging by TEC Pumps:
In this mode both TES Pump set-1 & TEC Pump Set-2 will be enabled once the required valve
status are proved open.
Based on the healthy status of the pumps & the running hours, the system will run 2 pumps
from TEC Pump set-1 & 2 pumps from TEC Pump set-2. 3 pumps in each group will act as stand
by pump.

Discharging mode:
In this mode the chilled water stored in the thermal storage tanks is used to satisfy the building
load.
During the peak load conditions the Discharging mode can be enabled based on time schedule
or mode selection from BMS operator station.
When the discharging mode is enabled message will appear on the operator screen to select
“Discharge to Chiller” mode or “Discharge to Network” mode.
Based on the operator selection system will operate in one of the bellow modes.
Discharge to Chiller:
by pump.
Discharge to Network:
by pump.
Tank 1 & Tank 2 MOV:
In any mode charging or discharging operator can select any tank as per requirement.

Valve Matrix in Different Modes
Charge By
Stand Charge By Discharge Discharge
Valve Secondary
By TES Pumps To Chiller To Network
Pump
TES-MOV0001 Close Open Open Close Close
TES-MOV0002 Close Close Close Open Open
TES-MOV0011 Close Close Open Close Close
TES-MOV0013 Close Close Open Close Close
HEX-MOV0001 Close Open Close Close Close
HEX-MOV0003 Close Open Open Open Open
HEX-MOV0006 Close Close Open Close Open
HEX-MOV0007 Close Close Close Open Close
HEX-MOV0008 Close Close Open Close Open
HEX-MOV0009 Close Close Close Open Close
HEAT
EXCHANGER Close Open Open Open Open
VALVES
Tank valve Matrix in Different Modes


Charge By
Stand Charge By Discharge Discharge
Valve Secondary
By TES Pumps To Chiller To Network
Pump
TANK 1
TES1 MOV001 Close Open Open Open Open
TANK 2
End of Section

R4 Chiller Plant Sequence of Operation001

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PNU P3-Chiller Plant Sequence of Operation 06-DEC-2012

Chiller Plant Sequence of Operation

Chiller Plant SOP R5 Page 1 of 17

Johnson Controls Inc

Sub Chiller Plant 1 serving Utility Tunnel:

 3 Secondary Pumps (13500 GPM).

Sub Chiller Plant 2 Serving Buried Site Network:

 4 Secondary Pumps (13500 GPM).

Chiller Plant SOP R5 Page 2 of 17

Johnson Controls Inc

The controls are achieved with following individual controls as follows

Controller/ DDC NO Description Controls

Chiller Plant SOP R5 Page 3 of 17

Johnson Controls Inc

Controller/ DDC NO Description Controls

Chiller Plant SOP R5 Page 4 of 17

Johnson Controls Inc

Controller/ DDC NO Description Controls

Group of two chillers it's respective, primary

Chiller Plant SOP R5 Page 5 of 17

Johnson Controls Inc

Controller/ DDC NO Description Controls

Chiller Plant SOP R5 Page 6 of 17

Johnson Controls Inc

( Ts - Tr ) ≤ [ (y) x (Design ∆T) ]

Where: y = 1 - (1 ÷ # of On-line Chillers)

 The chiller with minimum/Maximum running hours.

Johnson Controls Inc

 Chiller healthy (ready) signal from chiller controller.

Chiller Train Modified Sequence

Chiller Plant SOP R5 Page 8 of 17

Johnson Controls Inc

Chiller Plant SOP R5 Page 9 of 17

Johnson Controls Inc

 Not receipt of open status for manual butterfly valves.

 Failure for condenser or evaporator butterfly valve status.

 Failure of radiator valve status.

 Condenser Pump Fault/ Alarm or failure of status.

 Primary Pump Fault/ Alarm or failure of status.

 Chiller Alarm/ Fault.

 Disable the chiller; this will stop the chiller compressor.

Load Sharing Between Two Sequencers:

Chiller Plant SOP R5 Page 10 of 17

Johnson Controls Inc

Thermal Storage Tanks

Thermal Energy Storage

The system consist of

 Thermal storage tanks (2 Nos.)

Chiller Plant SOP R5 Page 11 of 17

Johnson Controls Inc

The main components of this system are:

The installed system operates in 5 modes (refer attached diagrams):

Mode 1 – TES Charging By Secondary

Mode2 – TES Charging By TES Pumps

Chiller Plant SOP R5 Page 12 of 17

Johnson Controls Inc

MODE 3 – TES Discharge To Network

Mode 4- TES Discharge to Chillers

When disabled the systems will be in Standby Mode.

Chiller Plant SOP R5 Page 13 of 17

Johnson Controls Inc

TES Pump Set-1 & TES Pump Set-2 will be disabled.

Charging by Secondary Pumps: