Figure 47 - Primary Vs.
Secondary Flow
Figure 47 shows primary flow vs. secondary flow.
Secondary flow is based on the load in the
100
building. Specifically, the secondary flow rate is
Primary Flow
produced to maintain the necessary system
75
pressure differential. Primary flow must always
meet or exceed the secondary flow. Any excess
% Flow
50
primary water flows through the decoupler to the
Secondary Flow return side and back to the chillers. Any time the
25
primary flow is less than the secondary flow,
warm return water will flow “backwards” through
0
0 25 50 75 100
the decoupler and mix the primary flow going out
% Plant Load to the building.
Decoupler Sizing
Decouplers should be sized for the flow rate of the largest primary pump. This may be more than the
design flow rate of the largest chiller if overpumping is being considered. The pressure drop should
not exceed 1.5 ft. As the pressure drop through the decoupler increases, it tends to make the primary
and secondary pumps behave like they are in series.
Figure 48 - Decoupler Sizing
To avoid thermal contamination, the
decoupler should be at least three
Minimum 10 pipe Decoupler
Diameters From Decoupler pipe diameters in length. Longer
To First Chiller
decouplers tend to increase the
pressure drop. When the secondary
3 Pipe Diameters return flows straight through in the
Minimum Length
tee to the primary return, there
Friction Loss < 1.5 ft. should be at least 10 pipe diameters
to the first chiller. This is to help
avoid the possibility of having
stratification in the primary return
line, which can lead to unmixed
water to the first chiller. This can
lead to chiller cycling.
Decoupler Location
The location of the decoupler
line will change how the ſTip: In situations where a new chiller is added to an older
chillers are loaded. Figure 43 existing chiller plant, relocating the decoupler can take full
shows the typical layout with advantage of the new chiller’s part load performance. Older
the decoupler between the chiller may operate at 1 kW/ton or more at full load, worse at
chillers and the load. In this part load. Relocating the decoupler allows the older chillers to
situation, each chiller sees the be base loaded (their best operating point) while the new chiller
same return water temperature is operated at part load. Consider either a VFD or dual
even at part load conditions. compressor chiller for additional savings.
Figure 49 shows the decoupler line in a different location. Locating the chillers between the
secondary loop and the decoupler line causes the return water temperature to each chiller to vary.
This is often referred to as “backloading” or “preferentially” loading the chillers. Chiller 2 in Figure
49 will see close to the secondary loop return water temperature. Chiller 1 will see a mixture of
supply water and return water. As a result Chiller 2 is more heavily loaded than Chiller 1.
54 Application Guide AG 31-003-1
