Types of Cooling
Systems in
HVAC
1. Direct Expansion (DX) System
Working Principle:
Heat is absorbed directly by the refrigerant from indoor air
through an evaporator coil. The refrigerant circulates
through the compressor, condenser, and expansion valve in
a closed loop.
Main Components:
• Compressor (heart of the system, pumps refrigerant)
• Condenser (releases heat to outside air or water)
• Expansion Valve (reduces refrigerant
pressure/temperature)
• Evaporator Coil (absorbs heat from room air)
• Fans (air circulation)
Advantages:
• Compact system, easy installation.
• Lower initial cost.
• Best for small to medium spaces (residential, small
offices).
Disadvantages:
• Limited to smaller capacities.
• Lower efficiency compared to chilled water systems.
• Difficult to maintain in large buildings.
Load Capacity:
Up to 20–50 TR (Tons of Refrigeration) typically.
2. Chilled Water System
Working Principle:
Water is chilled by a chiller and circulated through chilled
water pipes to Air Handling Units (AHUs) or Fan Coil Units
(FCUs). These coils cool down the air, which is then
supplied to the conditioned space.
Main Components:
• Chiller (centrifugal, screw, or absorption type)
• Cooling Towers (in water-cooled systems)
• Pumps (chilled water pump & condenser water pump)
• AHU / FCU (air cooling distribution units)
• Piping & Valves
Advantages:
• Suitable for large buildings & complexes.
• Flexible distribution over long distances.
• High energy efficiency with water-cooled chillers.
Disadvantages:
• Higher installation cost.
• Requires large space for plant room & cooling tower.
• More complex operation and maintenance.
Load Capacity:
From 100 TR to several thousand TR (ideal for
commercial buildings, airports, malls, hospitals).
3. Evaporative Cooling System
Working Principle:
Air is cooled by evaporation of water. Warm air passes over
wet pads or sprays, and water absorbs heat from the air
during evaporation.
Main Components:
• Cooling Pads or Spray Chamber
• Water Pump & Distribution System
• Fan/Blower
• Water Reservoir
Advantages:
• Low energy consumption (uses water instead of
refrigerant).
• Simple and eco-friendly system.
• Effective in dry climates (low humidity).
Disadvantages:
• Not effective in humid regions.
• Requires continuous water supply.
• Cooling is limited (cannot achieve very low
temperatures).
Load Capacity:
Small to medium loads (up to 30–50 TR), mostly for
warehouses, factories, dry-climate offices.
4. VRV / VRF (Variable Refrigerant Volume/Flow)
System
Working Principle:
A single outdoor unit connects to multiple indoor units. The
refrigerant flow is varied using electronic expansion valves
to match each zone’s load.
Main Components:
• Outdoor Condensing Unit (inverter-driven compressor)
• Indoor Units (cassette, ducted, wall-mounted)
• Refrigerant Piping Network
• Control System
Advantages:
• Excellent zoning & flexibility (each room controlled
individually).
• Energy efficient due to inverter technology.
• No water piping → less maintenance.
Disadvantages:
• High initial cost.
• Complex piping & installation.
• Not economical for very large centralized plants.
Load Capacity:
6 TR – 200 TR (modular, scalable for medium to large
buildings).
5. Packaged Unit (PU)
Working Principle:
Factory-assembled unit containing compressor, condenser,
evaporator, and fans in a single casing. Supplies conditioned
air directly or via ducts.
Main Components:
• Compressor
• Evaporator Coil & Fan
• Condenser & Fan
• Filter Section
• Controls
Advantages:
• Compact, plug-and-play solution.
• Suitable for medium buildings (cinema halls,
restaurants).
• Less on-site installation effort.
Disadvantages:
• Limited flexibility compared to chillers.
• Larger units can be noisy.
• Less efficient than VRF or chilled water systems.
Load Capacity:
5 – 50 TR, depending on model.
6. District Cooling System
Working Principle:
Centralized chiller plant produces chilled water and
distributes it to multiple buildings through an underground
piping network.
Main Components:
• Central Chiller Plant
• Chilled Water Distribution Network
• Energy Transfer Stations (ETS) in each building
• Pumps & Valves
Advantages:
• Very high efficiency.
• Reduces equipment cost for individual buildings.
• Ideal for smart cities, campuses, business districts.
Disadvantages:
• Very high initial infrastructure cost.
• Requires extensive planning and land.
• Dependency on central provider.
Load Capacity:
Several thousand TR (largest-scale cooling).
INTERVIEW QUESTIONS RELATED TO COOLING
SYSTEMS IN HVAC
Basic Conceptual Questions
What are the main types of cooling systems used in
HVAC?
The main types of cooling systems are Direct Expansion
(DX) Systems, Chilled Water Systems, Evaporative
Cooling Systems, and Hybrid/Variable Refrigerant Flow
(VRF) Systems.
Explain the difference between DX system and Chilled
water system.
The key difference lies in the cooling medium. A DX system
uses refrigerant directly in a coil to cool the air inside the
space. This makes it a self-contained system. A chilled
water system uses a central chiller to cool water, which is
then pumped through a piping network to Air Handling
Units (AHUs) or Fan Coil Units (FCUs) in various parts of
the building to cool the air. DX is typical for small to
medium-sized applications, while chilled water systems are
used for large commercial and industrial buildings.
What is ton of refrigeration (TR) and how is it
calculated?
A Ton of Refrigeration (TR) is a unit of cooling capacity.
One TR is defined as the heat absorption rate required to
melt 1 short ton (2,000 lbs) of ice at 0°C in 24 hours. The
value is equivalent to 12,000 BTUs per hour or
approximately 3.517 kilowatts.
Define sensible cooling and latent cooling.
• Sensible cooling is the process of removing heat from
the air to lower its temperature without changing its
moisture content. This is the heat you can "sense" with
a thermometer.
• Latent cooling is the process of removing moisture
from the air by condensing it, which involves converting
water vapor into liquid water. This process removes
"latent heat" and lowers the humidity of the air.
What is the difference between air-cooled and water-
cooled chillers?
The difference is in how they reject heat.
• An air-cooled chiller uses large fans to blow ambient
air over a condenser coil, transferring heat from the
refrigerant to the outdoor air.
• A water-cooled chiller uses a separate cooling tower
to cool water, which is then circulated through the
chiller's condenser to remove heat from the refrigerant.
Water-cooled systems are generally more efficient but
require more space and maintenance due to the cooling
tower.
Explain the working principle of a VRF/VRV system.
VRF (Variable Refrigerant Flow), also known as VRV
(Variable Refrigerant Volume), is an advanced DX system
that uses a single outdoor unit connected to multiple indoor
units. It uses a variable-speed compressor to precisely
control the amount of refrigerant sent to each indoor unit.
This allows for simultaneous heating and cooling in
different zones of a building, and it is significantly more
energy-efficient than traditional systems due to its ability to
modulate its output based on the exact demand.
What is the difference between evaporative cooling and
mechanical cooling?
• Evaporative cooling cools air by evaporating water, a
natural process that absorbs heat. It is a simple, low-
energy method best suited for hot, dry climates.
• Mechanical cooling uses a vapor-compression
refrigeration cycle with a compressor and refrigerant
to actively remove heat. This method is much more
powerful and can dehumidify the air, making it suitable
for all climates, including humid ones.
How does a cooling tower work and why is it used?
A cooling tower is a specialized heat exchanger used to
reject waste heat to the atmosphere. It works by
evaporating a small amount of water to cool a larger body of
water. A fan draws air over a film of warm water, causing a
portion of the water to evaporate. This evaporation process
removes heat, and the cooled water is then returned to the
chiller's condenser. Cooling towers are essential for water-
cooled chillers and other large-scale processes that need to
efficiently dissipate heat.
What are the main components of a DX cooling cycle?
The four main components are:
1. Compressor: Raises the pressure and temperature of
the gaseous refrigerant.
2. Condenser: A coil where the high-pressure refrigerant
gas releases heat to the outside air and condenses into a
liquid.
3. Expansion Valve: Reduces the pressure of the liquid
refrigerant, causing it to cool and prepare for the next
stage.
4. Evaporator: A coil where the low-pressure refrigerant
absorbs heat from the indoor air, evaporating back into
a gas.
What is the function of an expansion valve in cooling
systems?
The primary function of an expansion valve is to reduce
the pressure of the liquid refrigerant coming from the
condenser. This pressure drop causes the refrigerant's
temperature to fall to a very low level, preparing it to
absorb heat from the air in the evaporator. It also controls
the flow rate of refrigerant entering the evaporator,
ensuring that the coil operates efficiently and doesn't get
starved or overfed.
Design & Calculation Questions
How do you calculate the cooling load of a building?
Calculating a building's cooling load is a complex process
that involves determining the total amount of heat that
needs to be removed from a space to maintain a comfortable
temperature. It's not a simple formula but a summation of
all heat gains, which are categorized as:
• External heat gains: From sunlight (solar radiation)
through windows and walls, and heat conduction
through the building envelope (walls, roof, floor).
• Internal heat gains: From people (metabolic heat),
lights, and equipment (computers, machinery, etc.).
• Ventilation load: The heat and moisture brought in by
fresh outdoor air. Specialized software and design
standards like ASHRAE are used to perform these
calculations accurately.
What factors affect cooling load calculation
(internal/external gains)?
• External Gains:
o Solar radiation through windows and skylights.
o Conduction through walls, roofs, and floors due to
temperature differences.
o Outdoor air infiltration and ventilation.
• Internal Gains:
o Occupants: Heat generated by people in the space.
o Lighting: Heat from light fixtures.
o Equipment: Heat from computers, servers,
appliances, and machinery.
o Building use: Activity levels, kitchen appliances,
etc.
What is coil bypass factor (CBF) and why is it important?
The Coil Bypass Factor (CBF) is the fraction of air that
passes through a cooling coil without coming into direct
contact with the coil surface. This air does not undergo
the cooling or dehumidification process. It is an important
factor in psychrometric calculations and system design
because it indicates the efficiency of the coil in a given
application and affects the final supply air conditions. A
lower CBF means the coil is more effective at treating the
air.
How do you size chillers for a commercial building?
Chillers are sized based on the total cooling load of the
building, which is calculated using the detailed methods
mentioned above. The total load (in BTUs/hr or kW) is
divided by 12,000 to get the required tonnage. It's crucial
to account for a safety margin (typically 10-20%) and
select a chiller (or multiple chillers) with a capacity that can
handle the peak load, as well as part-load conditions for
efficiency.
What is the typical temperature difference (∆T) in
chilled water systems?
The typical temperature difference ( ΔT) between the chilled
water supply and return lines is usually 5 to 6°C (9 to
11°F). This is a design parameter used to balance pump
energy consumption, piping size, and chiller efficiency. A
smaller ΔT requires a higher flow rate, while a larger ΔT
requires a lower flow rate.
How do you calculate chilled water flow rate?
The chilled water flow rate is calculated using the following
formula:
Q=m˙×cp×ΔT
Where:
• Q is the cooling load (in kW).
• m˙ is the mass flow rate of water (in kg/s).
• cp is the specific heat capacity of water (approximately
4.186 kJ/kg°C).
• ΔT is the temperature difference between the return
and supply water.
This can be converted to volumetric flow rate (L/s or GPM)
using the density of water.
Why is the chilled water supply temperature usually
around 6–7 °C?
The chilled water supply temperature is typically set around
6-7°C (43-45°F) because this temperature is low enough to
effectively dehumidify the air (as it is below the dew point
of the return air) while being high enough to prevent
frosting on the coils. It also balances energy efficiency, as a
lower supply temperature would require more energy from
the chiller.
What is the approach temperature in a cooling tower?
The approach temperature is the difference between the
cooled water temperature leaving the cooling tower and
the ambient wet-bulb temperature. A smaller approach
temperature indicates a more efficient cooling tower, as it is
able to cool the water closer to the theoretical minimum
temperature.
Explain primary, secondary, and tertiary pumping
systems in chilled water plants.
These systems are used to optimize chilled water
distribution in large buildings:
• Primary Loop: Consists of pumps that circulate water
through the chillers. The flow rate in this loop is
constant.
• Secondary Loop: Consists of pumps that circulate
water through the AHUs and FCUs throughout the
building. The flow rate in this loop is variable,
controlled by the cooling demand of the zones. A
decoupler line connects the primary and secondary
loops to maintain independent flow rates.
• Tertiary Loop: A third set of pumps used for very large
campuses or buildings to serve distinct zones, such as a
specific wing or floor, further optimizing flow control
and energy use.
How do you decide between a DX system and a chilled
water system for a project?
The decision depends on several factors:
• Building Size: Small to medium buildings often use DX
due to lower initial cost and simplicity. Large buildings
or campuses are better suited for chilled water systems
due to their superior efficiency and scalability.
• Initial vs. Operating Cost: DX systems have a lower
initial cost but can have higher operating costs in large -
scale applications. Chilled water systems have a higher
upfront cost but offer better long -term energy
efficiency.
• Control and Zoning: VRF/VRV DX systems offer
excellent individual zone control. Chilled water systems
provide centralized control, which can be beneficial for
managing a large building.
• Maintenance: DX systems require individual unit
maintenance. Chilled water systems have centralized
maintenance, which can be more complex but is often
more manageable for a facilities team.
Practical & Standards-Related Questions
What standards are followed for HVAC cooling design in
GCC (e.g., ASHRAE, SMACNA, DW 144)?
The main standards used in the GCC region are:
• ASHRAE (American Society of Heating, Refrigerating
and Air-Conditioning Engineers): Provides guidelines
for design, energy efficiency, and indoor air quality
(IAQ).
• SMACNA (Sheet Metal and Air Conditioning
Contractors' National Association): Offers standards
for ductwork construction and installation.
• DW 144 (Ductwork): A UK standard often referenced
for sheet metal ductwork fabrication and installation.
Local regulations and building codes also apply, often
based on these international standards.
What are the typical supply air and return air
temperatures in comfort cooling?
• Supply air temperature is typically around 12-14°C
(54-57°F). This is a balance between providing enough
cooling and preventing discomfort from a strong, cold
draft.
• Return air temperature is usually around 24-26°C (75-
79°F), which is the desired indoor temperature. The
difference between these two temperatures is known as
the temperature drop, and it's a key factor in system
design.
What is the difference between comfort cooling and
process cooling?
• Comfort cooling is for maintaining a comfortable and
healthy environment for people. The temperature and
humidity are controlled within a specific range, usually
around 24°C and 50% relative humidity.
• Process cooling is for maintaining a specific
temperature for industrial processes or equipment.
This often requires lower temperatures, higher
precision, and is critical to a manufacturing or data
center operation. The cooling load and temperature
requirements can be significantly different from
comfort cooling.
What is the COP (Coefficient of Performance) of a
chiller?
COP (Coefficient of Performance) is a measure of the
efficiency of a chiller or heat pump. It's the ratio of the
cooling output (useful effect) to the energy input (work
done by the compressor
For example, a COP of 4 means the chiller produces 4 kW of
cooling for every 1 kW of electrical energy consumed.
What is EER (Energy Efficiency Ratio) and how is it
different from COP?
EER (Energy Efficiency Ratio) is similar to COP but is
specifically used for air conditioners and is calculated at a
single, fixed set of conditions (typically 35°C outdoor
temperature).
The key difference is that COP is a dimensionless ratio
calculated in consistent units (e.g., kW/kW), while EER is a
ratio of different units (BTU/hr to Watts).
Explain the role of AHUs and FCUs in chilled water
systems.
• Air Handling Unit (AHU): A large, centralized unit that
conditions and circulates air for a building or a large
zone. It typically contains a cooling coil (fed by chilled
water), fans, filters, and a heating coil. It is connected to
a network of ducts to distribute the conditioned air.
• Fan Coil Unit (FCU): A smaller, localized unit that
provides cooling to a single room or zone. It consists of
a fan, a chilled water coil, and an air filter. FCUs are
often used for individual room control, such as in hotels
and apartments.
Why is insulation important in chilled water piping?
Insulation is crucial for chilled water piping to:
1. Prevent heat gain: It minimizes the transfer of heat
from the surrounding environment into the cold water,
ensuring the water temperature remains stable and the
chiller doesn't have to work harder.
2. Prevent condensation: The cold pipes can cause
moisture in the surrounding air to condense on their
surface, leading to water dripping, rust, and potential
damage to the building structure or equipment.
What is the difference between open loop and closed
loop cooling systems?
• Closed loop system: The fluid (e.g., chilled water) is
recirculated within a sealed system and does not
come into contact with the atmosphere. This prevents
contamination and water loss. Chilled water systems
are a prime example.
• Open loop system: The fluid (e.g., cooling tower water)
is exposed to the atmosphere during the cooling
process. This can lead to evaporation, a build-up of
impurities, and a need for water treatment. Cooling
towers are an example of an open loop system.
Why do we maintain a minimum air change rate in
buildings even when cooling demand is low?
A minimum air change rate is maintained for Indoor Air
Quality (IAQ). Fresh, outdoor air is brought in to dilute
contaminants, odors, and carbon dioxide produced by
occupants. This ensures a healthy and comfortable
environment, regardless of the cooling demand. The
minimum rate is often specified by standards like ASHRAE.
How do you control humidity in cooling systems?
Humidity is controlled by dehumidification, which is
achieved when the air passes over a cooling coil that is
below the dew point temperature of the air. As the air cools,
the moisture vapor condenses into liquid water on the coil
surface. This water is then collected and drained away,
effectively lowering the relative humidity of the air. The
coil's surface temperature is a critical factor in this process.
Troubleshooting & Maintenance Questions
What are common problems in cooling towers and how
do you fix them?
Common problems include:
• Scale formation: Mineral buildup from hard water.
Solution: Regular water treatment and chemical
descaling.
• Biological growth (algae, bacteria): Can clog pipes
and create health risks (e.g., Legionella). Solution:
Routine chemical treatment with biocides and regular
cleaning.
• Corrosion: Rusting of metal components. Solution:
Water treatment to control pH, use of corrosion
inhibitors, and protective coatings.
• Drift: Water droplets are carried out of the tower by
the airflow. Solution: Installation of drift eliminators.
What causes low suction pressure in a DX system?
Low suction pressure indicates that the compressor is not
receiving enough refrigerant vapor. Common causes
include:
• Low refrigerant charge (leakage): The most common
cause.
• Blocked or dirty air filter: Reduces airflow over the
evaporator coil.
• Blocked return vents or dirty evaporator coil : Limits
heat absorption from the air.
• Malfunctioning expansion valve: Not allowing enough
refrigerant to flow.
What happens if the condenser is dirty or airflow is
blocked?
If the condenser coil is dirty or its airflow is blocked, the
system's ability to reject heat to the outside is
compromised. This leads to a rise in the condenser's
pressure and temperature (high head pressure). The
compressor must work harder, increasing energy
consumption, reducing cooling capacity, and potentially
shortening the lifespan of the compressor.
What is air balancing and why is it important in cooling
distribution?
Air balancing is the process of adjusting the airflow
through an HVAC system to ensure that the proper amount
of conditioned air is delivered to each room or zone. It's
important for:
• Comfort: To ensure all spaces are at the desired
temperature and humidity.
• Efficiency: To prevent over-cooling or under-cooling,
which wastes energy.
• System Performance: To ensure the HVAC unit
operates under its designed conditions.
What are the causes of frosting on evaporator coils?
Frosting occurs when the evaporator coil's surface
temperature drops below 0°C (32°F). Common causes are:
• Low refrigerant charge: The lack of refrigerant causes
the remaining refrigerant to absorb heat and evaporate
too quickly, dropping the coil temperature too low.
• Insufficient airflow: A dirty air filter, a blocked return
vent, or a fan motor issue prevents warm air from
flowing over the coil, which leads to the coil getting too
cold.
• Thermostat set too low: Can cause the unit to run
continuously and freeze up.
How would you identify and fix a refrigerant leakage?
• Identify: Signs of a leak include:
o Low cooling performance.
o Frosting on the evaporator or liquid line.
o Bubbles in the system's sight glass.
o A hissing sound.
o A strange smell (if the refrigerant has a scent
added).
o Using a refrigerant leak detector or a soap bubble
solution on connections and joints.
• Fix:
o Locate the leak.
o Recover any remaining refrigerant.
o Repair the leak by brazing or replacing the
component.
o Evacuate the system to remove all moisture and
non-condensable gases.
o Recharge the system with the correct type and
amount of refrigerant.
What is the effect of non-condensable gases in a
refrigeration system?
Non-condensable gases (like air) are those that will not
condense into a liquid under normal operating conditions.
Their presence in a refrigeration system, even in small
amounts, can:
• Increase head pressure and discharge temperature.
• Decrease system efficiency and cooling capacity.
• Cause the compressor to work harder, leading to
potential overheating and failure.
• Contribute to moisture and acid formation within the
system.
Why do we need water treatment in chilled water and
cooling tower systems?
Water treatment is vital to prevent:
• Corrosion: To protect metal pipes, chillers, and cooling
tower components from rust.
• Scaling: To prevent the buildup of mineral deposits that
reduce heat transfer efficiency.
• Biological growth: To control algae, bacteria, and other
microorganisms that can clog pipes and create health
hazards. Proper water treatment ensures system
longevity, efficiency, and safety.
How do you check the performance of a chiller in
operation?
You can check a chiller's performance by monitoring key
parameters:
• Supply and Return Water Temperatures: Check that
the ΔT is within the design range.
• Refrigerant Pressures and Temperatures : Compare
high-side (condenser) and low-side (evaporator)
pressures to the manufacturer's specifications.
• Power Consumption: Measure the electrical input to
the compressor.
• Approach Temperature: For water-cooled chillers, a
rising approach temperature indicates a dirty
condenser.
• COP or EER: Calculate the efficiency to ensure it's
meeting the design standard.
How do you optimize energy efficiency in HVAC cooling
systems?
• Proper design and sizing: Avoid oversized or
undersized equipment.
• Preventive Maintenance: Regular cleaning of coils,
filters, and condensers.
• Controls and Automation: Use a Building
Management System (BMS) to schedule operation,
manage setpoints, and optimize part-load efficiency.
• Variable Speed Drives (VSDs): Install VSDs on fans
and pumps to match motor speed to the actual load,
saving significant energy.
• Insulation: Ensure all pipes and ducts are properly
insulated.
• Use of Free Cooling: In colder weather, use the outdoor
air to cool the chilled water or ventilation air, reducing
the need to run the compressor.
