This presentation is being brought to you

by:
ASHRAE India Chapter and Xylem, Inc.

Large Chilled Water System

Design Seminar

Presented by:
Larry Konopacz, Manager of Training & Education
Bell & Gossett Little Red Schoolhouse
Saturday, September 21, 2013
Large Chilled Water System Design Seminar
The Production Loop
 Chilled Water Sources

Chillers
Cooling towers
Free-Cooling &
Waterside Economizer
Thermal Storage
Water Source Heat Pumps
Whats a Ton?

I Ton Ice =
2000 LB;
1LB Ice =
144 Btu;
1 Ton ice =
288,000 Btu
 Rule of 24

12,000 Btu/h = 500 x gpm x tF = 1 ton

gpm/ton = 12,000/(500 x tF)
= 24/tF
 What Types of Chillers
are Available?
Compressor

Centrifugal
Condenser
Rotary screw
Reciprocating
Absorption

Evaporator
 Refrigeration Cycle
Expansion Device

Hot Water Liquid Flow Supply

Low Pressure Zone

Water

Evaporator
High Pressure Zone
Condenser
Cooling

Load
Tower

Cool Water
Vapor Flow Return
Water

Compressor Chilled
Condenser Motor Water
Water Pump
Pump
 Where is What Used?
Large chilled water plants - centrifugal
Mid-range size - rotary screw
Smaller chilled water applications -
reciprocating
Inexpensive source of steam or other
energy source - absorption
Combinations of the above
Chiller Piping - Evaporator Side

Chiller 2

H
C
R
E
L
L
I
Chiller 1

Return Common Pipe Supply

 Typical Piping Method

Chiller 3

Chiller 2

Triple
Chiller 1 Duty
Supply
Triple
Duty

Common
Pipe

Return
Adding Pump Redundancy

Chiller 2

Triple
Chiller 1 Duty
Supply
Triple
Duty

Common
Pipe
Return
 Headered Primary Pumps
Actuated Control Valve

Chiller 3

Chiller 2 Supply
Piped for Triple
Standby Chiller 1 Duty
Pumps

Common
Pipe
Triple
Duty Return
Chiller Piping - Condenser Side
Cooling Towers

SRS SRS SRS

Pumps
Triple Duty

Condenser
Condenser

Condenser
Multi-celled Cooling Tower

Condenser

Condenser

Condenser

Multi-cell Cooling Tower

Triple
Duty

SRS

Standby Pump
Tower Equalization
Cooling Towers

Equalization
Line

Condenser

Condenser
SRS

Triple Duty
Condenser
 Cooling Tower Piping Practices
Fill all sections of pipe to purge air.
Size piping at a minimum of 2 fps to
move free air bubbles to tower.
All piping installed below system purge
level.
Condenser Water Piping Above Grade

System Purge Level

SRS
 Overhead Piping Concerns
Piping manifolds can result in low velocities.
Low velocity will allow air to be released.
Air trapped in piping increases head required.
Piping installed above purge level compounds
problem.
Unpurged areas are potential sources of
problems when pumps are turned on.
 Elevated Suction Piping Concerns
Condenser water pump difficult to purge.
At start-up a manual air vent may be required.
During operation air will again accumulate.
Automatic air vent may not work.
If above the basin fill level, the result is
cavitation.
Improper Piping Above Basin Level

System Purge Level

Basin Fill Level

Multi-tower System, Properly Piped

System Purge Level

SRS
 Tower Piping Observations
At part load reduced velocities in headers may
allow air to be released.
Idle pumps will accumulate air that should be
released prior to starting the pump.
Tower basins should be elevated to ensure
positive pressure under all flow conditions.
Pump casings should be fitted with automatic
air vents.
Condenser Head Pressure Control
With centrifugal chillers a minimum supply
water temperature is needed to:

Maintain optimum efficiency

Maintain a minimum pressure differential
between condenser and evaporator
Prevent pressure imbalance
Hermetic Compressor Guidelines
Condenser water temperature > 75 F.
Establish 75 F within 15 minutes.
N/O condenser water throttling valve.
Three-way bypass valve can be used.
Constant condenser water flow.
Water temperature control through fan
modulation, or other methods.
 Open Compressor Guidelines
Condenser water temperature > 55 F.
Three-way bypass valve can be used.
Constant condenser water flow.
Water temperature control through fan
modulation, or other methods.
 Cooling Towers

Air in Air out

Water In Water out

Induced Draft, Counter-flow Tower
Air Out

Water in

Air in Air in

Water out
Forced Draft, Cross-flow Tower
Air Out

Air in Air in

Water out

Water in
 Dynamic Relationship of Load,
Approach, and Range
Temperature Water Flow

L lb/min of water
Hot water F (R F)

Load
Range

Heat Load = L x R

Cold water F
Approach

L lb/min of water
(F)

Wet bulb F
 Tower Size Relationships
Variables:
Heat Load (Varies Directly)
Range (Varies Inversely)
Approach (Varies Inversely)
Wet-bulb Temperature (Varies Inversely)

Varying any of these variables will affect

the size of the tower.
 Types of Free-Cooling
(Waterside Economizer)
Air Out

Water in

Air in Air in

Water out

Earth Contact
Evaporative
 Earth Contact Characteristics
Usually indirect.
Cooling medium and load separated by heat
exchanger.
Stable temperatures.
Water temperature limitations.
Water treatment and pumping costs.
Environmental concerns.
Heat Exchangers
 How do they work?
Thin plates are stamped with
a unique chevron pattern and
assembled in a frame
Four holes punched in the
plate corners form a
continuous tunnel which acts
as a distribution manifold for
the inlet and outlet of each
fluid
 How do they work?
Each plate has a gasket that
confines the fluid to the port
or to the heat transfer area of
the plate
Units are built to order with a
standard 150 psi ASME Code
stamped design or to custom
designs
Earth Contact - Summer Cycle

C E H E
O V E X
N A GPX LOAD
D P A C
TOWER T H

Triple Duty

Sediment Removal Triple Duty

Separator
Earth Contact - Winter Cycle

C E H E
O V E X
N A GPX LOAD
D P A C
TOWER T H

Triple Duty

Sediment Removal Triple Duty

Separator
 Evaporative Characteristics
Heat rejection device (tower) exists.
As temperature declines, opportunity
arises.
Higher sensible vs. latent loads
Leaving water temperature approaches
42 F.
Freeze protection may be required.
 Freeze Protection
Sump heaters.
Close temperature control.
Accurate water level control.
Prevention of moist air recirculation.
External piping freeze protection.
Evaporative Cooling - Direct

C E
TOWER O V
N A LOAD
D P

Triple Duty
Triple Duty
Sediment Removal
Separator

Single Tower, Summer Cycle

 Evaporative Cooling - Direct

NOT RECOMMENDED
C E
TOWER O V
N A LOAD
D P

Triple Duty Triple Duty

Sediment Removal * Alternate location of SRS, depending on

Separator system conditions

Single Tower, Winter Cycle

 Evaporative Cooling - Indirect

C E H E
O V E X
N A GPX
A C LOAD
D P
TOWER T H

Triple Duty

Sediment Removal Triple Duty

Separator

Single Tower/GPX, Summer Cycle

 Evaporative Cooling - Indirect

C E H E
O V E X
N A GPX
A C LOAD
D P
TOWER T H

Triple Duty

Sediment Removal Triple Duty

Separator

Single Tower/GPX, Winter Cycle

Temperature Cross and Approach
57= T1
TEMP.
DEG. F

CH. WATER

52= t2

7F TEMPERATURE
45= T2
CROSS

3F COOLING
COND. WATER APPROACH

42= t1

EXCHANGER
LENGTH
 Heat Transfer Area vs Approach
COND. WATER CH. WATER LMTD AREA EXCH. COST
EWT LWT FLOW EWT LWT FLOW DEG F SQ.FT. MODEL INDEX
42 52 1000 57 45 834 3.92 1390 GPX807 1.00

42 52 1000 58 46 834 4.93 1135 GPX807 0.85

42 52 1000 59 47 834 5.94 975 GPX807 0.76

Temperatures are in F Flow is in USGPM

Heat exchanger selection based on max pressure drop of 7 psi
10/3.92=2.55 Approach = 3F
10/4.93=2.03 Approach = 4F
10/5.94=1.69 Approach = 5F
Production Source - Thermal Storage
Application Criteria
Economics
Storage Media
Storage Technologies
System Configurations
 Application Criteria
High maximum load.
Significant premium for peak demand.
Incentives.
Limited space available.
Limited electrical capacity.
Back-up or redundancy required.
 Storage Media
Chilled Water
Ice Harvesting
External/Internal Ice Melt
Stratified Chilled Water System
T
Load

Variable volume
distribution Vent
pump

Warm Storage
Cool

Pressure sustaining Constant volume

and check valve primary pump

Chiller
 Temperature Stratification
Top 0
Depth of tank, ft

-5

-10 Thermocline

-15

Bottom -20
30 40 50 60 70
Temperature, F
Use of Pressure Sustaining Valves
Load

Distribution Primary
pump pump
Chiller

Direction
Transfer Pump control
valves

Vent
Warm
Storage Cool

Constant volume
Pressure sustaining primary pump
and check valve
Incorporating Heat Exchangers
Load T
Variable volume
secondary
pump

T Heat
Exchanger
Variable volume
primary Vent
pump
Warm
Storage Cool

Constant volume
Pressure sustaining
primary pump
and check valve
Chiller
 Ice Harvesting System

Section Section Section Section

1 2 3 4
Ice harvester
chiller

Load

Ice water
recirculation
Chilled water
pump pump
 External Melt Ice Storage

Discharging Mode
Charging Mode
 Encapsulated Ice Storage
Charge and Discharge Modes

Charging Mode Discharging Mode

Ice
Cold glycol Warm glycol
Ice
Water
 Full Storage Strategy
Chiller on

Charging Charging
Storage Storage
Chiller off
Tons

Cooling load
(met by storage)
Chiller meets load directly

Time of Day
 Partial Storage - Load Leveling

Charging Cooling load Charging

Storage (met by storage) Storage
Tons

Chiller runs continuously

Cooling load
(met by chiller)

Time of Day
 Partial Storage - Demand Limiting
Reduced on-peak demand

Charging Charging
Storage (met by storage) Storage
Tons

Cooling load

(met by chiller)

Time of Day
Production Source - Water Source Heatpumps

Growing market segment

System temperature range 40 - 90 F
Energy added below 40 F (heat)
Heat removed above 90 F (cooling
tower)
 Heat Pump Cycles - Water Source
Supply
System Water
Return
Air Coil Water Coil Air Coil Water Coil
(Evaporator) (Condenser) (Condenser) (Evaporator)

Cool Warm
Air Compressor Air
Compressor

Reversing Valve Refrigerant Reversing Valve

Capillary Loop Capillary

Air Conditioner Cooling Air Conditioner Heating

 Design Considerations
Use slow closing two-way valves for
each zone
Good system balance required
Use staged c/s or v/s pumps
Use with cooling towers and GPX
Use with closed circuit cooling towers
Heat Pump-Water Source Schematic
Compression
Tank
Gasketed
Cooling Plate Heat
Tower Exchanger

Water Source Water Source Water Source Water Source Water Source
Heat Pump Heat Pump Heat Pump Heat Pump Heat Pump

Buffer
Tank Water Source Water Source Water Source Water Source
( Optional ) Heat Pump Heat Pump Heat Pump Heat Pump
Heat Pump-Water Source Schematic
Closed Circuit Cooler Compression
Heat Rejecter Tank

Water Source Water Source Water Source Water Source Water Source
Heat Pump Heat Pump Heat Pump Heat Pump Heat Pump

Buffer
Tank Water Source Water Source Water Source Water Source
( Optional ) Heat Pump Heat Pump Heat Pump Heat Pump
 Comments?
Questions?
Observations?
Large Chilled Water System Design Seminar
Variable Volume Distribution
 Variable flow through coil Variable flow through coil
Constant flow through system Variable flow through system

Three Way Valve Two Way Valve

 Three-Way Valve Systems

Low return temperatures

Balance problems
Increased flow at part load
Extra chillers to provide flow at low t
Chillers operate at high kW/ton
 Two-Way Valve System with
A Chiller Bypass

C C
H H
I I
L L
L L
E E
R R
 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 Terms
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 Pipe

Return
 Fundamental Idea

Secondary
Pump

Tee Tee
Primary A B
Pump
Low pressure drop in the common pipe
Primary-Secondary Pumping
The idea is based on:

Conservation of Mass

Conservation of Energy
 Law of the Tee: Diversion

50 GPM

50 GPM
100 GPM
 Law of the Tee: Mixing

100 GPM

60 GPM 40 GPM
 No Secondary Flow

Secondary
Pump
Off

A B
100 GPM @ 45F
100 GPM @ 45F 100 GPM @ 45F
Primary
Pump
 Primary = Secondary

100 GPM @ 45F 100 GPM @ 55F

Pump On

A B
100 GPM @ 45F 100 GPM @ 55F
0 GPM
 Primary > Secondary

50 GPM @ 45F 50 GPM @ 55F

Pump On Mixing at Tee B

A B
100 GPM @ 45F 100 GPM @ 50F
50 GPM @ 45F
 Primary < Secondary

200 GPM @ 50F 200 GPM @ 55F

Pump On

A B
100 GPM @ 45F 100 GPM @ 55F
100 GPM @55F
Mixing at Tee A
Control Valve in Secondary

Two-way Valve
 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
 Production = Distribution
CHWS Temp
45oF

1500 1500

Chiller 1, on Secondary
Chiller 2, off

Pumps

1500

Common -- No Flow
0 1500 1500

ECW Temp CHWR Temp

55oF 55oF
 Distribution > Production
CHWS Temp
47.5oF
2000

1500
Secondary
Chiller 1, on
Chiller 2, off

Pumps

2000

Mixing (1500 @ 45) + (500 @ 55)

Common -- 500
0 1500 2000

ECW Temp CHWR Temp

55oF 55oF
 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.
 Production > Distribution
CHWS Temp
45oF
P/S Chiller Bridge - Front Loaded Common
(Flow in GPM)
3000
Secondary
Chiller 2, on

Chiller1, on Pumps

2100

Common -- 900

Mixing (2100 @ 55) + (900 @ 45)

1500 1500
2100

ECW Temp CHWR Temp

52oF 55oF
 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
Chiller Performance Curve
1.1

1.0

0.9
KW per Ton

0.8

0.7

0.6

0.5
10 20 30 40 50 60 70 80 90 100
Percent Load
 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
Applying a Variable Speed Chiller
100

Ch 1
75

Ch 2
Ch 1
% Flow
50

Ch 2 Ch 3
Ch 1
25

Ch 2 Ch 3 Ch 4
Ch 1

25 50 75 100

% Load
 Back Loaded Common

To Loads
Chiller 3

Chiller 2

Chiller 1

Common

From loads
 Production = Distribution
CHWS Temp
45oF 1500

1500
Secondary
Pumps

Chiller 1, on
Chiller 2, off

1500
Common
0 Flow

1500 1500

CHWR Temp
55oF
 Distribution > Production
CHWS Temp
47.5oF
Mixing (1500 @ 45) + (500 @ 55)
500
Secondary
1500

Chiller 1, on
Chiller 2, off

Pumps

Common 2000
500 gpm

0 1500 2000

500
CHWR Temp
55oF
 Production > Distribution

CHWS Temp
45oF

900 600
Secondary
Chiller 2, on

Chiller 1, on
1500 Pumps
1500

Common 2100
900

1500 GPM 1500 GPM

@ 49oF @ 55oF
2100
900 GPM 600 GPM
@ 45oF @ 55oF
CHWR Temp
55oF
Mixing (900 @ 45) + (600 @ 55)
 Maximize Free Cooling

Secondary
Pumps
Primary-
Secondary Supply
Common
Free Cooling
Chiller 3

Chiller 2

Pump
Controller

Return
 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

Primary Pumps = V/V

25

25 50 75 100

Design Coil Flow

%
2012 ASHRAE Handbook - HVAC Systems and Equipment, p 44.11
Constant vs Variable Volume
Constant Flow, C/S Pump Pump Over-headed by 150%
150
(3 Way Valve)
140

130 C/S Pump

(2 Way Valve)
120

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

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

Pipe Length, Feet

Always Size the Pump to the System!

But...
Uncertainties
Coils
Control valves
Primary data
Lead times
Dealing With an Overheaded Pump

Throttle at the discharge valve

Limits on the valve
Flow balance & trim pump impeller
Required by ASHRAE/IES 90.1
 Additional Concerns

Pump Protection at minimum flow

Chiller Staging and De-staging

instrumentation.
 Pump Protection

Minimum recommended flow from ESP Plus = 900 gpm

 Bypass Options
1. Establish a minimum flow equal to or greater than
the minimum required to protect the pump.
2. Install a bypass at the end of the mains with a
balance valve to set minimum flow.
3. Install a bypass at ends of zones.
4. In retrofits, leave a three way valve at the end of the
system.
5. Use P or flow sensing to open pump bypass only
when needed.
6. V/S pumps are not as big a problem because of
lower head at reduced flow.
 System Bypass Options
3

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?
Large Chilled Water Design Seminar
Variable Speed Pumping
 Why variable speed?

1. When should I use it?

2. How does it work?
3. What about variable primary flow?
Typical operating load profile

30%

20%

15% 15%

5% 5%
2% 3% 3% 2%
Bell & Gossett 70V
1970s
 Adjustable Frequency Drives
Rectifier section
converts AC to DC
several varieties available
Inverter section
forms a synthetic sine wave
several varieties available
maintains a controlled frequency/voltage ratio
Requires an automatic control system
Adds to the initial cost of the system
 Affinity Laws
1. Capacity varies as the RPM change ratio:

FLOW 2 = FLOW 1 ( SPEED2 / SPEED 1)

2. Head varies as the square of the RPM change ratio:

2
HEAD 2 = HEAD 1 (SPEED 2 / SPEED 1)

3. Brake horsepower varies as the cube of the RPM change ratio:

3
BHP 2 = BHP 1 (SPEED 2 / SPEED 1)
 Affinity Laws for Centrifugal Pumps

100
90
80 Flow
70 Head
Percent

60 Horsepower
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100

Flow/Speed, Percent
 Theoretical Savings
120 120
Pump Curves 100% Speed
110 110
100 90% 100
Design
90 90
80 80% Head 80

70 70
% Head

% BHP
60 70% 60

50 60% 50

40 HP Draw 40
50%
30 30
Head
20 40% 20
BHP
10 30% 10
Flow
0 0
0 10 20 30 40 50 60 70 80 90 100
% Design Flow
Required Differential Pressure

P Sensor/Transmitter
25 Ft. Head
 System Curve
& V/S Control System
110

100 25 FT Differential Head

Maintained Across Load Set Point
80 (Set Point)
Head

Pump TDH
60
Overall
40 system curve
Distribution
20 piping head
loss curve
0
0 200 400 600 800 1000 1200 1400 1600
Flow
 Effect of Constant* Set Point
110
As the valve closes,
100 the pump slows down
Set point,
Control curve
80 25 FT
Head

Pump TDH
60
Overall system curve

40
Distribution
20 piping head
loss curve

0
0 200 400 600 800 1000 1200 1400 1600
Flow

*Whats Constant?
 Pump Control Curve
Initial Speed
B
A

Head, H
(feet)
Pipe, Fitting
Friction Loss

Q2 Q1
Flow, Q
(gpm)
Decrease in Heat Load Results in Troom < T set point
Causes Two Way Valves to Throttle Flow
 Pump
Curve Speed 1
B Control Curve
A
Speed 2

Head, H C
(feet)
Pipe, Fitting
Friction Loss

Q3 Q2 Q1
Flow, Q
(gpm)

Decrease in Pump Speed Reduces Flow, Reduces Error

 Control Curve
Speed 1
B
A

Head
(ft) Pipe, Fitting
Final Speed C Friction Loss

Flow, Q Q4 Q1
(gpm)

System Operation on Control Curve at Lower Speed

 Variable vs Constant Head Loss
Constant Head Loss

Variable Head Loss

Supply

C C C
H H H Pump
I I I Controller
L L L
L L L
E E E
R R R
Adjustable Freqy. Drives

Return
 Variable Head Loss Ratio
C/S, Constant Flow System Pump Head Matched to
Base 100 System at Design Flow
90

80 C/S, Variable Flow

V/S, 0% Variable Hd Loss, 100% Constant Hd
Percent Design BHP

70
V/S, 25% Variable Hd Loss, 75% Constant Hd
60
50
V/S, 50% Variable Hd Loss, 50% Constant Hd
40
V/S, 75% Variable Hd Loss, 25% Constant Hd
30
20 V/S, 100% Variable Hd Loss, 0% Constant Hd

10

0 10 20 30 40 50 60 70 80 90 100
% Flow
 Variable Head Ratio w/
Overheading
Constant Flow, C/S Pump Pump OHeaded by 150%
150
(3 Way Valve)
140

130 C/S Pump

(2 Way Valve)
120

110
Base Constant Flow, C/S Pump Pump HD Matched
100
Design (3 Way Valve) to System @
90 Design Flow
HP %
80

70

60
% Full Load 50
* 25/75 Means:
(Design) HP 40 25 % Variable HD Loss
30 75 % Constant HD Loss
20

10

0 10 20 30 40 50 60 70 80 90 100
 V/S Curves
120 50 % 60 % 70 %
80 % 85 % % Efficiency
110 85 %
80 %
100 100 %
90

80 90 %
Head, Feet

70
% Speed Curves
60 80 %
Constant
50 Efficiency
70 %
Curve
40
60 %
30
50%
20
40 %
10 30 %
GPM
0
0 100 200 300 400 500 600 700 800 900 1000
 Efficiency Changes
120
50 % 60 % 70 % 80 % % Efficiency
85 %
110 85 %
80 %
100 100 %
90

80 90 %
Head, Feet

70 % Speed Curves
80 %
60
Constant
50 70 % Efficiency
Curve
40
60 %
30
50%
20
40 %
10 30 %
GPM
0
0 100 200 300 400 500 600 700 800 900 1000
 Minimum Drive Speed
120
50 % 60 % 70 % 80 % % Efficiency
85 %
110 85 %
80 %
100 100 %
90

80 90 %
Head, Feet

70 % Speed Curves
80 %
60
Constant
50 70 % Efficiency
Curve
40
60 %
30
50%
20
40 %
10 30 %
GPM
0
0 100 200 300 400 500 600 700 800 900 1000
 Multiple Pump System Staging
Constant Differential Head Loss

Variable Head Loss

Supply

C C C
H H H Pump
I I I Controller
L L L
L L L
E E E
R R R
Adjustable Freqy. Drives

Return
Parallel V/S Operation

Pump 1

Pumps 1 & 2 Pumps 1, 2 & 3

Control Curve 1770 RPM

1450 RPM

1150 RPM
600 RPM 900 RPM
 Variable Speed Pumping Equipment
3f , 60 Hz Power
(Control Agent)

Set Point Adjustable

Technologic +/- error Frequency
Set Point Pump
(Input Signal) Drive
Controller (Controlled Device)

Feedback 3f, Variable Frequency

Signal Variable Voltage

Controlled
Sensor/ Variable
System
Transmitter
The Controlled Variable Determines the Type of Sensor

Pressure

Differential
Pressure
Pump
4-20 Controller
ma
signal
Temperature

Differential
Temperature

Flow
 3f , 60 Hz Power
(Control Agent)

Set Point Adjustable

Technologic +/- error Frequency
Set Point Pump
(Input Signal) Drive
Controller (Controlled Device)

Feedback 3f, Variable Frequency

Signal Variable Voltage

Controlled
Sensor/ Variable
System
Transmitter
 Technologic Pump
Controller
Controls pumps and drives
Accept set point, analyze sensor input
PID function
Pump staging
Pump alternation
Recognize and react to component failure
Provide message display
Central management system link
Safeguard system
 PID Control
Eliminates offset from set point
Allows for timely speed change
Handles large, sudden disturbances
Prevents oscillation and over-damping
 3f , 60 Hz Power
(Control Agent)

Adjustable
Set Point
Technologic +/- error Frequency
Set Point Pump
(Input Signal) Controller Drive
(Controlled Device)

Feedback 3f, Variable Frequency

Signal Variable Voltage

Controlled
Sensor/ Variable
System
Transmitter
 Adjustable Frequency Drive

Constant Variable
Voltage & Rectifier Direct Inverter Voltage & Pump
Frequency Section Current Section Frequency Motor
Power Power

Some important issues:

Rectifier and Inverter Design
Drive Efficiency
RFI and EMI Noise
Audible Noise
Size and Cost
Manual drive bypass
 Typical Efficiency Range
Variable Speed Drives
120

100
Currently Available
Efficiency, %

80 AFDs
60 Typical Older AFDs

40 Other Types

20

0
0 20 40 60 80 100
Design Speed, %
Pump and Motor
 The Pump

Minimum Flow
Minimum Speed
Inverter Duty
Motors
Motor Couplers
 Maintaining Minimum Flow
120
100 % Speed
110
100
90
80
70
Head

60
30% Speed
50
40
30

20
10
0
0 10 20 30 40 50 60 70 80 90 100

% Flow
EPDM couplers on variable-speed pumps
Failed Hytrel Coupler from a Variable
Speed Pump
 Variable Flow
Through
The Evaporator
 Primary-Secondary System
Constant Differential Head Loss

Variable Head Loss

Supply

C C C
H H H Pump
I I I Controller
L L L
L L L
E E E
R R R
Adjustable Freqy. Drives

Return
 Primary-Secondary

Common Practice.

Why?
Protection.
Nuisance shutdowns.

Freezing.

Costly downtime.
 Variable Primary Flow
Two-position Control Valves Flow Meter, option

C C C

DP Sensor
H
DP Sensor

H H

DP Sensor
DP Sensor

I I I
L L L
L L L
E E E
R R R

Modulating
Valve

AFD AFD AFD Controller

Whats different?
Primary pumps only
Flow meters or p sensors at each
chiller.
Two-position isolation valves at each
chiller
Minimum flow bypass with a modulating
control valve.
Smarter controller.
Alternative #1

Minimum Flow Bypass at Chillers

Minimum Chiller Flow

Minimum Pump flow

Ganged Pumps
 FLOW SUPPLY
T METER

F F F
SIGNAL
TO TECH

DP DP
SENSOR SENSOR
DP DP DP
CHILLER CHILLER CHILLER
SENSOR SENSOR SENSOR

SIGNAL SIGNAL BYPASS:

TO TECH TO TECH FOR SYSTEMS WITH
EXTENDED LIGHT
LOADS/WEEKEND
SIGNALS SIGNALS SHUTDOWNS. SET
TO TECH TO TECH BALANCE VALVE
FOR LOW FLOW TO
SIGNALS REDUCE THERMAL
TO TECH STRATIFICATION
AND ALLOW QUICK
START UP AFTER
SHUT DOWN.

TDV TDV TDV

T
NOTE:
ALL SENSOR RETURN
SIGNALS WIRED TO
TECHNOLOGIC
5500 AFD AFD AFD

ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
Monitoring Chiller Flow
P sensors - Technologic controller ensures the chiller
is in proper working condition by monitoring each
working chillers differential pressure. Flow through the
chiller is calculated using the values defined in the user
setup.
OR
Flow sensors - Technologic controller ensures the chiller
is in proper working condition by monitoring each
working chillers flow rate.
Technologic 5500
Initial programming is
crucial.
Must use accurate data
from the chiller
manufacturer.
Start-up coordination
should include the BMS
too.
Technologic 5500 Control Variables

1. Monitor zone differential pressure sensors,

compare actual values to the required set points.
Pump speed is modulated to maintain set point.
Pump staging will occur as required to meet set point.

Control sequence is exactly as described earlier.

Technologic 5500 Control Variables
2. Determine if the minimum flow requirements are
being met for all working chillers.
Prevents freeze-up or chiller low-flow trips
If chiller flow is too low, controller opens minimum flow
bypass valve in programmed increments. Size the valve
for system p.
Requests de-staging action from the chiller control
system or BMS.
Allows for operator intervention, decision making.
Required by code in some areas.

Ganged pumps allow operation of two chillers with one

pump.
Technologic 5500 Control Variables
3. Monitors chiller flow rate to prevent operation
above the maximum flow for the chillers and the
pumps.
Excess chiller flow generates a request to stage on an
additional chiller. Minimum flow bypass valve is closed.
Operator or BMS intervention required.
Ganged pumps allow operation of one chiller, two
pumps.
Optional system flow meter provides end-of-curve
protection for the pumps
Alternative #2

Bypass at End of System

Minimum chiller flow
Minimum pump flow
Ganged Pumps
 FLOW
T SUPPLY
METER

F F F
SIGNAL
TO TECH

DP DP DP
CHILLER CHILLER CHILLER DP DP
SENSOR SENSOR SENSOR
SENSOR SENSOR

SIGNAL SIGNAL
SIGNALS SIGNALS TO TECH TO TECH
TO TECH TO TECH
SIGNALS
TO TECH

TDV TDV TDV

T
NOTE:
ALL SENSOR RETURN
SIGNALS WIRED TO
TECHNOLOGIC
5500 AFD AFD AFD

ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
Alternative #2
Minimum flow bypass valve is controlled
to protect both the pumps and the
chillers.
Pump requires >25% BEP flow
Minimum flow of largest chiller
Size the bypass valve using the zone
p.
Best for systems with extended light
loads or weekend shut-down.
Alternative #3

Primary pumps piped directly to chillers.

More common in retrofit systems.
Easier for applying un-equally sized
chillers in parallel.
 FLOW
SUPPLY
T METER

F F F
SIGNAL
TO TECH

DP DP
SENSOR SENSOR
DP DP DP
CHILLER CHILLER CHILLER
SENSOR SENSOR SENSOR

SIGNAL SIGNAL
BYPASS:
TO TECH TO TECH
FOR SYSTEMS WITH
EXTENDED LIGHT
LOADS/WEEKEND
SHUTDOWNS. SET
SIGNALS SIGNALS SIGNALS BALANCE VALVE
TO TECH TO TECH TO TECH FOR LOW FLOW TO
REDUCE THERMAL
STRATIFICATION
AND ALLOW QUICK
START UP AFTER
SHUT DOWN.
TDV TDV TDV

T
NOTE:
ALL SENSOR RETURN
SIGNALS WIRED TO
TECHNOLOGIC
5500 AFD AFD AFD

ISOLATION VALVE
CHECK VALVE
F FLOWMETER/TRANSMITTER
T TEMPERATURE SENSOR
 Pump Selection
Equal size pumps.
Redundancy.
Parts.
Maintenance.
Unequal size pumps.
Control issues.
Flow issues.
Premature failure, large pump at low flow.
 Chiller Selection
Equal size chillers.
Redundancy.
Parts.
Maintenance.
Unequal size chillers.
Control issues.
Flow issues
Additional equipment.
Design Considerations

Size bypass for minimum flow of largest chiller.

Minimum building load?
Size bypass modulating valve
for system p, if its installed near the chillers
for zone p, if its out in the system.
Program the controller with the chiller p set
points for minimum and maximum chiller flow.
Verify with chiller manufacturer.
Design Considerations

Sequence chillers based on p or temperature

sensors.
Use accurate, calibrated flow meter or p sensors
at each evaporator
Allow for operator training.
Initial
On-going
 Consider this design if:
System flow can be reduced by 30%.

System can tolerate modest changes in water

temperature.

Operators are well trained.

Demonstrates a greater cost savings.

High proportion of operating hours at:

Part load.

Full load with low entering condenser water.

 Turn-down Ratio
Chiller manufacturers publish 3 - 11 fps
evaporator velocity range (typically).
You may have to increase your
acceptable head loss targets, use more
pump head.
Nominal base of 7 fps desirable.
Variation of 1 to 2 fps.
Work with the manufacturer.
Rate of Change*
Maximum rate of flow change, % design flow per minute

Source Vapor Compression Absorption

#1 4-12 **

#2 20-30 2-5

#3 ** 30

#4 2 **

#5 ** 1.67

*Table 2-2
ARTI-21CR/611-20070-01, 2004, Bahnfleth & Peyer
** Information not provided
 Do not use if:
Supply temperature is critical.

Three-way valves are used throughout.

Existing controls are old, inaccurate.

Operators are unlikely to operate the

system as designed.
Supply Water Temperature
Dependant on :
System volume.
Rate of flow change.
Application specific.
Consider thermal storage
Operator Ability
Within operators ability?.
Commercial buildings may not have well
qualified operators.
Training is mandatory.
Initial
Periodic, in view of operator turnover.
Start-Up & Shut-down
In systems that start-up and shut-down, it
may be advisable to anticipate, and
avoid, rapid changes in flow as control
valves all tend to act together.
Control system, BMS, manual
procedures.
Use slow opening/closing valves at the
chiller, 60-90 seconds.(?)
 Controls Complexity
Additional controls for the chillers
Additional controls the pumps.
Pumps operate on flow, temperature, and
P.
Chiller P.
 Sensor Calibration
Multiple sensors control:
Flow.
Temperature.
Delta p
Maintenance.
Calibration.
 Summary
Evaluate all the options.

Read some articles:

Variable Primary Flow CHW: Potential Benefits and Application Issues
by Bahnfleth and Peyer. Pennsylvania State University, ARTI-
21CR/611-20070-01

Chilled Water System for University Campus by Stephen W. Duda, PE,

ASHRAE Journal May, 2006

Another tool for the toolbox.

 Comments?
Questions?
Observations?
Large Chilled Water System Design Seminar
Primary-Secondary-Tertiary Pumping Systems
Primary-Secondary-Tertiary
Zone C

Zone A

Zone B

C C
H H
I I
L L
L L Variable Speed Pump
E E
R R
 Direct Pumped Zones
Zone B Zone C
Zone A

WRONG !

C C
H H
I I DP Controller
L L
L L
E E
R R
 Constant Demand Zones
Zone A Zone B
Zone C

T
WRONG !

C C
H H
I I
L L Automatic
L L
E E
Flow Control
Hard set valve Valve
R R
 Primary-Secondary-Tertiary
Zone C

Zone A
RIGHT ! Zone B

C C
H H
I I
L L
L L Variable Speed Pump
E E
R R
 Three Different Buildings
A has coils selected for 44F.
B has coils selected for 45F.
C has coils selected for 46F.

Therefore, the supply water temperature

must be at least 44F for A.

But what about B and C?

Primary-Secondary-Tertiary
can be even more useful
Zone C

Zone A

Zone B

C
H
C
H ?
I I
L L
L L Optional Variable
E E Speed Pump
R R
Temperature Sensor Locations
MV
Load

MV
Load

Load MV
T1 T4 T1
T2 T3 T4

Tertiary
Zone
Pump Common T2
T3
Pumped Circuit Setter
Chilled
Water
Supply

Chilled
Water
Return
 Tertiary Bridge
MV
Load

MV
Load

Load MV
T1 T4

Tertiary
Zone Common
Pump T2
T3
Pumped
Chilled
Water
Supply
Tertiary Bridge

Chilled
Water
Return
Temperature Sensor Locations
MV
Load

MV
Load

Load MV
T1 T4 T1
T2 T3 T4

Tertiary
Zone
Pump Common T2
T3
Pumped
Chilled
Water
Supply

Chilled
Water
Return
 ADVANTAGES
1. Permits operating at highest allowable zone temperature
2. Maximizes coil flow rate, good film coefficients
3. Maximizes flow rate through each control valve
4. Ensures good humidity control
5. Minimizes the amount of coil reheat
 DISADVANTAGES
1. Temperature of return water is unknown
2. Temperature of return water to chiller may be too high
3. Will not recognize increased supply water temperature
 T2 Operation
MV
Load

Load MV

Load MV
T1 T4 T1 T2 T3 T4

Tertiary
Zone
Pump Common T2
T3
Pumped
Chilled
Water
Supply

Chilled
Water
Return
 ADVANTAGES
1. Maintains chilled water return temperature at setpoint
2. Will not overload the chiller
 DISADVANTAGES
1. No control of zone supply water temperature
2. Could lose humidity control
3. Will not recognize increased supply water temperature
 T3 Operation
MV
Load

MV
Load

Load MV
T1 T4
T1 T2 T3 T4
Tertiary
Zone
Pump Common T2
T3
Pumped
Chilled
Water
Supply

Chilled
Water
Return
 ADVANTAGES
1. There are no perceived advantages at this location
 DISADVANTAGES
1. Little, if any, valve modulation unless it is set to
close on sensing supply temperature lower than
permissible in the zone
 T4 Operation
MV
Load

MV
Load

Load MV
T1 T4
T1 T2 T3 T4
Tertiary
Zone
Pump Common T2
T3
Pumped
Chilled
Water
Supply

Chilled
Water
Return
 ADVANTAGES
1. Maximizes coil flow rate
2. Ensures good humidity control
 DISADVANTAGES
1. Temperature of return water is unknown
2. Temperature of return water to chiller may be too high
3. Will not recognize increased supply water temperature
No single sensor location
satisfies all design criteria
SO........
Applying Zone Valve Controller
MV
Load

MV
Load

MV T1 T2 T3
Load
T1

Tertiary
Zone
Pump Common T2
T3
Pumped
Chilled
Water
Supply

Chilled
Water
Return
 Control Algorithm
1. Temperature control to the zone (T1 sensing).
2. If T1 is satisfied, return water temperature to the chiller
plant (T2 sensing).
3. Monitor secondary chilled water supply temperature
(T3 sensing) for temperature increase due to secondary
return water recirculation or temperature decrease due to
chiller leaving water temperature reset.
4. Reference point for automatic reset and T (T2 - T3)
control (T3 sensing).
 So what?

Satisfy zone cooling requirement at the

maximum possible supply temperature

Minimize secondary flow rate

Optimize return water temperature

 3-way Valve Application

Tertiary Tertiary Tertiary

Pump Pump Pump
Chiller Plant

Secondary Pumps
 Problems
Bypass returns cold water to chillers,
reduces system t.
Linear valve characteristics can cause
increased flow at part load.
Balancing required in bypass pipe and
coil-to-coil.
High cost per ton at the chiller.
 3-way Valve System
Load MV

Load MV

Load MV T1 T2 T3
T1

Common
T2
Flow
Meter
T3 Small
By-Pass

Secondary Supply

Secondary Return
 Multi-zone Application
Zone 1 Zone 2 Zone 3 Zone 4
Terminal Terminal
Unit Control Unit Balance Zone
Valve Valve (Tertiary)
Pump

Zone Supply
Temperature
T1 T1 T1 T1

Chiller Supply Common Common Common

Temperature T3 GPX T3 T3 T3
Return
Flow Water
Meter ]e
Temperature

Zone Bias
3D Valves Control Valve
T2 T2 T2 T2
C C C
h h
C Distribution
h
i i i o (Secondary)
l l l m Pumps
l l l m
e e e o Rolairtrol
r r r n
 District Cooling Application
Individual building temperature control
Static pressure isolation
Return water temperature control
Btu/hr totalization
Outdoor temperature reset
Independent operation
 District Cooling Application
with GPX

Independent pressure control

HVAC fluid isolation

 VPF Application
Zone 1 Zone 2 Zone 3 Zone 4
Terminal Terminal
Unit Control Unit Balance Zone
Valve Valve (Tertiary)
Pump

Zone Supply
Temperature
T1 T1 T1 T1

Chiller Supply Common Common Common

Temperature T3 GPX T3 T3 T3
Return
Flow Zone Water
Balance
Meter Valve
Temperature

Zone Bias
3D Valves Control Valve
T2 T2 T2 T2
C C C
h h h
i i i
l l l
l l l
e e e
r Rolairtrol
r r
 Comments?
Questions?
Observations?
Large Chilled Water System Design Seminar
Primary-Secondary Zone Pumping Systems
Primary-Secondary Zone Pumping

Zone A Zone B Zone C

C C
H H
Supply
I I
L L
L L
E E
R R

Return
 Shared Piping

Zone A Zone B Zone C

C C
H H
Supply
I I
L L
L L
E E Shared Pipe
R R

Return
 Shared Piping

Zone A Zone B Zone C

C C
H H
Supply
I I
L L
L L
E E Shared Pipe
R R

Return
 Present and Future Piping
1500 gpm 1500 gpm (1500 gpm)

Flow :
Current = 3000
Future = 4500
Zone A Zone B Zone C

C C
H H Supply
I I Current = 0
L L Current = 1500 Future = 1500
L L Future = 3000 Future Zone C
E E
R R
Return
 Zone A Requirements
1500 gpm @ 80 (1500 gpm) (1500 gpm)

Zone A Zone B Zone C

4500 gpm*

A Zone A A1 Supply A2 A3
Pressure drop:A to A1+B to B1
Present = 20.8
*Future = 45.2
B1 Return B2 B3

B 4500 gpm*
 Zone A Calculations

Table 9-1 Zone A calculations

Zone A (A to A1 + B to B1) Future Flow @ 4500 gpm Present Flow @ 3000 gpm
Pipe Size 14 14
Pressure Drop - ft / 100 ft 2.26 1.04
Equivalent Length
(supply & return) 1000 ft x 2 = 2000 ft 1000 ft x 2 = 2000 ft
Pressure drop 45.2 ft 20.8 ft
Zone pressure drop 80 ft 80 ft
Total pressure drop 125.2 ft 100.8 ft
Pump Selection @ 1500 gpm 1510-6G @ 56.4 hp = 75 hp* 1510-6G @ 45.8 hp = 60 hp*

Note: 15 hp additional for future requirements

* Nominal horsepower motor for NOL pump
 Zone B Requirements
1500 gpm @ 80 1500 gpm @ 80 (1500 gpm)

Zone A Zone B Zone C

4500 gpm* 3000 gpm*

A1 Supply A2 A3
A
Pressure drop: Zone B
AtoA1+ BtoB1 + A1toA2 + B1toB2
Present =20.8 9.0
*Future = 45.2 33.4 B1 Return
B2 B3

B 4500 gpm* 3000 gpm*

 Zone B Calculations
Table 9-2 Zone B calculations
Zone B(A1to A2+B1 to B2) Future Flow @ 3000 gpm Present Flow @ 1500 gpm
Pipe Size 12 12
Pressure Drop - ft / 100 ft 1.67 0.45
Equivalent Length
(supply & return) 1000 ft x 2 = 2000 ft 1000 ft x 2 = 2000 ft
Pressure drop 33.4 ft 9.0 ft
Previous pressure drop 45.2 ft 20.8 ft
Zone pressure drop 80 ft 80 ft
Total pressure drop 158.6 ft 109.8 ft
Pump Selection @ 1500 gpm 1510-6G @ 71.4 hp = 100 hp* 1510-6G @ 49.6 hp = 60 hp*
Note: 40 additional hp required for future requirements
* Nominal horsepower motor for NOL pump
 Zone C Requirements
1500 gpm @ 80 1500 gpm @ 80 1500 gpm @ 80

Zone A Zone B Zone C

4500 gpm 3000 gpm 1500 gpm

A1 Supply A2 A3
A
Pressure drop: Zone C
AtoA1+ BtoB1 + A1toA2 + B1toB2 + A2toA3+ B2toB3
Present = 45.2 + 33.4 + 21.4
Future = Present
B1 Return B2 B3

B 4500 gpm 3000 gpm 1500 gpm

 Zone C Calculations
Zone C (A2 to A3 + B2 to B3) Future Flow @ 1500 gpm Present Flow @ 0 gpm
Pipe Size 10
Pressure Drop - ft / 100 ft 1.07
Equivalent Length
(supply & return) 1000 ft x 2 = 2000 ft
Pressure drop 21.4 ft
Previous pressure drop 78.6 ft
(A to A2, B to B2)
Zone pressure drop 80 ft
Total pressure drop 180.0 ft
Pump Selection @ 1500 gpm 1510-6G @ 82.7 hp = 125 hp*; Note: 50 hp more
than Zone A
 Zone Pumping Summary
Present Requirement Future Requirement
Summary Duty Pump Standby Pump Duty Pump Standby Pump
Zone A 1 @ 75 hp 1 @ 75 hp 1 @ 75 hp 1 @ 75 hp
Zone B 1 @ 100 hp 1 @ 100 hp 1 @ 100 hp 1 @ 100 hp
Zone C 1 @ 125 hp 1 @ 125 hp
2 @ 175 hp 2 @ 175 hp 3 @ 300 hp 3 @ 300 hp
Total 4 @ 350 hp 6 @ 600 hp
* Nominal horsepower motor for NOL pump
 Pressure Diagram - Zone Pumped
System
Zone Zone Zone
Pump A Pump B Pump C

Load
Friction
Loss
0 0

Friction Loss
Supply Header

Friction Loss
Return Header
Primary-Secondary Equivalent
1500 GPM 1500 GPM (1500 GPM)

3000 GPM A1 1500 GPM A2 A3

Supply
Chiller 3

Chiller 2

Chiller 1

AFDs Pump
Controller

B1 Return B2 B3
B
1500 GPM
3000 GPM
 P-S Calculations

Primary-Secondary pressure drop calculation:

Pipe Segment Pressure Drop Pipe Segment Pressure Drop
Present, feet Future, feet
A to A1 + B to B1 20.8 A to A1 + B to B1 45.2
A1 to A2 + B1 to B2 9.0 A1 to A2 + B1 to B2 33.4
A2 to A3 + B2 to B3 DNA A2 to A3 + B2 to B3 21.4
Zone B 80.0 Zone C 80.0
Total 109.8 Total 180
 P-S Calculations
Distribution pump selection:

Present = 3000 gpm @ 109.8 feet, increase impeller to 13.5 for future head requirements:
2 @ VSCS 8x10x17L @ 111.0 hp 125 NOL
1 @ VSCS 8x10x17L @ 111.0 hp 125 NOL, standby
Total 3 Pumps 375 NOL, Total

Future = 4500 gpm @ 180 feet:

3 @ VSCS 8x10x17L @ 114.4 hp 375 NOL
1 @ VSCS 8x10x17L @ 114.4 hp 125 NOL
Total 4 Pumps 500 NOL
 Comparison
Zone Pumping P/S Pumping
Present Present
350 hp 375 hp
Future Future
600 hp 500 hp
 Primary-Secondary Zone
Pumping Cautions
Excessive initial horsepower

Initial equipment investment

Future considerations

Reduced Horsepower
 Comments?
Questions?
Observations?
Large Chilled Water System Design Seminar
Variable Speed Sensor Selection and Location
 Direct Return Piped System

Supply
Differential
Pressure
Pump Sensor
Chiller 3

Chiller 2

Chiller 1

Controller

AFDs

Return
 Single Point Pressure Sensor

Supply

WRONG!
Single
Point
Pressure
Chiller 3

Chiller 2

Chiller 1

Sensor

Pump
AFDs Controller
Return
Control Curve Using Single Point
Pressure Sensor
90

80

Shut-off head Design Point

70
Constant Pressure
60
Head, FT

50

40 1750 RPM
(Maximum rpm)
30

20 1480 RPM
(Minimum rpm)
10

0
0 200 400 600 800 1000 1200 1400 1600
Flow, gpm
Single Point Pressure Sensor
in a CHW System
A rise in the average water temperature
results in a net expansion of the water.
This net expansion volume flows into
the compression tank, raising the
system pressure.
The pump slows down.
 What if?
Zone A Zone B Zone C
P Sensor here
Supply

C C C
H H H
I I I
L L L
L L L
E E E
R R R
Pump
AFDs Controller
Return
Sensor Across Mains At Pump
Whats the set point?
Its the greatest branch and distribution
piping head loss calculated at design
flow. In other wordsdesign head.
What will the flow be in each zone?
Determined by the zone path CV
Differential Pressure Sensor
at the Pump
90

80
Design Point
70

60
Head, FT

50

40 Maximum rpm

30

20
Minimum rpm
10

0
0 200 400 600 800 1000 1200 1400 1600
Flow, gpm
 Variable Head Loss Ratio
C/S, Constant Flow System Pump Head Matched to
Base 100 System at Design Flow
90

80 C/S, Variable Flow

V/S, 0% Variable Hd Loss, 100% Constant Hd
Percent Design BHP

70
V/S, 25% Variable Hd Loss, 75% Constant Hd
60
50
V/S, 50% Variable Hd Loss, 50% Constant Hd
40
V/S, 75% Variable Hd Loss, 25% Constant Hd
30
20 V/S, 100% Variable Hd Loss, 0% Constant Hd

10

0 10 20 30 40 50 60 70 80 90 100
% Flow
Coil or Valve?

25 Head
Maximizing Variable Head Loss
Constant Head Loss

Variable Head Loss

Supply
Differential
Pressure
Pump Sensor
Chiller 3

Chiller 2

Chiller 1

Controller

AFDs

Return
 Control Area
Zone 1 Zone 2
20 ft 20 ft

A B C D

DP Sensor
C C C
H H H
I I I
L L L
L L L
E E E
R R R
Pump
AFDs Controller

E
F
Pressure Drops in Piping (Table 11-1)

P AB+EF P Zone 1 P BC+DE P Zone 2

20FT 20FT 20FT 20FT

TDH = P AB + EF + BC + DE + P ZONE 2 = 60 FT
 Control Area Calculation
Table 11-2 Control Area Calculation
Flow Flow Friction Friction P Friction Friction P TDH
Zone 1 Zone 2 Loss Loss Zone 1 Loss Loss Zone 2
AB+EF Zone 1 BC+DE Zone 2
0 gpm 600 gpm 5 0 40 20 20 20 45
300 gpm 300 gpm 5 5 25 5 20 20 30
600 gpm 0 gpm 5 20 20 0 0 20 25
0 gpm 0 gpm 0 0 20 0 0 20 20
600 gpm 600 gpm 20 20 40 20 20 20 60
What pump head is required at:
zero flow?
full flow?
less than full flow?
 Control Area
60

50

40
Head, FT

30

20
Lower Limit
10 Upper Limit
Single Point
0
0 100 300 500 600 900 1100 1200
Flow, gpm
 So What...?
Staging pumps in a closed loop HVAC
system by flow alone may not work
because of different head requirements
for a given flow.
Wire to water pump efficiency
calculations at part load depend heavily
on the assumptions made about the
nature and shape of the control curve.
 Single Sensor, Including
Balance Valve Pressure Drop
Zone 1 Zone 2
25 ft 20 ft

B (50) C
A

E (10) D
F
 What do you mean...?
The head loss across the coil and the
wide open valve in zone 1 is 25 feet at
full flow.
If thats true, then we need to add an
extra 15 feet of head loss in the balance
valve to insure adequate flow out to
Zone 2 when the Zone 1 valve is wide
open.
 Set Point, Zone 1, 40 ft

Flow Zone 1 Flow Zone 2 Friction Loss Friction Loss Head Required Setpoint -
AB+EF BC+DE Zone 2 Friction Loss
0 gpm 600 gpm 5 20 20 0
300 gpm 300 gpm 5 5 5 30
600 gpm 0 gpm 5 0 0 40

Excess head means wasted energy

 Sensor Location
Zone 1 Zone 2

A B C D

DP Sensor
C C C
H H H
I I I
L L L
L L L
E E E
R R R
Pump
AFDs Controller

E
F
 Single Sensor in Zone 2
Zone 1 requires 600 gpm at 25 ft
Zone 2 requires 600 gpm at 20 ft

P Avail -
Flow Flow Friction Loss Friction Loss Friction Loss P Zone1, Friction Loss
Zone 1 Zone 2 AB+EF Zone 1 BC+DE Available Zone 1
0 gpm 600 gpm 5 0 20 40 40
300 gpm 300 gpm 5 6.25 5 25 13.75
600 gpm 0 gpm 5 25 0 20 -5

Inadequate head for Zone 1

 Sensor in Zone 1
Zone 1 requires 600 gpm at 25 ft
Zone 2 requires 600 gpm at 20 ft

Flow Zone 1 Flow Zone 2 Friction Loss Friction Loss Head Required Setpoint -
AB+EF BC+DE Zone 2 Friction Loss
0 gpm 600 gpm 5 20 20 5
300 gpm 300 gpm 5 5 5 20
600 gpm 0 gpm 5 0 0 25

Inadequate flow in Zone 2

 What can we do...?
In this system:
Single sensor in Zone 2 at 20 ft fails to
provide adequate flow only when
load in Zone 2 < 50% and
load in Zone 1 > 75%
Is this a predictable, recurring situation?
manual adjustment
programming
Add a second sensor
 Applying Multiple Sensors
Zone A Zone B Zone C

Supply

DP Sensors
C C C
H H H
I I I
L L L
L L L
E E E
R R R
Pump
AFDs Controller
Return
Use Multiple Sensors?
Load
Similarity
Priority
Diversity
One building or several
Redundancy
First cost vs operating cost
 The Active Zone
Zone set points do not have to be the
same.
Technologic pump controller scans all
zones often, comparing process
variable to set point in each case.
Pumps are controlled to satisfy the
worst case.
What happens to the rest of the zones?
 Effect of Sensor Location
Zone 1 Zone 2

B
C
A
OR

E D
F
 Multiple Sensors & Setpoints
Multiple sensors, set point across Zone 1, = 25 FT and setpoint across Zone 2 = 20 FT, (Table 11-6)
Flow Flow Friction Loss Minimum P Friction Loss Minimum P
Zone Zone AB+EF Reqd Zone1 BC+DE Reqd Zone 2
1 2 P Zone 1, Available P Zone2 Available
0 600 5 0 40 20 20 20
300 300 5 6.25 25 5 5 20
600 0 5 25 25 0 0 25

Row 1. Sensor 2 is controlling, Zone 1 is over pumped.

Row 3. Sensor 1 is controlling, Zone 2 is over pumped.
Total pump head required:
row 1 45 ft
row 2 30 ft
row 3 30 ft
 Reverse Return Piped System

Supply

C
H
I
L
L
E
R

Return
 Reverse Return Systems
If all the circuits are the same length,
will the pump still change speed?
Suppose a coil with a high p
requirement and another with a lower p
requirement are served by the same
reverse return piping system. OK?
If the coils are serving different sides of
the building, could we have a problem?
 Tertiary Piped System

Zone A Zone B Zone C

C C
H H
I I
L L
L L
E E
R R

Return
 Zone Piped System

Zone A Zone B Zone C

C C
H H
Supply
I I
L L
L L
E E
R R

Return
 Summary
Give priority to the needs of the branch.
The rule of sensor location is simple and easy
to apply:
If you have to use a single sensor, put it across
the critical branch.
Whats the critical branch?
Its the same one that determined the pump head.
As weve seen, the analysis is more important
than the rule.
 Comments?
Questions?
Observations?
Large Chilled Water System Design Seminar
Achieving Hydronic System Balance
Systems Approach

Control M

Load
Distribution Air Management
Verification

Philosophy

Source
Systems Approach
All components work together as team
Components interact and work as well as we
understand them
A collection of mismatched components will
not perform as expected
Owner, engineer, architect, contractor, and
operators are part of the system too!
Hydronic Balancing
We worry about balance because:
Load calculations are approximate
Piping circuitry analysis is approximate
Control valve selection is approximate
Approximations will lead to underflow and
overflow situations
Results of overflow or underflow
Design Dt cannot be achieved
Supply temperature controller hunts (?)
Sequence of operation can be upset.
For example:

Published by
ASHRAE &
Hydraulic
Institute
Darcy-
Weisbach
Equation.

Add 15%!
What Is Balancing?
Its test, adjust & balance
Test: The system, now built, is verified in
operation to perform to the expected level.
What do we measure?
temperature, flow, pressure drop, energy
consumption.
What do we test with?
Can we test with what is installed?
Can we obtain accurate readings?
Adjust

Adjust: tested in operation, the system is

found lacking and needs fine tuning.
What level of adjustment, and for what
purpose?
Create comfort conditions
Minimize energy consumption
Prevent equipment damage
How do we adjust?
Balance
Balance is often interpreted to mean 10%
of design flow.

This generalization may or may not yield

satisfactory heat transfer required for
comfort conditions
Redefining Balance
Evaluate System Operation
If the goal is occupant comfort, then heat
transfer becomes the key concern.
We control heat transfer as a sensible
temperature control process between controller,
control valve and coil
Analysis should account for interaction of all key
components, and how they affect the rest of the
system
Balanced Hydronic Systems
All terminals receive enough flow to produce
satisfactory heat transfer (97.5% - 102.5%)
At design conditions, all terminals receive
satisfactory flow with the pump in a specified
range of operation
Under temperature control modulation to
match load, circuit flow does not exceed
design flow accuracy
Chilled Water Coil Flow vs. Heat Transfer

120% 45
Total
40
100%
35

Waterside T (F)
% Heat Emission

80% 30
Sensible
25
60%
20
Latent
40% 15

10
20%
5

0% 0
0% 20% 40% 60% 80% 100% 120% 140% 160% 180% 200%
% Flow
30H X 46W 10 FPI / 4 Row 30 GPM / 10T 85 DB/ 71 WB Ent 45 EWT 15 Circuits 3/8 Tube 4000 CFM Nominal 10 Ton Rating
Chilled Water Coil Flow vs. Emission

100
97%
90
80
70
60
50
40
30
20
10

80% 100%
30H X 46W 10 FPI / 4 Row 30 GPM / 10T 85 DB/ 71 WB Ent 45 EWT 15 Circuits 3/8 Tube 4000 CFM Nominal 10 Ton Rating
Flow Tolerance 97% Design HT
-0 / +10% 5% 10% 15% 20%
Supply Water Temperature F

260
240
220

Heating
200
180
160
140
120
100
80

Cooling
6
70 16
60
50
40
0 2 4 6 8 10 12 14 16 18 20 22 24
Suggested Flow Tolerance (%)
Balancing, The Obvious Answer
Maximum branch flows need to be controlled
Balancing valves are one solution
Pressure independent flow control is another
method
Systems perspective needs to be
maintained; pipe, valves, calculations.
Pressure Dependent Balancing Valve
Pressure Dependent Balancing Valve

140

120

100
Head (Feet)

80

60

40

20

0
0 50 100 150 200 250

Flow (USGPM)
Pressure Independent Flow Limiting Valve

Orifice is sized for

the design flow

Cartridge
Cartridge Operation
Flow Flow

P1 P2 P1 P2

P1 is low P1 is high
Cartridge Opens Cartridge Closes
P1 - P2 = Constant P1 - P2 = Constant
Pressure Independent Flow Limiting Valve
Fixed
Orifice

Control Range
Flow in GPM

Design Flow Accuracy

Range

Differential Pressure in PSI

Pressure Independent Flow Limiting Valve
2 sizes available

.18 to 45.46 GPM

Externally adjustable flow limiting balance valves

Pressure Independent Control Valves
2 sizes available

.13 to 37 GPM

Externally adjustable flow limiting balance valve and

a modulating control valve
Its more than just balancing valves

Piping system decisions:

Usually have a choice between two size pipes
Varied methods of pipe head loss calculation
Have to account for safety factors, aging
Control valve selection: may not get the exact flow
coefficient you need.
Have to have a way to validate (test) and make
adjustments (branch & system)
It takes some judgment and experience.
Design Criteria For Piping

ASHRAE recommends: Consider:

Velocity Branch to riser pressure
General 4 -10 fps drops should be 2:1 or
Mechanical rm. 6 -15 fps greater
Maximum velocity Direct return circuits in
1500 hr/yr 15 fps variable speed / variable
3000 hr/yr 13 fps flow hydronic circuits
6000 hr/yr 10 fps require much more
Pressure drop attention to detail and
1.0 to 4.0 ft / 100 ft.
control sequence
ASHRAE 90.1-2010
CHAPTER 6
HEATING, VENTILATING, AND AIR CONDITIONING
SECTION 6.5
Prescriptive Path

TABLE 6.5.4.5 Piping System Design Maximum Flow Rate in GPM

Operating Hours/Year <2000 Hours/Year <2000 and <4400 Hours/Year >4400 Hours/Year

Variable Flow/ Variable Flow/ Variable Flow/

Nominal Pipe Size, in. Other Other Other
Variable Speed Variable Speed Variable Speed

2 120 180 85 130 68 110

3 180 270 140 210 110 170
4 350 530 260 400 210 320
5 410 620 310 470 250 370
6 740 1100 570 860 440 680
8 1200 1800 900 1400 700 1100
10 1800 2700 1300 2000 1000 1600
12 2500 3800 1900 2900 1500 2300
Maximum Velocity for Pipes 8.5 fps 13.0 fps 6.5 fps 9.5 fps 5.0 fps 7.5 fps
over 12 in. Size
 Piping System Design Maximum Flow Rate
Friction Loss Rate Comparison
Friction Loss Rate
Operating <2000 and <4400
Hours/Year <2000 Hours/Year Hours/Year >4400 Hours/Year

Nominal Pipe Friction Variable Friction Friction Variable Friction Friction Variable Friction
Size, in. Other Loss Rate Speed Loss Rate Other Loss Rate Speed Loss Rate Other Loss Rate Speed Loss Rate
(GPM) (Ft/100 Ft) (GPM) (Ft / 100 Ft) (GPM) (Ft / 100 Ft) (GPM) (Ft / 100 Ft) (GPM) (Ft / 100 Ft) (GPM) (Ft / 100 Ft)
2 1/2 120 10.01 180 21.78 85 5.2 130 11.66 68 3.42 110 8.48
3 180 7.26 270 15.78 140 4.5 210 9.74 110 2.86 170 6.51
4 350 6.55 530 14.56 260 3.72 400 8.46 210 2.48 320 5.52
5 410 2.84 620 6.25 310 1.67 470 3.68 250 1.12 370 2.34
6 740 3.47 1100 7.44 570 2.11 860 4.63 440 1.3 680 2.96
8 1200 2.2 1800 4.79 900 1.27 1400 2.95 700 0.79 1100 1.86
10 1800 1.52 2700 3.3 1300 0.82 2000 1.86 1000 0.5 1600 1.21
12 2500 1.18 3800 2.63 1900 0.7 2900 1.57 1500 0.45 2300 1.01

Velocity
Operating <2000 and <4400
Hours/Year <2000 Hours/Year Hours/Year >4400 Hours/Year

Nominal Pipe Variable Variable Variable

Size, in. Other Velocity Speed Velocity Other Velocity Speed Velocity Other Velocity Speed Velocity
(GPM) (ft/sec) (GPM) (ft/sec) (GPM) (ft/sec) (GPM) (ft/sec) (GPM) (ft/sec) (GPM) (ft/sec)
2 1/2 120 8.04 180 12.06 85 5.69 130 8.71 68 4.56 110 7.37
3 180 7.81 270 11.72 140 6.08 210 9.12 110 4.78 170 7.38
4 350 8.82 530 13.36 260 6.55 400 10.08 210 5.29 320 8.07
5 410 6.57 620 9.94 310 4.97 470 7.53 250 4.01 370 5.93
6 740 8.22 1100 12.22 570 6.33 860 9.55 440 4.89 680 7.55
8 1200 7.7 1800 11.55 900 5.78 1400 8.98 700 4.49 1100 7.06
10 1800 7.32 2700 10.98 1300 5.29 2000 8.13 1000 4.07 1600 6.51
12 2500 7.17 3800 10.89 1900 5.45 2900 8.31 1500 4.3 2300 6.59
 SYSTEM SYZER
Flow/Pressure Drop

ASHRAE 90.1 max

pipe size information

Estimated annual
energy cost based
on pipe size
Note that cost is based on a constant load it is
independent of the info in ASHRAE frame
Branch to Riser Pressure Drop Ratio

Ratio, Branch To
% Design Flow
Distribution
In End Circuit

4 95
2 90
1 80

And it falls off much more below 1:1

Branch:Riser Pressure Drop Ratio
Pump head constant
100% Improved
Head

0
Distance From Pump
Branch:Riser Pressure Drop Ratio
100%
constant
Reduced pump head
Head

0
Distance From Pump
Issue: System Curve

When we have many paths, we have many

system curves depending upon which valves
are open.
In VS/VF systems, the pump flow changes
as the control valves modulate. The pump
speed adjusts to those changes.
A much larger system
Friction
Flow Pipe Velocity Reynolds Friction
Loss Flow Type
(USGPM) Size (FPS) Number Factor
(Feet)
5000 12 4.48 14.34 1172764 Transition 0.014
14 2.77 11.86 1066660 Transition 0.0139
16 1.41 9.08 933291 Transition 0.0138
18 0.78 7.17 829403 Transition 0.0138
20 0.45 5.77 743901 Transition 0.0138
24 0.18 3.99 618839 Transition 0.0138

5500 14 3.33 13.04 1173326 Transition 0.0138

16 1.7 9.99 1026626 Transition 0.0137
18 0.94 7.89 912343 Transition 0.0136
20 0.54 6.35 818292 Transition 0.0136
24 0.22 4.39 680723 Transition 0.0137

6000 14 3.94 14.23 1279992 Transition 0.0137

16 2.01 10.89 1119949 Transition 0.0136
18 1.11 8.61 995283 Transition 0.0135
20 0.64 6.92 892682 Transition 0.0135
24 0.26 4.79 742607 Transition 0.0136
 Balanced
Flow
Set Point = 20 Ft Coefficient Available Branch
Branch CV P Flow

10 10 0 1 340 20 1000
CV
2 287 28 1000
G 1 g
4 8 4 3 1000
CV 253 36
F 2 f
4 16 4 4 229 44 1000
CV
E 3 e
5 211 52 1000
4 CV 24 4
D 4 d 6 196 60 1000
4 CV 32 4
C 5 c Total 6000@68
4 CV 40 4
B 6 b

4 4
Branch = 20
Risers = 48
A a
Ratio = 0.4
 70.0

60.0

50.0

40.0
Head (Feet)

30.0

20.0

Inner Valves Close Head

Outer Valves CLose
System Curve
10.0

0.0
0.0 1000.0 2000.0 3000.0 4000.0 5000.0 6000

Flow (USGPM)

2
Q2
h2 h1 Min Control Head
Q1
2:1 BRPDR
70.0
10 10 0
CV

60.0
G 1 g
.83 CV
1.7 .83
F 2 f
50.0

.83 CV
3.4 .83
E 3 e
40.0
.83 5.1 .83
Head (Feet)

CV
D 4 d
30.0
.83 CV
6.8 .83
C 5 c
20.0 .83 CV
8.5 .83
Out Valves Close Head
Inner Valves Close
B 6 b
System Curve
10.0
.83 .83

0.0 A a
0.0 1000.0 2000.0 3000.0 4000.0 5000.0 6000.0
6000 @ 30
Flow (USGPM)

Plot of Valve & Head Combinations 6000 GPM @ 30

2:1 Branch Riser Pressure Drop Ratio (BRPDR)
Variable Primary Flow System
4 F 4 E 4 D 4 C 4 B 4 A

VFD
6 10 5 10 4 10 3 10 2 10 1 10
6000 GPM
@88 Ft Hd
10 10 10 10 10 10
1 40 32 24 16 8 0
2
2 2 F 4 E 4 D 4 C 4 B 4 A
3
20

These Must Be Balanced!

 Control Area for Variable Flow-Variable Speed Primary Distribution System

120.0
Valve 6 Closed

Valve 6 & 5
Closed
100.0

Valve 6,5,4
Valve 6,5,4,3
Closed All Open
Closed
80.0
Valve 6,5,4,3,2
Closed
Head (Feet)

60.0

40.0
Valve 1 Closed
System Curve

All Closed Inboard

Valve 1,2 Closed
Outboard

20.0 Valve 1,2,3 Closed

Valve 1,2,3,4 Closed

Valve 1,2,3,4,5 Closed

0.0
0 1000 2000 3000 4000 5000 6000 7000
Flow (GPM)
Thoughts On Selection
Coil pressure drop dominates system
controllability.
Control valve selection with = 0.5
Balancing valves: provide trim
Use as much PD as possible in control valves
Absorb the rest at the balancing valve.
Use independent flow measurement
Triple Duty Valve
Pump
Circuit Setters
Summary: Why Test & Balance?

Load calculations can be inaccurate causing

excess flow
Pipe and fitting predicted losses will vary from
actual performance
Aging factors / fouling will actually occur many years in
the future
Safety factors result in pump over-heading, improper
pump selection and over flow.
Control valve sizing is not exact.
Systems are not built as designed.
Additional Resources
Questions?
Thanks for Attending!
http://www.bellgossett.com
Resources & Tools
XylemKnowsH2o
http://mediasite.xyleminc.com
Our Representative in your area.