Chiller System BMS PDF

CBP @ Plot 61 Honeywell
DESIGN DOCUMENTATION
FUNCTIONAL DESCRIPTION
FOR
Chiller System
OFFICE
25th June 2012
Project: CBP @ Plot 61 Page 1 of 42

Document: Chiller FDS
Date: 25-June-2012
Rev: 3
Revision History
Rev Date Description Prepared Checked Approved

th
0 26 May 2012 Initial Release Andrew Turley S. Mahandra Lay Lwin
1 th
6 June 2012 Revised as per comments Andrew Turley S. Mahandra Lay Lwin
2 th
20 June 2012 Revised as per comments Loon YS S. Mahandra Lay Lwin
3 th
25 June 2012 Revised as per comments Loon YS S. Mahandra Lay Lwin

Date: 25-June-2012
Rev: 3
Table of Contents
1.1 System Description .............................................................................4
1.2 Flow Chart...........................................................................................6
1.2.1 Chiller Set Enable....................................................................................... 6
1.2.2 Chiller Staging Control .............................................................................. 7
1.3 Chiller Set Sequencing Control .........................................................8
1.2.3 CH-BP-1, CH-BP-2 & CH-BP-3 Sequencing Control............................... 8
1.2.4 CH-BP-4 & CH-BP-5 Sequencing Control................................................ 8
1.2.5 Chiller Set Fault Monitoring and Lockout ............................................... 10
1.2.6 Chilled and Condenser Water Pumps Failure .......................................... 11
1.4 Cooling Tower Sequence Control....................................................12
1.4.1 CT-BP-01, CT-BP-02 & CT-BP-03......................................................... 12
1.4.2 CT-BP-04 & CT-BP-05 ........................................................................... 12
1.4.3 Cooling Tower “Lock Out” Mode ........................................................... 13
1.5 Monitoring of Auto / Manual Control Switches ............................15
1.6 System Maintenance Mode ..............................................................15
1.7 Chiller Set Staging Control ..............................................................16
1.7.1 General Overview .................................................................................... 16
1.7.2 Chiller Start-Up and Shut-Down Sequence ............................................. 17
1.7.3 Staging “On” of “Lag” Chiller Sets ......................................................... 18
1.7.4 Staging “Off” of “Lag” Chiller Sets......................................................... 18
1.7.5 Staging Table............................................................................................ 19
1.7.6 Calculation of Building Load ................................................................... 20
1.8 Chilled Water Pump VSD control...................................................22
1.9 Chilled Water Bypass Valve Control ..............................................25
1.10 Condenser Water Pump VSD control.............................................26
1.11 Cooling Tower System Control .......................................................28
1.11.1 Cooling Tower Fan VSD Control ............................................................ 29
1.12 System Energy Monitoring ..............................................................31
1.13 Heat Balance Calculation and Monitoring .....................................32
1.14 Hardware Point Summary ...............................................................36
1.15 High Level Point Summary..............................................................39
1.16 Chilled Water Schematic..................................................................42

Date: 25-June-2012
Rev: 3
1.1 System Description

The chilled water system is located in the chiller plant room on level 9 of the building
and consists of six chillers operating in a parallel arrangement on the supply side of
the primary supply and return headers. The total duty load of all Duty and Lag chillers
is set at 3440 Ton.
 Three Trane chillers with a capacity of 1030 Ton (Duty/Lag/Lag)

 Two chillers with a capacity of 515 Ton (Duty/Standby)
 One chiller with a capacity of 350 Ton (Duty)
The chillers are staged in order to meet the system efficiency requirements based on a
percentage of the total duty load of 3440 Ton (3 x 1030 Ton + 350 Ton):
• 8.33% to 20% = 0.65 kW/Ton

• 20% to 100% = 0.6 kW/Ton
The chillers are staged “On” and “Off” by means of the Honeywell Direct Digital
Control system by controlling the set refrigeration compressor “Enable” interlock
signal. The individual chiller sets load and unload as required under their own integral
package control system.
Evaporator Condenser
Capacity Capacity
Chiller Type Flow Rate Flow Rate
(Ton) (KWR)
(L/S) (L/S)
CH-BP-01 Trane 1,030 3,514 123.28 204
CH-BP-02 Trane 1,030 3,514 123.28 204
CH-BP-03 Trane 1,030 3,514 123.28 204
CH-BP-07 Trane 350 3,514 41.9 74.6
CH-BP-04 Trane 515 3,514 61.64 102
CH-BP-05 Trane 515 3,514 61.64 102
The Chillers are served by 6 variable speed chilled water pumps that operate in a
parallel arrangement and are connected to the supply side of the primary supply and
return headers. The chilled water pumps are dedicated to chillers as detailed in the
below table under the “associated chiller” column.
Pump Associated Chiller Power (Kw) Flow (L/S)
CHWP-BP-01 CH-BP-01 37 123.28

CHWP-BP-02 CH-BP-02 37 123.28
CHWP-BP-03 CH-BP-03 37 123.28
CHWP-BP-07 CH-BP-07 15 41.9
CHWP-BP-04 CH-BP-04 18.5 61.64
CHWP-BP-05 CH-BP-05 18.5 61.64

Date: 25-June-2012
Rev: 3
The Chillers are served by 6 variable speed condenser water pumps that operate in a
parallel arrangement and are connected to the supply side of the primary supply and
return headers. The condenser water pumps are dedicated to chillers as detailed in the
below table under the “associated chiller” column.
Pump Associated Chiller Power (Kw) Flow (L/S)
CNWP-BP-01 CH-BP-01 55 204

CNWP-BP-02 CH-BP-02 55 204
CNWP-BP-03 CH-BP-03 55 204
CNWP-BP-07 CH-BP-07 22 74.6
CNWP-BP-05 CH-BP-04 30 102
CNWP-BP-06 CH-BP-05 30 102
The cooling tower system for the complex consists of five multi cell cooling towers
with each cell fitted with a variable speed fan. The cooling towers are located in the
Roof level plant room area and are connected in a parallel arrangement. The cooling
towers are sized as detailed in the below table. Similar sized towers are not dedicated
to any particular chiller and are sequenced separately depending on the system load
and enabled chillers.
Fan Power
CT Comment Flow (L/S)
(Kw)
CT-BP-01 7 Fan Cells CT-1-1~7 (1030 RT) 5 kW X7 204
CT-BP-07 3 Fan Cells CT-7-1~3 (350 RT) 5 kW X3 74.6
Sensors are installed in the primary chilled and condenser water flow and return lines
in the following piping:
a) Common Chilled Water Supply and Return Temperature

b) Common Condenser Water Supply and Return Temperature
c) Individual Chiller Evaporator Inlet and Outlet Temperature (6)
d) Individual Chiller Condenser Inlet and Outlet Temperature (6)
e) Individual Chiller Chilled Water Flow Rate (6)
f) Individual Chiller Condenser Water Flow Rate (6)
g) Individual Chiller Evaporator Pressure (6)
h) Individual Chiller Condenser side Pressure (6)
Refer to “Hardware Point List” section for full details of all input / output points.

Date: 25-June-2012
Rev: 3
1.2 Flow Chart

1.2.1 Chiller Set Enable

Date: 25-June-2012
Rev: 3
1.2.2 Chiller Staging Control

Date: 25-June-2012
Rev: 3
1.3 Chiller Set Sequencing Control
1.2.3 CH-BP-1, CH-BP-2 & CH-BP-3 Sequencing Control
The sequence of the three chiller sets CH-BP-1, CH-BP-2 and CH-BP-3 is initially
rotated on a weekly basis at 4:30 am (user adjustable) every Sunday depending on the
actual run hours of each set. The time, day and frequency of the sequence reset are
fully adjustable. The frequency can be adjusted to a daily, weekly or monthly reset.
The operating status of each chiller set compressor motor is monitored by the
Honeywell DDC control system and the actual run hours of each set is accumulated
within the controller software and is displayed on the chilled water system graphic.
The chiller set with the lowest accumulated number of run hours is positioned as the
“Lead” set in the control sequence for that week and the set with the next highest
number of run hours is positioned as the “1st Lag”.
The set with the greatest number of run hours is then positioned as “2nd Lag” in the
control sequence.
The sequence of the chiller sets will be arranged as detailed in the following table.
“Lead” Unit “1St Lag” Unit “2nd Lag” Unit

nd
Lowest Runtime 2 Lowest Runtime Highest Runtime
1.2.4 CH-BP-4 & CH-BP-5 Sequencing Control
The sequence of the two chiller sets CH-BP-4 and CH-BP-5 is initially rotated on a
weekly basis at 4:30 am (user adjustable) every Sunday depending on the actual run
hours of each set. The time, day and frequency of the sequence reset are fully
adjustable. The frequency can be adjusted to a daily, weekly or monthly reset.
The operating status of each chiller set compressor motor is monitored by the
Honeywell DDC control system and the actual run hours of each set is accumulated
within the controller software and is displayed on the chilled water system graphic.
The chiller set with the lowest accumulated number of run hours is positioned as the
“Lead” set in the control sequence for that week and the set with the highest number
of run hours is positioned as the “Standby”.

Date: 25-June-2012
Rev: 3
The sequence of the chiller sets will be arranged as detailed in the following table.
“Lead” Unit “Standby” Unit

Lowest Runtime Highest Runtime
In addition, the two 515 RT chiller sets CH-BP-4 and CH-BP-5 also have the
following functions as described below.
Backup for chiller sets CH-BP-1, CH-BP-2 and CH-BP-3
The two 515 RT chiller sets CH-BP-4 and CH-BP-5 also acts as backup units for the
1030 RT units of CH-BP-1 to 3. In the event of a failure or maintenance scenario of
any one of the 1030 RT chiller sets, CH-BP-4 and CH-BP-5 will be ready to backup
any of the 3 1030 RT chiller sets.
Backup for chiller sets CH-BP-7 during Failure or Maintenance
The two 515 RT chiller sets CH-BP-4 and CH-BP-5 also acts as backup units for the
350 RT unit CH-BP-7. I
In the event of a failure or maintenance scenario of the 350 RT CH-BP-7 chiller set,
CH-BP-4 and CH-BP-5 will act as backup and the “Lead” set will take over to replace
CH-BP-7.
Backup for chiller sets CH-BP-7 during Normal Operation
Similarly, during normal operation of the 350 RT CH-BP-7 chiller set (without any
failure or maintenance), when the calculated base load exceeds that of the 350 RT
chiller set, the “Lead” set of CH-BP-4 and CH-BP-5 will also cut in to meet the
required cooling load.
If the load only requires a 515 RT set (“Lead” set of CH-BP-4 and CH-BP-5) to
replace CH-BP-7 during this load demand condition, CH-BP-7 will cut out once the
“Lead” set of CH-BP-4 and CH-BP-5 cuts in so that only one unit of 515 RT chiller
set is operating.

Date: 25-June-2012
Rev: 3
1.2.5 Chiller Set Fault Monitoring and Lockout
1.1.5.1 Chiller Common Fault
The common fault for all chiller sets is monitored by the chiller system DDC
controller by means of hard wired connections from the chiller set electrical control
panel. An alarm condition is generated whenever a chiller common fault is active.
1.1.5.2 Chiller “Fail to Start”
Should a chiller set be “Enabled” to operate by the Honeywell DDC controller and the
correct status input signal is not received at the controller within a time delay period of
2 minutes (Adjustable) then a “fail to start” alarm will be generated.
1.1.5.3 Chiller Shut off Valve “Fail To Open”
Shut off valves are installed in the supply lines of both the chilled water and condenser
water serving each chiller. The valves are controlled by the DDC and driven to the
open position whenever a chiller is enabled. Valve position status inputs are also wired
to the DDC controller. If any valve is enabled to “open” and the status input signal is
not received at the controller within a time delay period of 2 minutes (Adjustable) then
a “fail to open” alarm will be generated.
1.1.5.4 Chiller Manual “Off” Condition
Individual “Auto / Off / Manual” switches are installed within the mechanical
electrical switch board for the chiller.
An auxiliary voltage free contact associated with the “Auto” position of each switch is
connected as a digital input signal into the Honeywell DDC system and the contacts
close whenever the switch is in the “Auto” position.
If the switch is not in the auto position and the associated chiller is in the “Off” state
for a continuous period of 2 minutes (adjustable) then an alarm condition will be
generated.
1.1.5.5 Chiller Lockout and Reset
When a chiller set is in any of the “Fault” conditions detailed above then that set,
along with its associated chilled and condenser water pumps, will be “Locked Out” of
the chiller sequence and an alarm condition enunciated on the operator’s terminal of
the Building Management System.

Date: 25-June-2012
Rev: 3
The next available chiller set and associated chilled and condenser water pumps in the
control sequence will then be commanded “On”. Generally a failed chiller will be
replaced by a similar sized chiller if available. If no similar sized chiller is available
then available chillers will be started according to load requirements.
Upon reset of the “Fault” condition at the chiller control panel or in the field the
chiller system will remain “Locked Out” of the sequence until the “Fault” condition
has been manually acknowledged, and reset by the operator or building engineer by
means of a command signal on the relevant graphic display on the operators terminal
of the Building Management System.
Once the “Fault” condition has been reset the chiller set will be returned to its original
position in the staging sequence for that day.
1.2.6 Chilled and Condenser Water Pumps Failure

Should a chiller set chilled or condenser water pump be in any of the following
conditions then the associated chiller set chilled and condenser water pumps will be
“Locked Out” of the chiller sequence and an alarm condition enunciated at the
operator’s terminal of the Building Management System:
1. Fail To Start (Start/Stop is ON and Status is OFF after pre-set internal time
tolerance; Default = 30 sec (adjustable), (Reset Required)
2. Active Trip Alarm (Reset Required)
3. Pump manual OFF condition (Mode= Remote and Status= OFF After preset
Internal Time tolerance; Default = 120 Sec (Adjustable)
The associated chiller set will then be controlled in an identical manner to that detailed
in the “Chiller Lockout and Reset” section above.

Date: 25-June-2012
Rev: 3
1.4 Cooling Tower Sequence Control
1.4.1 CT-BP-01, CT-BP-02 & CT-BP-03
The sequence of the three cooling towers sets CT-BP-01, CT-BP-02 & CT-BP-03 are
initially rotated on a weekly basis at 4:30 am (user adjustable) every Sunday
depending on the actual run hours of each set. The time, day and frequency of the
sequence reset are fully adjustable. The frequency can be adjusted to a daily, weekly or
monthly reset.
The operating status of each cooling tower is monitored by the Honeywell DDC
control system and the actual run hours of each set is accumulated within the
controller software and is displayed on the chilled water system graphic.
The cooling tower with the lowest accumulated number of run hours is positioned as
the “Lead” set in the control sequence for that week and the cooling tower with the
next highest number of run hours is positioned as the “1st Lag”.
The cooling tower with the greatest number of run hours is then positioned as “2nd
Lag” in the control sequence.
The sequence of the cooling towers will be arranged as detailed in the following table.
“Lead” Unit “1St Lag” Unit “2nd Lag” Unit

nd
Lowest Runtime 2 Lowest Runtime Highest Runtime
1.4.2 CT-BP-04 & CT-BP-05
The sequence of the two cooling towers CT-BP-04 & CT-BP-05 are initially rotated
on a weekly basis at 4:30 am (user adjustable) every Sunday depending on the actual
run hours of each set. The time, day and frequency of the sequence reset are fully
adjustable. The frequency can be adjusted to a daily, weekly or monthly reset.
The operating status of each cooling tower fan motor is monitored by the Honeywell
DDC control system and the actual run hours of each set is accumulated within the
controller software and is displayed on the chilled water system graphic.
The cooling tower with the lowest accumulated number of run hours is positioned as
the “Lead” set in the control sequence for that week and the set with the highest
number of run hours is positioned as the “Standby”.

Date: 25-June-2012
Rev: 3
The sequence of the cooling tower will be arranged as detailed in the following table.
“Lead” Unit “Standby” Unit

Lowest Runtime Highest Runtime
1.4.3 Cooling Tower “Lock Out” Mode

Assuming there are available towers, when any cooling tower has an adjustable
number of fans (see table below) that are not available to run then that tower will be
“Locked Out” of the sequence and an alarm condition annunciate on the operator’s
terminal of the Control System. The following conditions will result in a cooling tower
being “Locked Out”:
1. Fan Fail To Start (Start/Stop is ON and Status is OFF after pre-set internal time
tolerance; Default = 30 sec (adjustable), (Reset Required)
2. Fan Active Trip Alarm (Reset Required)
3. Fan Manual OFF condition (Mode = Remote and Status = OFF After preset
Internal Time tolerance; Default = 120 Sec (Adjustable)
4. Cooling Tower Maintenance Mode (Maintenance Mode S/W switch is
“Enable”).
5. Cooling Tower Fan Cell has an active low or high level alarm.
Once a cooling tower has been locked out then the next cooling tower in the sequence
will be commanded to start. If no cooling tower is available however and there are
some fans still available then the tower will not be locked out but will continue to run
with the available fans.
Upon reset of the “Fault” condition at the control panel or in the field the cooling
tower will remain “Locked Out” of the sequence until the “Fault” condition has been
manually acknowledged and reset by the operator or building engineer by means of a
manual command signal on the relevant graphic display on the operators terminal of
the Building Management System.
Once the “Fault” condition has been acknowledged and reset by the operator the
cooling tower will be returned to its original position in the staging sequence in an
orderly manner.
As detailed earlier some cooling towers have differing numbers of cells. Cooling
tower “lockout” will depend on the number of cells that are deemed to have failed.
The number of failed cells that will determine a cooling tower lockout will be operator
adjustable and the default values will be initially set up as follows:-

Date: 25-June-2012
Rev: 3
Fan Cells Cell Failure Setpoint

7 Cell Tower 1
4 Cell Tower 1
3 Cell Tower 1
In the event that a cooling tower has fans that are unavailable and there are no other
cooling towers available to operate then the tower will not be “locked out” but will
continue to operate with the remaining fans until such a time as another similar size
cooling tower is available. When the fans are once again available they will be started
automatically.

Date: 25-June-2012
Rev: 3
1.5 Monitoring of Auto / Manual Control Switches
Individual “Auto / Off / Manual” switches are installed within the mechanical
electrical switch board for the following:
 Chillers
 Chilled Water Pumps
 Condenser Water Pumps
 Cooling Towers Fans
An auxiliary voltage free contact associated with the “Auto” position of each switch is
connected as a digital input signal into the Honeywell DDC system and the contacts
close whenever the switch is in the “Auto” position.
Should any switch not be in the “Auto” position then an alarm condition is enunciated
on the relevant chiller set system graphic display on the operator terminal of the
Building Management System.
1.6 System Maintenance Mode

To enable the chiller sets and cooling towers to be taken “Out Of Service” for routine
maintenance an override facility is provided on the chiller set graphic display on the
operator terminal of the Building Management System.
The “Out Of Service” function will be entered by manual commands from the operator
terminal.
During the period that the chiller set “Out Of Service” command is active the affected
equipment will be treated as unavailable and will be “Locked Out” of the associated
sequence and all alarms will be inhibited.

Date: 25-June-2012
Rev: 3
1.7 Chiller Set Staging Control

1.7.1 General Overview
The “Lead” chiller set and cooling towers are started from a “Cooling” call signal
from the DDC controllers serving the air handling and fan coil units for the building.
The signal is “Globally” transferred from the air handling and fan coil unit DDC
controllers to the chiller system DDC controller.
The “Cooling” call signal will be transferred from the air handling unit controller(s) to
the chiller system controller whenever any field air handling or fan coil unit cooling
coil control valve actuator is 80% open (Adjustable) AND the unit status is in the
active state.
A time schedule is also included and whenever the time schedule is in the off state
then the cooling call is ignored and the system is disabled. The time schedule will
initially be set to 24/7 operation.
The time schedule will have the following states:
• Off
• Day Mode
• Night Mode
Whenever the chiller time schedule is in the Off state then the system will be
shutdown.
When the system is in “day” mode all chillers will be available to operate and the
“Lead” chiller will be set to the Lead of the three 1030 Ton capacity chillers.
Irrespective of which chiller is set as the lead the system will always stage down to the
least capacity chiller whenever the system load allows.
Night mode is intended for low load times such as after normal hours, weekends and
public holidays. In this mode all chillers will be available to operate according to the
system load but the “Lead” chiller will be set to the 350 Ton capacity chiller. The duty
515 ton chiller can be set as the lead with a simple operator change.
The time program schedule can be changed and customised to suit the particular
application. The default schedule is as follows (24 Hour, 7 day operation):

Date: 25-June-2012
Rev: 3
Day “Off” Mode “Night” Mode “Day” Mode

00:00 - 08:00
Monday - 08:00 - 18:00
18:00 - 24:00
00:00 - 08:00
Tuesday - 08:00 - 18:00
18:00 - 24:00
00:00 - 08:00
Wednesday - 08:00 - 18:00
18:00 - 24:00
00:00 - 08:00
Thursday - 08:00 - 18:00
18:00 - 24:00
00:00 - 08:00
Friday - 08:00 - 18:00
18:00 - 24:00
00:00 - 08:00
Saturday - 08:00 - 13:00
13:00 - 24:00
Sunday - 00:00 - 24:00 -
Holiday - 00:00 - 24:00 -
Note:
Sunday/ Public Holiday : Upon request by tenant
After Office Hours : Upon request by tenant
Cooling towers are sequenced separately so whenever a chiller is to be commanded to

start then the cooling towers are started in their sequence according to the cooling
tower staging section of this document.
In general the number of chillers that can be in operation is always limited by the
available capacity of cooling towers.
Refer to the staging table later in this section for details.
1.7.2 Chiller Start-Up and Shut-Down Sequence
Whenever a chiller set is commanded “On” the following control action will occur in
sequence.
a) The chiller condenser water shut off valve will be commanded to open.
b) Upon receipt of an “On” status from the above valve the condenser water pump in
will be commanded to start.
c) Upon receipt of an “On” status from the condenser water pump flow switch then
the next cooling tower in the sequence will be enabled.
d) Upon receipt of an “On” status from the cooling tower then the chiller chilled
water shut off valve will be commanded to open.

Date: 25-June-2012
Rev: 3
e) Upon receipt of an “On” status from the above valve the chilled water pump will
be commanded to start.
f) Upon receipt of an “On” status from the chilled water pump flow switch the chiller
will be “Enabled”.
Whenever the chiller set has been commanded “Off” the following control action will
occur in sequence.
a) The chiller “Enable” signal will be de-energised.

b) When the chiller set status signal has returned to “Off” a time delay period of 10
seconds (Adjustable) will be invoked after which the chilled water pump will be
commanded “Off” followed immediately by the chilled water shut off valve.
c) After a further time delay period of 180 seconds (Adjustable) the condenser water
pump will also be commanded “Off” followed immediately by the condenser water
shut off valve and the cooling tower if required to stop.
1.7.3 Staging “On” of “Lag” Chiller Sets
After the “Lead” chiller set has started and a stabilising time delay period of 15
minutes (Adjustable) has expired, the next available chiller set in the control sequence
will be commanded to start whenever either of the following condition arises for a
continuous period of 300 Seconds (Adjustable) :-
• The System Load Tonnage remains above the “Stage Up” setpoint
• The common primary chilled water supply temperature is greater than 10 ºC
(Adjustable)
After a “Lag” chiller set has been commanded “On” a stabilising delay period of 15
minutes (Adjustable) will be invoked before the next available chiller can be started.
Depending on the system load subsequent chillers will be started in sequence until all
available units are on line and operational. The “Stage Up” setpoints are detailed in the
section “Staging Table”.
1.7.4 Staging “Off” of “Lag” Chiller Sets
The trailing chiller set in the control sequence will be commanded to stop whenever
the following condition arises:-
• The System Load Tonnage remains below the “Stage Down” setpoint for a
continuous period of 300 seconds (Adjustable).
Date: 25-June-2012
Rev: 3
After a “Lag” chiller set has been commanded “Off” a stabilising delay period of 5
minutes (Adjustable) will be invoked before the next trailing chiller set can be
stopped.
Depending on the system load subsequent chillers will be stopped in sequence until
only a single chiller set is on line and operational. The “Stage Down” setpoints are
detailed in the section “Staging Table”.
1.7.5 Staging Table
The stage “On” setpoint is calculated as follows:-
Stage “On” Setpoint (Ton) = “Adjustable Percentage (%)” X “Total Run

Capacity (Ton)”
The stage “Off” setpoint is calculated as follows:-
Stage “Off” Setpoint (Ton) = “Adjustable Percentage (%)” X (“Total Run Capacity” –
“Capacity of Next Chiller Off”)
Where:
“Adjustable Percentage” = adjustable percentage divided by 100, default values are

given in the table under the columns Stage Up (%) and Stage Down (%)
“Total Run Capacity” = the total capacity in RT of all chillers that are currently
operating (indicated in the column “Online Capacity”)
“Capacity of Next Chiller Off” = the capacity in RT of the next chiller that is
sequenced to be commanded off. For example staging down from 2060 ton to 1380
ton requires one 1030 ton chiller to be stopped and one 350 ton chiller to be started. In
this case the next off capacity will be 1030 – 350.
The Staging set point values for the system are detailed in the table below. The table
shows both the “stage up” and “stage down” setpoints in RT and the percentage of the
current chiller online capacity. All values are fully adjustable.
The number shown after the OFF 1 in the table indicates the sequence in which chillers
will be started under failure scenarios. For example 1 indicates that this chiller will
start if any of the operating chillers fail, 2 indicates that this chiller will be started if

Date: 25-June-2012
Rev: 3
the chiller with 1 is unavailable and so on. Where there are chillers with numbers of
the same value then both chillers will be started.
Online Stage Up Stage Down Lead Lag1 Lag2 Duty Stand

Capacity RT / % RT / % (1030) (1030) (1030) (515) by 350
(515)
2064
3440 N/A ON ON ON OFF 1 OFF 2 ON
(67%)
2408 1854
3090 ON ON ON OFF 1 OFF 2 OFF 1
(78%) (90%)
2039 1242
2060 ON ON OFF 1 OFF 2 OFF 3 OFF 2
(99%) (90%)
1366 927
1380 ON OFF 1 OFF 2 OFF 3 OFF 4 ON
(99%) (90%)
1020 463
1030 ON OFF 1 OFF 2 OFF 3 OFF 4 OFF 3
(99%) (90%)
510 315
515 OFF 2 OFF 3 OFF 4 ON OFF 1 OFF 5
(99%) (90%)
346
350 N/A OFF 3 OFF 4 OFF 5 OFF 1 OFF 2 ON
(99%)
1.7.6 Calculation of Building Load

The “Building Load” expressed as Ton is used to stage the chillers “On” and “Off”
and is calculated as described:
The actual load in the field is calculated using the following formula.
kWr = Flow X TD X 4.187

Where:-
Flow = Total Chilled water flow rate of operating chiller sets in litres /
second.
TD = Common primary return temperature minus common supply
temperature.
4.187 = The constant for specific heat capacity of water.
The total chilled water flow rate is determined from the flow meters installed in the
two common discharge piping from the chillers.
The refrigeration tonnage is also calculated within the software program of the DDC
controller and is used in the sequencing control module.
Date: 25-June-2012
Rev: 3
Tonnage = 0.2856 X kWR
The instantaneous thermal tonnage value is then used to stage the trailing chiller sets
in the staging sequence as detailed in the previous section.
The chillers are staged in order to meet the system efficiency requirements (based on a
percentage of the total duty load of 3440 Ton):
• 8.33% to 20% = 0.65 kW/Ton

• 20% to 100% = 0.6 kW/Ton

Date: 25-June-2012
Rev: 3
1.8 Chilled Water Pump VSD control
Differential pressure sensors are installed across the main chilled water flow and
return lines in each of the four risers adjacent to the “Index” air handling unit.
The sensors are connected as analog inputs into the Honeywell DDC controller and the
differential pressures are monitored whenever a chiller set primary chilled water pump
is operating.
Each differential pressure sensor will have a separate setpoint assigned. The
differential pressure and the setpoint of each sensor are compared and the deviation
from setpoint calculated. The deviation from setpoint is used to reset the chilled water
flow setpoint as detailed below. A software switch is included to allow the operator to
select between the following strategies:
• Average deviation from setpoint of the four risers (default)

• Maximum deviation from setpoint of the four risers
Should any of the four differential pressure sensors be in a faulty condition then that
sensor will be automatically excluded from the calculation.
The speed of the operating chiller set primary chilled water pumps is reset from
maximum to minimum design flow rate values to maintain the required differential
pressure set point across the system flow and return lines under all load conditions.
As the selected differential pressure deviation in the field increases the flow rate
through the operating chiller sets will be driven towards the minimum design flow rate
value and as the selected differential pressure deviation decreases below zero the flow
rate will be driven towards the maximum design flow rate value.
Should the selected differential pressure deviation in the field fall below minus 10 kPa
(Adjustable) for a continuous period of 2 minutes (Adjustable) then the following
control action will occur.

Date: 25-June-2012
Rev: 3
a) The chilled water flow set point of the operating chiller sets will be raised in
increments of 2 litres / second for every 5 minute time interval until the required
field differential pressure set point value has been reached. At this time the control
action will cease and the speed of the operating chiller set primary chilled water
pumps will be maintained at this value.
b) Should the chilled water flow set point of all operating chiller sets be raised to the
maximum design flow rate value then the control action will be maintained at that
set point irrespective of the field differential pressure value.
Should the selected differential pressure in the field rise above plus 10 kPa
(Adjustable) for a continuous time period of 2 minutes (Adjustable) then the following
control action will occur.
a) The chilled water flow set point of all operating chiller sets will be decreased in
increments of 2 litres / second for every 5 minute time interval until the required
field differential pressure set point value has been achieved. At this time the
control action will cease and the speed of the operating chiller set primary chilled
water pumps will be maintained at this value.
b) Should the chilled water flow set point of all operating chiller sets be reduced to
the minimum design flow rate value then the control action will be maintained at
that set point irrespective of the field differential pressure value.
Whenever a “Lag” chiller set primary chilled water pump is commanded “On” the
output signal from each control module is to be identical so that the speed of all
operating pumps is controlled at the same speed setting.
The default set points for all four chilled water system differential pressure sensors
will initially be set as detailed in the table:
DP Setpoint
DP sensor Location
(kPa)
Riser 1 120
Riser 2 120
Riser 3 120
Riser 4 120
The total chilled water flow rate is determined from the flow meters installed in the
two common discharge piping from the chillers.
The chilled water flow setpoints are determined by the maximum and minimum flow
rates of all chillers currently in operation. For example if CH-BP-01 and CH-BP-04
only are operating then the maximum and minimum flow setpoints will be:
Date: 25-June-2012
Rev: 3
• Maximum Flow = 123.28 + 41.9 = 165.18 litres/s

• Minimum Flow = 43.61 + 21.48 = 65.09 litres/s
The maximum and minimum flow rates for each chiller are detailed in the table:
Design
Minimum Flow
Chiller (Maximum) Flow
(L/S)
(L/S)
CH-BP-01 123.28 43.61
CH-BP-02 123.28 43.61
CH-BP-03 123.28 43.61
CH-BP-07 41.9 13.67
CH-BP-04 61.64 21.48
CH-BP-05 61.64 21.48
An input signal of 2 - 10 Volts D.C. is provided to the pumps variable frequency drive
units from the DDC and the input signal will modulate the output of the drive unit
from the minimum set speed to the maximum set speed. The minimum and maximum
set speeds for the Chilled water pumps are set and adjusted within the variable
frequency drive unit by the mechanical contractor and mimicked in the DDC software.
The proportional plus integral control module within the controller will have the
following default values:
.
a) Set Point (L/S) Calculated
b) Throttling Range 1000 L/S (initial value only)
c) Integral Time 30 Seconds (initial value only)
d) Minimum Speed Setting 35Hz
e) Maximum Speed Setting 50Hz
Note: Tuning of the PI parameters will be required during commissioning.

Date: 25-June-2012
Rev: 3
1.9 Chilled Water Bypass Valve Control

A bypass valve is installed across the common flow and return lines of the chilled
water system. The valve is fitted with a Honeywell electric valve actuator which
accepts a 2 - 10 volt D.C. signal from a hard wired analog output signal from the DDC
controller.
Whenever all of the chiller sets are “Off line” the by-pass valve will be driven to the
fully closed position with an input signal of 2 volts D.C.
Whenever a chiller set primary chilled water pump is commanded “On” the bypass
valve will be maintained in the closed position for a minimum time delay period of 2
minutes (Adjustable) to enable the chiller set flow control system to stabilise.
Should the flow rate through an operating chiller set fall below the minimum design
value then the chilled water system bypass valve will be driven towards the open
position to maintain the flow rate at or above the minimum design value.
In addition should the flow rate through any operating chiller set fall below the
minimum design value then an “Alarm” condition will be enunciated on the relevant
chiller set system graphic display on the operator terminal of the Building
Management System.

Date: 25-June-2012
Rev: 3
1.10 Condenser Water Pump VSD control

All condenser water pumps are variable speed devices controlled from individual
variable frequency drive units.
Whenever a condenser water pump is commanded “On” the flow control system is
“Enabled” to operate.
The condenser water flow rate is monitored by means of magnetic flow meters
installed in the common condenser water return line from each of the chillers. The
output signal from the flow meter is connected as an analogue input into a proportional
plus integral control module within the Honeywell DDC controller. The output signals
from the control module are connected into the condenser water pump variable speed
drive units.
The summation of the flow rate from each of the operating chillers is calculated within
the DDC controller and is used to control the VSD of all operating pumps.
Similarly the summation of all operating chiller design flow rates is calculated within
the DDC controller and this value is then used as the flow setpoint.
The condenser water pump variable speed drives are modulated in unison in order to
maintain the condenser water flow rate at setpoint under all load conditions. Should
the flow rate fall below the setpoint then the VSD speed is modulated up towards the
maximum speed. Should the flow rate rise above the setpoint then the VSD is
modulated down towards the minimum speed setting.
Should the flow rate fall below the setpoint by 50 L/S (adjustable) then an “Alarm”
condition is enunciated on the relevant chiller system graphic display on the operator
terminal of the Building Management System.
The condenser water design flow rates are detailed in the following table:-
Condenser Water Range Of Flow

Chiller
Flow Design Meter
1030 Ton 204 L/S
515 Ton 102 L/S 0 - 300 L/S
350 Ton 74.6 L/S
An input signal of 2 - 10 Volts D.C. is provided to the pumps variable frequency drive
units from the DDC and the input signal will modulate the output of the drive unit
from the minimum set speed to the maximum set speed. The minimum and maximum
Date: 25-June-2012
Rev: 3
set speeds for the condenser water pumps are set and adjusted within the variable
frequency drive unit by the mechanical contractor and mimicked in the DDC software.
The proportional plus integral control module within the controller will have the
following default values:
.
f) Set Point Calculation based on running chillers
g) Throttling Range 1000 L/S (initial value only)
h) Integral Time 30 Seconds (initial value only)
i) Minimum Speed Setting 35Hz
j) Maximum Speed Setting 50Hz
Note: Tuning of the PI parameters will be required during commissioning.

Date: 25-June-2012
Rev: 3
1.11 Cooling Tower System Control

The number of cooling towers in operation and the speed of the operating fans will be
determined by the actual chiller online capacity.
The percentage load will be used to determine the number of cooling towers enabled at
any one time.
In addition to using the percentage load, the following condition will also trigger the
next available cooling tower to operate:
• The condenser water supply temperature is greater than 29.5 ºC (Adjustable)
The total capacity of the system is 3,440 tons, so the system will be fully loaded
(100%) when the system load is at this value. All subsequent load percentages will be
based on a percentage of this maximum system load of 3,440.
For example the system is considered at 50% loaded when the system load is at 50%
of 3,440 tons or 1,720 tons.
The following table details the relationship between the number of towers enabled and
the system online capacity:
Online Online Lead Lag1 Lag2 Duty Duty

Capacity Capacity CT1~3 CT1~3 CT1~3 (515) (515)
(%) (RT)
100 3440 ON ON ON ON ON
40 1376 ON ON ON OFF OFF
30 1032 ON ON OFF OFF OFF
20 688 ON OFF OFF OFF OFF
8 275 ON OFF OFF OFF OFF
Once cooling towers are enabled all associated fans will be commanded to start and
the VSD speed of all operating fans will be controlled in unison according to the next
section.

Date: 25-June-2012
Rev: 3
1.11.1Cooling Tower Fan VSD Control

A temperature sensor is installed in the common condenser water supply line from the
cooling towers and is connected into a proportional + integral control module within
the Honeywell DDC controller. The output signal from the control module is
connected to the associated cooling tower fan variable frequency drive units.
The temperature control system for each cooling tower is “Enabled” to operate
whenever a cooling tower fan is running.
As the common condenser water temperature rises above set point the speed of the
operating cooling tower fans will be increased to maintain the water temperature at the
required set point value.
Should the common condenser water temperature fall below the set point value then
the output to the operating fan variable frequency drive units will be modulated
towards the minimum speed.
Whenever more than one cooling tower system is required to operate the variable
frequency drive units of the operating cooling tower fans will be controlled from a
common output signal from the DDC controller so that each fan is controlled at the
same speed.
Whenever a “lag” cooling tower system is initially commanded “On” the speed of the
operating cooling tower fans is reduced to 50% (Adjustable) of the design speed and
the input signal into the “lag” cooling tower fan variable frequency drive unit is slowly
ramped up to operate the fan at 50% of the design speed. The speed of the fans is
maintained at this value for a continuous time period of 2 minutes (Adjustable) to
allow the temperature control system to stabilize. At the expiration of the time delay
period the fans are controlled in a parallel arrangement to maintain the required
discharge temperature set point value from the operating cooling towers.
The control of the operating cooling tower fans from the common condenser water
supply temperature sensor is depicted in the following diagram.

Date: 25-June-2012
Rev: 3
The temperature control module for the cooling tower fans will be set up with the
following default parameters.
a) Set Point = 29.5º C (Adjustable)
b) Throttling Range = 100º C.
c) Integral Time = 20 seconds.
As detailed the number of cooling towers in operation will be determined by the

system load. To prevent cycling of towers adjustable hysteresis is included as detailed
in the diagram below. As well as hysteresis adjustable time delay is also included
between cooling tower steps.

Date: 25-June-2012
Rev: 3
1.12 System Energy Monitoring

Electrical Power Meters are installed and monitored by the BMS system to monitor the
electrical KW for the following equipment:-
• Chiller Sets
• Chilled Water Pumps
• Condenser Water Pumps
• Cooling Towers
The total KW is summed for all operating equipment and displayed on a relevant
custom graphic.
As mentioned previously the system load is calculated in both Tonnage and KWR
units these values are also displayed on the custom graphics.
A calculation of plant efficiency is carried out as follows:-
“Total Electrical KW” divided by “System Tonnage”

(System Efficiency = KW/Tonnage)
This value of system efficiency is displayed on the custom graphics and is also
included in a system trend on a 24/7 basis. Custom reports can then be generated to
track the efficiency of the system over time.
The chillers are staged in order to meet the system efficiency requirements (based on a
percentage of the total duty load of 3440 Ton):
• 8.33% to 20% = 0.65 kW/Ton

• 20% to 100% = 0.6 kW/Ton

Date: 25-June-2012
Rev: 3
1.13 Heat Balance Calculation and Monitoring

The heat balance is calculated as detailed in this section.
The heat balance percentage is calculated within the DDC controller and is displayed
on the operator’s terminal of the Building Management System. The values are also
trended for graphical monitoring and archived for future retrieval if required.
If more than 20% of the computed heat balance percentage values are not within the
±5% range then an indication will be given on the relevant system graphic.
The heat balance percentage will be calculated within the DDC controller at one
minute intervals (stored for one year recording) and the percentage of the samples
within the ±5% range will be calculated and displayed in the following formats.
Current - Current percentage taken in 10 minute windows

This Hour - Percentage for the current hour (updated every minute)
Last Hour - Percentage for the previous hour
Today - Percentage today (updated every minute)
Yesterday – Percentage for the previous day
This month - Percentage for current month (updated every minute)
Last Month - Percentage for the previous month
The temperature readings and water flow rate are connected directly to the field BTU
calculator having a 16 bit A/D resolution to comply to Green Mark version 4.
The heat balance is represented by the following equation:
qcondenser = qevaporator + Winput

Where
qcondenser = Heat Rejected

qevaporator = Cooling Load
Winput = Measured electrical power input to compressors
The following pressure enthalpy diagram shows the concept of heat balance equation
in a vapour compression cycle:

Date: 25-June-2012
Rev: 3
The computation of the heat balance percentage (the total heat gain and total heat
rejected) is calculated using the following equation:
Percent Heat balance = [(qevaporator + Winput - qcondenser) / qcondenser] X 100%
The aim here is that the total heat gain and the total heat rejected must be within ±5%
for 80% of the sampled points.
NOTE: For open drive chillers the Winput shall take into account the motor efficiency
provided by the manufacture. For example if the efficiency is 90% and the measured
input power is 100Kw then the value used in the calculation will be 90% of 100Kw =
90kW.
The individual values in the heat balance equation are derived as follows:
qevaporator = 4.19 X “CHW Flow” X (CHWRT – CHWST)
qcondenser = 4.19 X “CW Flow” X (CWRT – CWST)
Winput = Sum of chillers input electrical power kW (readings are taken from the power
meters installed within the chiller electrical switchboards and interfaced to the DDC
controller via a Modbus RS485 connection)
The diagram below shows the actual BP Office chiller system and how the above
equation is derived from actual installed devices.

Date: 25-June-2012
Rev: 3
A: qevaporator
= 4.19 X “CHW FlowFM-1” X (CHWRT1 – CHWST1) + 4.19 X “CHW FlowFM-2” X (CHWRT2 – CHWST2)
B: qcondenser
= 4.19 X “CW FlowFM-3” X (CWRT – CWST)
C: Winput = Sum of chillers input electrical power kW
Percent Heat Balance = [(A + C) – B] / B x 100%

Date: 25-June-2012
Rev: 3
The diagram below shows an example of a successful heat balance calculation where
more than 80% of the computed values fall within ±5% range.

Date: 25-June-2012
Rev: 3
1.14 Hardware Point Summary

 Chilled Water Headers, Bypass and DP sensors
(For the two headers each tag name is preceded with Chw-Hdr-0X, where X= Header
Number. For the bypass system the tag name is preceded with CH-Bypass)
Point Signal Sensor

Tag Name Description Eng Unit
Type Type Range
_ChwST Header 1 CHW Supply Temp. AI PT1000 PT1000 ºC
_ChwRT Header 1 CHW Return Temp. AI PT1000 PT1000 ºC
_ChwFlw Header 1 CHW Supply Flow AI 2-10V TBA l/s
_SPres Header 1 CHW Supply Pressure AI 2-10V TBA kPa
_RPress Header 1 CHW Return Pressure AI 2-10V TBA kPa
_ChwST Header 2 CHW Supply Temp. AI PT1000 PT1000 ºC

_ChwRT Header 2 CHW Return Temp. AI PT1000 PT1000 ºC
_ChwFlw Header 2 CHW Supply Flow AI 2-10V TBA l/s
_SPres Header 2 CHW Supply Pressure AI 2-10V TBA kPa
_RPress Header 2 CHW Return Pressure AI 2-10V TBA kPa
_InPres Bypass Line Inlet Pressure AI 2-10V TBA kPa

_OutPress Bypass Line Outlet Pressure AI 2-10V TBA kPa
_VlvFdb Bypass Valve Feedback AI 2-10V 0-100% %
_Vlv Bypass Valve Control AO 2-10V 0-100% %
_DiffPres1 Differential Pressure Sensor 1 AI 2-10V TBA kPa

 Condenser Water Header

(Each tag name is preceded with Cnw-Hdr)
Tag Name Description

Point Signal Sensor Eng Unit
Type Type Range
_CnwST Header 1 CHW Supply Temp. AI PT1000 PT1000 ºC
_CnwRT Header 1 CHW Return Temp. AI PT1000 PT1000 ºC

Date: 25-June-2012
Rev: 3
 Chilled Water Pumps

(Each tag name is preceded with CHWP-BP-0X, where X = Pump Number)

Type Type Range
_SPres Pump Inlet Pressure AI 2-10V TBA kPa
_RPress Pump Outlet Pressure AI 2-10V TBA kPa
_VSDFdb Variable Speed Drive Feedback AI 0-10V 0-100% %
_Sts Pump Run Status DI N/O Open=Off Off/On
_Mode Pump Mode Switch Input DI N/O Open=TBA Local/Remote
_Trip Pump Trip Input DI N/C Open=Trip Norm/Alarm
_VSD Variable Speed Drive Control AO 2-10V 0-100% %
_SS Pump Start / Stop Control DO N/O Open=Off Off/On
 Condenser Water Pumps

(Each tag name is preceded with CNWP-BP-0X, where X = Pump Number)

Type Type Range
_SPres Pump Inlet Pressure AI 2-10V TBA kPa
_RPress Pump Outlet Pressure AI 2-10V TBA kPa
_VSDFdb Variable Speed Drive Feedback AI 0-10V 0-100% %
_Sts Pump Run Status DI N/O Open=Off Off/On
_Mode Pump Mode Switch Input DI N/O Open=TBA Local/Remote
_Trip Pump Trip Input DI N/C Open=Trip Norm/Alarm
_VSD Variable Speed Drive Control AO 2-10V 0-100% %
_SS Pump Start / Stop Control DO N/O Open=Off Off/On
 Chillers
(Each tag name is preceded with CH-BP-0X, where X = Chiller Number)
Point Signal Sensor

Type Type Range
_Sts Chiller Run Status DI N/O Open=Off Off/On
_ChwFlowSts CHW Flow Switch Status DI N/O Open=Off Off/On
_CnwFlowSts CDW Flow Switch Status DI N/O Open=Off Off/On
_Mode Chiller Mode Switch Input DI N/O Open=TBA Local/Remote
_Trip Chiller Fault Input DI N/O Open=Norm Norm/Alarm
_ChwVlvSts CHW Shut Off Valve Status DI N/O Open=Close Close/Open
Date: 25-June-2012
Rev: 3
_CnwVlvSts CDW Shut Off Valve Status DI N/O Open=Close Close/Open

_Setpoint Chiller Remote Setpoint AO 2-10V TBA ºC
_ChwVlvCtrl CHW Shut Off Valve Control DO N/O Open=Close Close/Open
_CnwVlvCtrl CDW Shut Off Valve Control DO N/O Open=Close Close/Open
_SS Chiller Start / Stop Control DO N/O Open=Off Off/On
 Chillers (Sensors)
Tag Name Description Point Signal Sensor Eng Unit

Type Type Range
_ChwInPress Evaporator In Water Pressure AI 2-10 V TBA kPa
_ChwOutPress Evaporator Out Water Pressure AI 2-10V TBA kPa
_ChwFlw Evaporator Water Flow AI 2-10V TBA l/s
_ChwInTemp Evaporator In Water Temp AI PT1000 PT1000 ºC
_ChwOutTemp Evaporator Out Water Temp AI PT1000 PT1000 ºC
_CnwInPress Condenser In Water Pressure AI 2-10 V TBA kPa
_CnwOutPress Condenser Out Water Pressure AI 2-10V TBA kPa
_CnwFlw Condenser Water Flow AI 2-10V TBA l/s
_CnwInTemp Condenser In Water Temp AI PT1000 PT1000 ºC
_CnwOutTemp Condenser Out Water Temp AI PT1000 PT1000 ºC
 Cooling Towers Cells

(Each tag name is preceded with CT-BP-X-Y, where X = CT Number and Y = Cell
Number)
Point Signal Sensor

Type Type Range
_InletTemp CT Cell Inlet Temperature AI PT1000 PT1000 ºC
_OutletTemp CT Cell Outlet Temperature AI PT1000 PT1000 ºC
_FanVSDFdb Fan Variable Speed Feedback AI 0-10V 0-100% %
_FanSts Fan Run Status DI N/O Open=Off Off/On
_FanMode Fan Mode Switch Input DI N/O Open=TBA Local/Remote
_FanTrip Fan Trip Input DI N/O Open=Norm Norm/Alarm
_LvlLo CT Cell Low Level Alarm DI N/O Open=Norm Norm/Alarm
_LvlHi CT Cell High Level Alarm DI N/O Open=Norm Norm/Alarm
_FanVSDFdb Fan Variable Speed Control AO 0-10V 0-100% %
_FanSS Fan Start / Stop Control DO N/O Open=Off Off/On

Date: 25-June-2012
Rev: 3
1.15 High Level Point Summary

 Chillers (From Power Meters)
Register Register
Type Address
_AmsA Chiller Phase A Amps Holding TBA Amps
_AmpsB Chiller Phase B Amps Holding TBA Amps
_AmpsC Chiller Phase C Amps Holding TBA Amps
_VoltsA Chiller Phase A to Neutral Volts Holding TBA Volts
_VoltsB Chiller Phase B to Neutral Volts Holding TBA Volts
_VoltsC Chiller Phase C to Neutral Volts Holding TBA Volts
_kWh Chiller Power Consumption Holding TBA kWh
_kW Chiller Power Demand Holding TBA kW
 Chilled Water Pumps (From Power Meters)

(Each tag name is preceded with CHWP-BP-0X, where X = Pump Number)

Register Register Eng Unit
Type Address
_AmsA Pump Phase A Amps Holding TBA Amps
_AmpsB Pump Phase B Amps Holding TBA Amps
_AmpsC Pump Phase C Amps Holding TBA Amps
_VoltsA Pump Phase A to Neutral Volts Holding TBA Volts
_VoltsB Pump Phase B to Neutral Volts Holding TBA Volts
_VoltsC Pump Phase C to Neutral Volts Holding TBA Volts
_kWh Pump Power Consumption Holding TBA kWh
_kW Pump Power Demand Holding TBA kW

Date: 25-June-2012
Rev: 3
 Condenser Water Pumps (From Power Meters)

(Each tag name is preceded with CNWP-BP-0X, where X = Pump Number)

Type Address
_AmsA Pump Phase A Amps Holding TBA Amps
_AmpsB Pump Phase B Amps Holding TBA Amps
_AmpsC Pump Phase C Amps Holding TBA Amps
_VoltsA Pump Phase A to Neutral Volts Holding TBA Volts
_VoltsB Pump Phase B to Neutral Volts Holding TBA Volts
_VoltsC Pump Phase C to Neutral Volts Holding TBA Volts
_kWh Pump Power Consumption Holding TBA kWh
_kW Pump Power Demand Holding TBA kW
 Cooling Tower Fans (From Power Meters)

(Each tag name is preceded with CT-BP-X-Y, where X = CT Number and Y = Cell
Number)

Type Address
_AmsA Cooling Tower Fan Phase A Amps Holding TBA Amps
_AmpsB Cooling Tower Fan Phase B Amps Holding TBA Amps
_AmpsC Cooling Tower Fan Phase C Amps Holding TBA Amps
_VoltsA Cooling Tower Fan Phase A to Neutral Volts Holding TBA Volts
_VoltsB Cooling Tower Fan Phase B to Neutral Volts Holding TBA Volts
_VoltsC Cooling Tower Fan Phase C to Neutral Volts Holding TBA Volts
_kWh Cooling Tower Fan Power Consumption Holding TBA kWh
_kW Cooling Tower Fan Power Demand Holding TBA kW

Date: 25-June-2012
Rev: 3
 Chiller High Level Interface (From Chiller Processor)


Type Address
TBA BAS Base Loading Enable BV1 40007
TBA BAS Base Loading Setpoint AV4 40006
TBA BAS Chilled Water Setpoint AV1 40003
TBA BAS Chiller Auto Stop Command MV1 40001
TBA BAS Chiller Mode Command MV2 40002
TBA BAS Current Limit Setpoint AV2 40004
TBA BAS Diagnostic Reset BV2 40008
TBA BAS Hot Water Setpoint AV3 40005
TBA Base Loading B19 30046
TBA Calculated Chiller Capacity AI5 30008
TBA Carbon Tank Temp AI39 30071
TBA Chiller Control Mode MI2 30027
TBA Chiller Running BI1 30003
TBA Chiller Running Status MI1 30026
TBA Compressor Refrigerant Discharge
AI36 30065
Temperature
TBA Compressor Running MI11 30055
TBA Compressor Running Time AI49 30088
TBA Compressor Starts AI48 30086
TBA Cond Differential Wtr Press AI15 30022
TBA Cond Entering Water Temp AI10 30013
TBA Cond Leaving Water Temp AI11 30014

Date: 25-June-2012
Rev: 3
1.16 Chilled Water Schematic

Date: 25-June-2012
Rev: 3

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CBP @ Plot 61 Honeywell

25th June 2012

Project: CBP @ Plot 61 Page 1 of 42

Rev Date Description Prepared Checked Approved

Project: CBP @ Plot 61 Page 2 of 42

Project: CBP @ Plot 61 Page 3 of 42

1.1 System Description

 Three Trane chillers with a capacity of 1030 Ton (Duty/Lag/Lag)

• 8.33% to 20% = 0.65 kW/Ton

CHWP-BP-01 CH-BP-01 37 123.28

Project: CBP @ Plot 61 Page 4 of 42

Pump Associated Chiller Power (Kw) Flow (L/S)

CNWP-BP-01 CH-BP-01 55 204

a) Common Chilled Water Supply and Return Temperature

Project: CBP @ Plot 61 Page 5 of 42

1.2 Flow Chart

Project: CBP @ Plot 61 Page 6 of 42

1.2.2 Chiller Staging Control

Project: CBP @ Plot 61 Page 7 of 42

1.3 Chiller Set Sequencing Control

1.2.3 CH-BP-1, CH-BP-2 & CH-BP-3 Sequencing Control

“Lead” Unit “1St Lag” Unit “2nd Lag” Unit

1.2.4 CH-BP-4 & CH-BP-5 Sequencing Control

Project: CBP @ Plot 61 Page 8 of 42

“Lead” Unit “Standby” Unit

Backup for chiller sets CH-BP-1, CH-BP-2 and CH-BP-3

Backup for chiller sets CH-BP-7 during Failure or Maintenance

Backup for chiller sets CH-BP-7 during Normal Operation

Project: CBP @ Plot 61 Page 9 of 42

1.2.5 Chiller Set Fault Monitoring and Lockout

1.1.5.1 Chiller Common Fault

1.1.5.2 Chiller “Fail to Start”

1.1.5.3 Chiller Shut off Valve “Fail To Open”

1.1.5.4 Chiller Manual “Off” Condition

1.1.5.5 Chiller Lockout and Reset

Project: CBP @ Plot 61 Page 10 of 42

1.2.6 Chilled and Condenser Water Pumps Failure

Project: CBP @ Plot 61 Page 11 of 42

1.4 Cooling Tower Sequence Control

1.4.1 CT-BP-01, CT-BP-02 & CT-BP-03

“Lead” Unit “1St Lag” Unit “2nd Lag” Unit

1.4.2 CT-BP-04 & CT-BP-05

Project: CBP @ Plot 61 Page 12 of 42

“Lead” Unit “Standby” Unit

1.4.3 Cooling Tower “Lock Out” Mode

Project: CBP @ Plot 61 Page 13 of 42

Fan Cells Cell Failure Setpoint

Project: CBP @ Plot 61 Page 14 of 42

1.5 Monitoring of Auto / Manual Control Switches

1.6 System Maintenance Mode

Project: CBP @ Plot 61 Page 15 of 42

1.7 Chiller Set Staging Control

The time schedule will have the following states:

Project: CBP @ Plot 61 Page 16 of 42

Day “Off” Mode “Night” Mode “Day” Mode

Cooling towers are sequenced separately so whenever a chiller is to be commanded to

Refer to the staging table later in this section for details.

1.7.2 Chiller Start-Up and Shut-Down Sequence

Project: CBP @ Plot 61 Page 17 of 42

a) The chiller “Enable” signal will be de-energised.

1.7.3 Staging “On” of “Lag” Chiller Sets

1.7.4 Staging “Off” of “Lag” Chiller Sets