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HVAC Fundamentals and BMS Controls

Topic 1 – Vapour-Compression Cycle (SOLUTIONS)

1. Draw the vapour-compression cycle. State the refrigerant flow direction and
energy flow at each of the components. What will you experience if the
refrigerant flow is reversed?

If the cycle is reversed, for example, by interchanging the inlet and


discharge connections at the compressor, the evaporator will become a
condenser and the condenser will become an evaporator. The room will
become heated instead of cooled. This is called a heat pump and is used in
cold countries for indoor heating.

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2. In the pressure-enthalpy (P-h) diagram below, identify the following points
and the corresponding state of the refrigerant (liquid or gas or liquid-gas
mixture).

a) P = 200 kPa, T = -20°C b) P = 200 kPa, T = 70°C


c) P = 3 MPa, T = 70°C d) P = 1 Mpa, T = 40°C
e) P = 500 kPa, quality = 70 %, T = 17°C f) T = 10°C, quality = 0 %,
P = 420kPa

d can be anywhere on this line

f e

a b

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3. The following measurements were taken on an AC system using R134a.
Draw the cycle on the P-h diagram and identify the evaporating and
condensing temperatures. What are the degrees of superheat and sub-cool?

Evap. pressure at 0.35 MPa, Cond. pressure at 1.75 MPa


Compressor inlet at 20°C, Compressor outlet at 100°C, Condenser outlet at 30°C

Deg of subcool = 30°C

3 2
Pcond= 1.75 MPa, Tcond =
60°C

4 Pevap= 0.35 MPa, Tevap = 5°C


1
Deg of superheat
= 15 °C

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4. For the AC system described in Qn 3, the refrigerant flow rate is found to be
0.7 kg/s and the compressor efficiency is 80%. Answer the following
questions:

a) Find the cooling capacity, compressor work, condenser heat rejection


and COP of the system.

The cooling capacity can be found by:


𝑄𝑒𝑣𝑎𝑝 = 𝑚̇(ℎ1 − ℎ4 ) = 0.7(265 − 90) = 122.5 kW

The compressor work is:


𝑊𝑐𝑜𝑚𝑝 = 𝑚̇(ℎ2 − ℎ1 ) = 0.7(325 − 265) = 42 kW

According to the 1st Law of Thermodynamics, the heat rejection at the


condenser is simply
𝑄𝑐𝑜𝑛𝑑 = 𝑄𝑒𝑣𝑎𝑝 + 𝑊𝑐𝑜𝑚𝑝 = 122.5 + 42 = 164.5 kW

The COP is therefore:


𝑄𝑒𝑣𝑎𝑝 122.5
𝐶𝑂𝑃 = = = 2.33
𝑊𝑖𝑛,𝑐𝑜𝑚𝑝 (42/0.8)

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b) As a result of the indoor temperature set point being increased from
18°C to 25°C, the evaporating temperature was increased to 12°C. Find
the new COP and state your observations.

At the new evaporating temperature, the superheat is maintained at


15°C. See new P-h diagram below:

Deg of subcool = 30°C

3 2
Pcond= 1.75 MPa, Tcond =
60°C

4 Pevap= 0.44 MPa, Tevap = 12°C


1

Deg of superheat
= 15 °C

The new enthalpy at the compressor inlet is: h 1 = 270 kJ/kg. Therefore,
the new cooling capacity and compressor work are:

𝑄𝑒𝑣𝑎𝑝 = 𝑚̇(ℎ1 − ℎ4 ) = 0.7(270 − 90) = 126 kW

𝑊𝑐𝑜𝑚𝑝 = 𝑚̇(ℎ2 − ℎ1 ) = 0.7(325 − 270) = 38.5 kW

The new COP is:

𝑄𝑒𝑣𝑎𝑝 126
𝐶𝑂𝑃 = = = 2.62
𝑊𝑖𝑛,𝑐𝑜𝑚𝑝 (38.5/0.8)

The COP is higher at a higher evaporating temperature and the


compressor consumes less power. Therefore, the temperature should
not be set too low in order to save energy.

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c) In the night, it is found that due to lower outdoor temperatures, the
condensing temperature can be reduced to 45°C. Correspondingly,
the temperature at the compressor discharge was reduced to 80°C.
Find the COP of the AC system for night operation.

See new P-h diagram below:

3 Pcond= 1.25 MPa, Tcond = 2


45°C

4 Pevap= 0.35 MPa, Tevap = 5°C


1
Deg of superheat
= 15 °C

The new enthalpy at the compressor discharge is: h 2 = 310 kJ/kg.


Therefore, the new compressor work is:

𝑊𝑐𝑜𝑚𝑝 = 𝑚̇(ℎ2 − ℎ1 ) = 0.7(310 − 265) = 31.5 kW

The new COP is:

𝑄𝑒𝑣𝑎𝑝 122.5
𝐶𝑂𝑃 = = = 3.11
𝑊𝑖𝑛,𝑐𝑜𝑚𝑝 (31.5/0.8)

The COP improves as lesser compressor work needed to compress


the refrigerant to a lower condensing pressure. This indicates that the
compressor consumes more energy when the outdoor temperature is
higher. Therefore, turning on the AC during the day consumes more
energy than during the night.

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d) Find the COP when the conditions for (b) and (c) are combined.
Discuss your observations.

At the combined conditions, the enthalpies are h 1 = 270 kJ/kg, h2 = 310


kJ/kg and h3 = 90 kJ/kg.

Therefore, the new cooling capacity and compressor work are:

𝑄𝑒𝑣𝑎𝑝 = 𝑚̇(ℎ1 − ℎ4 ) = 0.7(270 − 90) = 126 kW

𝑊𝑐𝑜𝑚𝑝 = 𝑚̇(ℎ2 − ℎ1 ) = 0.7(310 − 270) = 28 kW

The new COP is:

𝑄𝑒𝑣𝑎𝑝 126
𝐶𝑂𝑃 = = = 3.6
𝑊𝑖𝑛,𝑐𝑜𝑚𝑝 (28/0.8)

As expected, the highest COP is achieved at a higher indoor set point


temp and a lower outdoor air temperature.

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HVAC Fundamentals and BMS Controls

Topic 2 – Chilled Water system

1. Fill in the blanks

Direct Expansion
System

Unitary Single Split


System System

Air-cooled Water-cooled

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2. A chiller is rated at a full load cooling capacity of 435 Rton with an input
power of 240 kW.

a. What is the chiller full load capacity in kW?

b. What is the COP and efficiency of the chiller in kW/RT?

c. At 50% part load condition, if the chiller efficiency is 0.74 kW/RT, what
is the chiller input power?

Answer:

a. Chiller full load capacity in kW:

𝐿𝑜𝑎𝑑 = 435 × 3.517 = 𝟏𝟓𝟑𝟎 𝒌𝑾

b. The efficiency of the chiller at 100% load is:

1530 𝑘𝑊
𝐶𝑂𝑃 = = 𝟔. 𝟑𝟕𝟓
240 𝑘𝑊

240 𝑘𝑊
𝐶ℎ𝑖𝑙𝑙𝑒𝑟 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = = 𝟎. 𝟓𝟓 𝒌𝑾/𝑹𝒕𝒐𝒏
435 𝑅𝑡𝑜𝑛

c. At 50 % part load condition, the chiller only delivers 217.5 Rton of


cooling. The input power to the chiller is therefore:

𝑃𝑖𝑛 = 0.74 × 217.5 = 𝟏𝟔𝟎. 𝟗𝟓 𝒌𝑾

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3. An energy manager conducted an energy audit on a shopping centre chiller
plant. He obtained the following information from sensors readings in the
building management system.

Chilled water flow rate = 45.8 l/s


CHWS temperature = 8.7 °C
CHWR temperature = 12.3 °C
Condenser water flow rate = 52.7 l/s
ECWT = 30.0 °C
LCWT = 33.9 °C

Additional information:
• The designed delta T (ΔT) is 5.5 °C for both evaporator and condenser.
• The designed flow rate for chilled water and condenser water is 45.8
l/s and 52.7 l/s respectively.
• The compressor efficiency is 90%
• Cooling towers, chilled and condenser water pump power: 18 kW, 16
kW & 18 kW respectively.

Determine the following:

a. Plant cooling load (RT) and condenser load


b. Power input of chiller for current load
c. Plant overall efficiency in COP & kW/Ton
d. Plant rated cooling capacity and condenser load
e. Power input of chiller for full load
f. Plant rated efficiency for full load in COP & kW/Ton
g. Percentage loading of chiller plant
h. Comment on the part load efficiency of the chiller plant

Answer:

a. 𝑃𝑙𝑎𝑛𝑡 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝐿𝑜𝑎𝑑 (𝑄𝑒𝑣𝑎𝑝 ) = 𝑚̇ × 𝑐𝑤 × ∆𝑇𝑐ℎ𝑤


= 45.8 × 4.19 × (12.3 − 8.7)
= 691 𝑘𝑊
691
= = 𝟏𝟗𝟔 𝑹𝑻
3.517

𝐶𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 𝐿𝑜𝑎𝑑 (𝑄𝑐𝑜𝑛𝑑 ) = 𝑚̇ × 𝑐𝑤 × ∆𝑇𝑐𝑤


= 52.7 × 4.19 × (33.9 − 30)
= 𝟖𝟔𝟏 𝒌𝑾

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b. Applying heat balance equation,

𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝑤𝑜𝑟𝑘(𝑊𝑐𝑜𝑚𝑝 ) = 𝑄𝑐𝑜𝑛𝑑 − 𝑄𝑒𝑣𝑎𝑝


= 861 − 691
= 170 𝑘𝑊

𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑙𝑜𝑎𝑑(𝑘𝑊) 691


c. 𝐶𝑂𝑃 = 𝑇𝑜𝑡𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛𝑝𝑢𝑡(𝑘𝑊) = 170+18+16+18 = 3.11

𝑘𝑊 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛𝑝𝑢𝑡(𝑘𝑊)
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑇𝑜𝑛) = 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝐿𝑜𝑎𝑑(𝑇𝑜𝑛)
170+18+16+18
= 196
= 1.13𝑘𝑊/𝑅𝑇

d. 𝑃𝑙𝑎𝑛𝑡 𝑅𝑎𝑡𝑒𝑑 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 (𝑄𝑒𝑣𝑎𝑝 ) = 𝑚̇ × 𝑐𝑤 × ∆𝑇𝑑𝑒𝑠𝑖𝑔𝑛𝑒𝑑


= 45.8 × 4.19 × 5.5
= 1055 𝑘𝑊
1055
= 3.517 = 300 𝑅𝑇

𝐶𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 𝐿𝑜𝑎𝑑 (𝑄𝑐𝑜𝑛𝑑 ) = 𝑚̇ × 𝑐𝑤 × ∆𝑇𝑑𝑒𝑠𝑖𝑔𝑛𝑒𝑑


= 52.7 × 4.19 × 5.5
= 1214 𝑘𝑊

e. 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝑤𝑜𝑟𝑘(𝑊𝑐𝑜𝑚𝑝 ) = 𝑄𝑐𝑜𝑛𝑑 − 𝑄𝑒𝑣𝑎𝑝


= 1214 − 1055
= 159 𝑘𝑊

𝑘𝑊 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛𝑝𝑢𝑡(𝑘𝑊)
f. 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑇𝑜𝑛) = 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝐿𝑜𝑎𝑑(𝑇𝑜𝑛)
159+18+16+18
= 300
= 0.70 𝑘𝑊/𝑅𝑇

𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝐿𝑜𝑎𝑑 196


g. 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝐿𝑜𝑎𝑑𝑖𝑛𝑔 = 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 300 = 65%

h. The part load efficiency is very poor as can be seen from the above
calculation. The main reason is due to the constant flow rate even with
a varying load. This will result in low delta T which deviates from the
designed delta T. One solution to solve this problem is to install VSD
to reduce the flow rate for both chilled water and condenser water
loop. This will also reduce energy consumption at the pumps.

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4.
Location Parameter Recorded value from
Building Management
System
Chilled-water Supply
7.1 °C
Temperature (T1,°C)
Evaporator
Chilled-water Return
12.5 °C
Temperature. (T2,°C)
Entering condenser water
28.6 °C
temp. (T3,°C)
Condenser
Leaving Condenser water
33.2 °C
temp. (T4,°C)
Chilled water Chilled-water flowrate to AHU
16.6 l/s
header & FCU (q, l/s)
Chiller input
400
Chiller control voltage (V, volts)
board Chiller input
100
current (I, A)

a) From the above parameters, calculate the cooling load (in kW) that the
chiller is delivering
b) Calculate the cooling load (in RT)
c) If the full-load cooling capacity of the chiller is 120 Ton, what part-load
percentage is the chiller operating at?
d) Calculate the input power (in kW) to the chiller (Assume a power factor of
0.92)
e) Calculate the chiller efficiency (in kW/RT).
f) Calculate the expected condenser water flow rate. (Given that the
compressor efficiency is 90%)

Answer:

a) From the chilled-water parameters, calculate the cooling load (in kW) that the
chiller is delivering.

Qevap = m x c w x delta T
= 16.6 x 4.19 x (12.5 – 7.1)
= 376 kW

b) Calculate the cooling load (in RT).

Cooling Load in Ton = 376/3.517 = 107 RT

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c) If the full-load cooling capacity of the chiller is 120 Ton, what part-load
percentage is the chiller operating at?

Part Load percentage = 107/120 = 89 %

d) Calculate the input power (in kW) to the chiller.

Pin = 31/2 x 400 x 100 x 0.92 = 63.7kW

e) Calculate the chiller efficiency (in kW/RT).

Chiller Efficiency = 63.7/107 = 0.60 kW/RT

f) Calculate the expected condenser water flow rate. (Given that the heat balance
is 0%)

Qcond = Qevap + Win


= 376 + 63.7
= 439.7 kW

Qcond = m x c w x delta T
m = 439.7/(4.19 x (33.2-28.6))
= 22.8 kg/s = 22.8 l/s

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5. Determine whether the proposed chiller plant design for a building with
900RT peak load met the Minimum Design System Efficiency for Green Mark
Platinum award. Hence, calculate the Green Mark Score.

Equipment Designed efficiency (kW/RT)

Water cooled chiller 0.42

Chilled water pump 0.052

Condenser water pump 0.049

Cooling Tower 0.048

System Efficiency = 0.42 + 0.052 + 0.049 + 0.048 = 0.569 kW/RT

Green Mark Score = 15 + [(0.7 – 0.569) / 0.7 x 100] x 0.25


= 15 + 4.7
= 19.7

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HVAC Fundamentals and BMS Controls

Topic 3 – Building Management System Controls (SOLUTIONS)

1. Describe the main differences between Pressure Dependent and Pressure


Independent VAV control.

Answer:

For pressure dependent VAV box control, the room temperature controls the
VAV damper position directly, whereas for pressure independent VAV box
control, the room temperature adjust the air flow set point first, and the air
flow sensor control the VAV damper position.

Therefore, for PI control, there is an additional air flow sensor mounted at


the outlet of the VAV box.

2. Given that the room is cooled by cold air distributed into the room through a
Pressure Independent VAV box, describe the course of event when a cabinet
is placed in front of the thermostat.

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Answer:

Course of event:
• When the cabinet is placed in front of the thermostat, the temperature
sensor reading will increase and will be higher than the true space
temperature.
• Thus, the air flow set point will increase accordingly.
• This will cause the VAV damper to throttle open to allow more cold air to
enter the room.
• Static pressure reading in the supply air duct will start to decrease with the
opening of VAV damper.
• VSD installed at the SA fan will respond by increasing the fan speed.

Consequences:
• Room will be overcooled.
• Energy consumption at the AHU will increase.

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3. With reference to the diagram below, calculate the approach temperature
between CWS temp and ambience wet bulb temperature. Given that the cooling
tower fan speed is modulated based on the approach temperature (Set point =
1°C), describe the course of event if the wet bulb temperature sensor is faulty
and consistently gives a reading that is 1°C lower that it’s actual value.

True value
= 27.85°C

Approach temperature = CWS temp – TWB = 28.618 - 26.85 = 1.77 °C

Course of event:
• If the wet bulb temperature sensor is faulty and gives a lower value, it will cause
the approach temperature to be higher than its true value.
• Since the set point is 1 °C, the VSD installed at the cooling tower fans will
respond by increasing its fan speed.
• If the set point cannot be achieved, the cooling tower fans will operate at
maximum speed continuously.

Consequences:
• There will be energy wastage at the cooling tower fans.

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4. A building has the following chiller configuration.

Chiller 1 – 500 RT
Chiller 2 – 500 RT
Chiller 3 – 300 RT
Chiller 4 – 300 RT

Given that the chiller sequence is 2341 2143, describe the chiller staging
with reference to the load profile shown below.

1000
Cooling load (Rton)

800
600
400
200

0 4 8 12 16 20 24
Time of day (hrs)

At 7am, Chiller 2 will start by time schedule


At 8.45am, Chiller 1 will start as the load exceeds 450RT (500RT x 90%)
At 10.30am, Chiller 4 will start as the load exceeds 900RT (1000RT x 90%)

At 4.30pm, Chiller 4 will stop as the load is below 800RT (1000RT x 80%)
At 9pm, Chiller 1 will stop as the load is below 400RT (500 x 80%)
At 11pm, Chiller 2 will stop by time schedule.

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5. An increase in cooling tower fan speed USUALLY will reduce the Entering
Condenser Water Temperature (ECWT). Under what circumstances will the
fan speed has NO effect on ECWT?

• Condenser water temperature decreases after going through the cooling


tower due to the evaporative effect induced by the cooling tower fans.
• If evaporation is not able to take place at the cooling tower, there will be no
effect on ECWT even when air is blow across the condenser water.
• This happens when the wet bulb temperature of the ambience air is equal to
ECWT, which occurs when the air is very humid with high wet bulb
temperature.

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HVAC Fundamentals and BMS Controls

Topic 4 – Energy Efficiency Improvement

1. You are to evaluate two possible chiller configuration proposed by the


consultant for a new office building. They are:

Configuration 1
3 x 800 RT + 2 x 350 RT chiller (Capital cost: $2,600,000)
Configuration 2
6 x 500 RT chiller (Capital cost: $3,200,000)

The estimated load profile and chiller efficiency table is as follow:

2000

1600
Cooling load (Rton)

1200
% load 100 80 60 40 20
800 Chiller A (800 Rton) 0.54 0.48 0.51 0.66 0.8
Chiller B (500 Rton) 0.51 0.49 0.54 0.63 0.77
400
Chiller C (350 Rton) 0.55 0.57 0.59 0.63 0.71

0 4 8 12 16 20 24
Time of day (hrs)

a. By observation, what is the best operating chiller sequence for both


configurations daily? State the operating percentage loading respectively.

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Configuration 1:

Day – 2 x Chiller A at 100 % loading


Night – 1 x Chiller C at ~85% loading

Configuration 2:

Day – 4 x Chiller B at 80 % loading


Night – 1 x Chiller B at 60% loading

b. What is the weekly energy consumption for both chillers, given that the
office building requires 300 RT of cooling for the whole of Saturday and
Sunday?

Configuration 1:

Weekday: 13 x 0.54 x 1600 + 11 x 0.565(eff at ~85% loading) x 300 = 13,097


kWh
Weekend: 24 x 0.565 x 300 = 4,068 kWh
Weekly Total Consumption = 13,097 x 5 + 4,068 x 2 = 73,621 kWh

Configuration 2:

Weekday: 13 x 0.49 x 1600 + 11 x 0.54 x 300 = 11,974 kWh


Weekend: 24 x 0.54 x 300 = 3,888 kWh
Weekly Total Consumptuion = 11,974 x 5 + 3,888 x 2 = 67,646 kWh

c. If configuration 2 is selected over configuration 1, calculate the simple


payback period given that the tariff rate is $0.30/kWh.

Weekly energy savings using configuration 2 = 73,621 – 67,646 = 5,975 kWh


Annual energy savings = 5,975 x 52 = 310,700 kWh
Annual savings = 310,700 x 0.30 = $93,210

Simple payback using configuration 2


= (3,200,000 – 2,600,000)/93,210 = 6.4 years

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2. List down the methods of chiller plant optimisation strategies. With
reference to an example, explain why some methods need to be considered
carefully before implementation.

Chilled water side:


1. Increase CHWS temperature

Condenser water side:


2. Decrease CWS temperature
3. Maintain condenser water tubes
4. Use automatic tube cleaning system (ball or brush type)

Pumps:
5. Reduce flow losses
6. Avoid over sizing pump
7. Avoid oversizing motor
8. Use high efficiency pump
9. Use high efficiency motor
10. Use VSD to reduce flow

Using Method 2 as example, in order to decrease CWS temperature, the cooling


tower fan may need to operate at a higher speed. This will result in increase in
energy consumption at the cooling tower fans. Therefore, the overall efficiency of
the plant should be taken into consideration rather than focussing on the chiller
consumption only.

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