CHAPTER 14. CONDENSER WATER SYSTEMS

1/28/2016 CHAPTER 14.
CONDENSER WATER SYSTEMS
CHAPTER 14. CONDENSER WATER SYSTEMS

AS part of the vaporcompression cycle for mechanical refrigeration, the heat of compression produced must be rejected
to complete the refrigeration cycle. Refrigerant systems may be cooled by air or water. In watercooled systems, water
flows through the condenser and is called condenser water. Condenser water systems are classified as (1) oncethrough
systems (e.g., city water, wellwater, or lake/groundwater systems), or (2) recirculating or cooling tower systems.
ONCETHROUGH CITY WATER SYSTEMS
Oncethrough city water systems use water from the city’s potable water supply and circulate through the refrigeration
equipment condenser (e.g., walkin cooler, computer room unit) to reject heat and discharge water directly to the sewer.
Many municipalities prohibit this type of direct water cooling because of water conservation restrictions, although some
localities allow its use as a standby or emergency condenser water system for critical refrigeration needs such as for
computer rooms, research laboratories, or critical operating room or life support machinery. If city water is allowed for
condenser water purposes, then allowed flow may be limited to less than 0.2 gpm per ton. The designer should contact
the local water department to determine the viability of this system.
Figure 1 shows a watercooled condenser using city water. The return (leaving water) is run higher than the condenser
so that the condenser is always full of water. Water flow through the condenser is regulated by a control valve in the
supply or discharge line, usually actuated from condenser head pressure to (1) maintain a constant condensing
temperature with load variations and (2) close when the refrigeration compressor turns off. City water systems should
always include approved backflow prevention devices and open (air gap) drains. When more than one condenser is used
on the same circuit, individual control valves are used.
Piping materials for these systems are generally nonferrous, usually copper but sometimes highpressure plastic because
corrosionprotective chemicals cannot be used. Scaling can be a problem with highertemperature condensing surfaces
when the water has a relatively high calcium content. In these applications, mechanically cleanable straight tubes should
be used in the condenser.
Figure 1. Condenser Connections for OnceThrough City Water System
Piping should be sized according to the principles outlined in Chapter 22 of the 2009 ASHRAE Handbook—
Fundamentals, with velocities of 5 to 10 fps for design flow rates. A pump is usually not required where city water is used.
Well water can be used in lieu of city water, connected on the service side of the pumping/pressure control system.
Because most well water has high calcium content, scaling on the condenser surfaces can be a problem.
Another oncethrough system uses lake or river water. Although these systems eliminate the need for a cooling tower,
they require particular attention to filtering out sediment, particulates, and other materials that could foul the system. In
the United States, special permitting is required from the local Department of Natural Resources (DNR) and the
Environmental Protection Agency (EPA). Particular attention must be paid to the design of intake structures and keeping
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1/28/2016 CHAPTER 14. CONDENSER WATER SYSTEMS
the velocity below 0.5 fps so as not to intake aquatic wildlife.
OPEN COOLING TOWER SYSTEMS
Open systems have at least two points of interface between the system water and the atmosphere; they require a
different approach to hydraulic design, pump selection, and sizing than do closed hot and chilledwater systems. Some
heat conservation systems rely on a split condenser heating system that includes a twosection condenser. One section of
the condenser supplies heat for closedcircuit heating or reheat systems; the other section serves as a heat rejection circuit,
which is an open system connected to a cooling tower (see Chapter 40).
In selecting a pump for a cooling tower/condenser water system, consideration must be given to the static head and the
system friction loss. The pump inlet must have an adequate net positive suction head (see Chapter 40). In addition,
continuous contact with air introduces oxygen into the water and concentrates minerals that can cause scale and
corrosion on a continuing basis. Fouling factors and an increased pressure drop caused by aging of the piping must be
taken into account in the condenser piping system design (see Chapter 22 of the 2009 ASHRAE Handbook—
Fundamentals). Corrosion and erosion are not just limited to condenser water piping: the chiller condenser water bundle
sees the same water. It is not uncommon to coat the condenser water box with epoxy paint to prolong its life. Similarly,
adding nylon tube inserts extends the life of the tube ends at the tube sheet walls.
The required water flow rate depends on the refrigeration unit used and on the temperature of the available condenser
water. Cooling tower water is available for return to the condenser at a temperature several degrees above the design wet
bulb temperature, depending on tower performance. An approach of 7°F to the design wetbulb temperature is frequently
considered an economically sound design. In city, lake, river, or well water systems, the maximum water temperature that
occurs during the operating season must be used for equipment selection and design flow rates and temperature ranges.
The required flow rate through a condenser may be determined with manufacturers’ performance data for various
condensing temperatures and capacities. With airconditioning refrigeration applications, a return or leaving condenser
water temperature of 95°F is considered standard practice. If economic feasibility analyses can justify it, higher leaving
water temperatures may be used.
Figure 2. Cooling Tower Piping System
Figure 2 shows a typical cooling tower system for a refrigerant condenser. Water flows to the pump from the tower basin
or sump and is discharged under pressure to the condenser and then back to the tower. When it is desirable to control
condenser water temperature or maintain it above a predetermined minimum, water is diverted through a control valve
directly back to the tower basin.
Piping from the tower sump to the pump requires some precautions because, at this point, the water is basically flowing
due to gravity. The sump level should be above the top of the pump casing for positive prime, and piping pressure drop
should be minimized such that there is always adequate net positive suction on the pump. All piping must pitch up to the
tower basin, if possible, to eliminate air pockets. It is not unusual to have this piping a diameter or two larger than the
pump discharge or pressurized piping.
If used, suction strainers should be equipped with inlet and outlet gages to indicate through excessive pressure drop
when cleaning is required. Inline pipe strainers are not recommended for cooling tower systems because they tend to
become blocked and turn into a reliability problem in themselves. Many designers depend on large mesh screens in the
tower sump and condenser heads designed with settling volumes to remove particulate matter. If a strainer is deemed
necessary, twolarge capacity basket strainers, installed in parallel such that they can be alternately put into service and
valved out for cleaning, are recommended.
Air and Vapor Precautions
Both vapor and air can create serious problems in open cooling tower systems. Water vaporizes in the pump impeller if
adequate net positive suction head is not available. When this occurs, the pump loses capacity, and serious damage to the
impeller can result. Equally damaging vaporization can occur in other portions of the system where pressure in the pipe
can drop below the vapor pressure at the operating water temperature. On shutdown, these very low pressures can result
from a combination of static pressure and momentum. Vaporization is often followed by an implosion, which causes
destructive water hammer. To avoid this problem, all sections of the piping system except the return line to the upper
tower basin should be kept below the basin level. When this cannot be achieved, a thorough dynamic analysis of the
piping system must be performed for all operating conditions, a soft start and stop control such as a variablefrequency
drive on the pump motor is recommended as an additional precaution, and all actuated control valves should be slow
closing.
Air release is another characteristic of open condenser water systems that must be addressed. Because the water/air
solution in the tower basin is saturated at atmospheric pressure and coldwater basin temperature, the system should be
designed to maintain the pressure at all points in the system sufficiently above atmospheric that no air will be released in
the condenser or in the piping system (see Figures 2 and 3 in Chapter 13).
Another cause of air in the piping system is vortexing at the tower basin outlet. This can be avoided by ensuring that
the maximum flow does not exceed that recommended by the tower manufacturer. Release of air in condenser water
systems is the major cause of corrosion, and it causes decreased pump flow (similar to cavitation), water flow restrictions
in some piping sections, and possible water hammer. Antivortexing devices can be added to the piping to mitigate this
occurrence.
Pump Selection and Pressure Calculations
The elements of required pump head are illustrated in Figure 3. Because there is an equal head of water between the
level in the tower sump or interior reservoir and the pump on both the suction and discharge sides, these static heads
cancel each other and can be disregarded.
The elements of pump head are (1) static head from tower sump or interior reservoir level to the tower header, (2)
friction loss in suction and discharge piping, (3) pressure loss in the condenser, (4) pressure loss in the control valves, (5)
pressure loss in the strainer, and (6) pressure loss in the tower nozzles, if used. Added together, these elements determine
the required pump total dynamic head.
Figure 3. Schematic Piping Layout Showing Static and Suction Head
Normally, piping is sized for water velocities between 5 and 12 fps. As stated previously, piping on the discharge of the
pump may see the higher velocities, and piping on the suction side should see the lower velocities. Refer to Chapter 22 of
the 2009 ASHRAE Handbook—Fundamentals, for piping system pressure losses. Friction factors for 15yearold pipe are
commonly used. Manufacturers’ data contain pressure drops for the condenser, cooling tower, control valves, and
strainers.
If multiple cooling towers are to be connected, the piping should be designed so that the pressure loss from the tower
to the pump suction is exactly equal for each tower. The basin water operating level should physically be at the same
elevation. Additionally, large equalizing lines or a common reservoir can be used to ensure this. However, for reliability,
redundancy, and ease of maintenance, multiple basins are often preferred.
Evaporation in a cooling tower concentrates the dissolved solids in the circulating water. This concentration can be
limited by discharging a portion of the water as overflow or blowdown. This may be accomplished by discharging or
bleeding a continuous stream of water, or by using a conductivity sensor to activate blowdown valves in the system. A
rough estimate of the bleed rate should equal the amount of evaporation occurring in the tower.
Makeup water is required to replace water lost by evaporation, blowdown, and drift. Automatic float valves or level
controllers are usually installed to maintain a constant water level. If float valves are used, the control system should be
tuned to desensitize the readings from turbulent, foaming water in the cooling tower basin. If a reservoir is used, the level
devices may be installed in a “stilling” tube to read lessturbulent water levels.
Water Treatment
Water treatment is necessary to prevent scaling, corrosion, and biological fouling of the condenser and circulating
system. The extent and nature of the treatment depends on the chemistry of the available water and on the system design
characteristics. On large systems, fixed continuousfeeding chemical treatment systems are frequently installed in which
chemicals, including acids for pH control, must be diluted and blended and then pumped into the condenser water
system. Corrosionresistant materials may be required for surfaces that come in contact with these chemicals. In piping
system design, provisions for feeding the chemicals, blowdowns, drains, and testing must be included. Because cooling
towers move great quantities of air and the water flow acts as an air washer, towers can introduce a great deal of airborne
particulate into the basin and condenser water system. Therefore, sidestream filtration with separate pumping systems is
recommended. For further information on water treatment, refer to Chapter 40 of this volume and Chapter 49 of the 2015
ASHRAE Handbook—HVAC Applications.
Freeze Protection and Winter Operation
Outdoor piping must be protected (insulated and heat traced) or drained when a tower operates intermittently during
cold weather. The most satisfactory arrangement is to provide an indoor receiving tank into which the coldwater basin
drains by gravity, as shown in Figure 4A. The makeup, overflow, and pump suction lines are then connected to the indoor
reservoir tank rather than to the tower basin. This arrangement may also use vertical turbine pumps that save floor space
compared to a basemounted centrifugal pump. The indoor basin also serves as a settling basin for any waterborne
particulate; thus, the basin should be drained or cleaned annually to avoid biological growth and potential fouling of the
chiller’s condenser surfaces. If the system is small, many cooling tower manufacturers have remote sump tanks as an
option.
The reservoir or sump should be sized for the entire system water volume that drains back into the sump when the
pumps deenergize. A common rule of thumb is to add the volume of water required if the condenser water pumps were to
run for 3 min as a minimum level to have enough water to prime the piping system. The reservoirs should have high and
lowwater alarms and makeup water level controls. Consideration should also be given to the pump suction requirements
to prevent vortexing to determine the depth. Because the pipe entering the sump also may contain great quantities of air,
the sump should have a vent or open grate installed of adequate size.
For winter operation, a condenser water bypass directly to the reservoir should be considered to prevent water that is too
cold entering the condenser. A cooling tower should never be operated in the winter without a heat load. If the tower has
variablefrequency drives (VFDs), they should be modulated to keep the water temperature above freezing. Fan reversal for
several minutes can be used for deicing, but must be discussed with the tower manufacturer to determine any limitations.
Figure 4. Cooling Tower Piping to Avoid FreezeUp
A control sequence for the piping arrangement of Figure 4A with rising water temperature would be as follows:
A temperature sensor measures the temperature of the water leaving the indoor sump.
As the temperature starts to rise, the diverting valve begins directing some of the water over the tower.
After the water is in full flow over the tower, and the temperature continues to rise above set point, the fan is
started on low speed, with the speed increasing until the water temperature reaches set point.
With falling water temperature, the opposite sequence occurs.
Tower basin heaters or heat exchangers connected across the supply and return line to the tower can also be selected.
Steam or electric basin heaters are most commonly used. An arrangement incorporating an indoor heater is shown in
Figure 4B.
LOWTEMPERATURE (WATER ECONOMIZER) SYSTEMS
When open cooling tower systems are used for generating chilled water directly, through an indirect heat exchanger
such as a plate frame heat exchanger, or with a chiller thermocycle circuit, the bulk water temperature is such that icing
can occur on or within the cooling tower, with destructive effects. The piping circuit precautions are similar to those
described in the section on Open Cooling Tower Systems, but they are much more critical. For precautions in protecting
cooling towers from icing damage, see Chapter 40.
Water from open cooling tower systems should not be piped directly through cooling coils, unitary heat pump
condensers, or plateframe heat exchangers unless the water is first filtered through a highefficiency filtering system and
the water treatment system is managed carefully to minimize the dissolved solids. Even with these precautions, cooling
coils should have straight tubes arranged for visual inspection and mechanical cleaning, unitary heat pumps should be
installed for easy removal and replacement, and plate frame heat exchangers should be installed for ready accessibility for
disassembly and cleaning.
CLOSEDCIRCUIT EVAPORATIVE COOLERS
Because of the potential for damaging freezing of cooling towers, some designers prefer to use closedcircuit
evaporative/dry coolers for water economizer chilledwater systems. One of the many different configurations of these
systems is shown in Figure 5. The open water is simply recirculated from the basin to the sprays of the evaporative cooler,
and the cooling water system is a closed hydronic system usually using a glycol/water mixture for freeze protection. The
open water system is then drained in freezing weather and the cooling heat exchanger unit is operated as a dry heat
exchanger. This type of system in some configurations can be used to generate chilled water through the plateframe heat
exchanger shown or to remove heat from a closed heat pump circuit. The glycol circuit is generally not used directly either
for building cooling or for the heat pump circuit because of the economic penalty of the extensive glycol system. The
closed circuit is designed in accordance with the principles and procedures described in Chapter 13.
Figure 5. ClosedCircuit Cooler System
OVERPRESSURE CAUSED BY THERMAL FLUID EXPANSION
When open condenser water systems are used at low temperatures for winter cooling, special precautions should be
taken to prevent damaging overpressurization caused by thermal expansion. This phenomenon has been known to cause
severe damage when a section of piping containing water at a lower temperature than the surrounding space is isolated
while cold. This isolation could be intentional, such as isolation by two service valves, or it could be as subtle as a section
of piping isolated between a check valve and a control valve. If such an isolation occurs when water at 45°F is in a 1 in.
pipe passing through a 75°F space, Figure 41 in Chapter 13 reveals that the pressure would increase by 815 psi, which
would be destructive to many components of most condenser water systems. Refer to the section on Other Design
Considerations in Chapter 13 for a discussion of this phenomenon.
BIBLIOGRAPHY
Baltimore Aircoil Company. 2005. Product & application handbook, vol. 1. Baltimore Aircoil Company, Baltimore.
Hensley, J.C., ed. 1998. Cooling tower fundamentals. Marley Cooling Tower, Overland Park, KS.
The preparation of this chapter is assigned to TC 6.1, Hydronic and Steam Equipment and Systems.

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CONDENSER WATER SYSTEMS