May
Page
 Chiller System Design and Control
 Preface
 Contents
 100
 Chiller
Primary System Components
 Chiller evaporator
Primary System Components
 Effect of chilled-water flow rate and variation
Effect of chilled-water temperature
 Water-cooled condenser
Effect of condenser-water temperature
Effect of condenser-water flow rate
 Air-cooled condenser
Maintenance
Air-cooled versus water-cooled condensers
Packaged or Split System?
 Energy efficiency
Low-ambient operation
 Air-cooled or water-cooled efficiency
Loads
 Two-way valve load control
Three-way valve load control
 Face-and-bypass dampers
Variable-speed pump load control
 Chilled-water pump
Chilled-Water Distribution System
 Pump per chiller
Distribution piping
Manifolded pumps
 Constant flow system
Pumping arrangements
 Cooling tower
Condenser-Water System
Primary-secondary system
Variable-primary system
 Effect of load on cooling tower performance
Condenser-water pumping arrangements
Effect of ambient conditions on cooling tower performance
Single tower per chiller
 Chiller control
Unit-Level Controls
Recommended chiller-monitoring points per Ashrae Standard
 Centrifugal chiller with AFD
Centrifugal chiller capacity control
 AFD on both chillers
 Small Chilled-Water Systems 1-2 chillers
Application Considerations
 Variable flow
Application Considerations Constant flow
Condensing method
 Number of chillers
Application Considerations
Parallel or series
Part load system operation
 Managing control complexity
Mid-Sized Chilled-Water Systems Chillers
Preferential vs. equalized loading and run-time
 Large Chilled-Water Systems + Chillers, District Cooling
Large chilled-water system schematic
 Pipe size
Power
Water
 Limitations of field performance testing
Chiller performance testing
Chiller Plant System Performance
Controls
 SYS-APM001-EN
 SYS-APM001-EN
 Guidance for Chilled- and Condenser-Water Flow Rates
System Design Options
 Standard rating temperatures
Chilled-Water Temperatures
System Design Options
 Chilled- and Condenser-Water Flow Rates
Condenser-Water Temperatures
Standard rating flow conditions
 System Design Options Selecting flow rates
 Low-flow conditions for cooling tower Base Case Low Flow
DP2/DP1 = Flow2/Flow11.85
 System summary at full load
Total system power Component Power kW Base Case Low Flow
 Chilled water system performance at part load
Coil response to decreased entering water temperature
 Cooling-tower options with low flow
Entering fluid temperature, F C
Smaller tower
System design
 Same tower, smaller approach
ΔT2 = 99.1 78 = 21.1F or 37.3 25.6 = 11.7C
 Same tower, smaller approach Present Smaller Approach
Same tower, larger chiller
 Retrofit capacity changes Larger Present Chiller Same tower
Retrofit opportunities
 Cost Implications
 Misconception 1-Low flow is only good for long piping runs
Misconceptions about Low-Flow Rates
 KWh
 SYS-APM001-EN
 Parallel Chillers
System Configurations
 Parallel chillers with separate, dedicated chiller pumps
System Configurations
 Series chillers
Series Chillers
 Hydraulic decoupling
Primary-Secondary Decoupled Systems
 Check valves
 Production loop
System Configurations Production
 Distribution-loop benefits of decoupled system arrangement
System Configurations Distribution
 Campus
Common
Tertiary or distributed
 Tertiary pumping arrangement
Decoupled system-principle of operation
 Flow-based control
Temperature-sensing
Flow-sensing
 Adding a chiller
Multiple chilled-water plants on a distribution loop
Subtracting a chiller
 Double-ended decoupled system
Pump control in a double-ended decoupled system
 Chiller sequencing in a double-ended decoupled system
 Other plant designs
Variable-Primary-Flow Systems
 Operational savings of VPF designs
Advantages of variable primary flow
 Dispelling a common misconception
Chiller selection requirements
 Flow, ft.water Flow rate
 Flow-rate changes that result from isolation-valve operation
Managing transient water flows
 System Configurations
 Effect of dissimilar evaporator pressure drops
System design and control requirements
 Accurate flow measurement
 Bypass flow control
Chiller sequencing in VPF systems
 Flow-rate-fluctuation examples
Adding a chiller in a VPF system
 Sequencing based on load
Subtracting a chiller in a VPF system
 Select slow-acting valves to control the airside coils
Other VPF control considerations
 Consider a series arrangement for small VPF applications
Plant configuration
 Chiller selection
Guidelines for a successful VPF system
 Bypass flow
Plant configuration
Chiller sequencing
Airside control
 Chilled-Water System Variations
Heat Recovery
Condenser Free Cooling or Water Economizer
Plate-and-frame heat exchanger
 Refrigerant migration
Chilled-Water System Variations
 Well, river, or lake water
Refrigerant migration chiller in free-cooling mode
 Preferential loading parallel arrangement
Preferential Loading
 Sidestream plate-and-frame heat exchanger
Preferential loading sidestream arrangement
 Chilled-Water System Variations
Sidestream with alternative fuels or absorption
 Sidestream system control
Preferential loading series arrangement
 Series-series counterflow
Series-Counterflow Application
 Evaporators
Unequal Chiller Sizing
Condensers
 Low ΔT Syndrome
System Issues and Challenges
Amount of Fluid in the Loop
 Chiller response to changing conditions
System Issues and Challenges
System response to changing conditions
Example
 Minimum capacity required
Contingency
Type and size of chiller
 Alternative Energy Sources
System Issues and Challenges Location of equipment
Water and electrical connections
Ancillary equipment
 Alternative fuel
Plant Expansion
Thermal storage
 Applications Outside the Chiller’s Range
Retrofit Opportunities
Flow rate out of range
 Precise temperature control
System Issues and Challenges Temperatures out of range
 Precise temperature control, multiple chillers
 System Controls
Chilled water reset-raising and lowering
Chilled-Water System Control
Chilled-water pump control
 System Controls
Critical valve reset pump pressure optimization
Number of chillers to operate
 Minimum refrigerant pressure differential
Condenser-Water System Control
VFDs and centrifugal chillers performance at 90% load
Chillers Difference
 Cooling-tower-fan control
Condenser-water temperature control
 Chiller-tower energy consumption
Chiller-tower energy balance
 Chiller-tower-pump balance
System Controls Variable condenser water flow
 Effect of chiller load on water pumps and cooling tower fans
Decoupled condenser-water system
 CDWP-2
 Failure recovery
Failure Recovery
 Conclusion
 Glossary
 Pumps system
Glossary
 Glossary
 Plant. Idea 88th Annual Conference Proceedings 1997
References
 Engineering July
References
 102
 Ashrae
Index
 Index
 105
 106
Page
 Trane