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