Chiller Systems

Dr. A. Hammoud BAU- 007 BAU-2007

Terminal Unit Performance & Control

Chilled Water System

Type of Chilled water system y

Air cooled chilled water system

Water W t cooled chilled water system l d hill d t t

MiniMini-Chilled Water System

Air Cooled Water Chiller

Outdoor unit is Noisy system, (open large system, (open area )

Chilled water system

Heavy Duty & Long life cycle Air Cooled Large Capacity Chiller Range g p y g Economical for large systems (high Efficiency). Low Noise ( f L N i fan coil indoor) il indoor) i d Part Load or full load (25-50-75-100%) (25-50-75-100%) using multi compressors for capacity control. Plumbing works is required Extra control & Accessories Double cost with respect to DX system Application: Universities , Hospitals , Commercial Centre & Hotel,etc

Water cooled chiller

Closed area ( basement or very Hot place)

Water cooled chiller

Water cooled chiller system

Hot Air out Fan stack Drift eliminator Fan with gearbox, gearbox shaft and motor Spray Nozzle

Spray area
Air In

cold water basin

Cooling Tower Components

COMPACT DESIGN SHELL AND TUBE WATER COOLERS

Air cooled-Condensing unit chiller with multi-compressors p for capacity control.

Fan coil units

The Fan coil air flow rate in CFM ranges from 200,300, 400, 600, 800 and1200. 200,300, 400, 600, 1200. and1200 3 speeds (L ,M ,H)

Ducted D d

Chiller Equations q

Summer 2004

Heat Transfer equations used in Chiller system

The size of the chiller is rated in tonnage or tons of refrigeration, where the historic definition of a ton comes from making one ton of ice in 24 hours:

q W = 500 Q(gpm) T (Bth/hr)

1 ton = 12,000BtuIh; tons x 12,000= 500 gpm T 12,000BtuIh; 12,000=

Tons =

gpm T gpm T = 12 000 24 500

T=10.8F T=10.

This is a good formula for estimating flows versus T.

In the condenser, the heat transferred to the condenser condenser, water i l d th h t f t includes the heat from th E the Evaporator, plus th heat t l the h t of compression. For most practical comfort air-conditioning applications a airapplications, value of 14,400 Btu/h may be used as the total heat 14, transferred to the condenser water. water.

q W = 500 Q(gpm) T (Bth/hr)

14 400 = 500 Q(gpm) T 28.8 Tons gpm = T

Example 1:
What chilled water flow will a 100 -ton chiller handle for a 12F rise in water temperature and a 8F drop in tower water ? First determine the flow rate in the evaporator First, (chiller flow):

gpm T ; Tons = 24 Tons 24 100 Tons 24 gpm = = = 200 12 F T

The flow in the condenser:

28.8 Tons gpm = T

28.8 100 gpm = = 360 8F

Chiller Pump discharge & Pipe p g p sizing

We could also using the basic equation:

C . L. = 510 gpm (Tiin Toutt ) C . L. is the cooling load in BTU / hr . gpm is the flowrate or pump disch arg e Tin Tout i th t is the temperature d t drop of f water across Fan coil in F , (about 5.5 6 C )
o o

Example

Suppose you want to calculate the required flow rate in gpm for a chiller Fan coil , assuming that, the that required C.L. is 1 Tons-ref and T =10.8 F, (6 C ) Tons=10. (6 Solution: gpm T
; 24 Tons 24 1 Tons 24 gpm = = = 2.22 T 10.8 F Tons =

Or

1 12000 = 500 gpm 10.8 F The flow Rate = 2.22 gpm The correspond ing pipe size is = 1 / 2"
o

From Ch F Chart
Black steel pipe is recommended

Closed system

Chiller P mp s l ti n Chill Pump selection

Care should be taken when selecting chiller pump :

1- The required flow rate & head q 2- Up feed or down feed , If Up feed system is p p y used ,the shut off head of the pump must be greater than the required head to push water up to highest level, However if down feed system is used remember to include gravity assist flow effect. effect

Example p
Suppose y want to calculate the required flow rate pp you q for a chiller centrifugal pump ,assuming that, the C.L. is 180 Tons and T = 10.8 F The D.F=75-80% is 10. F. D.F=75 80% D F=75F=75 included in the calculation of the total Cooling Load. Solution: S l ti
180 12000 = 500 gpm 10.8 F The Pump di h Th P discharge = 400 gpm The corespondi ng pipe size = p g pp
o

Typical Fan coil arrangement T pi l F n il n m nt

Fan Coil
The Fan coil inlet cold water temperature is about 7 C the outlet 13 C. Whereas the hot C C water temperature inlet is about 40 C. Practically, the temperature change across the Fan coil varies from 5 -7 C in the summer. Whereas ,in Winter the hot water temperature difference is about 11C. 11C.
Maximum water operating pressure is about 3 Bars.

Cont Fan Coil C ont

The Fan il i fl Th F coil air flow rate in CFM ranges from i f and1200. 200,300, 400, 600, 200,300, 400, 600, 800 and1200. The Fan coil gpm is about = 2.4 gpm/ton. Based gp gp gpm/ton. on temperature difference between in & out 10 F, which is about 5.5 C.

Chiller Piping Systems

Chiller Pipe Systems

Two pipe Systems

Three pipe Systems

Four pipe Systems

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TwoTwo-pipe systems

Boiler - Off Consists of one supply and one return pipe for either chilled or hot water supply . The two-pipe system is limited ch lled he two-p pe s l m ted during changeover season.
24

TwoTwo-pipe systems
Chiller - Off

25

Three-Pipe System p y

It has three pipes to each terminal unit. These pipes are a cold water supply a hot water supply and a common return. supply, return. The return pipe has a mixture of chilled & hot water during changeover operation,. These systems are rarely used today because they consume excess energy. 26

Four-Pipe System

FourFour-pipe systems have a cold water supply, cold water return, hot water supply, and hot water return. The h l dh Th terminal unit usually has two independent secondary water coils: one served by hot water, the other by water, cold water. water. 27

Comparison
The four-pipe system has the following advantages: fouradvantages: 1- Responding quickly to load changes. changes. 2- O Operates with th summer-winter changeover. t ith the summer- i t changeover. h 3- Efficiency is greater and operating cost is lower though lower, initial cost is generally higher. higher. 4-The system can be designed with no interconnection of the hot and cold water secondary circuits. circuits.

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Two & Three way -valve

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Types of valves.

Control of water flow through the coil is typically accomplished using either two-way valves or three-way valves. li h d i i h l h l Two-way valves are available in single-seat or double-seat bodies (see Figure 1 a) Single seat bodies are most common ). but require adequate actuator size to overcome water system differential pressures. p
Figure 1-a

Figure 1-b

TwoTwo-way valve

ThreeThree-way valve

30

ThreeThree-way valves, available as a mixing or a diverting pattern, valves, are sometimes considered where continuous system fl i id d h i flow i is desired (see Figure 1-b ). However, this will have increased energy impacts on the system in pumping power and chiller load. Another application is where flow diversion is required, such as condenser flow to or bypassing a cooling tower. Threeyp g g Threeway control valves used in this manner throttle the flow through the coil from 100% down to minimum and increase flow 100% in th bypass from minimum up to 100% i the b f i i t 100% 100%. %. A balancing valve is provided in the bypass to set a pressure drop equal to the terminal drop when on full bypass The port bypass. controlling the flow through the terminal should be chosen with an equal percentage characteristic and the bypass port q p g yp p selected with a complimentary linear characteristic to maintain nearly constant total flow..
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Controlling Water Flow

Figure 1-a

Two way-Valve
32

Figure 1-b g

Three way-Valve w y V

33

Figure 1-b

Three way-Valve w y V

34

Figure 1-b

Three way-Valve

35

Flow coefficient Cv
The flow coefficient Cv is defined as the volume flow rate of water at 60 F, in gallons per minute (gpm), that will flow through the valve at a decrease in pressure of 1 Psi across the valve.

Where: Q= flow rate gpm P= Pressure drop Psi

P Q = Cv Sg

Sg = Specific gravity of water =1 Now

Cv =

4300 d 2 Kv

, where d in feet f
36

The Flow rate through the control valve

Q = 0.67 Cv H
Where: Q= flow rate gpm Q fl H= Pressure drop ft Note that ;
the control valve size is not necessarily the same as the pipe y pp size, but is based on the control valve Cv and may be one or two sizes smaller than pipe size. The Cv is based on the control manufacturer's valve test data. This Cv rating may g y vary when comparing different manufacturers' valve sizes.

37

Primary Secondary pumping y yp p g system

38

Figure (3-a)

39

PrimaryPrimary-secondary pumping
Controlling water temperature in a primary-secondary pumping primaryarrangement with a two way valve is another approach to improving valve coil control, as shown figure (3-a )in the (3 previous Figure .This permits constant flow at all times at a variable temperature in the coil circuit, at the design velocity, to maximize coil heat transfer transfer. A common pipe (a-b )is connected to both the primary and (asecondary circuits with no pressure drop. This common-pipe is commonusually located in a bridge between the supply and return mains of the primary. The common pipe is selected with "no"nopressure drop" to either the secondary or primary circuits. circuits.

40

As the temperature controller calls for an increase in cooling, the two-way valve opens, permitting primary water to mix into twoopens the secondary and an equal amount of secondary return water is displaced into the return main. When V-I is full open, chilled Vwater flows from supply main (a) into the bridge and into the secondary at (b), through the load and returns to the bridge at (c), where it flows through V-I to the return main. As valve (c) Vmain V-I is throttled by the zone thermostat, less chilled water is supplied to the bridge at (b) and the secondary pump draws the balance of flow from the common from (c) to (b), thereby causing a mixing action. When the zone thermostat is completely satisfied, valve V-I is closed and all the secondary Vflow is re-circulated from (c) to (b). reAdding a check valve to the common to prevent the possibility of short-circuit flow in the common as shown in the next shortFigure . When the check valve closes, this will cause the primary pump to go into series with the secondary. See figure 41 (3-b)

Figure (3-b) Fi (3 b)

42

The primary-secondary concept allows the distribution pumping of the source supply from a central pumping facility facility. (see Figure 4-a) or distributing the pumping to remote buildings or zones of a large facility (see Figure 4-b). The primary-secondary concept allows continual flow primaryg p two- y through the source and still permits two-way valve control in the loads. There is flexibility in dedicating a pump to a chiller or boiler or manifolding the pumps. This might simplify the need f h i backup pumps for every system. i lif th d for having b k f t Pumps, manifolds, accessories and associated pumping control may be assembled to match installation constraints, constraints or can be factory prepackaged as an assembly for a designated mounting location. The designer must weigh the g g g g pros and cons of cost, flexibility and installation requirements of the various concepts to determine the best arrangement . t
43

Figure (4-a) Fi (4 )

44

Figure (4 b) (4-b)
45

46

Remarks
Reverse return systems are closer to a natural balance of flows than direct return systems. If automatic control valves are employed, the design pressure drop selected should be as high as practical. A pressure drop at least equal to practical the drop in the terminal unit coil is a desirable goal. The valve should be sized for the design flow with the Cv flow formula, which may not be the same size as the coil inlet piping. i h il i l i i Centrifugal pumps with flat characteristics should be selected for systems with control valves. y TwoTwo-way valves should be considered over three-way valves because they threevary the volume of water flow in direct relationship with the control signal. Three-w y Three-way valves provide a continuous f w regardless of the load and are p n nu u flow g f n not suitable With variable volume pumping systems. Manual balancing valves should be chosen for a minimal pressure drop and provide the means to measure flows in various loops in the field as well as provide a shutoff valve for coil servicing. Performance is best assured by requiring proportional balancing after the system is operating. Variable volume pumping systems should be checked operating and adjusted for balance at 50%, 75% and 100%design flows. 50%, 75% 100%design 47

Chiller Pumps
&

Pump s Pumps selection

Centrifugal Pump Basics Closed System

Balancing Valve Isolating 3-Way Control Valve Valve
LOAD

LOAD

BUILDING HEIGHT

LOAD

LOAD

EXPANSION

SOURCE

Centrifugal Pump Basics Closed System Resistance Curve

System Resistance Curve Friction Losses

CAPACITY

Centrifugal Pump Basics Open System

Static Head

Static Suction Head

CONDENSER

Centrifugal Pump Basics Open System Resistance Curve

System Head Curve

Friction Losses

HEA AD

Total Static Head

CAPACITY

Centrifugal Pump Basics Closed System with Minimum Maintained Pressure

BALANCING VALVE 2 WAY CONTROL ISOLATING VALVE VALVE

LOAD

LOAD

BUILDING HEIGHT

LOAD

LOAD

EXPANSION

SOURCE

Centrifugal Pump Basics Closed System Resistance Curve with Minimum Maintained Pressure

System Head Curve

Friction Losses

HEAD D

Minimum Maintained Pressure

CAPACITY

Pumps in parallel & series

Refer to the Fundamental of pumps by Dr. Hammoud

Each pump operates @ this point hi i Both pumps-ON pumps-

System operating S t ti point Both pumps-ON pumps-

Single pump Operating point

Parallel pump operation

Single pump operating ti Point One pump is -ON

System Operating Point Both pump -On

Each pump operates @ this point Both B th pump -O On

Pumps in parallel & series

What happens to Flow, Head and Power with Speed?

So: Flow changes DIRECTLY (li Fl h (linear) with RPM ) ith RPM Head changes as a SQUARE of RPM Power is proportional to Flow times Head it changes as CUBE of RPM

Q ~ RPM H ~ RPM2 SP ~ RPM3

Affinity laws (For the same pump)

Affinity laws y
D u Doubling the pump rotational speed g p leads to: 1- Double the discharge discharge. 2- Increase the total head value by a factor f f t of 4. 3- Increase the power by a factor of 8.

Two Speed pumping

Multiple-speed motors can be used to reduce system over-pressure at reduced flow In overflow. this example standard two-speed motors are available in models with speeds of 1750/1150 rpm, 1750/850 rpm, 1150/850rpm and 3500/1750 rpm. The corresponding figure shows the performance of a system with a h h f f h 1750/1150 rpm multiple speed pump. In the figure, curve A shows the system's response when the pump runs at 1750 h th t 1750rpm. Wh the When th pump runs at 1150rpm, operation is at point 1 and not at point 2 . If the system was designed to operate as shown in curve B, the pump would operate at or above the shut-off , it will be damaged if it runs at 1150 rpm For that reason the rpm. designer must analyze the system carefully to determine the pump's limitations and the effect of lower speed on performance performance.

Two multi-speed pumps in parallel multi-

It can Replace the use of Multi-speed (3 speeds) Multi(3 manual adjusted circulated pump by VFD j p p y operation in heating system. (heating system (heating circulated pump) p p) )

He

H
H1

1st d t point duty i t

2nd duty point
3nd duty point
Q1

Radiators On-off !!! OnRefer to the VFD by Dr. Hammoud

Speed reduction

Pumps Shaft power

Pump & System curves

Application of chiller pumps pp p p

4 pipe systems

Down feed pumping Down Feed p system D - F d pum system

Operating point Hstatic = Negative t ti N ti

Fan Coil

Shut off head

Shut off head Operating i t O ti point

H
Hstatic = zero i

UpUp Feed Up F d pumsystem U -feed pumping p system

Stan y Standby pump

It is always good pr ctic t c nsid r a b ck up pump of equal l s d practice to consider back f qu l capacity and proper valves to permit operation when the normal pump is inoperable. Usually this is an application for a parallel pump. Failure can occur in extremely cold weather for heating or in the F l l ld h f h h middle of a hot spell during the cooling season, and the original investment cost of a by pass will be trivial compared to the yp p inconvenience for the building occupants or the operator. Depending on the system curve and the pump curve and how many pumps are in the full system, a standby pump can provide up to 80% n prov de 80% of design flow.

Pump performance must be considered not only at the design point but across its entire characteristic curve. Centrifugal pumps are available with steep curves that drop from high head at low flow to low head at high flow versus those with flat curves that show a small change in head between shutoff to design flow

Types of Pumps needed

Some designers like to limit this to a 15% to 25% rise-to-shut off curve. These
flat curve pumps are always recommended where two-way valves are applied to unit terminals. At part-loads, the valves will be operating at lower flows and this will move the system operating differential pressure up the pump curve.

Pump s selection p
When selecting a pump for chiller application, the follow ng quest ons & factors should be following questions considered:

Pumps selection

1-What is the nature of the liquid to be pumped? (Water or antifreeze liquids , cold or hot etc.. ). 2-What is the required volume flow rate (discharge)? What is the diversity factor?, what is the maximum and minimum amount of liquid to be q pumped? q pump 3- What is the head required from the p p and the pipe system curve ?. For circulating pump the head required from the pump is to overcome the total head l h d loss only. l 4-What are the conditions on the suction (inlet) side of the pump and on the discharge (outlet) side of f th d th di h ( tl t) id f the pump? check the NPSH. That is to say Cavitation must be avoided. Cavitation avoided

5- Check the specific speed. Read the corresponding catalogue. catalogue Select the range at which your pump may exist exist. 6-Flat curve pumps rather than steep curve pumps is selected 7-Plot the pipe syst m curve on each selected pump ot th p p system cur ach s ct characteristic curve and then compare the head discharge relationship, efficiency and power of the different pumps (f d ff (from catalogues). The pump, which is l ) h h h operating at or near the point of B.E.P, ( maximum efficiency) efficiency) should be selected. Afterwards, you should be selected Afterwards able to identify one or two pumps that are suitable. g f pump 8- Choose the lowest initial and running cost of the p p i.e. (power requirements). 9- What is the type of power source (electric motor, diesel engine, etc.)? i ) 1010- Check the space, weight, and location ( indoors or outdoors ) of the pump pump. 1111- Refer to the governing codes and standards.

Remember this Single pump - Selected for a simple application. Single pump application with trimmed impeller Optimizing pump capacity for a specific application. . Single pump with backup pump- In pumpaddition to a selected application provides I00% backup application, I00% backup. TwoTwo-speed pump - Provides limited variable flow steps with an added investment. Parallel pumps- Fl ibl capacity control without i P ll l pumps- Flexible i l i h increasing i system head; good for two-way valve control. Series pumps two- Steep head change with limited flow change; two-way p g g two- y valves would require high differential pressure operation l ld h h d ff l and capability. Primary secondary pumping Primary-secondary pumping- Flexible zoning approach with approach, minimum pumping energy. Distributed pumps - Special application of primary-secondary primarypumping. pumping Variable speed pumps- Applied to pumping systems to reduce pumpsp power by lowering pump speed to meet control differential y gp p p pressure in selected locations; usually applied to parallel l dl ll l d ll l pumping distribution systems employing primary-secondary primarytwoor distributed pumping, with two-way control valves.

End of the lecture