http://www.ashrae-socal.org/ppt/ROY_HUBBARD.

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Chilled Water Piping Systems (VPF Focus)

Agenda Chilled Water Distribution Systems

Chilled Water Distribution Systems

Primary (Constant) / Secondary (Variable 2W Valves)
Low Delta T
Primary Only (Variable Flow - 2W Valves)

VPF Design/Control Considerations

Primary (Constant Flow) / Secondary (Variable Flow)

Primary/Secondary System

Secondary Pumps

Typical
load
with
two
way
valve

Primary Pumps
Common Pipe

Primary (Constant Flow) / Secondary (Variable Flow)

2 Way Valves
Higher Capital Cost Installed (vs Constant Flow 3W Valve system)
Lower CHW Pumping Energy (vs Constant Flow 3W Valve system)
Well Understood & Easy to Control

Primary/Secondary System at Design

56.0 F

44.0 F

500 ton chillers

1000 GPM Each
56.0-44.0F

Secondary Pumps
3000 GPM @ 44.0 F
56.0 F
44.0 F

44.0 F
56.0 F

Typical
Coil
44.0 F

Primary Pumps

1000 GPM Each

No flow
56.0 F

3000 GPM @ 56.0 F

Primary/Secondary System at Part Load

53.0 F

44.0 F

75% System Load

Secondary Pumps
2250 GPM @ 44.0 F

53.0 F
44.0 F

44.0 F
53.0 F

Typical
Coil
44.0 F

Primary Pumps

1000 GPM Each

750 GPM @ 44.0 F

56.0 F

3000 GPM @ 53.0 F

2250 GPM @ 56.0 F

Primary/Secondary System

50% System Load

OFF

Secondary Pumps
1500 GPM @ 44.0 F
53.0 F
44.0 F

44.0 F
53.0 F

Typical
Coil
44.0 F

Primary Pumps

1000 GPM Each

500 GPM @ 44.0 F

56.0 F

2000 GPM @ 53.0 F

1500 GPM @ 56.0 F

Low Delta T Syndrome

Major Causes of Low Delta T

Dirty Coils

10

Chilled Water Coil

Major Causes of Low Delta T

Dirty Coils
Controls Calibration
Leaky 2 Way Valves
3 Way Valves at end of Index circuit

12

Primary/Secondary System

Secondary Pumps

Primary Pumps
Common Pipe

Primary/Secondary System

Secondary Pumps

Primary Pumps
Common Pipe

Major Causes of Low Delta T

Dirty Coils
Controls Calibration
Leaky 2 Way Valves
3 Way Valves at end of Index circuit
Coils piped up backwards

15

Chilled Water Coil

Primary (Constant) / Secondary (Variable)

P Load = Flow X Delta T

S Load = Flow X Delta T

Secondary Pumps

Typical load with 2 way valve

Primary Pumps

17

Decoupler
/Bypass

Primary (Constant) / Secondary (Variable)

Ideal Operation
100% Load = 100% Sec Flow

Secondary Pumps

100% Flow = 3000 gpm

Primary Pumps
100% Flow = 3000 gpm

18

1
2

Decoupler
/Bypass
0 gpm

Primary (Constant) / Secondary (Variable)

Ideal Operation
67% Load = 67% Sec Flow

Secondary Pumps

67% Flow = 2000 gpm

Primary Pumps
67% Flow = 2000 gpm

19

1
2

Decoupler
/Bypass
0 gpm

Primary / Secondary Rule of Flow

Primary flow must always be equal

to or greater than Secondary flow.

20

Primary (Constant) / Secondary (Variable)

Low Delta T Operation
67% Load = 80% Sec Flow

Secondary Pumps

80% Flow = 2400 gpm (400 gpm over-pumped)

Primary Pumps
100% Flow = 3000 gpm

21

1
0

Decoupler
/Bypass
600 gpm

Major Effects of Low Delta T

Higher Secondary Pump Energy

Higher CHW Plant Chiller/Auxiliary Energy

Solution to (or reduce effects of) Low Delta T

Address the causes

Clean Coils
Calibrate controls occasionally
Select proper 2W valves (dynamic/close-off ratings) and maintain them
no 3W valves in design

find and correct piping installation errors

Over pump chillers at ratio of Design Delta T / Actual Delta T

Increase Delta T across chillers with CHW Re-set (down).
Use Variable Speed Chillers & sequence to operate from 30 to 70% Load
Use VPF Systems (mitigates energy waste in plant)
Header pumps & operate more pumps than chillers
If dedicated pumping, over-size (design at 80% speed).

23

Primary/Secondary System

Secondary Pumps

P
Primary Pumps
Common Pipe

Primary Only (Variable Flow)

Primary/Secondary System
Secondary Pumps

Typical load with 2 way valve

Primary Pumps

Automatic Isolation Valve

Variable Primary System

Primary Pumps

Typical load with 2 way valve

Bypass
Valve
Flow Meter

Primary Only (Variable Flow)

2 Way Valves
Lower Capital Cost Installed (vs Primary/Secondary)
No secondary pumps/piping/valves/electrical to buy and install
No large Common pipe, but smaller Bypass pipe/valve/flow meter/controls

Lower CHW Pumping Energy

Smaller Footprint (vs Primary/Secondary)
Relatively New & More Complex Controls
Reduces Negative Impacts from Low Delta T
Chillers are not staged on by flow requirements
Chillers can load up and are staged on load

Primary Only (Variable Flow)

Disadvantages
Higher (potentially) PSID rated 2-Way valves in system
Requires more robust (complex and calibrated) control system
Requires coordinated control of chillers, isolation valves, and pumps in sequencing
Longer (potentially) Commissioning time
Requires greater operator sophistication

Variable-Primary-Flow System

Automatic
Isolation Valve

Primary Pumps

Bypass

Flow Meter

Typical
load
with
two
way
valve

Variable Primary System at Design

Automatic
Isolation Valve

500 ton chillers

1000 GPM Each
56.0-44.0F

56.0 F
44.0 F

56.0 F
44.0 F

Primary Pumps

3000 GPM @ 44.0 F

Typical
load
with
two
way
valve

56.0 F

1000 GPM Each

44.0 F
Bypass
Closed

3000 GPM @ 56.0 F

Variable Primary System Part Load

75% System Load

Automatic
Isolation Valve

56.0 F
44.0 F

56.0 F
44.0 F

Primary Pumps

2250 GPM @ 44.0 F

56.0 F

750 GPM Each

44.0 F
Bypass
Closed

2250 GPM @ 56.0 F

Typical
load
with
two
way
valve

Variable Primary System Part Load

Chiller off

50% System Load

Automatic
Isolation Valve

Pump off
56.0 F
44.0 F

Primary Pumps

1500 GPM @ 44.0 F

56.0 F

750 GPM Each

44.0 F
Bypass
Closed

1500 GPM @ 56.0 F

Typical
load
with
two
way
valve

Variable Primary System Part Load

Chiller off

50% System Load

Low T

Automatic
Isolation Valve

Pump on
52.0 F
44.0 F

Primary Pumps

2250 GPM @ 44.0 F

52.0 F

750 GPM Each

44.0 F
Bypass
Closed

2250 GPM @ 52.0 F

Typical
load
with
two
way
valve

Variable Primary System Min Flow (400 gpm each)

Chiller off
Automatic
Isolation Valve

System flow below chiller

minimum flow

Closed

Chiller off

Pumps
off

Closed

200 GPM @ 44.0 F

Primary Pumps
400 GPM (one
operating)

50.0 F
44.0 F
Bypass
Open
200 GPM @ 44.0

400 GPM @ 50.0 F

Flowmeter

200 GPM @ 56.0 F

Typical
load
with
two
way
valve

Chiller Design Considerations

Flow rate changes Staging on additional chillers

Variable Primary System (1 chiller running)

Automatic
Isolation Valve

1000 GPM @ 44.0 F

Primary Pumps

Typical
load
with
two
way
valve

56.0 F
44.0 F

333 GPM Each

1000 GPM

Bypass
Closed

1000 GPM @ 56.0 F

Variable Primary System (Staging on second chiller)

Automatic
Isolation Valve

Need to add chiller

1100 GPM @ 45.0 F

Primary Pumps

Typical
load
with
two
way
valve

57.0 F
45.0 F

333 GPM Each

1100 GPM

Bypass
Closed

1100 GPM @ 57.0 F

Variable Primary System (Open isolation valve)

Load = F X DT DT = 12 = 57- 45
24
Load = 1/2F X 2DT
DT = 24
24
LCHWT = 35!

Automatic
Isolation Valve

1100 GPM @ 45.0 F

550 GPM

Primary Pumps

Typical
load
with
two
way
valve

57.0 F
45.0 F

333 GPM Each

550 GPM

Bypass
Closed

1100 GPM @ 57.0 F

Variable Primary System (Open isolation valve)

LCHWT approaches 35
Automatic
Isolation Valve

LWT Cutout at 4 deg below

44 set-point or 40
Off goes chiller 1

1100 GPM @ 45.0 F

550 GPM

Primary Pumps

Typical
load
with
two
way
valve

57.0 F
45.0 F

333 GPM Each

550 GPM

Bypass
Closed

1100 GPM @ 57.0 F

Variable Primary System (Open isolation valve slowly)

Automatic
Isolation Valve

Open over 1.5 to 2 min

1100 GPM @ 45.0 F

Primary Pumps

Typical
load
with
two
way
valve

57.0 F
45.0 F

333 GPM Each

1100 GPM

Bypass
Closed

1100 GPM @ 57.0 F

VPF Systems Design/Control Considerations Summary

Chillers
Equal Sized Chillers preferred, but not required
Maintain Min flow rates with Bypass control (1.5 fps)
Maintain Max flow rates (11.0 to 12.0 fps)
Isolation Valves (Modulating or Stroke-able to 1.5 to 2 min)
Dont vary flow too quickly through chillers (VSD Ramp function typical setting of 10%/min)
Chiller Type
System Water Volume
Chiller Load
Active Loads
Sequence
If Constant Speed run chiller to max load (Supply Temp rise). Do not run more chillers than
needed (water-cooled)
If Variable Speed run chillers between 30% and 70% load (depending on ECWT). Run more
chillers than load requires.
Add Chiller - CHW Supply Temp or Load (Adjusted* Flow X Delta T) or amps (if CSD)
Subtract Chiller - Load (Adjusted* Flow X Delta T) or Amps (if CSD)
42

VPF Systems Design/Control Considerations Summary

Pumps
Variable Speed Driven
Headered arrangement preferred
Sequence
with chillers (run more pumps than chillers for over-pumping capability)

on flow (add pump when existing inadequate, subtract when can)

optimized algorithm (total kW of more pumps, lower than less pumps)
Stay within pump/motor limits (25% to 100% speed)
Subtract a Pump at 25 to 30% speed
Add a pump back when speed of operating pumps high enough
Speed controlled by pressure sensors at end of index circuit

43

VPF Systems Design/Control Considerations Summary

Bypass Valve
Maintain a minimum chilled water flow rate through the chillers
Differential pressure measurement across each chiller evaporator
Flow meter preferred
Modulates open to maintain the minimum flow through operating chiller(s).
Bypass valve is normally open, but closed unless Min flow breeched
Pipe and valve sized for Min flow of operating chillers
High Rangeability (100:1 preferred)
PSID Ratings for Static, Dynamic, And Close Off = Shut Off Head of Pumps
Linear Proportion (Flow to Valve Position) Characteristic preferred
Fast Acting Actuator
Locate in Plant around chillers/pumps (preferrred)
Energy
Avoid Network traffic

44

VPF Systems Design/Control Considerations Summary

Load Valves
High Rangeability (200:1 preferred)
PSID Ratings for Static, Dynamic, And Close Off = Shut Off Head of Pumps
Equal Percentage (Flow to Load) Characteristic
Slow Acting Actuator

Staging Loads
Sequence AHUs On/Off in 10 to 15 min intervals

45

Summary on VPF Design

Chillers

Size equally with same WPDs (best)

Respect Min/Max Flows through chillers
Set Pump VSD Ramp function to about 10%/min (600 sec 0 to Max Speed)
Use Modulating or Strokeable Valves (preferred) on chiller evaps, headered pumping
Use 2 Position Valves (1 min stroke) on chiller evaps, dedicated pumping

Pumps

VSD Controllers
Headered Pumping Arrangement (preferred)
Dedicated Pumping OK (over-size pumps)

2 Way Valves

Select for Static, Dynamic, Close-off ratings (PSID) equal to pump SOH (plus fill pressure)
Range-ability 100 to 200:1
If Bypass fast acting, linear proportion
If Coils slow acting, equal percentage, On-Off stagger air units (10-15 min intervals)

Controls

46

Set-point far out in index circuit (lower the value, the better the pump energy)
Set Ramp function in VSD Controller (10%/min average)
Run 1 more pump than chillers (when headered)
Chillers On by common Supply Temp, Load, Amps, Adj Flow (Adj for Low Delta T)
Chillers Off by Amps, Load, Adj Flow (Adj for Low Delta T)
Over-pump Chillers to combat Low Delta T and get Max Cap out of chillers
Bypass controlled by Min flow (preferred) or Min WPD of largest chiller (locate in plant for best energy, but can go anywhere in system)

Chilled Water Piping Systems (VPF Focus)

Questions?

2 Way Valve/Coil Detail

Air

2-Way
Control
Valve

Service Valve

Return

Supply

Terminal

Balance
and
Service
Valve

Electric Energy Cost Equations

Mass Flow/t X Lift

Energy Cost =

Chiller
=
Energy Cost

Pump
=
Energy Cost

Fan
=
Energy Cost

0.7459

X Hours X Cost/Unit Energy

X
33,015 X Efficiency

Mot Eff

Lbs Refrig/hr X Head

0.7459
X Hours X Cost/Unit Energy

X
33,015 X Comp Eff

Mot Eff

GPM X Head

0.7459

X Hours X Cost/Unit Energy

X
3960 X Pump Eff

Mot Eff

CFM X TSP

0.7459
X Hours X Cost/Unit Energy

X
6356 X Fan Eff

Mot Eff