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Module 1/4
Objectives:
To define basic heating, chilled water
and condenser water systems
To define their components
To understand how they are used
INTRODUCTION TO MODULE
The commissioning of water
systems requires a basic
knowledge of heating, chilled
water and condenser water
systems.
In this module we will look at the
different types of systems that
you will see, the equipment used
in them and their safety aspects.
1. HEATING SYSTEMS
Heating is normally carried out by either low, medium or high temperature
hot water systems.
Water is used because it is one of the most efficient fluids for heat transfer.
You will often find that low temperature hot water is abbreviated to LTHW,
medium temperature to MTHW and high temperature to HTHW.
Also, the word pressure is sometimes used in place of temperature, giving
the abbreviations LPHW, MPHW and HPHW.
The different types of system are classified by their flow temperature as
shown in the table below:
TYPE
LTHW
MTHW
HTHW
FLOW TEMPERATURE
Up to 100C
100C to 120C
Greater than 120C
Boiler:
The boiler plant provides heat for the
water in the system.
Boilers are normally oil or gas fired; coal
firing is not used very often nowadays.
The feed and expansion tank is open topped and installed at the highest
point in the heating system. As water is lost from the system, the system
pressure will fall, because the tank is Open Topped and at a higher level than
the system, a combination of atmospheric pressure and gravity will act on
the water in the tank to force it to flow down the cold feed pipe to offset the
pressure loss (water loss) in the system. Feed and expansion tanks are
installed at the highest point in the building for this reason.
As water expands in the heating system, the system pressure will rise, forcing
system water up the cold feed pipe from the system to the tank, causing the
water level in the tank to rise. The water in the open vent pipe will also rise to
a similar level. (Sometimes there is a combined cold feed and open vent).
There are instances where a feed and expansion tank is replaced by a
pressurisation unit. This is usually the case either if the building is only one or
two stories high and the system has a large water volume, or if the building is
very tall. The section on medium temperature hot water systems talks more
about pressurisation units.
A system with a feed and expansion tank is called an atmospheric or open
vented system. A system with a pressurisation unit is called a sealed
system.
Pipework:
The pipework system is used to distribute
the heated water from the boiler to the
respective heat emitters.
Usually a two pipe system is used; the flow
pipe taking the water from the boiler to the
heat emitters and the return pipe returning
the water to the boiler.
FIGURE 2 - SCHEMATIC
OF AN MPHW SYSTEM
The boilers and pumps used in a HTHW system are similar to those already
described for low temperature and medium temperature hot water systems. The
pipework, valves, pipe fittings and heat emitters used in this type of system are of
stronger construction to allow them to cope with the far higher system
temperature and pressure.
SAFETY ASPECTS
Low temperature hot water systems can be, and normally
are, balanced and commissioned at operating temperatures.
Medium and high temperature systems must be balanced
when they are cold.
As already explained to you, these systems are pressurised
so that the system temperature can be raised above boiling
point. This is potentially very dangerous.
If, for example, you are balancing a medium temperature
system and one of the connections should break, at your
water meter, the system water will be allowed to escape. As
the system water temperature is above boiling point, it will
flash off to steam as soon as it is exposed to normal
atmospheric pressure. This can cause severe burns.
If ever you are working on an MTHW or HTHW system
and you are asked to work with the system at normal
operating temperature, refuse ! This point cannot be
emphasised enough.
Heat Emitters
Type
Description
These are used to heat air at an air handling unit. They are normally
made up of copper tube with copper or aluminium fins. The air is
passed over the fins. Control is by a sensor in the air stream and a
three port control valve. They can be used in LTHW, MTHW and
HTHW systems. They are normally served by constant temperature
circuits.
Radiators
Natural convectors
Heat Emitters
Type
Description
Fan convectors
Unit heaters
Radiant panels/strip
IMPORTANT NOTE:
All chilled water circulation pipework is insulated with
vapour sealed insulation. When balancing or
commissioning a chilled water system it is important to
ensure that the vapour seal is not damaged in any way. If
the vapour seal is damaged, condensation may occur
which will in turn cause damage to the pipework,
pipework fittings and valves.
FIGURE 4 - TYPICAL
CHILLED WATER SYSTEM
Chiller
The chiller is the heart of a chilled water system. It contains the
evaporator, compressor, condenser and expansion valve
components of the mechanical refrigeration process. Basically,
the chiller operates in the following way.
System water is passed over tubes containing refrigerant
in the evaporator section of the chiller.
Heat from the system water is transferred to the
refrigerant by a heat exchange process, having the effect
of cooling the system water.
The heated refrigerant is compressed by a compressor
then passed through the condenser. Condensers can be
either water or air cooled.
At the condenser, a further heat exchange takes place
from the refrigerant to the condensing medium. The cooled
refrigerant is then passed back to the evaporator through
an expansion valve to pick up more heat from the chilled
water system.
Chiller
Air cooled condensers are made up of a finned tube coil and a fan,
housed in a cabinet. The refrigerant runs through the finned tube
coil. Air is drawn across the coil by the fan, causing a heat exchange
between the refrigerant and the air. That is, the heat taken from the
chilled water system and being passed onto the refrigerant at the
chiller, is finally rejected to outside air by the condenser.
Water cooled condensers are served by a condenser water
system. The refrigerant passes through tubes in the condenser.
Condenser water is passed across the tubes. This causes a heat
exchange to take place between the refrigerant and the condenser
water. The condenser water is then pumped around a pipework
system and passed through a further heat exchanger. At the heat
exchanger, the heat in the system is finally rejected to outside air.
Part 3 of this module looks at condenser water systems and the
different types of heat exchangers.
Condensers are usually remote from the chiller. However, in some
systems a chiller, compressor, expansion valve and an air cooled
condenser are combined in one casing. These are known as
packaged chillers.
Secondary Circuit
Chilled water is usually circulated at a constant temperature,
however, when the system includes fan coil units, they are normally
served by a secondary circuit taken off the main or primary circuit.
A chilled water secondary circuit is exactly the same as a heating
system secondary circuit except that it serves fan coil units instead
of radiators. The temperature of the water in the secondary circuit
is again compensated to outside temperature.
The amount of main flow water that the valve mixes with the
secondary circuit return water is determined by comparing outdoor
temperature with either secondary circuit return temperature or
room temperature, You should be able to realise that as outside
temperature rises, more cooling will be required (a lower secondary
flow temperature) so the valve will open to allow more main flow
water through to the secondary circuit until the valve is fully open
and the secondary flow temperature is the same as the main flow.
As outside temperature falls, the valve will close, allowing more
secondary return water and less main flow water to be mixed,
creating a higher secondary circuit flow temperature.
3. CONDENSER WATER
SYSTEMS
As stated in part 2, a condenser water system is used as the
method of heat rejection for a water cooled chiller. The drawing
below shows a typical condenser water system. The system is
made up of the condenser section of a water cooled chiller, a
pump set, a pipework distribution system and a cooling tower (the
method of heat rejection).
FIGURE 5 - SCHEMATIC OF A
CONDENSER WATER SYSTEM
Cooling Tower
A cooling tower comprises a matrix of packing material, a
water sump and a fan all located in a casing.
The fan is normally located at the top of the casing.
Condenser water, containing heat rejected from the chilled
water system, is sprayed over the matrix and allowed to
collect in the sump. The fan draws air up through the tower
and across the matrix. Any heat contained in the condenser
water is rejected to the air passing over the matrix.
Water is taken from the sump and returned to pick up more
heat from the chilled water system. The cooling tower
contains moisture eliminators to prevent water being blown
out of the tower by the fan.
Due to the operating temperature of condenser water
systems, the water in the sump of cooling towers can assist
in the formation of the bacteria causing Legionnaires
Disease. Cooling towers, are used less frequently nowadays
for this very reason.
Dry Cooler
A dry cooling coil consists of one or more
finned tube coils and a fan (or fans).
Outside air is drawn across the coil by the
fans. Condenser water is passed through
the coil.
A heat exchange takes place between the
condenser water running through the coil
and the air passing across it.
Because cooling towers can cause
Legionnaires disease, dry coolers are being
used more and more frequently.
4. VENTING OF SYSTEMS
It is a fact of life that when water systems are filled for
the first time, or have been drained down and refilled,
pockets of air become trapped in the system. This
means that the system is not completely full of water.
When the circulation pumps in the system are switched
on, the pockets of air will be circulated around the
system. This will cause a reduction in the efficiency of
the system. This is because air is not as good a heat
transfer medium as water. Air in a system can also affect
pump impellers. The impeller is designed to move water
only. With air pockets in the system, the impeller will be
moving a mixture of water and air bubbles instead. The
air bubbles will scour the impeller as they hit it and it
will cause noise at best or cause very erratic
unrepeatable readings at worst.
From a commissioning viewpoint, air trapped in a water
system will drastically affect the readings taken by a
water meter, causing the meter to indicate a lower
water flow rate than there actually is.
4. VENTING OF SYSTEMS
In the longer term, air mixed with water can create
hydrogen, which, being the basis of all acids can corrode
any metal parts of the system, such as pipework. Any
hydrogen contained within the system will escape when
venting is carried out.
Air vents should be installed in all water systems to allow
the air in the system to be removed. They are installed at
all high points in the system and at every item of
equipment such as heat emitters, fan coil units and
cooling coils. Air vents come in two types; manual and
automatic. Automatic air vents (AAV's) are sometimes
installed at system high points. Manual air vents are
installed at the high points if AAV's are not used and also
at items of equipment, such as heating or cooling coils.
The process of removing air from a water system is
called venting. All water systems, whether heating,
chilled water or condenser water must be vented
before the system is balanced or commissioned.
Method of Venting
1. Ensure that the system is completely switched off. That means all
boilers and pumps if it is a heating system, all chillers and pumps if it is
a chilled water system and all cooling towers/dry coolers and pumps if it
is a condenser water system. The system should be allowed to stand for
at least 30 minutes to allow any pockets of air in the system to rise to
the high points of the system.
2. Identify the location of all manual air vents in the system from the
layout drawings and a visual inspection. This includes all vents at
radiators and coils.
3. Open the valve at the each vent until all air is released and water flows.
Air vents built into radiators and coils require a special key called a vent
key.
Ensure air is being discharged from the vent point and not being sucked
in. This can happen especially at the higher points of the system if the
system is not sufficiently pressurised to overcome the height of the
system.
If this is the case, it could be why there is air present in the system
anyway, being drawn by the negative pressure through valve glands,
AAV's etc.
4. Check the operation of all automatic air vents if fitted in the system.
In old systems AAV' s stick up so it is most important to check that
they work.
EXERCISES
1. What are the design flow and return water temperatures for:
a) Low temperature heating systems
b) Medium temperature heating systems
c) High temperature heating systems
2. Why is venting of a system so important?
3. Describe a secondary chilled water circuit and provide a schematic
diagram.
4. Describe a fan convector
ANSWERS TO EXERCISES
1.
a) 82C Flow
71C Return
b) 120C Flow
110C Return
c) 140C Flow
120C Return
2. Reduction in efficiency
Damage to pump impellers
Affect readings during commissioning Long term affect causes
corrosion
ANSWERS TO EXERCISES
3. Chiller/s
Pumps Primary
Primary Circuit Main Commissioning station
Pumps Secondary
Secondary Circuit Main commissioning station
3 port mixing valve (diverting application)
Bypass Double Regulating Valve
Secondary circuit compensated to outside temperatures
Fan coil units
Control valves on Fan coil units
Possible Commissioning device on fan coil unit or Groups of units