Chilled Water System Presentation

COMMERCIAL BUILDING SERVICES FLOW THINKING
Chilled Water System Presentation

Constant Volume Distribution

Constant Volume Distribution
Air-conditioning System Components

Constant Volume System Components

Typical 3-way Valve Zone

Full Load Condition

Fully Loaded Coil
• Supply water temperature 45°F

• Design return water temp. 55°F
• Coil design flow 100 GPM
• Coil design pressure drop 20 FT
• Load (flow x 10°F∆ x 500) 500,000 Btuh
• Coil ∆P @ design flow 20 FT
• Bypass flow 0 GPM
• Bypass ∆P 3-way valve closed
• 3-way valve pressure drop 10 FT
• Pump flow and head 100 GPM @ 30 FT
• Actual return water temp 55 °F
Unloaded Condition
Unloaded Coil

• Coil design pressure drop 3-way valve closed
• Load (flow x 10°F∆ x 500) 0.0 Btuh
• Bypass flow 100 GPM
• Bypass ∆P 20 FT
• Actual return water temp 45 °F
So What?
• When the load on the coil is zero, the valve is returning “unused”
chilled water at essentially supply temperature.
• Cold return water “unloads” the chillers, causing them to operate
inefficiently.
Part Load Condition

Partially Loaded Coil

• Bypass flow ??? GPM
• Bypass ∆P 3-way partially closed
• Pump flow and head ??? GPM @ 30 FT
• Actual return water temp ?? °F
3-way Valve Characteristic
1/2 Through Coil

125 1/2 Through Bypass
100
Through Bypass
Through Coil
% Flow
75
Full Flow
Full Flow
50
25
0
25 50 75 100
% Valve Stroke
What’s Really Happening?

Coil with 3-way Valve at Mid-position
• Supply water temperature 45 °F

• Design return water temp. 55 °F
• Coil flow 62.5 GPM
• Coil ∆P @ 62.5% flow 7.8 FT
• Coil leaving water temp 53 °F
• Bypass flow 62.5 GPM
• Bypass ∆P 7.8 FT
• Actual return water temp 49 °F (62.5 GPM @ 53 °F+
62.5 GPM @ 45 °F)
Head2 = Head1(Flow2/ Flow1)2
Head2 = 20(.625/1)2
Head2 = 20(.3906 )
Head2 = 7.8
∆T = Load/ Flow X 500
∆T = 250,000/62.5 X 500
∆T = 8
Therefore, LWTcoil = 45 + 8 = 53
RWT = (Flow1 X EWT + Flow2 X LWT)/ Flow1 + 2
RWT = (62.5 X 45 + 62.5 X 53)/125
RWT = 49
3-way Valve in Mid Position

3-way Valve System Deficiencies
1.Low return water temperatures.

2.Robs chilled water from other coils at part
load conditions.
3.Increases flow in primary piping.
4.Adds additional chillers on line.
5.Chiller performance is reduced.
Chiller Performance Curve
1.1
1.0
0.9
KW per Ton
0.8
0.7
0.6
0.5
10 20 30 40 50 60 70 80 90 100
Percent Load
Pump Sizing
• Select for full chiller flow

• Head must be adequate for:
– Chiller evaporator
– Longest circuit
– Coil
– Three way valve
– Air separator
System Configuration
Constant Volume
Any Questions?
Variable Volume Constant Speed
Primary – Secondary System
Primary – Includes Chillers & Primary Pump.

Circuit Constant water flow through the chiller
is maintained and chilled water is
produced
Secondary – Chilled water is circulated to the

Circuit demand area (load) by using
Secondary pumps.
PRIMARY - SECONDARY
Other Famous Names of Primary-

Secondary
Primary – Production Loop
Secondary – Distribution Loop

Fundamental Idea
No Secondary Flow
Primary = Secondary
Primary > Secondary

Primary < Secondary

Control Valve in Secondary

Common Pipe Design Criteria
• Use the flow of the largest chiller

– Chiller staging at half of this flow is common
• Head loss in common <1 1/2 ft
– Distribution pipe size is often used where reductions would be
inconvenient
• Three pipe diameters between tees
– Excessive length increases total head loss
• Low velocities in system piping
Control Valve in Secondary
Variable flow through coil Variable flow through coil

Constant flow through system Variable flow through system
Three Way Valve Two Way Valve


PRIMARY – SECONDARY CIRCUIT
Control Valves Change the Secondary
System Curve
H1
H2
H3
Head
F1 F2 F3
Flow
Head Absorbed by 2-way Valves
Pump curve
150
TDH of pump
125
Varying differential pressure
HD 100 absorbed by control valve
75
50
System resistance
25
25 50 75 100
% Flow
Pump Horsepower Comparison
150
Constant Flow Primary Pumps, only
125
HP 100
75
Secondary Pumps +
50
Primary Pumps = V/V

25
25 50 75 100
% Design Flow
Constant vs Variable Volume
C onstant Flow , C /S P um p P um p O ver-haded by 150%

150
(3 W ay Valve)
140
130 C /S P um p
(2 W ay V alve)
120
110
B ase C onstant Flow , C /S P um p P um p H D M atched
100
D esign (3 W ay Valve) to System @
HP % 90
lv e) D esign Flow
Va
80 ay
W
70 (2
mp
Pu
S
60
C/
% Full Load 50
(D esign) H P 40
30
20
10
0 10 20 30 40 50 60 70 80 90 100
% Flow
Any Questions?
Step Function of Chillers
Production = Distribution
Distribution > Production

Production > Distribution

“Loading” a Chiller
• A chiller is a heat transfer device. Like most equipment, it is

most efficient at full load.
• To “load” a chiller means:
– Supply it with its rated flow of water
– Insure that water is warm enough to permit removal of rated Btu
without freezing the water
Chiller Performance Curve
1.1
1.0
0.9
KW per Ton
0.8
0.7
0.6
0.5
10 20 30 40 50 60 70 80 90 100
Percent Load
Check Valve in Common?

What can we do?

What else can we do?
Reset Supply Temperature
• Lower chiller set point when mixing occurs to maintain a constant

temperature to the system.
• Expect increases in cost of chiller operation at lower set point: 1-3% per
degree of reset.
• Delays start of the next chiller.
What else can we do?
• Coils that are selected at higher supply temperatures will not be

impaired by small changes.
• Loads that require fixed temperatures may use a small chiller to
reverse the effects of mixing.
Multiple Chillers
60/40 Chiller Split to Help Minimize Low Part Load Operation

Typical Load Profile

30
25
20
% Time
15
10
0
0-10 30-40 60-70 90-100
% Load
Three Unequally Sized Chillers

Approaching Flow = Load
% Load
Time
Any Questions?Alternate
Pumping Methods
Comparison
Two Pipe Direct Return

Two Pipe Reverse Return

Primary-Secondary Pumping.
• Simplest to install.
• Simplest to operate.
• Flexible in design for present and future.
• Efficient to operate.
• May over-pressurize near zones.

Primary-Secondary-Tertiary
Primary-Secondary-Tertiary Pumping.
• Best piping flexibility.
• Best expansion flexibility.
• Provides hydraulic decoupling.
• Efficient to operate.
• May require added horsepower.

• Requires additional pumps and piping.
• Increased controls complexity.
Primary-Secondary-Tertiary Hybrid
Primary-Secondary-Tertiary Hybrid Pumping.

• Low present horsepower.
• Low future horsepower.
• Good piping flexibility.
• Good expansion flexibility.
• Provides hydraulic decoupling.
• May require added horsepower

• Requires additional pumps and piping.
• Increased controls complexity.
Primary-Secondary Zone Pumping

Primary-Secondary Zone Pumping.

• Low ‘built out’ horsepower.
• Low system head.
• Increased control complexity.

• Present horsepower total higher due to future needs.
• Present pumps sized for future requirements.
• Difficult to apply in retrofits projects.
Any Questions?
Variable Volume Variable Speed
Why Do We Need Variable Speed

Secondary Pumps ???
•For Energy Saving….

•For better & optimise operation….
How Do We Achieve This Reduction In Power

Consumption ??
By Using Variable Frequency Drive and Logic controller

with the Secondary Pumps….
Power Comparison at Reduced Speed

Basic Law which helps in achieving this – Affinity

law
1. Flow2 = Flow1(Speed2/ Speed1)
2. Head2 = Head1(Speed2/ Speed1)2
3. BKW2 = BKW1(Speed2/ Speed1)3
If Diameter of Impeller is to be trimmed then instead of

speed the same can be used in above formulas.
Operating Cost
450
400
350
Annual Operating Cost $1000
300
250
$0.10/kWh
200
150
100
50
0
50 100 150 200 250 300 350 400 450 500
Motor Horsepower
Variable flow system
System Curve
as two way
Pump valves close
Curve
Head
System
Curve
Flow
Energy savings offset

System Curve
at part load
Pump System Curve
Curve at design flow
Increased
head loss
Q
Pumps in parallel
System
Curve
Head Pumps in
Parallel
Single
Pump
Flow
Parallel pumping power savings
100
90 Single Large Pump
80
Horsepower 70 Two Parallel
% 60 Pumps
50
40
30
Single Parallel
20
Pump
10
00 10 20 30 40 50 60 70 80 90 100
Flow
%
Theoretical Savings
Establishing Efficiency Curves
120
50 % 60 % 70 % 80 % % Efficiency
85 %
110 85 %
80 %
100 100 %
90
80 90 %
Head, Feet
70 % Speed Curves
80 %
60
Constant
50 70 % Efficiency
Curve
40
60 %
30
50%
20
40 %
10 30 %
GPM
0
0 100 200 300 400 500 600 700 800 900 1000
Variable Speed Efficiencies
4500 gpm @ 100 FT, 85.9 %
600 900 1150 A 1450 1770
B
1770
E C
1450
D 1150
900
750
600
“No Valve” System Curve
110
25 FT Differential Head
Maintained Across Load
100
(Set Point)
Set Point
80
Head
Pump TDH
60
Overall
40 system curve
Distribution
20 piping head
loss curve
0
0 200 400 600 800 1000 1200 1400 1600
Flow
110 Effect of Constant Set Point
100
Control curve Set point,

80 25 FT
Head
Pump TDH
60
Overall system curve
40
Distribution
20 piping head
loss curve
0
0 200 400 600 800 1000 1200 1400 1600
Flow
Control curve
P1 P2
100% Control
Curve
75%
Head 50%
Variable
Head
∆P Loss
Flow
Large systems, long pipe runs
d
50
de
ea
45
rh
ve
O
Annual 40
0%
Operating 35
20
Cost
p,
30 ing
m
d
($1000/year ea
Pu
25 er h
Ov
S
@
C/
o
$0.10/kwh) ,N
le
20
p
ng
m
15
Si Pu
C/S
l e
10
Sing
e d P ump
le Spe
05 Variab
00
1000 2000 3000 4000 5000
Total Equivalent Pipe Length
(feet)
Variable Head Loss Ratio

C/S, Constant Flow System Pump Head Matched to
100
System at Design Flow
Base 90
80 C/S, Variable Flow

Percent Design BHP
70
V/S, 0% Variable Hd Loss, 100% Constant ∆ Hd
60
50 V/S, 25% Variable Hd Loss, 75% Constant ∆ Hd
40 V/S, 50% Variable Hd Loss, 50% Constant ∆ Hd

30
20
10
0 10 20 30 40 50 60 70 80 90 100 % Flow
Variable Head Ratio w/ Overheading

Constant Flow, C/S Pump Pump O’Headed by 150%
150
(3 Way Valve)
140
130 C/S Pump

(2 Way Valve)
120
110
Base Constant Flow, C/S Pump Pump HD Matched
100
Design (3 Way Valve) to System @
90 Design Flow
HP % lve)
a
80
a yV
70 (2 W HD
u mp tant
60 / S P o ns
C C
0%
% Full Load 50
, 10
*
(Design) HP 40 V/S 5 /75 * 25/75 Means:
/ S , 2 /50
e HD 25 % Variable HD Loss
V 0 l
30
/ S ,5 r i ab 75 % Constant HD Loss
V 5
20 75 /2 Va
, 0%
V/S 10
10
/S,
V
0 10 20 30 40 50 60 70 80 90 100
Locations of Sensor
Where to install the Sensor?
What type of Sensor?

Single Point Pressure Sensor
Load
Balancing Valve 2 – Way

Valve
Single Point Pressure

Sensing
Chillers
Panel with
PLC & VFD`s
Common
Secondary
Pumps
Primary Pumps
Air -
Separator
Single Point Pressure Sensor

Is Single Point Pressure Sensor Correct?
Wrong !!
Why?
-Pump is a differential pressure device.
-A single point is only influence by pressure. This is good for booster only.
-In a closed loop system, system pressure rises due to thermal expansion,
pumps will slow down.
-When static pressure decrease, pumps will speed up.
-This is self-defeating since now the pump speed is not influence by the
system load changes, but rather by system water pressure.
-Therefore, single pressure sensor are a misapplication in a closed loop
HVAC system.
Single Point Differential Pressure Sensor
Primary - Secondary Circuit With Variable Speed

Secondary Pumps
Load
Balancing Valve 2 – Way

DPT Valve
Chillers
Panel with
PLC & VFD`s
Common
Secondary
Pumps
Primary Pumps
Air -
Separator
2 Way Valve Control
Opening/Closing of 2- Way Valve

-Signal from the sensor, installed at load
regulates the valve opening & closing.
-This way differential across 2-way valve also
changes & accordingly output signal is given to
PLC. Temperature Sensor
Load
`
`
Output to PFU from DPT
`
Question:
Can we put the DPT across coil

alone?
Question:
Across the pumps?

Single Point Differential Pressure Sensor
Primary - Secondary Circuit With Variable Speed

Secondary Pumps
To Maximize energy system, we must maximize the

variable head loss in the system. This is done by locating
the sensor at the most remote zone ( hydraulically) in the
system.
System Control Curve
110
100
Set point,
80 25 FT
Ft Hd
Control curve
Pump TDH
60
Overall
40 system curve
Distribution
20 piping head
loss curve
0
0 200 400 600 800 1000 1200 1400 1600
Flow, gpm
Variable vs Constant Head Loss

The “Active Zone”
• Zone set points do not have to be the same.

• Pump controller scans all zones often, comparing process
variable to set point in each case.
• Pumps are controlled to satisfy the worst case.
• What happens to the rest of the zones?
Basic Concept
Set Value
PMU
Output
4 – 20 mA
PFU To
From Field
VFD/Pump
Sensor (DPT)
PFU – Pump Functional Unit

PMU – Pump Management Unit
Multi Point Differential Pressure Sensor
Different Sensor Signal To Common PFU Panel

DPT
DPT
Balancing Valve
Load
Panel with
PLC & VFD`s
Secondary
Chillers Pumps
Common
POSSIBILITY OF MULTIPLE PROCESS

SIGNALS FROM DIFFERENT ZONES
Set Value
PMU
VFD
Module PFU VFD
Multiple Process Signals

From Field Sensors
All zones can have different set values

POSSIBILITY OF MULTIPLE PROCESS

SIGNALS FROM DIFFERENT ZONES
Multiple Process Signals Set Value
From Field Sensors PMU
VFD
Signal
Comparator PFU VFD
4 – 20 mA Sig
Signal All zones can have

Comparator
different set values
HVAC Control System
DPT Signal Comparator

HVAC Control System

- High and Low Signal Selections
- Signal Averaging
- High/Low Limit Control

The module has the addition following features :
1) LED status indications
2) Accepts voltage or milliamp input signal
3) DIP switch-selectable operating modes
4) Accepts 24 VAC/DC power

HVAC Control System
Benefits
1) We are able to supply VFD systems with multiple inputs signals ranges to compete
with our competitors.
2) We are able to use Grundfos PFU 2000 as the main processor to control the full system
operations.
3) We will be minimising outsourcing or external controller in order to serve the HVAC

market.
4) The MM allows us to integrate into the system multiple sensor control at a more cost
effective price.
HVAC System
Other Types of
Systems
Separate System for Each Zone
DPT
DPT
Balancing
Valve Load
2 – Way
Valve
Panel with
PLC & VFD`s
Secondary
Chillers Pumps
Common
Expansion
Tank
Primary Pumps Air -
Separator
Separate System for Each Zone
Systems In Multi - Zones

Two options:
1. Separate Systems can be used for
different zones. So each zone will
have its own sensor.
2. Signal from different zone sensors is

given to the common PFU and most
deviated signal, from the set point, is
given as output.
Tertiary Pumping System

VFD pumps For
DPT
Each Zone
DPT
Balancing
Valve Load
2 – Way
Valve
E-pumps
E-pumps
Chillers
Secondary
Pump
Common
Expansion
Air - Tank
Primary Pumps Separator
Reverse Return Pumping
Load
Balancing Valve DPT
Chillers
Panel with
PLC & VFD`s
Common
Secondary
Pumps
Primary
Air -
Pumps
Separator
Reverse Return Pumping
Benefits :
1) Equalize the pressure drops of each zone.

2) Selections of the sensor becomes easier.
3) If load are similar or symmetrical, 1 centrally located sensor
is adequate.
4) As in direct return system, multiple sensor can still provide a
benefit to the end user.
Type of VFD Systems

Possible Options of Variable Speed panels
Type ME - Multiple Pumps &

Multiple VFDs.
Type MF - Common VFD for Multiple

Pumps.
System with Multi Pumps & Multi VFDs

Signal from Field
Sensor(s) (DPT)
Panel with
PFU & PMU
VFD - 1 VFD - 2
Secondary Pumps
System with Common VFD for All Pumps

Signal from Field Sensor(s) (DPT)
Panel with
PFU & PMU
VFD
Secondary Pumps
APPROVAL FROM INTERNATIONAL

AGENCIES
Approval from – CE, U/L

Conforms to - Electromagnetic compatibility
(89/336/EEC) to standard EN 50 081 – 1 and EN 50
082 – 2 and Electrical equipment design 73/23/EEC
standard to EN 60 204-1.
Single PMU For Control of 8 Zones/Pumps
PMU
PFU PFU
Single PMU For Control of 8 Zones/Pumps
PMU
PFU PFU PFU PFU

The End

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COMMERCIAL BUILDING SERVICES FLOW THINKING

Chilled Water System Presentation

Constant Volume Distribution

Air-conditioning System Components

Constant Volume System Components

Typical 3-way Valve Zone

Full Load Condition

Fully Loaded Coil

• Supply water temperature 45°F

• Supply water temperature 45°F

Part Load Condition

Partially Loaded Coil

• Supply water temperature 45°F

3-way Valve Characteristic

1/2 Through Coil

What’s Really Happening?

Coil with 3-way Valve at Mid-position

• Supply water temperature 45 °F

Head2 = Head1(Flow2/ Flow1)2

∆T = Load/ Flow X 500

RWT = (Flow1 X EWT + Flow2 X LWT)/ Flow1 + 2

RWT = (62.5 X 45 + 62.5 X 53)/125

3-way Valve in Mid Position

3-way Valve System Deficiencies

1.Low return water temperatures.

Chiller Performance Curve

• Select for full chiller flow

Variable Volume Constant Speed

Primary – Secondary System

Primary – Includes Chillers & Primary Pump.

Secondary – Chilled water is circulated to the

Other Famous Names of Primary-

Primary – Production Loop

Secondary – Distribution Loop

Primary > Secondary

Primary < Secondary

Control Valve in Secondary

Common Pipe Design Criteria

• Use the flow of the largest chiller

Control Valve in Secondary

Variable flow through coil Variable flow through coil

Three Way Valve Two Way Valve

Variable Volume Constant Speed

Head Absorbed by 2-way Valves

Pump Horsepower Comparison

Primary Pumps = V/V

Constant vs Variable Volume

C onstant Flow , C /S P um p P um p O ver-haded by 150%

Distribution > Production

Production > Distribution

• A chiller is a heat transfer device. Like most equipment, it is

Chiller Performance Curve

Check Valve in Common?

What can we do?

• Lower chiller set point when mixing occurs to maintain a constant

What else can we do?

• Coils that are selected at higher supply temperatures will not be

60/40 Chiller Split to Help Minimize Low Part Load Operation

Typical Load Profile

Three Unequally Sized Chillers

Approaching Flow = Load

Two Pipe Direct Return

Two Pipe Reverse Return