Chiller Systems

Terminal Unit Performance

&
Control
 Chilled Water System
Type of Chilled
water system
y

Air cooled chilled water system W t cooled

Water l d chilled
hill d water
t system
t

Mini--Chilled Water System

Mini
 Air Cooled Water Chiller

Outdoor unit is Noisy system,

system, (open
(open large
area )
 Chilled water system
¾Heavy Duty & Long life cycle
¾Air Cooled Large
g Capacity
p y Chiller Range
g
¾Economical for large systems (high
Efficiency).
¾Low
L Noise
N i ( fan
f coil
il indoor)
indoor
i d )
¾Part Load or full load (25
(25-
-50
50-
-75
75-
-100%)
100%)
using multi compressors
for capacity control.
¾Plumbing works is required
¾Extra control & Accessories
¾Double cost with respect to DX system
¾Application:
¾Universities , Hospitals ,
¾Commercial Centre & Hotel,…etc
 Water cooled chiller

Closed area ( basement or very Hot place)

 Water cooled chiller

Water cooled chiller system

 Fan coil units

The Fan coil air flow rate in CFM ranges

D
Ducted
d
from 200
200,,300
300,, 400
400,, 600
600,, 800 and
and1200
1200.
1200.
3 speeds (L ,M ,H)
Chiller Equations
q
 Chill Pump
Chiller P mp selection
s l ti n
Care should be taken when selecting chiller pump :

1- The required
q flow rate & head
2- Upp feed or down feed , If Upp feed system
y is
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
Typical
T pi l Fan
F n coil
il arrangement
n m nt
 Chiller Piping Systems

Chiller
Pipe Systems

Two pipe Systems Three pipe Systems Four pipe Systems

23
 Two--pipe systems
Two

Boiler - Off

Consists of one supply and one return pipe for either

chilled
ch lled or hot water supply . The
he two-
two-ppipe
pe system iss limited
l m ted
during changeover season.

24
 Two--pipe systems
Two

Chiller - Off

25
 Three-Pipe
p System
y

It has three pipes to each terminal unit. These pipes are a

cold water supply
supply, a hot water supply and a common return.
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

Four-pipe systems have a cold water supply, cold water

Four-
return, hot
h water supply, l and
d hot
h water return. The
Th
terminal unit usually has two independent secondary
water coils: one served by hot water,
water, the other by
cold water.
water. 27
 Comparison

The four-
four-pipe system has the following advantages
advantages::

1- Responding quickly to load changes

changes..

2- Operates
O t with
ith the
th summer-
summer-winter
i t changeover
changeover.
h .

3- Efficiency is greater and operating cost is lower,

lower though
initial cost is generally higher
higher..

4-The system can be designed with no interconnection of the

hot and cold water secondary circuits.
circuits.

28
Two & Three way -valve

29
Types of valves.
Control of water flow through the coil is typically
accomplished
li h d using
i either
i h two-way valves
l or three-way
h valves.
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 p
pressures.

Figure 1-a
Figure 1-b

30
Two-
Two-way valve Three-
Three-way valve
Three-way valves,
Three- valves, available as a mixing or a diverting pattern,
are sometimes
i considered
id d where
h continuous
i system flflow iis
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
yp g a cooling
g tower. Three-
Three-
way control valves used in this manner throttle the flow
through the coil from 100%
100% down to minimum and increase flow
in
i th
the bypass
b from
f minimum
i i up to
t 100
100%
100%.
%
%.
A balancing valve is provided in the bypass to set a pressure
drop equal to the terminal drop when on full bypass
bypass. The port
controlling the flow through the terminal should be chosen
with an equal
q percentage
p g characteristic and the bypass
yp port
p
selected with a complimentary linear characteristic to
maintain nearly constant total flow..

31
Controlling Water Flow

Figure 1-a

Two way-Valve

32
 Figure
g 1-b

Three way-Valve
w y V

33
 Figure 1-b

Three way-Valve
w y V

34
 Figure 1-b

Three way-Valve

35
Primary
y –Secondary
y pumping
p p g
system

38
Figure (3-a)

39
 Primary-
Primary-secondary pumping

Controlling water temperature in a primary-

primary-secondary pumping
arrangement with a two way valve is another approach to
improving valve coil control, as shown figure (3
(3-a )in the
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-(a-b )is connected to both the primary and
secondary circuits with no pressure drop. This common-
common-pipe is
usually located in a bridge between the supply and return
mains of the primary. The common pipe is selected with "no-"no-
pressure drop" to either the secondary or primary circuits.
circuits.

40
As the temperature controller calls for an increase in cooling,
the two
two--way valve opens,
opens permitting primary water to mix into
the secondary and an equal amount of secondary return water
is displaced into the return main. When V-V-I is full open, chilled
water flows from supply main (a) into the bridge and into the
secondary at (b), through the load and returns to the bridge
at (c),
(c) where it flows through VV--I to the return main.
main As valve
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-
V-I is closed and all the secondary
flow is re-
re-circulated from (c) to (b).
Adding a check valve to the common to prevent the possibility
of short-
short-circuit flow in the common as shown in the next
Figure . When the check valve closes, this will cause the
primary pump to go into series with the secondary. See figure 41
(3-b)
Fi
Figure (3-b)
(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-
primary-secondary concept allows continual flow
throughg the source and still permits
p two-
two-way y valve control in
the loads. There is flexibility in dedicating a pump to a
chiller or boiler or manifolding the pumps. This might
simplify
i lif the
th need dffor h
having
i backup
b k pumps for f every system.
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
g mounting g location. The designer
g must weigh
g the
pros and cons of cost, flexibility and installation
requirements of the various concepts to determine the best
arrangementt .
43
Fi
Figure (4-a)
(4 )

44
Figure (4
(4-b)
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.
practical A pressure drop at least equal to
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
i as theh coilil inlet
i l piping.
i i
Centrifugal pumps with flat characteristics should be selected for
systems
y with control valves.
Two-
Two -way valves should be considered over three- three-way valves because they
vary the volume of water flow in direct relationship with the control signal.
Three--w
Three wayy valves provide
p a continuous
n nu u fflow
w regardless
g of
f the load and
n are
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.
operating Variable volume pumping systems should be checked
and adjusted for balance at 50%, 50%, 75
75%% and 100%design
100%design flows. 47
Remember this

Single pump - Selected for a simple application.

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