Chilled-Water Systems

A Trane Air Conditioning Clinic

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Chilled-Water Systems
period one
Types of Water Chillers

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

absorption
water chiller

centrifugal
water chiller
Driving Sources

compressor-driven heat-driven

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Vapor-Compression Cycle
reject heat

D C
condenser
compressor
expansion
device
energy in

evaporator
A B

absorb heat
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
 Compressor Types

scroll

reciprocating

helical-rotary centrifugal
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Variable-Speed Drives

variable-
speed
drive

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Condenser Types

air-cooled

water-cooled

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Air-Cooled or Water-Cooled

water-cooled
air-cooled

0 tons 500 tons 1,000 tons 1,500 tons 2,000 tons 2,500 tons 3,000 tons
[0 kW] [1,759 kW] [3,517 kW] [5,276 kW] [7,034 kW] [8,793 kW] [10,551 kW]

chiller capacity

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

air-cooled or water-cooled
Maintenance
 Water treatment
 Condenser tube brushing
 Tower maintenance
 Freeze protection
 Makeup water

cooling tower
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
air-cooled or water-cooled
Low-Ambient Operation

air-cooled
chiller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

air-cooled or water-cooled
Efficiency

dry bulb
outdoor temperature

wet bulb

12 12 12
midnight noon midnight
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
air-cooled or water-cooled
Comparison

air-cooled water-cooled
 Lower maintenance  Greater energy efficiency
 Longer equipment life
 Packaged system
 Better low-ambient
operation
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Packaged Air-Cooled Chiller

air-cooled chiller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Remote Evaporator Barrel

condensing unit

remote
evaporator

refrigerant
piping

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Remote Air-Cooled Condenser
air-cooled
condenser

refrigerant
piping

condenserless
chiller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Indoor Air-Cooled Condenser
indoor
air-cooled
condenser
refrigerant
piping

condenserless
chiller
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Absorption Refrigeration Cycle
reject heat
heat energy in
D C
condenser generator

expansion pump
device

evaporator absorber
A
B
absorb heat reject heat
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Absorption Chillers Offer Choice
 Avoid high electric
demand charges
 Minimal electricity
needed during
emergency situations
 Waste heat recovery
 Cogeneration

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Absorption Chiller Types

single-effect double-effect

direct-fired
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Equipment Rating Standards
 Air-Conditioning &
Refrigeration Institute (ARI)
 Standard 550/590–1998:
centrifugal and helical-rotary
water chillers
 Standard 560–1992:
absorption water chillers

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Part-Load Efficiency Rating
 Integrated Part-Load Value (IPLV)
 Weighted-average load curves
 Based on an “average” single-chiller installation
 Standard operating conditions
 Non-Standard Part-Load Value (NPLV)
 Weighted-average load curves
 Based on an “average” single-chiller installation
 Non-standard operating conditions

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Standard Rating Conditions
evaporator condenser rating
chiller type flow rate flow rate standard
vapor-compression
• reciprocating ARI
• scroll 2.4 gpm/ton 3.0 gpm/ton
550/590–1998
• helical-rotary [0.043 L/s/kW] [0.054 L/s/kW]
• centrifugal
absorption 2.4 gpm/ton 3.6 gpm/ton
• single-effect
[0.043 L/s/kW] [0.065 L/s/kW]
• double-effect, 4.0 gpm/ton ARI
indirect-fired
2.4 gpm/ton [0.072 L/s/kW] 560–1992
• double-effect, [0.043 L/s/kW]
4.5 gpm/ton
direct-fired [0.081 L/s/kW]
water leaving evaporator = 44°F [6.7°C]
© American Standard Inc. 2001
water entering condenser = 85°F [29.4°C] Air Conditioning Clinic TRG-TRC016-EN
 Flow Rates and Temperatures

QBtu/hr = 500  flow rate  T

[ QW = 4,184  flow rate  T ]

© American Standard Inc. 2001

equation for water only Air Conditioning Clinic TRG-TRC016-EN
 Flow Rates and Temperatures
95°F 44°F 100°F 41°F
[35°C] [37.8°C] [5°C]
[6.7°C]

85°F 85°F
[29.4°C] [29.4°C]

54°F 57°F
[12.2°C] [13.9°C]

ARI conditions low-flow conditions

evaporator 2.4 gpm/ton evaporator 1.5 gpm/ton
flow rate [0.043 L/s/kW] flow rate [0.027 L/s/kW]
condenser 3.0 gpm/ton condenser 2.0 gpm/ton
flow rate [0.054 L/s/kW] flow rate [0.036 L/s/kW]
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
ASHRAE/IESNA Standard 90.1–1999
 Energy standard
 Building design and
materials
 Minimum equipment
efficiencies
 HVAC system design

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

standard 90.1-1999 efficiency requirements
Electric Vapor-Compression Chillers
chiller type capacity minimum efficiency*
air-cooled all capacities 2.8 COP 3.05 IPLV

water-cooled
reciprocating all capacities 4.2 COP 5.05 IPLV

helical-rotary, scroll < 150 tons [528 kW] 4.45 COP 5.2 IPLV
150 to 300 tons [528 to 1,056 kW] 4.9 COP 5.6 IPLV
> 300 tons [1,056 kW] 5.5 COP 6.15 IPLV

centrifugal < 150 tons [528 kW] 5.0 COP 5.25 IPLV
150 to 300 tons [528 to 1,056 kW] 5.55 COP 5.9 IPLV
> 300 tons [1,056 kW] 6.1 COP 6.4 IPLV
* as of October 29, 2001
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
standard 90.1-1999 efficiency requirements
Water-Cooled Absorption Chillers

chiller type capacity minimum efficiency*

single-effect all capacities 0.7 COP

double-effect
indirect-fired all capacities 1.0 COP 1.05 IPLV

direct-fired all capacities 1.0 COP 1.0 IPLV

* as of October 29, 2001

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

ASHRAE Standard 15–1994
 Safety standard for
refrigerating systems
 Mechanical equipment
room
 Refrigerant monitors
 Alarms
 Mechanical ventilation
 Pressure-relief piping

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Chilled-Water Systems
period two
Chilled-Water System Design

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Chilled-Water System Components

cooling tower

cooling coil

chiller
pumps
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Chilled-Water System

air-cooled
chiller

coil
pump

control
valve

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Load-Terminal Control Options
 Three-way
modulating valve
 Two-way
modulating valve
 Face-and-bypass
dampers

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Three-Way Valve Control

airflow

three-way bypass
modulating pipe
valve

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Two-Way Valve Control

airflow

two-way
modulating valve

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Face-and-Bypass Damper Control

bypass
damper

airflow

face
damper
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Load-Terminal Control Options
 Three-way modulating valve
 Constant water flow
 Variable return-water temperature
 Two-way modulating valve
 Variable water flow (pump energy savings)
 Constant return-water temperature
 Face-and-bypass dampers
 Constant water flow
 Variable return-water temperature
 Enhanced dehumidification capability with “wild” coils
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Chiller Evaporator Flow
 Constant flow is most
common
 Variable flow is
possible
 Can reduce energy
consumption
 Use only with evaporator
advanced chiller and
system controls

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Single-Chiller System
air-cooled
chiller

coil
pump

© American Standard Inc. 2001

three-way valve Air Conditioning Clinic TRG-TRC016-EN
Multiple-Chiller Systems
 Redundancy
 Part-load efficiency

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

chillers piped in parallel
Single Pump
54°F
[12.2°C]
off

42°F 48°F
[5.6°C] [8.9°C]
on
54°F
[12.2°C]

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

chillers piped in parallel
Dedicated Pumps

off

42°F
[5.6°C]
on
54°F
[12.2°C] 60% to 70%
of system flow

coil starved for flow

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
chillers piped in parallel
Dedicated Pumps

2 pumps

1 pump
head pressure

system
curve
65% 100%

percent flow
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Chillers Piped in Series
electric
chiller
absorption
chiller

three-way valve

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

chillers piped in series
Equal Set Points
set point = 42°F [5.6°C] set point = 42°F [5.6°C]

42°F
48°F [5.6°C]
[8.9°C]

54°F
[12.2°C]

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

chillers piped in series
Staggered Set Points
set point = 48°F [8.9°C] set point = 42°F [5.6°C]

42°F
48°F [5.6°C]
[8.9°C]

52°F
[11.1°C]

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Primary-Secondary Configuration

production
pumps

ip e distribution
ss p
bypa pump
production
loop

distribution
loop

© American Standard Inc. 2001

two-way valve Air Conditioning Clinic TRG-TRC016-EN
Primary-Secondary System Rules
 The bypass pipe should be free of restrictions
 Sized for minimal pressure drop
 Avoid random mixing of supply- and return-water
streams
 No check valve

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Production Loop

production
pumps
supply
tee

s pip e
s
bypa
return
tee
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
 Manifolded Production Pumps

production
pumps

s pip e
s
bypa
isolation
valves

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Distribution Loop
supply
tee
s pip e
s distribution
bypa
pump

return
tee

two-way valve
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Primary-Secondary System Rules
 The bypass pipe should be free of restrictions
 Load terminals should use two-way
modulating control valves

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Varying Distribution Flow

B
pump
curve

head pressure
A

pressure 0 50 100
difference percent flow
variable-speed control riding the pump curve
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Multiple Distribution Pumps

s pip e
s
bypa

distribution
pumps

return
from loads

supply
© American Standard Inc. 2001
to loads Air Conditioning Clinic TRG-TRC016-EN
Multiple Distribution Pumps

ss pipe
bypa
distribution
pumps
return
from loads
A
B
supply
C to loads
B C
A
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Tertiary Pumping

s pip e
s
bypa
distribution
pump

tertiary
pump

two-way
valve
bleed line
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Distribution Loop Characteristics
 Reduced pump
energy use
 Distribution loop
sized for system
diversity
 Higher return-water
temperatures

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Primary-Secondary System Rules
 The bypass pipe should be free of restrictions
 Load terminals should use two-way
modulating control valves
 All chillers should be selected for the same
leaving chilled-water temperature and T

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

System Operation
sup
ply
flow supply
tee
production
loop
dem
pipe flow and
ass
byp
distribution
loop
return
tee

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Deficit Flow
1,000 gpm at 42°F
[63 L/s at 5.6°C]

6 ° F
1,000 gpm at 56°F
mat 5 ]
°CC
[63 L/s at 13.3°C] p
g t 13.3 1,200 gpm at 44.3°F
00
2 L/s a [76 L/s at 6.8°C]
[13

1,200 gpm at 56°F

© American Standard Inc. 2001 [76 L/s at 13.3°C] Air Conditioning Clinic TRG-TRC016-EN
 Excess Flow
2,000 gpm at 42°F
[126 L/s at 5.6°C]

2 ° F
2,000 gpm at
54.6°F at 4 ]
g pm 5.6°C 1,800 gpm at 42°F
[126 L/s at 12.6°C] 200 L/s at [114 L/s at 5.6°C]
[13

1,800 gpm at 56°F

© American Standard Inc. 2001 [114 L/s at 13.3°C] Air Conditioning Clinic TRG-TRC016-EN
Control of Primary-Secondary System
condition response

deficit flow for start another

specified period of chiller and pump
time

excess flow greater turn off next chiller

than 110% to 115% of and pump
next pump to turn off

neither do nothing
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Types of Fluid Flow Meters
 Pressure-based
 Pitot tube
 Venturi
 Orifice plate
 Differential pressure
 Turbine and impeller
 Vortex
 Magnetic
 Ultrasonic
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Temperature-Based Calculations
supply
tee

ipe
s p
pas
by

system-level
controller
return
tee

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Chilled-Water Systems
period three
System Variations

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Electric Utility Deregulation

0.30
price of electricity, $/kWh

0.20

0.10

San Diego, CA
2000 May June July August September
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Fuel Choice Options

absorption
thermal storage
power

indirectly-coupled,
gas-engine
chillers
control interface
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Chiller Efficiency Improvements
0.9 8.0
COP
chiller efficiency (kW/ton)

chiller efficiency (COP)

0.8 7.0

0.7 6.0

0.6 5.0
kW/ton
0.5 4.0

1970 1980 1990 2000

year
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Greater Focus on System Efficiency

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Trend Toward Lower Flow Rates
electric-driven chiller yesterday today

evaporator 2.4 gpm/ton 1.5 gpm/ton

flow rate [0.043 L/s/kW] [0.027 L/s/kW]

leaving 44°F 41°F

chilled-water [6.7°C] [5°C]
temperature

condenser 3.0 gpm/ton 2.0 gpm/ton

flow rate [0.054 L/s/kW] [0.036 L/s/kW]

entering 85°F 85°F

condenser-water [29.4°C] [29.4°C]
temperature
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Low-Flow Systems

750,000
annual energy consumption, kWh

600,000
chiller
450,000

300,000

150,000 pumps
cooling tower fans
0
base case low flow
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
 Variable-Primary-Flow Systems

variable-flow
pumps

y pass
check b
valves
control
valve
two-way
valve
optional bypass
with three-way valve
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Critical VPF System Requirements
 Chillers must handle variable evaporator flow
 System must include a bypass
 System-level controls must limit the rate-of-
flow change
 Adequate time to design and commission
controls
 Operator must understand the system

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Preferential Chiller Loading

distribution
pump
pip e
equally ypass
b
loaded
absorption
chiller
preferentially
loaded

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Sidestream Configuration

distribution
ip e pump
ss p
bypa

heat-recovery
chiller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Heat-Recovery Chiller
heat-recovery
condenser

standard
condenser
evaporator

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 Heat-Recovery Chiller Options
heat-recovery auxiliary
(dual) condenser condenser heat pump
 Second, full-size  Second, smaller-size  No extra condenser
condenser condenser  Large base-heating loads or
 Large heating loads  Preheating loads continuous operation
 High hot-water  Moderate hot-water  High hot-water temperatures
temperatures temperatures
  Controlled
Controlled  Uncontrolled
 Degrades chiller efficiency  Improves chiller efficiency  Good heating efficiency

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Heat-Recovery Chiller Efficiency
cooling heat-recovery
chiller type mode mode
cooling-only 0.57 kW/ton not
centrifugal chiller [6.2 COP] applicable

heat-recovery 0.60 kW/ton 0.69 kW/ton

centrifugal chiller [5.9 COP] [5.1 COP]

cooling mode conditions:

• evaporator T = 44°F to 54°F [6.7°C to 12.2°C]
• condenser T = 85°F to 95°F [29.4°C to 35.0°C]

heat-recovery mode conditions:

• evaporator T = 44°F to 54°F [6.7°C to 12.2°C]
• condenser T = 85°F to 105°F [29.4°C to 40.6°C]
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Control of a Heat-Recovery Chiller
120
percent maximum pressure differential

ble
100 s ta tion
un era ) B A
op urge
(s
unloading with
80 constant leaving hot-
C water temperature
unloading with
constant entering hot-
60 water temperature

0 50 100
© American Standard Inc. 2001
percent load Air Conditioning Clinic TRG-TRC016-EN
Asymmetric Design
 Different chiller
capacities 10,000
 Different chiller

annual operating hours

8,000
efficiencies
lag
6,000 chiller
4,000
lead
2,000
chiller
0
50% / 50% 60% / 40%
chiller split
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Swing Chiller
equal-capacity
large chillers
small-capacity
“swing” chiller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Swing Chiller
100
swing chiller
80
percent cooling load

swing chiller
60
chiller 2
40

20
swing chiller chiller 1
0
© American Standard Inc. 2001
chiller sequence Air Conditioning Clinic TRG-TRC016-EN
“Free” Cooling
 Airside economizer
 Waterside economizer
 Strainer cycle
 Plate-and-frame heat exchanger
 Refrigerant migration

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

waterside economizer
Plate-and-Frame Heat Exchanger

distribution
pump
pip e
ypass
b
condenser
water loop

plate-and-frame
© American Standard Inc. 2001
heat exchanger Air Conditioning Clinic TRG-TRC016-EN
waterside economizer
Refrigerant Migration
from
compressor

condenser
shutoff
valve
vapor
to migration
compressor
shutoff
valve evaporator
liquid
flow
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Application Outside Range of Chiller
240 gpm at 45°F
air-cooled
[15 L/s at 7.2°C]
chiller

240 gpm at 56.7°F

[15 L/s at 13.7°C]
a t 45°F 80 gpm at 45°F
gpm
160 7 .2 ° C] [5 L/s at 7.2°C]
at
/s
[10 L
80 gpm at 80°F
[5 L/s at 26.7°C]

process load

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Chilled-Water Systems
period four
Chiller-Plant Control

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Chiller Controls
 Start–stop
 Chilled-water
temperature
control
 Monitor and
protect
 Adapt to
unusual
conditions

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Key Issues for Chiller-Plant Control
 When to turn a chiller on or off
 Which chiller to turn on or off
 How to recover from an equipment failure
 How to optimize system efficiency
 How to communicate with the operator

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Chiller Sequencing
 Turning on an additional chiller
 Turning off a chiller
 Which chiller to turn on or off?

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 load indicators
Temperature

supply-water
temperature

return-water
temperature

chiller-plant
controller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

load indicators
Flow

ss pipe
bypa
flow
meter
chiller-plant
controller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

 load indicators
Capacity

supply-water
temperature
flow
meter

return-water
temperature

chiller-plant
controller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Chiller Rotation

equal-capacity chillers

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Chiller Rotation

small electric
chiller large electric
chiller
absorption
chiller

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Heat Recovery

standard
electric chillers

preferentially-loaded
heat-recovery
chiller
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
 Variable-Primary-Flow Systems

variable-flow
pumps

y pass
check b
valves
control
valve
two-way
valve
optional bypass
with three-way valve
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
System Failure Recovery
 Maintain flow of chilled water
 Keep it simple
 Lock out failed equipment
 Turn on the next chiller in the sequence
 Notify the operator
 Allow the operator to intervene

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Contingency Planning

piping
stubouts

electrical
connections
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
System Timers
 Load-confirmation timer
 Avoids transient conditions
 Staging-interval timer
 Allows time for the system to
respond to turning a chiller on
 Minimum-cycle timer
 Prevents excessive cycling

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Unload Before Start

2 pumps

1 pump
head pressure

system
curve

system flow rate 610 gpm 870 gpm

© American Standard Inc. 2001 [38.5 L/s] [54.9 L/s] Air Conditioning Clinic TRG-TRC016-EN
Soft Loading
80°F
[26.7°C]
soft loading
supply-water temperature

(one chiller)

60°F
[15.6°C]

set point
40°F
[4.4°C] two chillers

0 30 60
© American Standard Inc. 2001
operating time, minutes Air Conditioning Clinic TRG-TRC016-EN
constant-volume pumping system
Chilled-Water Set Point Control
54°F
off [12.2°C]

37°F 45.5°F
[2.8°C] [7.5°C]
on
54°F
[12.2°C]

lowering operating
chiller set point
helps regain control
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
System Optimization
 Chiller
 Decrease condenser-water temperature
 Increase chilled-water temperature
 Chilled-water pump (variable-flow system)
 Increase chilled-water T
 Cooling tower
 Increase condenser-water temperature
 Condenser-water pump (variable-flow system)
 Increase condenser-water T
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Chilled Water Reset
 Pros  Cons
 Reduces chiller energy  Increases pump energy
 in variable-flow systems
Can work in constant-
flow systems  Can cause loss of
space humidity control
 Complicates chiller
sequencing control

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Condenser-Water Temperature
300,000
annual energy consumption, kWh

cooling
tower
200,000

chiller
100,000

85°F 70°F 55°F optimal

[29.4°C] [21.1°C] [12.8°C] control
© American Standard Inc. 2001 condenser-water temperature set point Air Conditioning Clinic TRG-TRC016-EN
Control of Condensing Pressure

condenser

control
panel
evaporator

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Operator Training and Support

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Operator Interface

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

chiller operating log
ASHRAE Guideline 3
 Chilled-water inlet and outlet  Compressor-refrigerant suction
temperatures and pressures and discharge temperatures
 Chilled water flow  Oil pressures, temperature, and
 Evaporator-refrigerant levels
temperature and pressures  Refrigerant level
 Evaporator approach  Vibration levels
temperature
 Condenser-water inlet and outlet  Addition of refrigerant or oil
temperatures and pressures
 Condenser water flow
 Condenser-refrigerant
temperature and pressures
 Condenser approach
temperature
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Chilled-Water Systems
period five
Review

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN

Review—Period One
 Vapor-compression
water chillers
 Air-cooled versus water-
cooled
 Absorption water
chillers
 Equipment rating
standards
 ASHRAE/IESNA
Standard 90.1-1999
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Review—Period Two
 Load-terminal control
 Three-way valve
 Two-way valve
 Face-and-bypass
dampers
 Parallel configuration
 Series configuration
 Primary-secondary
configuration primary-secondary system
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Review—Period Three
 Hybrid systems
 Low-flow systems
 Variable-primary-flow systems
 Preferential loading
 Heat recovery
 Asymmetric design
 “Free” (reduced-energy) cooling
 Application of a chiller outside its normal
operating range
© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN
Review—Period Four
 Chiller sequencing
 Failure recovery
 Contingency
planning
 System tuning
 System optimization
 Operator interface

© American Standard Inc. 2001 Air Conditioning Clinic TRG-TRC016-EN