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VARIABLE FLOW
CHILLER PLANT DESIGN
Julian R. de Bullet
ASHRAE Distinguished Lecturer
2
Why Optimized Design?
DX or Flooded Evaporators
6
Cooling Tower Basics
7
Load Basics
Process Loads
Cooling Jackets
8
HVAC Controls
A S H
R A BACnet
E
Web-based?
3 Way valve
No valve
Commonly
called a Wild
Coil
3 Way valve
45f
50f
Temperature Differential on
the chilled water supply and
return
55f
Constant chilled water flow required because of the three way bypass valves on
each air handler
Multiple chiller applications require the chillers to be in series for capacity reduction
Ease of control
Increased installation cost because of parallel piping required to allow for service
or isolation of one unit
Fans
24% Tower
Pumps 5%
13%
Design Performance
Chiller
Fans 33%
43%
Tower
2%
Pumps
22%
2 Way modulating
CHW valve
Variable Flow
Secondary Chilled Check Valve in the Bridge or
Water Pump De-coupler Circuit
60% of chilled
60% valve water flow
position 52 deg f
42 deg f
40% flow
42 deg f
48 deg f
ON
ON
Example of 60% system load
with 40% bypass
Primary/Secondary Design
Pros
Variable Flow Through Secondary Loop
Stable Constant Flow through Chillers
Cons
Complexity
Low Delta T Syndrome
Stepped Primary Flow
(More Pump Work Than Variable Primary Flow)
19
Low Delta T-Definition
20
Low Delta T Syndrome
Low Delta T Symptoms And Solutions
3 Way Valves
Dont Use Them
22
Low Delta T Syndrome
VFD Chillers
Excellent Part Load Performance Allows Two Chillers To
Operate More Efficiently Even With Parasitic Losses
23
Low Delta T Syndrome
24
Low Delta T Syndrome
26
Variable Primary Chilled Water Flow Design
2 Way modulating
CHW valve
2 Way modulating
CHW valve
2 Way modulating
CHW valve
100% open
42 deg F 52 deg F
0% Open
Minimum flow bypass
42 deg F 52 deg F
CHWPs at
100% speed
ON
60% open
42 deg F 0% Open 52 deg F
42 deg F 52 deg F
CHWPs at
60% speed
ON
20%
42 deg F flow 5% 52 deg F
42 deg F 52 deg F
CHWP at
25% speed
ON
Automatic
Isolation Valves
Control
Valve, sized
for minimum
1050 gpm
chiller flow
(66 l/s)
34
Benefits of a variable primary chilled water flow design
When:
Operators will understand how the system works and will run it properly.
A single chiller is being replaced and the primary flow can be varied.
36
CHILLER STAGING
Condenser piping
not shown
Bypass piping,
CH-1 Lead CH-2 Lag isolation valves
T3 T2 T1 not shown
CH-1 Programmed as lead chiller, CH-2 programmed as lag chiller.
CH-1 loads up until compressor speed indicates 2nd chiller appropriate
Based on compressor speed, CH-1 commands CH-2 to turn on.
Since chillers are in series, pump flows are already established.
CH-1 and CH-2 operate together to regulate T3 to set point.
At appropriate compressor speed, CH-1 commands CH-2 to turn off.
If CH-1 becomes disabled, the on board controls rotate CH-2 as the lead chiller.
CH-2 regulates to the leaving temperature T3 via the sensor.
500000
450000
400000
350000
300000
kWh
250000
200000
150000
100000
50000
0
Chillers Pumps Towers Fans
39
More or Less?
40
Future Goals
Net- Zero Energy Buildings
Improving Technology