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Primary/Secondary System
Secondary Pumps
Typical
load
with
two
way
valve
Primary Pumps
Common Pipe
2 Way Valves
Higher Capital Cost Installed (vs Constant Flow 3W Valve system)
Lower CHW Pumping Energy (vs Constant Flow 3W Valve system)
Well Understood & Easy to Control
56.0 F
44.0 F
Secondary Pumps
3000 GPM @ 44.0 F
56.0 F
44.0 F
44.0 F
56.0 F
Typical
Coil
44.0 F
Primary Pumps
No flow
56.0 F
53.0 F
44.0 F
53.0 F
44.0 F
44.0 F
53.0 F
Typical
Coil
44.0 F
Primary Pumps
Primary/Secondary System
OFF
Secondary Pumps
1500 GPM @ 44.0 F
53.0 F
44.0 F
44.0 F
53.0 F
Typical
Coil
44.0 F
Primary Pumps
Dirty Coils
10
Dirty Coils
Controls Calibration
Leaky 2 Way Valves
3 Way Valves at end of Index circuit
12
Primary/Secondary System
Secondary Pumps
Primary Pumps
Common Pipe
Primary/Secondary System
Secondary Pumps
Primary Pumps
Common Pipe
Dirty Coils
Controls Calibration
Leaky 2 Way Valves
3 Way Valves at end of Index circuit
Coils piped up backwards
15
Secondary Pumps
17
Decoupler
/Bypass
Secondary Pumps
Primary Pumps
100% Flow = 3000 gpm
18
1
2
Decoupler
/Bypass
0 gpm
Secondary Pumps
Primary Pumps
67% Flow = 2000 gpm
19
1
2
Decoupler
/Bypass
0 gpm
20
Secondary Pumps
Primary Pumps
100% Flow = 3000 gpm
21
1
0
Decoupler
/Bypass
600 gpm
23
Primary/Secondary System
Secondary Pumps
P
Primary Pumps
Common Pipe
Primary/Secondary System
Secondary Pumps
Primary Pumps
2 Way Valves
Lower Capital Cost Installed (vs Primary/Secondary)
No secondary pumps/piping/valves/electrical to buy and install
No large Common pipe, but smaller Bypass pipe/valve/flow meter/controls
Disadvantages
Higher (potentially) PSID rated 2-Way valves in system
Requires more robust (complex and calibrated) control system
Requires coordinated control of chillers, isolation valves, and pumps in sequencing
Longer (potentially) Commissioning time
Requires greater operator sophistication
Variable-Primary-Flow System
Automatic
Isolation Valve
Primary Pumps
Bypass
Flow Meter
Typical
load
with
two
way
valve
Automatic
Isolation Valve
56.0 F
44.0 F
56.0 F
44.0 F
Primary Pumps
56.0 F
44.0 F
Bypass
Closed
Automatic
Isolation Valve
56.0 F
44.0 F
56.0 F
44.0 F
Primary Pumps
56.0 F
44.0 F
Bypass
Closed
Typical
load
with
two
way
valve
Automatic
Isolation Valve
Pump off
56.0 F
44.0 F
Primary Pumps
56.0 F
44.0 F
Bypass
Closed
Typical
load
with
two
way
valve
Automatic
Isolation Valve
Pump on
52.0 F
44.0 F
Primary Pumps
52.0 F
44.0 F
Bypass
Closed
Typical
load
with
two
way
valve
Closed
Chiller off
Pumps
off
Closed
Primary Pumps
400 GPM (one
operating)
50.0 F
44.0 F
Bypass
Open
200 GPM @ 44.0
Flowmeter
Typical
load
with
two
way
valve
Automatic
Isolation Valve
Primary Pumps
Typical
load
with
two
way
valve
56.0 F
44.0 F
Bypass
Closed
Automatic
Isolation Valve
Primary Pumps
Typical
load
with
two
way
valve
57.0 F
45.0 F
Bypass
Closed
Load = F X DT DT = 12 = 57- 45
24
Load = 1/2F X 2DT
DT = 24
24
LCHWT = 35!
Automatic
Isolation Valve
550 GPM
Primary Pumps
Typical
load
with
two
way
valve
57.0 F
45.0 F
Bypass
Closed
LCHWT approaches 35
Automatic
Isolation Valve
550 GPM
Primary Pumps
Typical
load
with
two
way
valve
57.0 F
45.0 F
Bypass
Closed
Automatic
Isolation Valve
Primary Pumps
Typical
load
with
two
way
valve
57.0 F
45.0 F
Bypass
Closed
Pumps
Variable Speed Driven
Headered arrangement preferred
Sequence
with chillers (run more pumps than chillers for over-pumping capability)
43
Bypass Valve
Maintain a minimum chilled water flow rate through the chillers
Differential pressure measurement across each chiller evaporator
Flow meter preferred
Modulates open to maintain the minimum flow through operating chiller(s).
Bypass valve is normally open, but closed unless Min flow breeched
Pipe and valve sized for Min flow of operating chillers
High Rangeability (100:1 preferred)
PSID Ratings for Static, Dynamic, And Close Off = Shut Off Head of Pumps
Linear Proportion (Flow to Valve Position) Characteristic preferred
Fast Acting Actuator
Locate in Plant around chillers/pumps (preferrred)
Energy
Avoid Network traffic
44
Load Valves
High Rangeability (200:1 preferred)
PSID Ratings for Static, Dynamic, And Close Off = Shut Off Head of Pumps
Equal Percentage (Flow to Load) Characteristic
Slow Acting Actuator
Staging Loads
Sequence AHUs On/Off in 10 to 15 min intervals
45
Chillers
Pumps
VSD Controllers
Headered Pumping Arrangement (preferred)
Dedicated Pumping OK (over-size pumps)
2 Way Valves
Select for Static, Dynamic, Close-off ratings (PSID) equal to pump SOH (plus fill pressure)
Range-ability 100 to 200:1
If Bypass fast acting, linear proportion
If Coils slow acting, equal percentage, On-Off stagger air units (10-15 min intervals)
Controls
46
Set-point far out in index circuit (lower the value, the better the pump energy)
Set Ramp function in VSD Controller (10%/min average)
Run 1 more pump than chillers (when headered)
Chillers On by common Supply Temp, Load, Amps, Adj Flow (Adj for Low Delta T)
Chillers Off by Amps, Load, Adj Flow (Adj for Low Delta T)
Over-pump Chillers to combat Low Delta T and get Max Cap out of chillers
Bypass controlled by Min flow (preferred) or Min WPD of largest chiller (locate in plant for best energy, but can go anywhere in system)
Questions?
Air
2-Way
Control
Valve
Service Valve
Return
Supply
Terminal
Balance
and
Service
Valve
Chiller
=
Energy Cost
Pump
=
Energy Cost
Fan
=
Energy Cost
0.7459
X
33,015 X Efficiency
Mot Eff
0.7459
X Hours X Cost/Unit Energy
X
33,015 X Comp Eff
Mot Eff
GPM X Head
0.7459
X
3960 X Pump Eff
Mot Eff
CFM X TSP
0.7459
X Hours X Cost/Unit Energy
X
6356 X Fan Eff
Mot Eff