ADVANCED WATER CHILLER
DESIGN
SAMIR R. TRABOULSI, PhD., P. Eng.
Order of Engineers & Architects
Beirut – Lebanon
2015
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Course Outline
I. Basic System
Why a chilled water system
Chiller Basics
Piping Basics
Pumping basics
Cooling tower Basics
Load Basics
Control Valves Basics
Loop Control Basics
Piping Diversity
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COURSE OUTLINE
II. Air Cooled Chillers
Evaporative Cooled Chillers
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COURSE OUTLINE
III. Dual Compressor Chillers
VFD Chillers
System Design Changes
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COURSE OUTLINE
IV. Mechanical Room Safety
ASHRAE Standard 34
ASHRAE Standard 15
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COURSE OUTLINE
V. Single Chiller System
Basic Operation
Basic Components
Parallel Chiller Sequence of operation
6
COURSE OUTLINE
VI. Parallel Chiller System
Basic Operation
Basic Components
Parallel Chiller Sequence of operation
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COURSE OUTLINE
VII. Series Chillers
Basic Operation
Basic Components
Series Chillers Sequence of Operation
Series Counter Flow Chillers
Using VFD Chillers in Series Arrangements
System Comparison
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COURSE OUTLINE
VIII. Primary / Secondary Systems
Basic Operation
Basic Components
Very Large Chiller Plants
Primary / Secondary Sequence of Operation
9
COURSE OUTLINE
IX. Water Side Free Cooling
Direct Water side Free Cooling
Parallel Waterside Free Cooling
Series Water ide Free Cooling
Water side Free Cooling Design Approach
Cooling Tower Sizing
Water side Free Cooling Sequence of Operation
Economizers and Energy Efficiency
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COURSE OUTLINE
X. Hybrid Plants & Heat Recovery
Hyprid Plants
Load profiles
Heat Recovery Chillers
ASHRAE Standard 90.1-2004/2010
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COURSE OUTLINE
XI. Variable Primary Flow Design
Basic Operation
Basic Components
Variable Primary Flow Sequence of Operation
Commissioning
Low Δ T Example
Low Δ T Syndrome Causes and Solutions
Other Solutions
12
COURSE OUTLINE
XII. Process Applications
Process Load Profiles
Condenser Relief
Winter Design
Chilled Water Volume
Temperature and Ranges
Estimating System Volume
Evaluating System Volume
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1. Basic System
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1.Basic System
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1. Basic System
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1.Basic System
• Water or Air cooled Chiller
• Compressor type: Reciprocating, Scroll, Screw or
Centrifugal
• Evaporator: can be remote ( freezing temperature )
• Multiple Chillers
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1.Basic System
• Part Load Performance is provided at Designer specified
conditions or the Non Standard Part Load Value( NPLV)
• To Convert from COP to KW/Ton:
• COP = 3.516/ ( kw/ton)
• EER = Tons x12/(total KW input)
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1.Basic System
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1.1 Acceptable Ranges of Temperature and Humidity
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1.2 Flow and Capacity Calculations
Common design condition is 44 ˚ supply water
temperature
2.4 gpm / ton
Q= W x C x Δ T
Btu/hr = USGPM x specific heat ( Btu/lb- ˚F) x ˚F
Water:
Load ( Btu/hr) =
Flow (USGPM) x (˚Fin - ˚Fout) x 8.33x60
Load ( Tons) = Flow (USGPM) x (˚Fin - ˚Fout) /24
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1.3 Static and Total Pressure
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1.3 A Decelerator
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1.4 Static pressure
Closed Loop versus Open Loop
Piping
Pumps difference ( evaporator and condenser)
High rise building may exceed static pressure of 150 psi
Use heat exchanger to isolate chillers from the static
pressure ( on the expense of temperature increase)
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1.4 Expansion Tanks
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1.5 Reverse Return / Direct Return Piping
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1.6 LOAD SOURCE
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1.6 SYSTEM
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1.6 Reverse Return / Direct Return Piping
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1.6 Reverse Return / Direct Return Piping
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1.6 Reverse Return / Direct Return Piping
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1.6 Reverse Return / Direct Return Piping
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1.6 SYSTEM
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1.7 COOLING & DEHUMIDIFICATION
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1.8 SINGLE ZONE CENTRAL AHU
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1.8 Air Handling Unit
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1.8 Air Handling Units
Types of air handling units:
Central-station unit
Cooling unit
Heating unit
Makeup air unit
Ventilating unit
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2.1 REVERSE RETURN PIPING
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2.2 DIRECT RETURN RISER PIPING AND REVERSE ZONE PIPING
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2.3 PIPING EXPANSION
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2.4 Control valves
Pressure differential between supply and return header
Could appear that reverse return piping may have
pressure drop be the same for all devices.
Changes in the pipe sizing in the main headers ,
different length and fittings all lead to different pressure
differentials for each device
Device pressure drop is large relative to piping
pressure losses, the differences is minimized
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2.5 Minimum Required Insulation
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2.6 Pumps Basics
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2.6 Pumps Basics
Different pumps provide different profiles each with
their own advantages
Steeper curves are better suited for open system such as
cooling towers where high lift and stable flow are
desirable
Flat profile is better suited for systems with control
valves .
Will maintain the necessary head over a wide flow
range.
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2.6 Pumps Basics
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2.6 Pumps Basics
Typically centrifugal pumps are used for both
condenser and chilled water systems
Inline or base mounted
Sized to maintain the system dynamic head and the
required flow rate.
Located so they discharge in the chiller heat exchangers
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2.6 Moody Chart
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2.6 Friction Curve
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QUESTIONS ?????
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