Chilled Water Distribution Systems. APPA Institute for Facilities Management New Orleans, LA January 19, 2016

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1 Chilled Water Distribution Systems APPA Institute for Facilities Management New Orleans, LA January 19,

2 Purpose of Today s Presentation To provide a broad understanding of chilled water distribution systems Explore in some detail various distribution system configurations Provide some useful observations and solutions 2

3 System Concepts Definitions Basic Formulae T Hydraulic Profile Agenda System Components System Configurations 3

4 WORDS OF WISDOM It s not how much you ve got; it s whether you can use it. Production Distribution Load 4

5 Definitions System (Static/Fill) Pressure: The non-flowing pressure to which the system must be filled to assure flooding of the highest device. Static pressure is created by the weight of water in the system. Static pressure has no effect on pump capacity. If you consider a water piping system as being an upright loop of water confined in a pipe, the static pressure in one of the vertical pipes is caused by the weight of the water column in the pipe. Static Pressure is equal to.434 pounds per sq. inch per foot of water above the measurement gauge. For example, if the highest device is 20 feet above the gauge, the static pressure at the gauge will be: 20 x.434 which equals 8.6 psig. At various elevations above the gauge, the static pressure becomes correspondingly less. At 10 feet, it is 4.3 pounds per sq. in., and at the top, located 20 feet above the gauge, there is no pressure. System pressure is usually set so that there is at least 5 psig measured at the highest device in the system. QUESTION: What pressure must there be in the system if the highest device is located 120 feet above the chilled water makeup water inlet? 5

6 Fill Pressure, Makeup, and Expansion ΔH= 120 ΔH= ΔH 120 Makeup/Fill Water Makeup/Fill Water System Pressure =.434 psi/ft X = 57 psig 6

7 Definitions (cont.) Dynamic Pressure: The flowing pressure the system pumps must develop to overcome the friction due to piping, coils, valves, fittings, and other devices in the system at a given flow rate. Head loss, measured in feet of head = 2.31 ft. W.C./psi (1/.434 psi/ft) Design Pressure The dynamic pressure the system pumps must develop at the maximum flow in the system. The differential pressure between the supply and return piping at the pump, i.e. the total head QUESTION: What will the supply and return pressures be in our 57 psig system if the design head loss at maximum flow is 100 W.C.? Supply Pressure = 100 W.C. X.434 psig/ft + 57 psig = 100 psig Return Pressure = 57 psig 7

8 Pressure Total Head = 100 System Hydraulic Profile 100 psig Typical Bldg Load 57 psig Plant Pumps Supply Piping Return Piping Relative Distance from Plant 8

9 Basic Formulae The heating and cooling capacity of water when it flows through a coil (heating or cooling) can be calculated as follows: Basic equation: Q = mc p ΔT = c p VΔT for water: Q = 60min/hr V 8.33 lb/gal 1.0 BTU/lb- o F T = 500 x GPM x T Converting to refrigeration tons: Q Tons = 500 x GPM x T 12,000 BTU/Ton-hr Q tons GPM T 24 Q = heat rate (Btu/hr, kj/hr) m = mass flow (lb m/ /hr, kg/hr) c p = specific const. press. = density (lb/cu. ft.) ΔT = temperature difference between supply and return 9

10 Chilled Water System Component Interactions Pumps/ Piping Parallel Pumping Series Pumping Variable Speed Pumping Effect of T on Pump Energy Effect of T on Pump Flow Effect of T on Dynamic Pressure 10

11 Pumping Arrangements 2 Pumps 2 Pumps 1 Pump 1 Pump 11

12 Varying Pump Speed Q tons GPM T 24 12

13 Horsepower Delta T vs. Req d System HP Q tons GPM T 24 ΔT vs. System HP For Fixed Load HP Temperature Difference 13

14 Specific Flow vs. ΔT System Pump HP ~ Q 3 14

15 Dynamic Pressure vs T Q tons GPM T 24 Increasing supply-to-return differential temperature requires less flow for same heat transferred Less flow in a given pipe system results in lower velocity Lower velocity equals lower friction and lower pressure loss Lower pressure and flow equals lower energy Three Rules for Chilled Water System Optimization Reduce Flow Reduce Flow Reduce Flow 15

16 Chilled Water Distribution System Configurations Constant/Variable Flow Combinations Primary Primary/Secondary Primary/Secondary/Tertiary Variable Direct Primary 16

17 Constant Primary Only (One unit on) Pump 1000 gpm Control Valve Chiller 500 Tons Bldg Coils Load equals 1 chiller = o F T = 500 Tons 17

18 CV Constant Primary Only (Two units on) Pump 1000 gpm Control Valves bypass excess water into return Chiller 500 Tons Bldg Coils Pump 1000 gpm Chiller 500 Tons Load equals 1.2 chillers = 600 Tons = o F T 18

19 Constant Primary / Secondary Pump 1000 gpm Building Secondary Pumps Chiller 500 Tons Pump 1000 gpm Bridge Bldg Coils Chiller 500 Tons 19

20 Constant Primary / Secondary / Tertiary Pump 1000 gpm Secondary Pump Building Secondary Pumps Chiller 500 Tons Bridge Bldg Coils Pump 1000 gpm Chiller 500 Tons 20

21 Constant Primary / Variable Secondary (primary and secondary pumps in central plant ) Chiller Pump 1000 gpm Variable Secondary Pump 3000 gpm max. Control Valve Chiller 500 Tons Bypass (Bridge) Bldg Coils Chiller Pump 1000 gpm Chiller 500 Tons System flow more less than chiller flow Chiller staging indicated by flow direction in the bridge 21

22 Variable Primary Only (One unit on) VF Pump 1000 gpm Control Valve Chiller 500 Tons Bldg Coils Load equals 1 chiller = o F T = 500 Tons 22

23 Variable Primary Only (Two units on) QUESTION: How can we improve this scheme? VF Pump 600 gpm Control Valves close against increased pressure Chiller 500 Tons Bldg Coils Chiller 500 Tons VF Pump 600 gpm Chiller and flow staging accomplished by measurement of P between supply and return at selected location Load equals 1.2 chillers = 600 Tons = o F T 23

24 Questions & Answers Thank You! 24

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