Applied Energy
journal homepage: www.elsevier.com/locate/apenergy
Diagnosis of the low temperature difference syndrome in the chilled water system
of a super high-rise building: A case study
Dian-ce Gao, Shengwei Wang , Yongjun Sun, Fu Xiao
Department of Building Services Engineering, The Hong Kong Polytechnic University, Hong Kong
a r t i c l e
i n f o
Article history:
Received 3 November 2011
Received in revised form 7 March 2012
Accepted 29 March 2012
Available online 22 May 2012
Keywords:
Chilled water system
Low delta-T syndrome
Decit ow
Fault diagnosis
a b s t r a c t
The low delta-T syndrome exists in many large primarysecondary chilled water systems, which results
in the degradation of the system overall energy performance. This paper presents a method and a case
study on diagnosing the low delta-T problem resulted from the decit ow that frequently occurred in
the chilled water system of a super high-rise building at its early operation stage. The history operation
data during the days when decit ow and low delta-T syndrome occurred are analyzed. The improper
set-point of outlet water temperature on the secondary side of heat exchangers is nally diagnosed as the
fault that resulted in the decit ow and low delta-T syndrome. Diagnosis of this fault was also validated
in the in situ experimental tests. The decit ow could be eliminated if temperature set-point was reset
higher. Compared with the original set-point of outlet water temperature on the secondary side of heat
exchangers, 87.67 kW (72.37%) of the total power of pumps on primary and secondary sides of heat
exchangers could be saved in the test cases when higher set-points were used.
2012 Elsevier Ltd. All rights reserved.
1. Introduction
Over the last two decades, primarysecondary chilled water
systems have been widely employed to offer comfortable indoor
environment in commercial buildings, especially in large buildings,
due to its higher energy efciency than the traditional constant
ow system [1]. Many researchers in HVAC&R eld have devoted
considerable efforts on increasing the operation and energy performances of chilled water systems [25]. While in real applications,
most of the primarysecondary systems, from time to time, cannot
work as efcient as expected because of the excess secondary ow
demand, which causes decit ow problem (i.e., the required ow
rate of secondary loop exceeds that of the primary loop). When the
decit ow problem exists, the temperature difference produced
by the terminal units will be much lower than its design values,
which is known as the low delta-T syndrome [69]. Kirsner [6]
pointed out that the low delta-T chilled water plant syndrome exists in almost all large distributed chilled water systems.
A series of operational problems might be caused by the decit
ow problem and low delta-T syndrome in practical applications,
such as the high supply water temperature, the over-supplied
chilled water, and the increased energy consumption of the
secondary pumps. When the decit ow occurs that means
the secondary water ow rates exceeds that of the primary loop,
the additional return water from terminal units ows back to the
supply chilled water through the bypass line, leading to the higher
supply water temperature supplied to the terminal air-handling
units (AHUs). The supply chilled water with increased temperature
consequently leads to an increased chilled water ow rate that further worsens the decit ow, which consumes more energy of secondary pumps. If the supply chilled water temperature continues
increasing to an extremely high value, the indoor temperature cannot be maintained at a comfortable level.
Existing studies [1012] demonstrated a lot of potential causes
for the decit ow problem and the low delta-T syndrome. The
causes mainly include improper set-points or poor control calibration, the use of three-way valves, improper coil and control valve
selection, no control valve interlock, and uncontrolled process load,
reduced coil effectiveness, outdoor air economizers and 100% outdoor air systems, and so on.
Measures to handle the low delta-T syndrome also have been
proposed to enhance the energy performance of chilled water systems [1317]. Among the studies, Fiorino [14] indicated that a
higher delta-T can be achieved by proper application of cooling
coils, controls systems, distribution pumps, and piping systems.
Up to 25 practical methods were recommended to achieve high
chilled water delta-T ranging from component selection criteria
to congurations of distribution systems. Wang et al. [16] presented an approach that experimentally validates the feasibility
of using a check valve in the chilled water bypass line to solve
the low delta-T syndrome. Results showed that about 9.2% of total
energy consumption of the chillers and secondary water pumps is
saved in the test case when compared with the case when no check
valve used.
The above studies demonstrate that low delta-T syndrome and
decit ow problem widely exist in the primarysecondary chilled
water system and the elimination of these problems can improve
the energy performance of the chilled water system. For practical
applications, it is essential to nd the causes before fully correcting them. However, the detailed study for detection and diagnosis
of the low delta-T syndrome and decit ow problem, particularly
in real applications, is still insufcient. This paper presents a case
study that diagnoses the low deltas-T syndrome based on operation data. The associated experiment validation is provided as
well. This paper offers some useful experiences for engineers
and operators to nd causes of the low delta T syndrome effectively and enhance the energy performance of chilled water
systems. In this study, the history operation data were analyzed
and experiments were designed and conducted to diagnose and
determine the causes for low delta-T syndrome in a complex
central chilled water system of a super high-rise building in Hong
Kong.
(S-B)
D
E
SCHWP-78-01 to 03
Chiller circuit
PCHWP-78-01
PCHWP-78-02
PCHWP-78-03
HX-78
HX-78
HX-78
SCHWP-06-09 to 11
SCHWP-42-04 to 06
B
HX-06
(S-B)
A
B
(S-B)
(S-B)
598
SCHWP-42-01 to 03
HX-06
TO OFFICE FLOORS(7-41)
(S-B)
PCHWP-42-01
HX-42
PCHWP-42-02
HX-42
PCHWP-42-03
PCHWP-42-04
HX-42
HX-42
PCHWP-42-05
HX-42
PCHWP-42-06
PCHWP-42-07
HX-42
HX-42
SCHWP-06-06 to 08
SCHWP-06-01 to 02
(S-B)
(S-B)
SCHWP-06-03 to 05
D
BYPASS LINE
PCHWP-06-01
PCHWP-06-02
PCHWP-06-03
PCHWP-06-04
PCHWP-06-05
PCHWP-06-06
EVAPORAROR
EVAPORATOR
EVAPORATOR
EVAPORATOR
EVAPORATOR
WCC-06a-01
(2040 Ton)
WCC-06a-02
(2040 Ton)
WCC-06a-03
(2040 Ton)
WCC-06a-04
(2040 Ton)
WCC-06a-05
(2040 Ton)
WCC-06a-06
(2040 Ton)
CONDENSER
CONDENSER
CONDENSER
CONDENSER
CONDENSER
CONDENSER
EVAPORATOR
599
Flow (l/s)
Head (kPa)
Power (kW)
Remarks
345
310
126
Constant speed
1(1)
2(1)
345
155
241
391
101
76.9
Variable speed
Variable speed
2(1)
345
406
163
Variable speed
2(1)
7
2(1)
2(1)
3
2(1)
345
149
294
227
151
227
297
255
358
257
202
384
122
44.7
120
69.1
36.1
102
Variable speed
Constant speed
Variable speed
Variable speed
Constant speed
Variable speed
300
200
100
-100
-200
-300
-400
-500
-600
16
24
32
40
48
56
64
72
80
88
96
104
112
Numbera
1
0
120
Sampling time(hour)
Fig. 2. Measured water ow rate in the by-pass line and temperature difference in secondary system in ve summer days.
the measured water ow rate in the bypass line and the measured
chilled water temperature difference of the main supply and return
pipes (i.e., namely the system temperature difference) in ve consecutive summer days respectively. It is obvious that the average
system temperature difference during the 5 days was very low,
only about 3.5 K. It is also noted the decit ow existed in nearly
half of the period and the average duration was about 12 h a day.
When the decit ow occurred, the system delta-T became much
lower, which indicates that the decit ow and the low delta-T
syndrome in this system seemed to be highly correlated. Since
the cooling coils are selected to produce a temperature rise at full
load that is equal to the temperature difference selected for the
chillers (i.e., 5 K in this case), the ow rate of secondary loop
should be therefore equal to that of the primary loop under full
load condition and should be less than that of primary loop under
part load condition. However, when the decit ow problem exists,
the excessive water ow rate of secondary loop will greatly reduce
the temperature difference produced by the terminal units, which
is known as low delta-T syndrome. Therefore, the low delta-T syndrome existing in this chilled water system was mainly due to the
occurrence of the decit ow problem. In order to raise the system
chilled water temperature difference, it is necessary to nd the exact faults that caused the decit ow problem, solve the low deltaT syndrome, and accordingly enhance the energy performance of
the overall chilled water system.
600
Start
Yes
validation of
detection/identification results &
evaluation of the energy impacts
Faults identification
7
Temperature difference of Zone 1
Temperature difference of Zone 2
Temperature difference of Zone 3&4
6
5
4
3
2
1
0
16
24
32
40
48
56
64
72
80
88
96
104
Sampling time(hour)
Fig. 4. Temperature difference of individual risers in ve summer days.
112
120
601
400
200
0
-200
-400
17:00
18:00
18:00
17:00
18:00
16:00
17:00
15:00
14:00
13:00
12:00
11:00
10:00
9:00
8:00
7:00
6:00
5:00
4:00
3:00
2:00
1:00
10
9.5
9
8.5
8
7.5
7
6.5
6
5.5
5
Operating number
7
6
5
4
3
2
1
0
Frequency (Hz)
60
50
40
30
20
10
0
16:00
15:00
14:00
13:00
12:00
11:00
10:00
9:00
8:00
7:00
6:00
5:00
4:00
3:00
2:00
1:00
0:00
16:00
15:00
14:00
13:00
12:00
11:00
10:00
9:00
8:00
7:00
6:00
5:00
4:00
3:00
2:00
0:00
1:00
Time(hour)
Fig. 5. The operation data in the typical day when decit ow existed during daytime.
18:00
17:00
16:00
15:00
14:00
13:00
12:00
11:00
10:00
9:00
8:00
7:00
6:00
5:00
4:00
3:00
0:00
2:00
Temperature (C)
0:00
-600
1:00
200
100
0
-100
-200
-300
18:00
17:00
16:00
15:00
14:00
13:00
12:00
11:00
10:00
9:00
8:00
7:00
6:00
5:00
4:00
3:00
2:00
1:00
-400
0:00
602
Temperature(C)
10
The set-point of outlet water temperature after HX-42
8
7
18:00
17:00
16:00
15:00
14:00
13:00
12:00
11:00
10:00
9:00
8:00
7:00
6:00
5:00
4:00
3:00
2:00
3
2
1
17:00
18:00
17:00
18:00
16:00
15:00
14:00
13:00
12:00
11:00
10:00
9:00
8:00
7:00
6:00
5:00
4:00
3:00
2:00
1:00
50
Frequency of pump(SCHWP-6-07)before HX-42
40
30
20
16:00
15:00
14:00
13:00
12:00
11:00
10:00
9:00
8:00
7:00
6:00
5:00
4:00
3:00
2:00
1:00
10
0:00
Frequency (Hz)
1:00
0:00
Operating number
0:00
Time(hour)
Fig. 6. Operation data in the typical day when decit ow occurred during night.
temperature that varies based on the outdoor dry-bulb temperature, as shown in Fig. 8. When Tout,ahx is larger than its set-point,
the modulating valves before heat exchangers will widely open
to demand more chilled water before heat exchangers. Moreover,
Temperature
set-point ( C)
603
9.3
8.5
6.3
5.5
15
34
Ambient dry-bulb
temperature ( C)
Fig. 8. The original scheme for determining the set-point of outlet water after heat
exchangers.
Increase active
heat exchanger number
Deficit flow
In order to validate the FDD method in above analysis, two repeated eld tests were conducted to verify the cause of the decit
ow in the bypass line by varying the set-point of the outlet water
temperature (Tout,ahx) after heat exchangers in two separate days.
The results of the two tests show the consistent conclusions and
the results presented as follows came from the latest test in the autumn of 2010. In this test, the set-point of Tout,ahx was rstly changed from 8.2 C (while no decit ow occurred) to 6.8 C, and 6 C
respectively. Then, the set-point was increased back to 7.4 C and
8.2 C respectively. During the whole test period, the chiller supply
water temperature was xed at 5.5 C, and the operating number
of chillers as well as the primary water ow rate remained
unchanged.
Fig. 10a and b shows the water ow rates in the bypass line,
Tout,ahx and its set-point. It can be observed that the decit ow
did not occur and Tout,ahx basically can be maintained at its setpoint before 11:10am. When the set-point of Tout,ahx was reduced
to 6.8 C, and 6 C respectively, the water ow rate of the bypass
line dropped rapidly from about 170 l/s to negative (25 l/s),
which means the decit ow occurred. Meanwhile, Tout,ahx experienced a gradual dropping process but could not be low enough to
reach its set-point. On the other hand, when the set-point of Tout,ahx
was increased again to 7.4 C and 8.2 C respectively, the decit
ow was eliminated and Tout,ahx also returned to be controlled
approximately at its set-point. The test results indicate that the
decit ow would most likely occur when the set-point of Tout,ahx
is too low to be reached. The decit ow can be eliminated when
the correct control of Tout,ahx is resumed, which conrms the preliminary conclusion in Section 4.1.
It is also worthy pointing out in Fig. 10a and b that the actual
measured outlet water temperature after heat exchangers was
not signicantly decreased and basically maintained stable at
about 7.2 C although the set-point of Tout,ahx changed from 6.8 C
to 6 C. The reason is that the inlet water temperature on the primary side of heat exchangers was signicantly increased because
of the decit ow. The more supplied chilled water with higher
temperature failed to improve the overall cooling effect of the heat
exchangers when the decit ow occurred.
Fig. 10c and d presents the openings of modulating valves before heat exchangers and the operating number of heat exchangers
during the test period. It can be observed that the openings of modulating valves were closely related to Tout,ahx and its set-point. Once
the set-point of Tout,ahx was lower than Tout,ahx, the modulating
valves opened rapidly. When one of the modulating valves fully
opened, additional heat exchangers were switched on by the control logic used in this case. When the set-point increased from 6 C
to 7.4 C and further to 8.2 C respectively, the modulating valves
closed down until reaching the minimum position and the operating number of heat exchangers also was reduced from four to two
eventually. The valve openings and the operating number of heat
exchangers greatly affected the controlled speed of pumps at the
primary side of heat exchangers, as shown in Fig. 10e. It can be
found that the speed (frequency) of the pumps before heat
exchangers signicantly increased when either the valves were
widely opened or extra heat exchangers were switched on. On
the other hand, when both the valve openings and operating number of heat exchangers were reduced, the speed of pumps before
heat exchangers dropped again. Both wider valve openings and
more operating heat exchangers mean a lower overall water resistance of the heat exchanger group at primary side. Therefore, the
pump speed had to be increased to transfer more water to meet
200
150
100
50
0
-50
-100
10:50
8.5
8
7.5
7
6.5
6
5.5
5
10:50
120
Frequency (Hz)
M1
(a)
M2
11:10
11:30
11:50
12:10
12:30
12:50
13:10
(b)
11:10
11:30
11:50
12:10
12:30
12:50
13:10
100
Operating number
Temperature(C)
604
80
(c)
60
40
20
0
10:50
11:10
11:30
11:50
12:10
12:30
12:50
13:10
5
4
3
(d)
Number of active HX
Number of active pumps before HX
2
1
0
10:50
50
45
40
35
30
25
20
10:50
11:10
11:30
11:50
12:10
12:30
12:50
13:10
(e)
Frequency of secondary pumps before HX-42
11:10
11:30
11:50
12:10
12:31
12:51
13:11
Sampling time(hour)
Fig. 10. The operation data during the test period.
the predetermined pressure differential set-point. It is worth noticing that the variation of overall water resistance of heat exchanger
group was more sensitive to the operating number of heat
exchangers compared with the valve openings. As indicated in
Fig. 10a, water ow variation (i.e., DM2) in the bypass line resulted
from valve openings was far less than that (i.e., DM1) resulted from
changing heat exchanger operating number.
Fig. 11 depicts the dynamic power of pumps on both sides of
heat exchangers during the test period. Clearly, the total energy
of the pumps signicantly increased when the set-point of Tout,ahx
was greatly reduced and decit ow occurred. Compared to that
without test, 87.67 kW (72.37%) of average power of all pumps
on both sides of heat exchangers was wasted during the test. It is
also found that the power of the three pump groups associated
with heat exchangers varied in different ways when the set-point
of Tout,ahx decreased. The secondary pumps before heat exchangers
and the primary pumps after heat exchangers consumed more energy while the secondary pumps after heat exchangers consumed
less energy. But the energy wasted by the rst two was far larger
than that saved by the third. The results demonstrated that a too
low set-point of Tout,ahx badly degraded the energy performance
of the chilled water system although the building cooling load still
can be satised.
The above test results conrmed the conclusion of the analysis
in Section 4.1. It demonstrated that the decit ow and the low
delta-T syndrome in the chilled water system under study were
mainly resulted from the improperly low set-point of the outlet
water temperature after heat exchangers.
4.3. Discussion and suggestions
The in situ operations and experiments have demonstrated that
it is not robust and is unreliable to reset the set-point of outlet
water temperature after heat exchangers (Tout,ahx) using a xed
temperature difference above the chiller supply water temperature,
particularly when the temperature difference is relatively small. It
is because that the inlet water temperature before heat exchangers
is not always equal to the chiller supply water temperature due to
the decit ow problem in practical applications. Once the inlet
water temperature before heat exchangers is higher than the chiller
supply water temperature, the actual temperature difference between the inlet water temperature before heat exchangers and
605
300
Power of pumps(kW)
250
200
150
100
50
0
10:50
11:10
11:30
11:50
12:10
12:29
12:50
13:10
Sampling time(hour)
Fig. 11. Power of pumps on both sides of heat exchangers.
400
100
Total power of pumps
Power of secondary pumps before HX
Power of secondary pumps after HX
Power of primary pumps after HX
Flow rate of bypass line
350
300
250
0
-100
200
-200
150
-300
100
-400
50
8.0
7.8
7.6
7.4
7.2
7.0
6.8
6.6
6.4
6.2
5. Conclusion
6.0
200
450
-500
606
exchangers was found to be the actual fault that caused the decit
ow problem in the system. The analysis results show that a too
low set-point of outlet water temperature at the secondary side
of heat exchangers would lead to more pumps to be activated with
higher speed on the primary side of heat exchangers, which easily
caused decit ow. Decit ow could be eliminated when this setpoint was reset reasonably higher.
Results of an in situ test conrmed the fault detection/identication results. In the meanwhile, a proper set-point of outlet water
temperature on the secondary side of heat exchangers achieved an
average power saving of 87.67 kW (72.37%) of pumps on primary
and secondary sides of heat exchangers.
It is also suggested to set the temperature difference between
the set-point of outlet water temperature and the supply chilled
water temperature at sufciently high level in real applications.
Acknowledgements
The research presented in this paper is nancially supported by
a Grant (PolyU5308/08E) of the Research Grant Council (RGC) of the
Hong Kong SAR, a Grant of The Hong Kong Polytechnic University.
The work is supported by Sun Hung Kai Real Properties Limited.
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