Barbour Guide

in association with
The Barbour Guides are intended to provide a short introduction to, or overview of, a given subject area. They should
not be viewed in any way as being complete or comprehensive. Barbour recommends further reading, starting with
the references listed in the Guide and other information held within the Barbour services.

CENTRAL REFRIGERATION PLANT

GUIDANCE
CHILLERS
Chiller selection strategy may depend on the use of the system or facility being served. For
instance, critical installations may require standby or redundancy plant in order to ensure that
the total design load can be met in the event of one chiller failing. This is becoming more of
an issue in modern high dependency facilities such as computer centres and data halls.
In many cases, multiple chiller units can prove more energy efficient than a single large unit
with a single or two-stage burner. Modulating control can offer a cost-effective alternative to
multiple chiller units, providing improved efficiency and space savings, but do not provide any
spare plant in the event of a chiller failure.
Check that the design noise levels are in accordance with the limits set by the local authority,
or suitable for the local occupants, whichever is the lower. The noise acceptable levels may
vary throughout the day, with night time levels needing to be lower than those permissible
during the day. This may necessitate a night setback arrangement to enable compliance.
Select chiller plant to operate at maximum efficiency as frequently as possible. The efficiency
of many chillers drops off dramatically at part load performance, so select chillers according to
the operating load profile of the system.
Choose a heat rejection method that can adequately deal with the requirements of the system
cooling plant. For example, dry coolers are generally unsuitable for use with absorption
chillers as the efficiency of such chillers is only a little over 1.1:1, whereas other forms of
electrically powered chillers have a coefficient of performance (COP) of around 3:1.
If the heat rejection device is being supplied separately to the chiller, make sure that both
have been selected on the same design criteria.
If a chilled water system is to have glycol added for protection from freezing in winter, make
sure that the output of the plant has been reassessed accordingly. A water/glycol mix has the
affect of reducing the output as the heat capacity of the mixture is lower than that of water.
Ensure that suitable safety and control devices are fitted to each chiller, e.g. low chilled water
flow rate safety device, chilled water low temperature thermostat, etc.
Ensure that external air cooled condensers are corrosion resistant and have weatherproof
motors. For coastal sites, ensure that appropriate coatings and materials are specified for
externally located packaged chillers (salty atmospheres can rapidly corrode air cooled
condensers). Similarly, plant in areas around airports is susceptible to corrosion from
discharged aircraft fuel and should be treated accordingly.
REFRIGERANTS
Check at an early stage that the refrigerant type meets with the clients approval. Many large
companies have their own policy and environmental agenda, and refrigeration is normally one
of the first issues to be dealt with due to the possible implications of certain refrigerant
materials. For key specification issues see the Barbour Report 'Greening a guide to

Barbour

Revised Dec 05

Page 1

sustainable engineering specification'. For details on reducing emissions from refrigeration

systems see the BRE Information Paper IP 1/94 and CIBSE Guidance Note GN1.
COMMISSIONING
Ensure that the division of responsibility between the designer and the specialist
commissioning contractor is clearly defined to avoid duplication of work, and possible site
disagreements.
Select pipework components and layouts to ensure that the system is as inherently stable and
self-balancing as can be economically justified. This will reduce the time required to regulate
branch flow rates and will often make it unnecessary to balance flow rates through terminal
units.
Consider the requirements for two and three port valves, gauges and fittings for measuring
system performance.
Check that design pressure losses across terminal units fed from the same branch are not
significantly different, e.g. within around 20kPa of each other. Mixing low resistance terminal
units such as radiators with high resistance units such as fan coils should be avoided.
Where possible ensure that terminal unit design pressure losses on reverse return branches
are the same, in order that flows to these terminal units fed from a reverse return branch will
achieve some degree of self-balancing.
Check that flow regulating and measurement valves are properly located. Usual locations
include risers, branches, sub-branches, terminal branches, by-passes from three way control
valves, pump sets, individual boiler and chiller circuits. Only where a degree of self-balancing
has been achieved might they be omitted.
Check that design flow rates are achievable with regulating valves more than 25% open.
Select regulating valves such that at their design flow rates, the required pressure losses
across them can be achieved without the need to close below the 25% open position. Valves
closed beyond this point can be prone to dirt and air blockages. Low flow 15mm valves have
a minute orifice and should be considered with caution.
Check that the accuracy of the specified flow measurement device is adequate to achieve the
required flow balance tolerance. Depending on the device selected, accuracy can vary
between +/-3% and +/-10%.
Flow measurement devices should be selected such that at design flow rates, the pressure
signals across them are greater than 1kPa. Anything less than this becomes difficult to
measure with site instruments which affects accuracy.
Tolerances of final flow measurements should be assessed and specified, and the
commissioning specialist given a realistic flow rate tolerance within which to establish a flow
balance (see CIBSE Commissioning Codes and BSRIA Guides). Note that the total of
tolerances may affect pump selection.
Valve and flow measurement device locations should be indicated on schematic design
drawings and contractor installation drawings with commissioning data.
Units such as fan coils can be grouped together to reduce the number of commissioning
valves required.
Eligibility for Enhanced Capital Allowances
Components within this section may be eligible for attracting an Enhanced Capital Allowance.
To select equipment that qualifies for an ECA, refer to the Energy Technology List at
http://www.eca.gov.uk/. For details on how the scheme works see the guidance section in
Barbour Report Greening a guide to sustainable engineering specification.

Barbour

Revised Dec 05

Page 2

REFERENCE DOCUMENTS
The following documents provide further guidance:
BSEN378: 2000 Parts 1-4 Refrigeration systems and heat pumps safety and environmental
requirements
Barbour Report 'Greening a guide to sustainable engineering specification' 2002
BRE Information Paper IP 1/94 Minimising refrigerant emissions from air conditioning
systems in buildings 1994
BSRIA Technical Note 00/16 Energy efficient chiller control 2000
BSRIA Technical Note 92/15 Refrigeration and the environment typical applications for air
conditioning 1992
Butterworth Heinemann Faber and Kells heating and air-conditioning of buildings 2002
Butterworth Heinemann Refrigeration equipment servicing and installation handbook 1997
CIBSE Guide B Heating, ventilating, air conditioning and refrigeration 2005
CIBSE Commissioning Code R Refrigeration systems 2002
CIBSE Guidance Note GN1 CFCs, HCFCs, HFCs and halons professional and practical
guidance on substances that deplete the ozone layer 2000
Energy Efficiency Best Practice Programme, Fuel Efficiency Booklet 11 Economic use of
refrigeration plant 1993
Energy Efficiency Best Practice Programme, Good Practice Guide 37 Commercial
refrigeration plant energy efficient design 1996
Institute of Refrigeration, Cold Store Code of Practice, Part 2 Design and construction of
refrigeration systems 1994
Institute of Refrigeration, Guidelines and Safety Codes

Barbour

Revised Dec 05

Page 3