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Johnson Controls

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11
Johnson
Controls

Proprietary & Confidential

Presentation Title

Add Photo/Graphic

Presenters:
Andrew Clancy, Business Development Sr Manager - Navy
Scott Schmittel, Account Executive
Jason Richwine , Application Engineer

Consulting Engineers Office

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The Project

University Classroom Building

Central Chilled Water Plant
This building cannot be connected
Cooling tower will not work
Variable Primary Flow

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Discovery

Scott

Branch Account Manager - Buddy

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Discovery

Low Delta T Syndrome

300Tons Cooling
Two 150 Ton Chillers
Scroll
Screw

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Johnson Controls Capabilities

Dave

Jason Richwin

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Primary/Secondary System

Variable Speed
Secondary Pumps

Typical
load
with
two
way
valves

Constant Speed
Primary Pumps
Common Pipe

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Primary/Secondary System at Design

54.0 F

44.0 F

150 ton chillers

360 GPM Each
54.0-44.0F

Secondary Pumps
1080 GPM @ 44.0 F
54.0 F
44.0 F
44.0 F
54.0 F

Typical
Coil
44.0 F

Primary Pumps
360 GPM Each

1080 GPM @ 54.0 F

No flow

54.0 F
1080 GPM @ 54.0 F
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Primary/Secondary System at Part Load

51.5 F

44.0 F

75% System Load

Secondary Pumps
810 GPM @ 44.0 F

51.5 F
44.0 F
44.0 F
51.5 F

Typical
Coil
44.0 F

Primary Pumps
360 GPM Each

270 GPM @ 44.0 F

54.0 F

1080 GPM @ 51.5 F

810 GPM @ 54.0 F

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Primary/Secondary System

67% System Load

Clean Coils

OFF

Secondary Pumps
720 GPM @ 44.0 F
54.0 F
44.0 F
44.0 F
54.0 F

Typical
Coil
44.0 F

Primary Pumps
360 GPM Each

No Flow
54.0 F

720 GPM @ 54.0 F

720 GPM @ 54.0 F

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Primary/Secondary System

67% System Load

Dirty Coils

OFF

Secondary Pumps
792 GPM @ 44.0 F
54.0 F
44.0 F
44.0 F
54.0 F

Typical
Coil
44.0 F

Primary Pumps
360 GPM Each

72 GPM @ 53.0 F
53.0 F

720 GPM @ 54.0 F

792 GPM @ 53.0 F

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Primary/Secondary System

67% System Load

Dirty Coils

OFF

Secondary Pumps
792 GPM @ 44.8 F
53.0 F
44.0 F
44.8 F
53.0 F

Typical
Coil
44.0 F

Primary Pumps
360 GPM Each

72 GPM @ 53.0 F
53.0 F

720 GPM @ 53.0 F

792 GPM @ 53.0 F

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Primary/Secondary System

67% System Load

Dirty Coils

OFF

Secondary Pumps
900 GPM @ 44.8 F
51.9 F
44.0 F
44.8 F
51.9 F

Typical
Coil
44.0 F

Primary Pumps
360 GPM Each

180 GPM @ 51.9 F

51.9 F

720 GPM @ 51.9 F

900 GPM @ 51.9 F

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Primary/Secondary System
Secondary Pumps

Typical load with 2 way valve

Primary Pumps

Automatic Isolation Valve

Variable Primary System

Primary Pumps

Typical load with 2 way valve

Bypass
Valve
Flow Meter
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Variable Primary System at Design

Automatic
Isolation Valve

150 ton chillers

360 GPM Each
54.0-44.0F

54.0 F
44.0 F

54.0 F
44.0 F

Primary Pumps

1080 GPM @ 44.0 F

Typical
load
with
two
way
valves

54.0 F

360 GPM Each

44.0 F
Bypass
Closed

1080 GPM @ 56.0 F

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Variable Primary System Part Load

Automatic
Isolation Valve

75% System Load

54.0 F
44.0 F

54.0 F
44.0 F

Primary Pumps
270 GPM Each

810 GPM @ 44.0 F

Typical
load
with
two
way
valve

54.0 F
44.0 F
Bypass
Closed

810 GPM @ 54.0 F

810 GPM @ 54.0 F

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Variable Primary System Part Load

Chiller off

50% System Load

Automatic
Isolation Valve

54.0 F
44.0 F

Primary Pumps
180 GPM Each

540 GPM @ 44.0 F

Typical
load
with
two
way
valve

54.0 F
44.0 F
Bypass
Closed

540 GPM @ 54.0 F

540 GPM @ 54.0 F

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Variable Primary System Min Flow (120 gpm each)

Chiller off
Automatic
Isolation Valve

System flow below chiller

minimum flow

Closed

Chiller off

Pumps
off

Closed

90 GPM @ 44.0 F

Primary Pumps
120 GPM (one
operating)

51.5 F
44.0 F
Bypass
Open
30 GPM @ 44.0

120 GPM @ 51.5 F

Flow meter

90 GPM @ 54.0 F
Proprietary & Confidential

Typical
load
with
two
way
valve

Designing a VPF Bypass

Size for minimum flow through one chiller

Bypass valve shall be the normally open type
Valve head ratings must be higher than pump dead head
Linear characteristic - valve position % equals flow %
Fast actuator
Valve control range 100:1
Flow meter controls bypass to maintain chiller minimum flow

Proprietary & Confidential

Variable Primary System Min Flow (120 gpm each)

Chiller off
Automatic
Isolation Valve

Pumps maintain system pressure

Closed

Bypass maintains minimum flow

Chiller off

Pumps
off

Closed

90 GPM @ 44.0 F

Primary Pumps
120 GPM (one
operating)

51.5 F
44.0 F
Bypass
Open
30 GPM @ 44.0

120 GPM @ 51.5 F

Flow meter

90 GPM @ 54.0 F
Proprietary & Confidential

Typical
load
with
two
way
valve

Selecting a VPF Flow Meter for Small Tonnage

Systems

Best accuracy job can afford

Minimum +/- 5% at evaporator minimum flow
Set bypass to open when flow equals minimum plus 2 times flow
meter accuracy rating
Example: 120 gpm minimum, flow meter +/- 5%, set minimum flow
at 120 + 120*10% = 132 gpm
Calibrate flow meter at least as often as manufacturer recommends
Buy the best

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Selecting VPF AHU Control Valves

All valve pressure ratings greater than pump dead head

Sized by pressure
% valve position equals % coil capacity
Control range 200:1

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Selecting VPF Chiller Isolation Valves

All valve pressure ratings greater than pump dead head

Linear characteristic - valve position % equals flow %
Modulating valve with slow actuator

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VPF Design Considerations

Flow rate changes Staging on additional chillers

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Variable Primary System (1 chiller running)

Automatic
Isolation Valve

360 GPM @ 44.0 F

Primary Pumps

Typical
load
with
two
way
valve

54.0 F
44.0 F

120 GPM Each

360 GPM

Bypass
Closed

360 GPM @ 546.0 F

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Variable Primary System (Staging on second chiller)

Automatic
Isolation Valve

Need to add chiller

396 GPM @ 45.0 F

Primary Pumps

Typical
load
with
two
way
valve

54.0 F
45.0 F

132 GPM Each

396 GPM

Bypass
Closed

396 GPM @ 55.0 F

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Variable Primary System (Open isolation valve)

Automatic
Isolation Valve

55.0 F

Primary Pumps

198 GPM

55.0 F

396 GPM @ 45.0 F

Typical
load
with
two
way
valve

55.0 F
35.0 F

132 GPM Each

198 GPM

Bypass
Closed

396 GPM @ 55.0 F

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Variable Primary System (Open isolation valve)

LCHWT approaches 35F

Automatic
Isolation Valve

LWT Cutout at 40F

Off goes chiller 1

55.0 F

Primary Pumps

198 GPM

55.0 F

396 GPM @ 45.0 F

Typical
load
with
two
way
valve

55.0 F
35.0 F

132 GPM Each

198 GPM

Bypass
Closed

396 GPM @ 55.0 F

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Variable Primary System (Open isolation valve)

Automatic
Isolation Valve

Open slowly
Chiller 2 comes on when flow
exceeds minimum

55.0 F

Primary Pumps

132 GPM

55.0 F

Chiller 1 unloads to maintain set

point
396 GPM @ 45.0 F
Typical
load
with
two
way
valve

55.0 F
40.0 F

132 GPM Each

264 GPM

Bypass
Closed

396 GPM @ 55.0 F

Proprietary & Confidential

Variable Primary System (Open isolation valve)

Automatic
Isolation Valve

Both valves fully open

Flow equalizes
Chillers modulate to maintain
chilled water set point
54.0 F

Primary Pumps

198 GPM

44.0 F

396 GPM @ 44.0 F

Typical
load
with
two
way
valve

54.0 F
44.0 F

132 GPM Each

198 GPM

Bypass
Closed

396 GPM @ 54.0 F

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Variable Primary System (Open isolation valve)

Automatic
Isolation Valve

Open to change flow 36gpm/min

Chiller 2 comes on when flow is
120gpm in 3 min 20 sec

55.0 F

Primary Pumps

120 GPM

55.0 F

Chiller 1 is still producing 100%

capacity
396 GPM @ 45.9 F
Typical
load
with
two
way
valve

55.0 F
42.0 F

132 GPM Each

276 GPM

Bypass
Closed

396 GPM @ 55.0 F

Proprietary & Confidential

Variable Primary System (Open isolation valve)

Automatic
Isolation Valve

Both valves fully open

Flow equalizes
Chillers modulate to maintain
chilled water set point
54.0 F

Primary Pumps

198 GPM

44.0 F

396 GPM @ 44.0 F

Typical
load
with
two
way
valve

54.0 F
44.0 F

132 GPM Each

198 GPM

Bypass
Closed

396 GPM @ 54.0 F

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Staging on Chiller 2 in VPF Systems

Maintain minimum flow through the operating chiller

Avoid sudden changes in flow anywhere in the system
Prefer schemes that work when bringing on any chiller

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Setting Flow Rate of Change

Start with 10% of design flow per minute

YORK small tonnage chillers can handle faster changes
If the project requires rapid flow changes, contact application
engineering
If problems occur during operation, adjust the rate

Proprietary & Confidential

Variable Primary System Handling Rapidly

Decreasing Loads

Automatic
Isolation Valve

150 ton chillers

360 GPM Each
54.0-44.0F

54.0 F
44.0 F

54.0 F
44.0 F

Primary Pumps

1080 GPM @ 44.0 F

Typical
load
with
two
way
valves

54.0 F

360 GPM Each

44.0 F
Bypass
Closed

1080 GPM @ 56.0 F

Proprietary & Confidential

Variable Primary System Handling Rapidly

Decreasing Loads

Automatic
Isolation Valve

150 ton chillers

360 GPM Each
54.0-44.0F

54.0 F
44.0 F

54.0 F
44.0 F

Primary Pumps

0 GPM @ 44.0 F
Typical
load
with
two
way
valves

54.0 F

360 GPM Each

44.0 F
Bypass
Open

1080 GPM @ 44.0 F

Proprietary & Confidential

Variable Primary System Handling Rapidly

Decreasing Loads

Automatic
Isolation Valve

Close the closest valve first

54.0 F
44.0 F

54.0 F
44.0 F

Primary Pumps
324 GPM Each

972 GPM @ 44.0 F

Typical
load
with
two
way
valves

54.0 F
44.0 F
Bypass
Closed

972 GPM @ 44.0 F

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Variable Primary System Handling Rapidly

Decreasing Loads

Automatic
Isolation Valve

Close the next closest valve

54.0 F
44.0 F

54.0 F
44.0 F

Primary Pumps
288 GPM Each

864 GPM @ 44.0 F

Typical
load
with
two
way
valves

54.0 F
44.0 F
Bypass
Closed

864 GPM @ 44.0 F

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Variable Primary System Handling Rapidly

Decreasing Loads

Automatic
Isolation Valve

Close the next closest valve

54.0 F
44.0 F

54.0 F
44.0 F

Primary Pumps
252 GPM Each

756 GPM @ 44.0 F

Typical
load
with
two
way
valves

54.0 F
44.0 F
Bypass
Closed

756 GPM @ 44.0 F

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Selecting a Small Tonnage Chiller for VPF

Look at all applicable selections

Evaluate based on full load performance
Evaluate based on part load performance
Evaluate based on evaporator minimum flow
Evaluate based on required temperature control accuracy

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Selecting a Small Tonnage Chiller for VPF

Proprietary & Confidential

Selecting a Small Tonnage Chiller for VPF

Proprietary & Confidential

Selecting a Small Tonnage Chiller for VPF

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Selecting a Small Tonnage Chiller for VPF

Proprietary & Confidential

Selecting a Small Tonnage Chiller for VPF

Proprietary & Confidential

Selecting a Small Tonnage Chiller for VPF

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Selecting a Small Tonnage Chiller for VPF

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Selecting a Small Tonnage Chiller for VPF

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Optimizing Air-cooled Chiller Operation

Optimize Chiller Efficiency

Optimize Pump Efficiency
Define loading and unloading sequences
Model annual energy use

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Optimizing Air-cooled Chiller Operation

Chiller is more efficient at 80% than at 40% for the given ambient temperature.

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Optimizing Air-cooled Chiller Operation

288 GPM
9 Ft. Head

288 GPM
144 GPM
each 2.5 Ft.
Head
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Optimizing Air-cooled Chiller Operation

Chiller is more efficient at 40% than at 80% for the given ambient temperature.

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Optimizing Air-cooled Chiller Operation

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STC Special Case How would you design

this system?

The Setup
20 ton VPF cooling system
One chiller, one AHU
44F chilled water with 54F return
Chiller has two scroll compressors (0%, 50%, or 100% capacity)

The Problem
Load remains constant at around 55% or 60% for several hours
Chiller cant meet demand with one compressor on
Chiller severely over-cools with both compressors on
System is unstable

The Hint
Start by thinking about how increasing system water volume can add stability

Proprietary & Confidential

Summary

How VPF systems work

How to select control components for system stability
How to sequence chillers on and off
How to control the chillers, pumps, and valves
How to size the bypass

56

Proprietary & Confidential

Quiz
1.

Must Open New Browser Window by clicking on:

2.

Access CASH Website for Quiz

To start the quiz, click on the

3.

to the right of the quiz title

Please complete the quiz at your leisure.

57

Proprietary & Confidential

Question & Answer Time

Open Forum
To ask a question:

Raise your WebEx Hand to ask a

question

You will be recognized at which point you

may proceed to ask your question

58

Proprietary & Confidential