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Application Guide
AG 31-003-1
© 2002 McQuay International

Chiller Plant Design

Elevation Difference
Column Height
When Pump Is Off

Building Load

600 Tons

(50% Load)
Secondary Pump
1440 gpm
480 gpm Flow Through
Decoupler
Flow

Two 400 Ton Chillers

Each At 300 Tons

(Balanced Load)
51.5F Return Water
To Chiller
Chiller 1- On
Chiller 2- On
Chiller 3- Off
44F
44F
54F
Two Primary Pumps
Each At 960 gpm
51.5F

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1e02ba7fe6/000.jpg' style='left: 4.19em; clip: rect(0.07em 46.82em 0.19em 0.07em);
height: 0.25em; top: 68.63em; width: 46.88em;'/>
2
Application Guide AG 31-003-1

Table of Contents
Introduction................................................................................................................. 4
Using This Guide............................................................................................................................... 4
Basic System............................................................................................................... 4
Chiller Basics..................................................................................................................................... 4Piping
Basics..................................................................................................................................... 7Pumping
Basics............................................................................................................................... 11Cooling Tower
Basics...................................................................................................................... 15Load
Basics..................................................................................................................................... 20Control Valve
Basics....................................................................................................................... 20Loop Control
Basics........................................................................................................................ 23Piping
Diversity............................................................................................................................... 24
Water Temperatures and Ranges............................................................................... 25
Supply Air Temperature................................................................................................................... 25Chilled Water
Temperature Range................................................................................................... 26Condenser Water Temperature
Range.............................................................................................. 26Temperature Range
Trends.............................................................................................................. 27
Air and Evaporatively Cooled Chillers..................................................................... 28
Air-Cooled Chillers......................................................................................................................... 28
Evaporatively Cooled Chillers......................................................................................................... 30
Dual Compressor and VFD Chillers......................................................................... 31
Dual Compressor Chillers................................................................................................................ 31VFD
Chillers................................................................................................................................... 31System Design
Changes................................................................................................................... 32
Mechanical Room Safety.......................................................................................... 34
Standard 34...................................................................................................................................... 34
Standard 15...................................................................................................................................... 34
Single Chiller System................................................................................................ 38
Basic Operation............................................................................................................................... 38Basic
Components........................................................................................................................... 38Single Chiller Sequence of
Operation.............................................................................................. 39
Parallel Chiller System.............................................................................................. 41
Basic Operation............................................................................................................................... 41Basic
Components........................................................................................................................... 41Parallel Chiller Sequence of
Operation........................................................................................... 42
Series Chillers........................................................................................................... 44
Basic Operation............................................................................................................................... 44Basic
Components........................................................................................................................... 44Series Chillers Sequence of
Operation............................................................................................ 46Series Counterflow
Chillers............................................................................................................. 47Using VFD Chillers in Series
Arrangements................................................................................... 49System
Comparison......................................................................................................................... 49
Primary/Secondary Systems...................................................................................... 51

<img class='absimg' src='http://html.scribd.com/giq7m4a24yubwu8/images/3-

5d3941e293/000.jpg' style='left: 5.32em; clip: rect(0.07em 46.82em 0.19em 0.07em);
height: 0.25em; top: 68.63em; width: 46.88em;'/>
Application Guide AG 31-003-1
3
Basic Operation............................................................................................................................... 51Basic
Components........................................................................................................................... 51Very Large Chiller
Plants................................................................................................................. 58Primary/Secondary Sequence of
Operation..................................................................................... 58
Water-Side Free Cooling........................................................................................... 61
Direct Waterside Free Cooling......................................................................................................... 61Parallel Waterside Free
Cooling...................................................................................................... 61Series Waterside Free
Cooling......................................................................................................... 62Waterside Free Cooling Design
Approach....................................................................................... 63Cooling Tower
Sizing...................................................................................................................... 63Waterside Free Cooling Sequence of
Operation.............................................................................. 64Economizers and Energy
Efficiency................................................................................................ 65
Hybrid Plants............................................................................................................. 66
Heat Recovery and Templifiers™............................................................................. 67
General............................................................................................................................................. 67Load
Profiles.................................................................................................................................... 67Heat Recovery
Chillers....................................................................................................................
67Templifiers™................................................................................................................................... 71ASHRAE Standard
90.1.................................................................................................................. 73
Variable Primary Flow Design.................................................................................. 75
Basic Operation............................................................................................................................... 75Basic
Components........................................................................................................................... 75Variable Primary Flow
Sequence of Operation................................................................................ 76Training and
Commissioning........................................................................................................... 78
Low Delta T Syndrome............................................................................................. 80
Low Delta T Example...................................................................................................................... 80Low Delta T Syndrome
Causes and Solutions................................................................................. 82Other
Solutions................................................................................................................................ 84
Process Applications................................................................................................. 86
Process Load Profiles...................................................................................................................... 86Condenser
Relief.............................................................................................................................. 87Winter
Design.................................................................................................................................. 87Chilled Water
Volume...................................................................................................................... 87Temperatures and
Ranges................................................................................................................ 88
Minimum Chilled Water Volume.............................................................................. 89
Estimating System Volume.............................................................................................................. 89
Evaluating System Volume.............................................................................................................. 89
Conclusions............................................................................................................... 92
References................................................................................................................. 93
The information contained within this document represents the opinions and suggestions ofMcQuay International.
Equipment, the application of the equipment, and the systemsuggestions are offered by McQuay International as
suggestions only, and McQuayInternational does not assume responsibility for the performance of any system as a
result ofthese suggestions. Final responsibility for the system design and performance lies with thesystem engineer.
4
Application Guide AG 31-003-1

IntroductionUsing chilled water to cool a building or process is efficient and flexible. A two-inch Schedule 40
The purpose of this manual is to discuss various piping and control strategies commonly used with
chilled water systems including variable flow pumping systems.
Using This Guide
Basic System
Figure 1 - Single Chiller Loop
Chiller Basics
The chiller can be water-cooled, air-cooled or evaporatively cooled. The compressor types typically
Condenser
Water Loop
Cooling Tower
Building Load
Chilled Water Loop
Chiller
Chilled Water Pump
Condenser
Water Pump

Application Guide AG 31-003-1

5
Flow and Capacity Calculations
°
Q = WxCx ∆ T

°
∆T = temperature change of fluid (°F )

°°
Load (tons) = Flow (USgpm) x (°Fin –°Fout)/24
Using this equation and the above design conditions, the temperature change in the evaporator is
found to be 10°F. The water temperature entering the evaporator is then 54°F.
°°°°°
The designer is not tied to these typical design conditions. In fact, more energy efficient solutions can
be found by modifying the design conditions, as the project requires.
Chillers and Energy Efficiency
6
Application Guide AG 31-003-1
Chiller part load performance can be given at designer-specified conditions or the NPLV (Non-
Standard Part Load Value) can be used. The definition of NPLV is spelled out in ARI 550/590-98,
Test Standard for Chillers. For further information refer to McQuay Application Guide AG 31-002,
Centrifugal Chiller Fundamentals.
Figure 2 - ASHRAE Std 90.1 Chiller Performance Table 1
1Copyright 2001, American Society Of Heating, Air-conditioning and Refrigeration Engineers Inc.,
www.ashrae.org. Reprinted by permission from ASHRAE Standard 90.1-2001
Water Chilling Packages – Minimum Efficiency Requirements
Equipment Type
Size Category
Minimum Efficient
Test Procedure
Air Cooled, with Condenser,
Electrically Operated
<150 tons
2.80 COP
3.05 IPLV
ARI 550/590
>150 tons
Air Cooled, without Condenser,
Electrically Operated
All Capacities
3.10 COP
3.45 IPLV
Water Cooled, Electrically Operated,
Positive Dis
p

lacement
(

Reci
p

rocatin
g )

All Capacities
4.20 COP
5.05 IPLV
ARI 550/590
<150 tons
4.45 COP
5.20 IPLV
ARI 550/590
>150 tons and
<300 tons
4.90 COP
5.60 IPLV
>300 tons
5.50 COP
6.15 IPLV
Water Cooled, Electrically Operated,
Centrifugal
<150 tons
5.00 COP
5.25 IPLV
ARI5 50/590
>l50 tons and
<300 tons
5.55 COP
5.90 IPLV
>300 tons
6.10 COP
6.40 IPLV
Air-Cooled Absorption Single Effect
All Capacities
0.60 COP
ARI 560
Water-Cooled Absorption Single
Effect
All Capacities
0.70 COP
Absorption Double Effect, Indirect-
Fired
All Capacities
1.00 COP
1.05 IPLV
Absorption Double Effect, Direct-Fired
All Capacities
1.00 COP
1.00 IPLV
aThe chiller equipment requirements do not apply for chillers used in low-temperature applications where the design leaving fluid temperature is <4°F.
b Section 12 contains a complete specification of the referenced test procedure, including the referenced year version of the test procedure.

☺Tip: To convert from COP to kW/ton;

COP = 3.516/(kW/ton)
To calculate EER = Tons x 12/(total kW input)
Application Guide AG 31-003-1
7
Piping Basics
Static Pressure
Figure 3 - Closed Loop
When open cooling towers are used in
condenser piping, the loop is an open
Figure 4 -Open Loop
Expansion Tanks
Water Column
Water Column
Static Head
Elevation Difference
Column Height
When Pump Is Off
☺Tip: Most chillers are rated for 150 PSI
water side pressure. This should be considered
carefully for buildings over 10 stories.

8
Application Guide AG 31-003-1
Figure 5 - Expansion Tank Location
a d d e dmin u s
Piping Insulation
Condenser Water Piping
Discharge Pressure =
Expansion Tank Pressure
Suction Pressure =
Expansion Tank Pressure
-Pump Head
Application Guide AG 31-003-1
9
Reverse Return/Direct Return Piping
Figure 6 - Reverse Return Piping
Figure 7 - Direct Return Piping
Control Valve Basics

10
Application Guide AG 31-003-1
Piping and Energy Efficiency
Y Pipe material. Different materials have different friction factors.
Y Pipe sizing. Smaller piping raises the pressure drop. This must be balanced against the capital
cost and considered over the lifetime of the system.
Y Fittings. Minimize fittings as much as possible.
Y Valves. Valves represent large pressure drops and can be costly. Isolation and balancing valves
should be strategically placed.
Y Direct return vs. Reverse return.
ASHRAE 90.1-2001 requires the following for piping systems:
Y Piping must be insulated as per ASHRAE Standard 90.1 Table 6.2.4.1.3. (See Table 1)
Exceptions include:
 Y Factory installed insulation.
Y Systems operating between 60°F and 105°F.
Y The hydronic system be proportionally balanced in a manner to first minimize throttling losses
and then the impeller trimmed or the speed adjusted to meet the design flow conditions
(6.2.5.3.3)
Exceptions include:
Y Pumps with motors less than 10 hp.
Y When throttling results in no greater than 5% of nameplate horsepower or 3 hp, whichever is
less.
Y Three pipe systems with a common return for heating and cooling are not allowed. (6.3.2.2.1)

Two pipe changeover systems are acceptable providing: (6.3.2.2.2)Controls limit changeovers based on15°F ambient drybulb deadband. System

will operate in one mode for at least 4 hours.Reset controls lower the changeover point to 30°F or less.
Y Systems with total pump nameplate horsepower exceeding 10 hp shall be variable flow able to
modulate down to 50%. (6.3.4)
Application Guide AG 31-003-1
11
Table 1 - Minimum Piping Insulation As Per Std 90.12
Insulation Conductivity
Nominal Pipe or Tube Size (in)
Conductivity
Btu•in/(h•ft2•°F)
Mean Rating
Temp °F
<1
1 to <1-1/2
1-1/2 to <4
4<8
>8
Cooling Systems (Chilled Water, Brine and Refrigerant)
40-60
0.22-0.28
100
0.5
0.5
1.0
1.0
1.0
>60
0.22-0.28
100
0.5
1.0
1.0
1.0
1.5
Pumping Basics
Figure 8 - Inline Centrifugal Pump
Figure 9 - Basic Pump Curve
2Copyright 2001, American Society Of Heating, Air-conditioning and Refrigeration Engineers Inc.,
www.ashrae.org. Reprinted by permission from ASHRAE Standard 90.1-2001
0
10
20
30
40
50
0
50
100
150
200
250
Capacity, gpm
TotalHead,f
t
Point of Operation
Pump Curve
SystemCu rve
12
Application Guide AG 31-003-1
Figure 10 - Pump Curve Profiles
Figure 11 – Typical Centrifugal Pump Curve
Required
NPSH
Flow (Usgpm)
Total Head (ft)
Impeller Dia.
Efficiency
BHP
Capacity
TotalHead
Steep
Flat
☺Tip: For a constant system curve, the following
p

ump affinity laws may be used;

At constant impeller diameter (Variable speed)
RPM1 / RPM2 = gpm1 / gpm2 = (H1)½ /(H2)½
At constant speed (Variable impeller diameter)
D1/ D 2 = gpm1 / gpm2 = (H1)½ /(H2)½
Application Guide AG 31-003-1
13
Multiple Pumps
Variable Flow Pumps
Many applications require the flow to change in response to load. Modulating the flow can be
accomplished by:

Riding the pump curve Staging on pumpsUsing variable frequency drives (VFDs)
if
Figure 12 - Secondary Pump Control in Direct Return Systems
Another method of controlling variable flow pumps is to monitor the valve positions of a control
valve in a critical part of the system. This valve is typically the furthest from the pumps. The control
Coil 1
Coil 5
Design PD Is
30 Ft
☺Tip: The differential pressure setpoint for variable
f
f

or the life of the building

HVAC Handbook - Chiller Plant Design

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