energydesignresources - Taylor Engineering

1 chilled water PlantDesign GuideDecember 2009energydesignresourcesiCOOLTOOLS chilled water PLANT DESIGN GUIDE - TABLE OF CONTENTSTABLE OF CONTENTS1. Overview .. 1-1 Introduction .. 1-1 Target Audience .. 1-1 Organization of Material .. 1-2 How to Use the Guide .. 1-32. chilled water Plant Loads .. 2-1 Understanding Loads and Their Impact on Design .. 2-1 Peak Loads Overview .. 2-3 Annual Load Profiles Overview .. 2-4 Oversizing / Undersizing Considerations .. 2-4 Determining Peak Loads .. 2-6 Calculations/Simulations .. 2-6 Site Measurements .. 2-7 Rules of Thumb.

2 2-8 Determining Hourly Load Profiles .. 2-8 Computer Simulation 2-8 Site Measurements .. 2-103. chilled water Plant Equipment .. 3-1 Introduction .. 3-1 water Chillers .. 3-1 Manufacturer Data .. 3-1 Refrigeration Cycle .. 3-2 Refrigerants .. 3-3 water Chiller Components .. 3-5 Compressors .. 3-5 Evaporators .. 3-12 Condensers .. 3-14 Safety Controls, Accessories, and Options .. 3-15 Performance Characteristics and Efficiency Ratings.

3 3-18 Heat Rejection .. 3-24 Manufacturer Data .. 3-24 Cooling Towers .. 3-24 Air-Cooled Refrigerant Condensers .. 3-32 Evaporative Condensers .. 3-34 Pumps .. 3-35 Manufacturer Data .. 3-35 Pump Types .. 3-36 Pump Performance Curves .. 3-37 Selecting Pumps .. 3-39 Pump Installation and Operation .. 3-44 Variable-Speed Drives .. 3-44 Manufacturer Data.

4 3-45 Power Quality Issues .. 3-46 Drive System Efficiency .. 3-46 VSD Accessories and Considerations .. 3-47iiCOOLTOOLS chilled water PLANT DESIGN GUIDE - TABLE OF CONTENTS4. Hydronic Distribution Systems .. 4-1 chilled water Systems .. 4-1 Introduction .. 4-1 Constant-Flow chilled water Systems .. 4-2 Variable-Flow chilled water Systems .. 4-7 Variable-Flow System Design Considerations .. 4-16 Condenser water Systems .. 4-33 Introduction .. 4-33 Choosing the Style of Cooling Tower .. 4-33 Locating the Condenser water 4-34 Piping Multiple Chillers and Cooling Towers.

5 4-36 Piping for Waterside Economizers .. 4-40 Auxiliary Condenser water Circuits .. 4-42 Piping Heat Recovery Options .. 4-435. Controls and Instrumentation .. 5-1 Introduction .. 5-1 Choosing Instrumentation Control and Monitor Points .. 5-1 Point Justification .. 5-1 Operating Environment for Controls and Instrumentation .. 5-2 Network Connections to Equipment 5-2 Sensors .. 5-3 Typical End to End Accuracy Requirements .. 5-3 Temperature Sensors .. 5-4 Humidity Sensors .. 5-6 Liquid Flow Sensors .. 5-7 Pressure Sensors.

6 5-9 Electric Current Sensors .. 5-10 Electric Power Sensors .. 5-11 Gas Flow Sensors .. 5-13 Control Valves .. 5-14 Valve Types .. 5-14 Valve Selection Criteria .. 5-15 Controllers .. 5-17 Minimum DDC Controller requirements .. 5-17 Interfacing with Chillers and Chiller Networks .. 5-18 Interfacing with Variable-Frequency Drive (VFD) Networks .. 5-19 Interfacing with Power Metering Networks .. 5-20 Performance Monitoring .. 5-21 Integrating Chiller Plant Efficiency Monitoring with Control.

7 5-21 Local Instrumentation .. 5-22 Evaluating the 5-22 Local Instruments .. 5-22 Pressure and Temperature Test Ports .. 5-22 Control Sequences .. 5-23iiiCOOLTOOLS chilled water PLANT DESIGN GUIDE - TABLE OF CONTENTS6. Optimizing Design .. 6-1 Design Procedure .. 6-1 Selecting chilled water Distribution System Flow Arrangement .. 6-3 Simplified Distribution System Selection .. 6-3 Primary-only versus 6-4 Optimizing chilled water Design Temperatures .. 6-7 Recommendations for Selecting Design chilled water Temperatures.

8 6-10 Selection of Condenser water Design Temperatures and Cooling Tower .. 6-11 Tower Fan Speed Control .. 6-12 Tower Efficiency .. 6-14 Tower Range and Approach Temperatures .. 6-16 Tower Flow Turndown .. 6-19 Fine-Tuning Tower Selections .. 6-20 Selecting Type, Number, and Size of Chillers .. 6-20 Optimizing Piping Design .. 6-20 Pipe Sizing .. 6-20 Selecting Valves and Fittings for Energy Savings .. 6-22 Optimizing Control Sequences .. 6-23 Staging Chillers .. 6-23 Pumps .. 6-26 chilled water Temperature Reset.

9 6-27 Condenser water Temperature Reset .. 6-28 Optimizing Control Sequences .. 6-29 Thermal Storage .. 6-30 Case Study .. 6-30 Sequence of Controls .. 6-347. Procurement .. 7-1 Design and Construction Approaches .. 7-1 Conventional Design/Bid/Build .. 7-1 Negotiated Design/Build .. 7-2 Negotiated Design/Assist .. 7-2 Design/Build-Bid and Design/Assist-Bid .. 7-3 General Recommendations .. 7-3 Chiller Procurement Procedures.

10 7-4 Procurement Step #1: Calculate Plant Tonnage .. 7-5 Procurement Step #2: Develop Vendor Short List .. 7-5 Procurement Step #3: Obtain Chiller Bids .. 7-5 Procurement Step #4: Adjust for Other First-Cost Impacts .. 7-9 Procurement Step #5: Estimate Utility Costs .. 7-10 Procurement Step #6: Estimate Maintenance Costs .. 7-13 Procurement Step #7: Calculate Life-cycle Costs .. 7-14 Procurement Step #8: Final Chiller Selection .. 7-16 Case Studies ..7-17 New Building .. 7-17ivCOOLTOOLS chilled water PLANT DESIGN GUIDE - TABLE OF CONTENTS8. Start-up and Commissioning .. 8-1 Commissioning Basics.