Optimizing Pumping Solutions For HVAC
Applications
Introduction & Practicalities
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Agenda – Optimizing Pumping Solutions For HVAC
Applications
Topic Duration
Hydronic chilled water system for air conditioning 5 mins
Law of the T 5 mins
Constant flow (constant primary) system 20 mins
Constant primary/variable flow secondary system 20 mins
Primary/secondary/tertiary pumping systems 10 mins
Mixing loop 5 mins
Variable primary flow systems 20 mins
Differential pressure sensor 10 mins
Q&A 15 mins
Feedback 5 mins
Topics for this module
• Hydronic chilled water system for air conditioning
• Law of the T
• Constant flow (constant primary) system
• Constant primary/variable flow secondary system
• Primary/secondary/tertiary pumping systems
• Mixing loop
• Variable primary flow systems
• Differential pressure sensor
Central (hydronic) air conditioning system
A central system overall consists of the following five sub-systems, which work
together to form a hydronic air-conditioning system
Five sub-systems of a central air conditioning system
2.
3. HEAT
1. CHILLED
4.
5. AIRREJECTION
WATER
SIDE LOOP
REFRIGERATION
CONTROLS LOOP
LOOP
LOOP
Chilled water loop
• Chilled water loop - Consists of circulation pumps, which carries the cool water from the chiller to the
various distribution systems like Fan Coil Units (FCU) or Ceiling Suspended Units (CSU) or Air Handling Units
(AHU) or Radiant Cooling Panels (RCP)
• Various distribution methods, piping/pumping schemes are employed to carry the chilled water to these
distribution systems based on load demand
Topics for this module
• Hydronic chilled water system for air conditioning
• Law of the T
• Constant flow (constant primary) system
• Constant primary/variable flow secondary system
• Primary/secondary/tertiary pumping systems
• Mixing loop
• Variable primary flow systems
• Differential pressure sensor
Law of the T
5 Amp
1 Amp 4 Amp
1Ω
Gustav Kirchhoff 4Ω
(1824-1887)
Kirchhoff's current law states that the sum of the currents
flowing into a node equals the sum of the currents flowing
out of the node.
Law of the T
Resistors for electric circuits
Valves = resistors for flow circuits
Topics for this module
• Hydronic chilled water system for air conditioning
• Law of the T
• Constant flow (constant primary) system
• Constant primary/variable flow secondary system
• Primary/secondary/tertiary pumping systems
• Mixing loop
• Variable primary flow systems
• Differential pressure sensor
Constant flow (constant primary) system
3-way
control valves
Chiller - 3
Chiller - 2
Chiller - 1
• High pump power
Cooling Loads consumption
• Loss of cooling
Primary Pumps performance
Constant
Low delta-T syndrome
Topics for this module
• Hydronic chilled water system for air conditioning
• Law of the T
• Constant flow (constant primary) system
• Constant primary/variable flow secondary system
• Primary/secondary/tertiary pumping systems
• Mixing loop
• Variable primary flow systems
• Differential pressure sensor
Constant primary/variable flow secondary system
Secondary
Chiller - 3 Pumps
Chiller - 2
Chiller - 1
• Constant primary flow
DP • Variable secondary flow
Secondary Control
Primary
Panel
2way control • More energy efficient
De-coupler
Pumps valves
Constant Variable
De-coupler sizing
Topics for this module
• Hydronic chilled water system for air conditioning
• Law of the T
• Constant flow (constant primary) system
• Constant primary/variable flow secondary system
• Primary/secondary/tertiary pumping systems
• Mixing loop
• Variable primary flow systems
• Differential pressure sensor
Primary/secondary/tertiary pumping systems
Chiller Plant Room Tertiary
Pump
Room
Secondary
Building 1
Pumps
Chiller - 3
Chiller - 2
Chiller - 1
Tertiary
Pump
• Zone divided
Building 2
De-coupler
Primary
Pumps
• Increased energy
efficiency
Tertiary Tertiary
Pump Pump
Building 4 Building 3
Constant Variable Variable
Primary/secondary/tertiary pumping systems
△P
Cooling Loads
Pump
Controller
• Proportional pressure
control based on P
Tertiary
Pump
Tertiary
pump
Supply 7 oC
△P
Return 13 oC
Constant Variable Variable
Signal to secondary pump controller
Topics for this module
• Hydronic chilled water system for air conditioning
• Law of the T
• Constant flow (constant primary) system
• Constant primary/variable flow secondary system
• Primary/secondary/tertiary pumping systems
• Mixing loop
• Variable primary flow systems
• Differential pressure sensor
Mixing loop
Tertiary
pump
Topics for this module
• Hydronic chilled water system for air conditioning
• Law of the T
• Constant flow (constant primary) system
• Constant primary/variable flow secondary system
• Primary/secondary/tertiary pumping systems
• Mixing loop
• Variable primary flow systems
• Differential pressure sensor
Variable primary flow (VPF) systems
Flow
meters
Cooling
Loads
Chiller - 1
Chiller - 2
Chiller - 3
Minimum flow
bypass valve
normally closed
2way control
valves
Primary
Pumps
Variable
Minimum flow bypass valve
20 M3/H 12 M3/H
Controller 8 M3/H
Cooling
Loads
Chiller
Minimum Flow Bypass
Valve Normally Closed
2 Way Control
Valves
20 M3/H 12 M3/H
Variable
Topics for this module
• Hydronic chilled water system for air conditioning
• Law of the T
• Constant flow (constant primary) system
• Constant primary/variable flow secondary system
• Primary/secondary/tertiary pumping systems
• Mixing loop
• Variable primary flow systems
• Differential pressure sensor
Differential pressure sensor – direct return piping
• Location of differential pressure sensor is critical in the performance of variable volume pumping system be it
primary/secondary or variable primary flow system.
• Only if the DP sensor is located at the most critical zones, it can sense the load changes effectively to modulate the
distribution pumps.
• For direct return piping scheme like the one shown below, load closest to the plant having the shortest path will
experience entire pump head. Pressure drop is minimal near to the plant and it is substantial at the end of the piping. Here
balancing valves are required to ensure right flow to each circuit.
Differential pressure sensor – reverse return piping
• For reverse return piping scheme, pressure drop is theoretically the same across all load points due to equal
length of piping from the chiller plant to the cooling loads. Pressure drop is nearly the same from the plant
to the end of the piping.
• Decision to use direct return or reverse return piping is based on system operability vs first cost, and it is left
to the designer and the owner to decide.
Single delta-P sensor or multiple?
• There is always a question on whether to use single sensor in
the system or need to use multiple sensor to ascertain the
load changes
• One DP sensor is good enough for closed loop application as
change in load affects complete piping system and if the DP
sensor is located correctly then it can sense the load changes
• When a larger number of sensors are used unnecessarily in
the smaller piping system, too many sensing points increase
the scan time and at any point of time, if one or the other
sensor is having a deviation from the set point, the pump
controller will try to respond – making the system unstable
• Key is to avoid too many sensors, have either one or
maximum two in the system and locate it properly in the
piping network
Q&A
Feedback
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