/umarshadab11

CHILLED WATER PUMPS

🔧🔧 Purpose of Chilled Water Pumps

Chilled water pumps are used to circulate chilled water from the chiller (or district cooling
plant) through the air handling units (AHUs), fan coil units (FCUs), or other terminal units,
and back to the chiller.
There are mainly two types of pumping arrangements:
 Primary-only pumping
 Primary-secondary pumping (most common in large projects)

⚙ Types of CHW Pumps

a. End Suction Pumps
o Most commonly used in low- to mid-rise buildings
o Suction: from the end; Discharge: from the top

b. Vertical Inline Pumps

 Saves floor space, suitable for compact mechanical rooms
 Suction and discharge in a straight line, Mounted vertically
 No need for baseplates or alignment

c. Split Case (Double Suction) Pumps

 Used for high flow rates and large installations
 More energy efficient at high capacities

🔁🔁 Pumping Systems
a. Primary-Only Pumping
 Simple layout, fewer pumps
 Suitable for smaller systems
 No decoupler line
b. Primary-Secondary Pumping
 Separate pumps for chillers (primary) and building loop (secondary)
 Provides better control and flexibility
 Requires a hydraulic decoupler or bypass line between loops
c. Variable Primary Pumping (VPP)
 Modern and efficient setup
 Uses variable speed drives (VFDs) to modulate flow
 Reduces energy usage

1 of 8
📐📐 Key Selection Parameters

1. Flow Rate (LPS or GPM)

o Based on cooling load and ΔT (usually 5–6°C)
o Formula: Flow = kW / (4.2 × ΔT)
2. Total Dynamic Head (TDH in meters)
o Includes elevation + pipe friction + valves + coil pressure drops
o Ensure proper head calculation is provided
3. Pump Efficiency (70–90%)
o Must operate near Best Efficiency Point (BEP)
o Avoid under or over-sizing
4. Motor Power (kW or HP)
o Covers hydraulic + mechanical losses
o Always check if enough margin is given
5. NPSH (Net Positive Suction Head)
o NPSHa > NPSHr to avoid cavitation
6. Pump Type
o End Suction, Vertical Inline, or Split Case based on flow/capacity
7. Control Type
o Constant Speed or VFD-based (for energy savings and variable load)
8. Redundancy
o Duty + Standby pumps (N+1) for critical systems
9. Material of Construction
o Cast iron or SS, depending on water type and system spec
10. Electrical Specs
o 400V / 3Ph / 50Hz, IP55 enclosure, Class F insulation

📚📚 Codes & Standards

 ASHRAE (HVAC Design Guidelines)

 SMACNA (for support and installation)
 CIBSE Guides
 Local authority regulations: DM / DEWA / ADM / ESTIDAMA etc.

2 of 8
🛠 🛠 CHILLED WATER PUMP INSTALLATION DETAILS

🔧🔧 1. Foundation and Base

 Concrete foundation must be flat, rigid, and properly cured.
 Anti-vibration isolators or inertia base are used:
o For high-rise and sensitive areas to reduce vibration/noise.
o Spring or rubber type isolators depending on the system.
 Grouting must be done under the pump baseplate (non-shrink grout).
 Baseplate must be level before grouting.

🔩🔩 2. Anchor Bolts
 Anchor bolts must be: Embedded in foundation (cast-in or chemical anchor) and
correct diameter and length as per drawing andTightened after alignment and
grouting
👉👉 Common Issue: Bolts are tightened before alignment → causes soft foot.

🔄🔄 3. Alignment
 Pump and motor shafts must be aligned using a dial gauge or laser.
 Alignment must be done after grouting and piping installation.
 Misalignment leads to vibration, seal failure, bearing wear.
👉👉 Consultant Note: Request alignment report. Recheck after piping is done.

🔄🔄 4. Piping Arrangement
 Piping must be independently supported – no load on the pump.
 Flexible connectors on suction and discharge sides:
o Compensate thermal expansion
o Reduce vibration transmission
 Suction piping:
o Must be straight and same size as inlet – avoid bends immediately before the
pump.
o Minimum 5D straight length before suction flange (D = pipe dia)
 Discharge piping:
o Should have non-return valve and isolation valve.
o Pipe must slope slightly upward to release air.

3 of 8
 👉👉 Checklist:

Suction Line Discharge Line

✅ Isolation Valve (Butterfly or Gate) ✅ Isolation Valve (Butterfly or Gate)
✅ Y-Strainer or Basket Strainer ✅ Non-Return Valve (Swing/Wafer Type)
✅ Flexible Connector(Rubber/Braided) ✅ Flexible Connector (Rubber/Braided)
✅ Pressure Gauge with Gauge Cock ✅ Pressure Gauge with Gauge Cock
✅ Balancing Valve (if specified) ✅ Balancing Valve or Circuit Setter
✅ Thermometer or Temp. Sensor (optional)
✅ Drain Valve (with cap or hose connection)

� 5. Vibration Isolation
 Spring isolators or rubber pads under base.
 Flexible connectors (rubber bellows or braided hose)
 If pump is on upper floors → acoustic/vibration breaks on piping.

⚡ 6. Electrical & Controls

 Motor power cable must be sized as per load.
 Earthing to be provided.
 Control cable to be laid to DDC or VFD panel.
 Phase rotation to be tested to ensure correct pump direction.

📏📏 7. Instrumentation
Provide:
 Pressure gauges on suction and discharge
 Thermometers (or temperature sensors for BMS)
 Flow meter (if required, or balancing valve with flow indication)
 Drain point (with plug or valve)

📶📶 8. VFD (Variable Frequency Drive)

 Located nearby in pump room or electrical room
 VFD panel must:
o Be easily accessible
o Have proper ventilation
o Be IP-rated (IP55 typically)
 Electrical termination must follow DEWA/ADDC standards

4 of 8
⚙ Working Principle of a Chilled Water Pump
A chilled water pump works on the centrifugal force principle to circulate chilled water from
the chiller to AHUs/FCUs and back.
🔄🔄 Step-by-Step Operation:
1. Suction:
Chilled water enters the pump through the suction pipe at low pressure.
2. Impeller Action:
The pump’s impeller rotates (powered by the electric motor), creating centrifugal force.
3. Pressure Generation:
This force pushes the water outward from the impeller center to its edge, increasing
pressure energy.
4. Discharge:
The high-pressure water is then pushed into the discharge pipe and circulated through
the chilled water system.

💡💡 Key Points:
 Centrifugal Action is the core operating principle.
 Flow depends on impeller speed, size, and system resistance.
 In VFD systems, pump speed is adjusted based on demand (ΔP or temperature).

🧠 🧠 Chilled Water Pump Control Strategies

The goal is to optimize energy use, maintain system pressure/flow, and ensure stable chilled
water circulation based on cooling demand.

🔘🔘 1. Constant Speed Control

 Pump runs at full speed all the time
 Simple but inefficient under partial load
 Used in old or small systems without BMS
Used in:
 Small buildings or where flow doesn’t vary much
 Systems without automation/BMS

⚙ 2. Variable Speed Control (VFD-Based) 🏆🏆 (Most preferred today)

 Pump speed varies depending on system demand
 Saves energy by reducing pump speed during low load
 Controlled by:

5 of 8
 o Differential pressure sensor (ΔP) across system
o Flow sensor
o Temperature sensors
Used in:
 Medium to large chilled water systems
 Primary-secondary or variable primary systems
 Systems with BMS/DDC integration

🔁🔁 3. Differential Pressure Control (ΔP control)

 VFD adjusts pump speed to maintain constant pressure difference between supply
and return
 ΔP sensor is installed at remote point in system (e.g., AHU header)
👉👉 Best for stable flow and energy savings

🌡🌡 4. Temperature-Based Control (ΔT control)

 VFD speed is adjusted based on return chilled water temperature
 Ensures chillers operate within proper ΔT range (e.g., 5–6°C)
👉👉 Useful when system performance is monitored closely

🧑🧑💻💻 5. BMS/Automation Integration

 Pumps are controlled by BMS/SCADA systems
 Features include:
o Auto-changeover between duty and standby pumps
o Alarm on failure/high temp/low flow
o Manual override and remote start/stop
o Trend logs for performance

Checklist for Control Strategy

Item Check
VFD installed with proper control wiring ✅
ΔP or temp sensors installed at correct locations ✅
BMS logic tested (start/stop, changeover, alarms) ✅
Manual override available at VFD/BMS ✅
Pump curve matches VFD range ✅
Auto-standby activation verified ✅

6 of 8
Testing & Commissioning for Chilled Water Pumps

🛠🛠 Pre-Commissioning Checks
Before energizing the pump:
Checkpoint Details
✅ Mechanical installation Foundation grouted, pump aligned, flexible connectors fixed
Suction and discharge piping completed, valves installed,
✅ Piping
independently supported
✅ Electrical Power supply connected, motor IR tested (>1 MΩ), earthing done

✅ Gauges & fittings Suction/discharge pressure gauges, thermometer, strainer installed

✅ VFD setup (if used) Parameter setting, safety interlocks ready

✅ Rotation direction Jog motor and confirm rotation as per arrow on pump casing

� Flushing & Cleaning

 Ensure system is thoroughly flushed to remove dirt/debris
 Strainer must be cleaned before final operation
 All flushing water to be drained before chemical dosing/final filling

🔄🔄 Alignment Check
 After piping is connected, verify pump-motor shaft alignment again
 Submit alignment report (laser/dial gauge)

⚙ Initial Start-up
 Start pump in manual mode at minimum speed
 Monitor for:
o Abnormal vibration/noise
o Leaks at flanges or mechanical seal
o Pressure readings on suction/discharge

🔁🔁 Flow & Head Measurement

Parameter Method
Flow rate Ultrasonic flow meter or balancing valve index
Pressure Compare suction/discharge gauge readings
Current Clamp meter to verify motor load
ΔT Use thermometer or sensors at supply & return lines

Ensure values are within design +/-10%

7 of 8
🧠🧠 VFD/BMS Control Testing
 Test Auto Start/Stop via BMS
 Simulate high/low pressure alarms
 Verify pump ramps up/down with demand (ΔP/ΔT)
 Check duty/standby auto changeover

� Performance Documentation
 Record the following in a commissioning log sheet:
Item Unit
Flow rate LPS or GPM
Suction pressure Bar or PSI
Discharge pressure Bar or PSI
ΔT (Temp diff) °C
Motor current Amps
VFD Frequency Hz
Vibration level mm/s (if measured)
Noise level dB (if measured)

✅ Final Checks & Handover

 Clean strainer again after 1st run
 Fix labels and tag numbers
 Submit Final Inspections with:
o T&C checklist
o Alignment report
o Flow/head/current report
 Submit O&M manual, Warranty & calibration certs (as applicable)

END OF THE NOTES

8 of 8