NOMENCULTURE

h Head loss (m)

p Pressure loss (Pa, N/m2)

T Temperature change of fluid (F )

p Pressure drop across valve, Pa

Friction coefficient

Density (kg/m3)

pump efficiency as a decimal

Av Valve coefficient, m3/(s Pa)

BEP Brake horse power

C Specific heat of fluid (Btu/lb F)

dh Hydraulic diameter (m)

dh Hydraulic diameter (m)

FCU Fan coil unit

g Acceleration of gravity (9.81 m/s2)

HVAC Heating, ventilation and air conditioning

ISA International Society for Automation

l Length of duct or pipe (m)

NPSH Net positive suction head

Q Quantity of heat exchanged (Btu/hr)

Q Flow rate, m3/s

Rpm Revolution per minute

Sch Schedule

SL Sound level, dB

t Downstream pipe wall thickness, mm

v Velocity (m/s)

W Flow rate of fluid (USgpm)

Whp Water horse power

 CHAPTER 5: CHILLED WATER SYSTEM

5 CHILLED WATER SYSTEM:

Systems that employ water chillers are commonly called chilled-water systems. As
its name suggest, this system makes use of water as its secondary refrigerant.
Chiller is used to remove heat from the water which is then circulated through other
components to absorb heat from the space.

Chilled water air conditioning systems are commonly used in applications that need
large cooling capacity such as hypermarket, industrial process, commercial air
conditioning such as offices and factories. More and more homes are using this
system to air conditioned their entire house because of its cost-effectiveness and no
hazard of having refrigerant piped all over the house (Selection Tips For Air-
Conditioning Cooling Systems 2012).

5.1 Components of chilled water system:

it through the machine.
It consists of the compressor (scroll, centrifugal, rotary screw). The condenser heat
exchanger, that can be either air-cooled consisted of coil(s) and fan(s), or water-
cooled where the heat exchanger is cooled by cooling tower. The evaporator heat
exchanger which cools the water that inserts the local units (central or FCU). Of
course, the system has also auxiliary safety and control parts, as: The buffer tank,
the expansion tank, water pump, filter, flow switch, safety valves, expansion valves,
temperature sensors, etc). The system is also supplied with an electric control board
and an LCD thermostat.
 Fig(5.1) Water Cooled Chiller Schematic Diagram

(KELOMPOK 9 Haeva Nurani Lisnawati M. Ghanim Ramadhan, 2015)

Chillers circulate chilled water to air-handlers in order to transfer heat from air to
water. This water then returns to the evaporator side of the chiller where the heat is
passed from the water to a liquid refrigerant (freon). The refrigerant leaves the
evaporator as a cold vapor and enters the compressor where it is compressed into a
hot vapor. Upon leaving the compressor, the vapor enters the condenser side of the
chiller where heat is transferred from the refrigerant to the water side of the
condenser where it is circulated to an open cooling tower for the final removal of
heat via evaporation in the cooling tower.

5.2 Flow and Capacity Calculations

Application Guide AG 31-003-1(2002) showed that the common design conditions

are 44F supply water temperature and 2.4 gpm/ton. The temperature change in the
fluid for either the condenser or the evaporator can be described using the following
formula:

Q = W x C x T (5.1)

Where

Q = Quantity of heat exchanged (Btu/hr)

W = flow rate of fluid (USgpm)

C = specific heat of fluid (Btu/lb F)

T = temperature change of fluid (F )

5.2.1 Pipe sizing

5.2.2 manual method

Once a system has been sized, it should be analyzed with more detailed methods of
calculation to determine the pump pressure required to achieve the desired flow.
Computerized methods are well suited to handling the details of calculating losses
around an extensive system, (ASHRAE,2009).

5.2.3 PRESSURE DROP EQUATIONS

5.2.4 Darcy-Weisbach Equation

ASHRAE (2009) showed that Pressure drop caused by fluid friction in fully
developed flows of all well-behaved (Newtonian) fluids is described by the
Darcy-Weisbach equation:

p = (l / dh) ( v2 / 2) (5.2)

where

p = pressure loss (Pa, N/m2)

= Darcy-Weisbach friction coefficient

l = length of duct or pipe (m)

v = velocity (m/s)

dh = hydraulic diameter (m)

= density (kg/m3)

This equation is often presented in specific energy form as:

h = (l / dh) (v2 / g 2) (5.3)

where

h = head loss (m)

= friction coefficient

l = length of pipe or duct (m)

dh = hydraulic diameter (m)

v = velocity (m/s)

g = acceleration of gravity (9.81 m/s2)

Stewart and Dona (1987) surveyed the literature relating to water flow rate
limitations. Noise, erosion, and installation and operating costs all limit the
maximum and minimum velocities in piping systems. If piping sizes are too small,
noise levels, erosion levels, and pumping costs can be unfavorable; if piping sizes
are too large, installation costs are excessive. Therefore, pipe sizes are chosen to
minimize initial cost while avoiding the undesirable effects of high velocities
(ASHRAE,2009).

A variety of upper limits of water velocity and/or pressure drop in piping and piping
systems is used. One recommendation places a velocity limit of 1.2 m/s for 50 mm
pipe and smaller, and a pressure drop limit of 400 Pa/m for piping over 50 mm.
Other guidelines are based on the type of service (ASHRAE,2009).

Table (5.1) Water Velocities Based on Type of Service (Carrier1960 )

Type of Service Velocity, m/s

General service 1.2 to 3.0
City water 0.9 to 2.1
0.6 to 1.5
Boiler feed 1.8 to 4.6
Pump suction and drain lines 1.2 to 2.1

ASHRAE(2009) informed that These limitations are imposed either to control the
levels of pipe and valve noise, erosion, and water hammer pressure or for economic
reasons. Carrier (1960) recommends that the velocity not exceed 4.6 m/s in any
case.

5.2.5 Noise Generation

(ASHRAE,2009) investigated that Velocity-dependent noise in piping and piping

systems results from any or all of four sources: turbulence, cavitation, release of
entrained air, and water hammer. In investigations of flow-related noise, Marseille
(1965), Ball and Webster (1976), and Rogers (1953, 1954, 1956) reported that
velocities on the order of 3 to 5 m/s lie within the range of allowable noise levels
for residential and commercial buildings. The experiments showed considerable
variation in the noise levels obtained for a specified velocity. Generally, systems
with longer pipe and with more numerous fittings and valves were noisier. In
addition, sound measurements were taken under widely differing conditions; for
example, some tests used plastic-covered pipe, while others did not. Thus, no
detailed correlations relating sound level to flow velocity in generalized systems are
available. The noise generated by fluid flow in a pipe increases sharply if cavitation
or the release of entrained air occurs. Usually the combination of a high water
velocity with a change in flow direction or a decrease in the cross section of a pipe
causing a sudden pressure drop is necessary to cause cavitation.

Ball and Webster (1976) found that at their maximum velocity of 13 m/s,
cavitation did not occur in straight pipe; using the apparatus with two elbows, cold
water velocities up to 6.5 m/s caused no cavitation. Cavitation did occur in orifices
of 1:8 area ratio (orifice flow area is one-eighth of pipe flow area) at 1.5 m/s and in
1:4 area ratio orifices at 3 m/s (Rogers 1954). Some data are available for predicting
hydrodynamic (liquid) noise generated by control valves. The International Society
for Measurement and Control compiled prediction correlations in an effort to
develop control valves for reduced noise levels (ISA 1985).The correlation to
predict hydrodynamic noise from control valves is

SL = 10 log Av + 20 log p 30 log t + 76.6 (5.4)

Where

SL = sound level, dB

Av = valve coefficient, m3/(s Pa)

Q = flow rate, m3/s

p = pressure drop across valve, Pa

t = downstream pipe wall thickness, mm

5.2.6 Pipe material

Stainless steel is commonly used where water quality and hygiene is a priority
including food, pharmaceutical and healthcare environments. Pipes are available in
sizes up to 800 mm. Pipes are smooth bore and extremely resistant to corrosion.

Fig. (5.2) Friction Loss for Water in Commercial Steel Pipe (Schedule 40)
(ASHRAE,2009)

5.2.7 PIPE SIZER SOFTWARE:

According to the choice of diameter , maximum flow rate can be determined.

Example 1:
Pipe material used is: Sch 40 Steel

Pipe diameter chosen is: "

Fig(5.3). Pipesizer results

Where head loss is in ft/100ft.

5.3 PUMP SELECTION:

5.3.1 Things to Consider when it comes to pump selection (Basic
Pump Selection - Rocky Mountain ASHRAE,2011)

Pump location
Equipment room or plenum?
Close to occupied areas?
Available space
Installation footprint
Maintenance footprint
Maintenance requirements
Parts availability
Special skills, tools etc.
Reliability
Hydraulic requirements
Flow rate, head, efficiency, horsepower
NPSH
5.3.2 Hydraulic Requirements ( Basic Pump Selection - Rocky Mountain
ASHRAE,2011)

Analyze the system: determine head and flow

Evaluate individual pump curves for:

Duty point with respect to BEP

Horsepower requirement
Efficiency
NPSHR

Estimate life cycle costs

Initial cost
Annual operating cost
Use software to speed the process

The three most common pump speeds in HVAC applications:

2 pole, 3500 rpm

low flow rates, high head, intermittent operation.
4 pole, 1750 rpm
most common, low noise, long bearing and seal life.
6 pole, 1150 rpm
high flow rates, low head, quiet operation.
Fig(5.4). Pump used in a closed system (Basic Pump Selection - Rocky Mountain
ASHRAE,2011)

5.4 Pump power:

Following is a review of the various energy equations that must be used in
determining the energy requirements of a water system and the energy consumed by
pumps and their drivers in satisfying those requirements. It is important that the
HVAC system designer understand the difference between the energy absorbed by
the water and that consumed by the pump or its motor ( hvac pump handbook 2nd
Ed ,2006)

5.4.1 Water horsepower

The energy required by a pump, as indicated by the affinity laws, depends on its
speed and the diameter of its impeller. The energy imparted to the water by a pump
is called the water horsepower (whp). Its equation is

WHP= (5.5)

where

Q _ flow, in gal/min

h _ head, in ft

s _ specific gravity

(hvac pump handbook 2nd Ed ,2006) Most HVAC water systems operate from 32 to
240F water, where the specific gravity can vary from 1.001 at 32F to 0.948 at
240F. For these applications, the specific gravity is generally assumed to be 1.00;
systems designed to operate at 240F must be able to function at startup with water
temperatures near 50F or at specific gravities of around 1.00. Water horsepower
for these systems usually ignores the specific gravity and assumes it to be 1.00. This
should not be the case with medium- and high temperature water systems, where
the operating temperatures can vary from 250 to 450F. The specific gravity of
450F water is 0.825 and should not be ignored in calculating pump operating
energy for these systems. Again, pump motor or driver brake horsepower should
recognize that the pump may be required to operate with colder water and specific
gravities near 1.0

5.4.2 Pump brake horsepower

The energy required to operate a pump is determined in brake horsepower (bhp);
the difference between water horsepower and pump brake horsepower is the energy
lost in the pump. The pump brake horsepower equation is therefore

Bhp= (5.6)

where is the pump efficiency as a decimal (hvac pump handbook 2nd Ed ,2006).

.
5.4.3 Pump motor power in kilowatts
The electrical energy, pump kilowatts, for a motor-driven pump must take in
consideration the efficiency of the motor on constant-speed pumps and the wire-to-
shaft efficiency of the motor and variablespeed drive on variable-speed pumps.
Again, the difference between the pump brake horsepower and electric power input
to the motor or variable-speed drive and motor is the efficiency of these devices.
The power must be converted from brake horsepower to kilowatts, so the pump
brake horsepower must be multiplied by 0.746. The equation is

0.746
Pump kW= (5.7)

where is the efficiency of the electric motor or the motor and variable-speed drive
as a decimal.( hvac pump handbook 2nd Ed ,2006)