Application Guide AG 31-003

Chiller Plant
Design

94.1F 89.2F 85F

CONDENSER
PUMP
COOLING
TOWER 48.5F
54F 44F

CHILLER 1 CHILLER 2
CHILLED
WATER
PUMP

3-WAY
VALVES

LOADS

SECONDARY PUMP

VFD

PRIMARY PUMP
1920 gpm

PRIMARY PUMP 3200 gpm

1920 gpm

44F 44F
44F
CHILLER

CHILLER

3840 gpm
44F
400 400 A LOAD
(DECOUPLER)
TONS TONS 800 TONS
640 gpm COMMON
PIPE
44F 50F
B
49F 49F 3840 gpm 3200 gpm
50F
49F
 Table of Contents
Introduction........................................................................................................................... 3

Typical Piping Design Concepts ............................................................................................. 3

Single Chiller Loop............................................................................................................................................................3
Parallel Chillers...................................................................................................................................................................9

Water-Side Free Cooling..................................................................................................... 18

Hybrid Plants....................................................................................................................... 19

Variable Flow Design........................................................................................................... 20

Document Number: AG 31-003

Revision: February 2001

NOTICE

The information contained within this document represents the opinions and suggestions of
McQuay International. Equipment, and the application of the equipment and system suggestions
are offered by McQuay International as suggestions only, and McQuay International does not
assume responsibility for the performance of any system as a result of these suggestions. The
system engineer is responsible for system design and performance.

"McQuay " is a registered trademark of McQuay International

2001 McQuay International
"Illustrations, information, and data cover McQuay International products at the time of publication and we reserve the right to make
changes in design and construction at anytime without notice"

2 Application Guide AG 31-003

Introduction
Using chilled water to cool a building or process is efficient and flexible. A two inch
schedule 40 pipe of chilled water can supply as much comfort cooling as 42" diameter round
air duct. The use of chillers allows the design engineer to produce chilled water in a central
building location or even on the roof and distribute the water economically and without the
use of large duct shafts. Chilled water also provides accurate temperature control that is
especially useful for VAV applications.
The purpose of this manual is discuss various piping and control strategies commonly used
with chilled water systems including variable flow pumping systems.

Typical Piping Design Concepts

The most common piping strategies for HVAC systems are:
single chiller loop
parallel chillers
series chillers
primary/secondary (or decoupled) systems.

Single Chiller Loop

Figure 1 shows a basic chiller loop with a water-cooled chiller. The system consists of a
chiller, cooling tower, cooling load, chilled water and condensing water pumps and piping.

Figure 1, Single Chiller Loop

Chiller
The chiller can be either air- or water-cooled.
The compressor types typically are recipro-
cating, scroll, screw or centrifugal. The
evaporator can be remote from the condensing
section on air-cooled units. This has the
advantage of keeping the chilled water loop
inside the building envelope when using an
outdoor chiller.
The chilled water flows through the evaporator
of the chiller. The evaporator is a heat
exchanger where the chilled water gives up its
sensible heat (the water temperature drops)
and transfers the heat to the refrigerant as
latent energy (the refrigerant evaporates or
boils).

Application Guide AG 31-003 3

 For air conditioning applications, 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 (1)
Where
Q = Quantity of heat exchanged (btu/hr or kW)
W= flow rate of fluid (USgpm or l/s)
C= specific heat of fluid (btu/lb F or kJ/(kg K))
T= temperature change of fluid (F or C)

Assuming the fluid is water, the formula takes the more common form of;
Load (btu/hr) = Flow(USgpm) x (Fin Fout) x 500 (2)
Or
Load (tons) = Flow(USgpm) x (Fin Fout)/24 (3)

Using this equation and the above design conditions, the temperature change in the
evaporator is found to be 10F. The water temperature entering the evaporator is then 54F.
Most air conditioning design conditions are based on 75F and 50% RH in the occupied
space. The dew point for air at this condition is 55.08F. Most HVAC designs are based on
cooling the air to this dewpoint to maintain the proper RH in the space. Using a 10F
approach at the cooling coil means the supply chilled water needs to be around 44F or 45F.
The designer is not tied to these design conditions. In fact, more energy efficient solutions
can be found by modifying the design conditions as the project requires.
Changing the chilled water flow rate affects a specific chiller's performance. Too low a
flow rate lowers the chiller efficiency and ultimately leads to laminar flow. The minimum
flow rate is typically around 3 fps (feet per second). Too high a flow rate leads to vibration,
noise and tube erosion. The maximum flow rate is typically around 12 fps. The chilled
water flow rate should be maintained between these two limits.
The condenser water flows through the condenser of the chiller. The condenser is also a
heat exchanger. In this case the heat absorbed from the building plus the work of
compression leaves the refrigerant (condensing the refrigerant) and enters the condenser
water (raising its temperature). The condenser has the same limitations to flow change as
the evaporator.

Piping
The piping is usually steel, copper or plastic. The chilled water piping is a closed loop. A
closed loop is not open to atmosphere. Figure 2 shows a simple closed loop with the pump at
the bottom of the loop. Notice the static pressure created by the change in elevation is equal
on both sides of the pump. In a closed loop, the pump needs only to overcome the friction
loss in the piping and components. The pump does not need to lift the water to the top of
the loop.

4 Application Guide AG 31-003

 Figure 2, Closed Loop Figure 3, Open Loop
COOLING TOWER

LIFT
EXPANSION TANK
COOLING
LOADS
2ND FLOOR

2ND FLOOR

1ST FLOOR 1STFLOOR

WATER WATER
COLUMN COLUMN

CONDENSER BASEMENT
CHILLER BASEMENT

CW PUMP

An expansion tank is required in the chilled water

loop to allow for the thermal expansion of the water. Chilled water piping is insulated since
the water and hence the piping is below the dewpoint temperature. Condensate would form
on it and heat loss would occur.
The condenser water piping is an open loop. Figure 3 shows an open loop with the water
open to the atmosphere. When the pump is not running, the level in the supply and return
piping will be even at the level of the sump. When the pump operates, it needs to overcome
the friction loss in the system and lift the water from the sump level to the top of the loop.
Condenser water piping is typically not insulated since there will be negligible heat gain or
loss and sweating will not occur. However, if the piping is exposed to cold ambient
conditions it could need to be insulated and heat traced to avoid freezing.

Chilled Water and Condenser Water Pumps

Typically centrifugal type pumps are used for both condenser water and chilled water
systems. They can be either inline or base mounted. The pumps must be sized to maintain
the system dynamic head and the required flow rate. The pump selection and location must
take into account Net Positive Suction Head (NPSH). NPSH is usually a bigger issue on the
condenser pumps. Normally, the pumps are located so they discharge into the chiller heat
exchangers.
To provide redundancy, multiple pumps are used. Common approaches are (1) a complete
full-sized stand-by pump, or (2) the design flow is met by two pumps with a third stand-by
pump sized at half the load. When multiple pumps are used in parallel, check valves on the
discharge of each pump are required to avoid short circuiting.

Cooling Towers
Cooling towers are used in conjunction with water-cooled chillers. Air-cooled chillers do not
require cooling towers. A cooling tower rejects the heat collected from the building plus the
work of compression from the chiller. Since it is common (but not necessary) to use a
temperature range of 10F, the cooling tower flow rate will be 3.0 gpm/ton compared to the
chilled water flow rate which is 2.4 gpm/ton. The extra condenser water flow rate is
required to accommodate the heat from the work of compression.

Application Guide AG 31-003 5

 Cooling towers differ from closed circuit coolers in that closed-circuit coolers reject heat
sensibly while cooling towers reject heat latently. Consider ambient design conditions of
95F DB and 78F wb. If closed circuit coolers are used, the condenser water must be
warmer than the ambient dry bulb (typically 10F warmer or 105F). This raises the
condensing pressure in the chiller and requires more overall power for cooling. Closed
circuit coolers are larger than cooling towers for the same capacity and can be difficult to
locate on the roof.
Cooling towers expose the condenser water directly to the ambient air in a process that
resembles a waterfall. Approximately 1% of the design condenser water flow is
evaporated. The latent energy required to evaporate the water lowers the remaining waters
sensible temperature. The process is based on the ambient wet bulb temperature (78F wb
in the example) rather than the dry bulb temperature. ARI standard conditions at full load
are based on 85F entering condenser water temperature and 3.0 US gpm per ton. Lower
condenser water temperatures can be produced in many climates with low wet bulb
temperatures.
Loads
Figure 4, Air Handling Equipment

Chilled water coils are used to transfer the heat from the building air to the chilled water.
The coils can be located in air handling units, fan coils, induction units, etc. The air is cooled
and dehumidified as it passes through the coils. The chilled water temperature rises during
the process.
Process loads can reject heat in the chilled water in a variety of ways. A common process
load is a cooling jacket in machinery such as injection molding equipment. Here the chilled
water absorbs the sensible heat of the process.
Controls
There are two parameters that need to be considered for the chilled water loop. These are
temperature and flow. The loop supply temperature is controlled at the chiller. The unit
controller on the chiller will monitor and maintain the supply chilled water temperature
(within its capacity range). The accuracy to which the chiller can maintain the set point is
based on the chiller type, controller quality (a DDC controller with a PID loop is the best),
compressor cycle times, the volume of fluid in the system, etc. Systems with fast changing
loads (especially process loads) and small fluid volumes (close coupled) require special
consideration.

6 Application Guide AG 31-003

 Figure 5, Chiller Controller

The system flow control occurs at the load. To maintain the correct space condition, three-
way or two-way control valves are used. Three-way control valves direct chilled water
either through or around the coil to maintain the desired condition. If all the loads on the loop
use three-way valves then the chilled water flow is constant. The temperature range varies
directly with the load. That is, if the design chilled water Delta-T is 10F, then every 10%
drop in system load represents 1F drop in Delta-T.

Figure 6, Three-way Valves

Application Guide AG 31-003 7

 Diversity
A system incorporating three-way control valves is easy to design and operate. However,
the system pumps all the water all the time, which requires more pump horsepower. In most
cases the chiller is sized for the building peak load. Due to diversity, not all the connected
loads will peak at the same time as the building peak load. However, the pumps and piping
system must be designed for full flow to all the control valves all the time. Since the chiller
flow rate is the same as the flow rate through all the loads (theyre connected by the same
piping system and pump) the diversity is applied to the chiller
Delta-T.
For example, consider a building with an 80-ton peak load. However, summing all the
connected loads adds up to 100 tons. In short, this building has a diversity of 80%. Using a
delta of 10F at each control valve, the total system flow rate is;
Flow = 24 x 100 tons/10F = 240 gpm
However, an 80-ton chiller with 240 gpm will only have a Delta-T of 8F. The lower chiller
Delta-T is not a problem for the chiller operation, but it will lower the chiller efficiency. Care
must be taken to select the chiller at the proper Delta-T.

Figure 7, Two-way Valves

When two-way modulating control valves are used, the flow to the coil is restricted rather
than bypassed. If all the valves in the system are two-way type, the flow will vary with the
load. If the valves are properly selected, the temperature range remains constant and the
flow varies directly with the load. In this case the diversity is applied to the chilled water
flow rate.
Using the previous example, the peak load is 80 tons and the design flow is 2.4 x 80 tons or
192 gpm. The connected load is still 100 tons and requires 240 gpm if all the two-way

8 Application Guide AG 31-003

 control valves are open at the same time. The 80% diversity assumes only 80% of the
valves will be open at the peak load.
The advantage of two-way control valves is both the pump and the piping are sized for a
smaller flow rate offering both first cost and operating savings. The difficulty is the chiller
and control system must be designed for variable flow. The chiller has a minimum flow rate
so the piping design has to allow for enough flow during all operating conditions to meet the
chiller minimum flow rate. Using two-way valves at the loads is the main building block for
a variable flow system.

Parallel Chillers
Figure 8, Parallel Chillers
To provide some redundancy in the
HVAC design, most designers will
require two or more chillers. Multiple
chillers also offer the opportunity to
improve on overall system part load
performance and reduce energy
consumption.
Figure 8 shows two chillers in parallel
and three-way valves at the loads. The
chilled water temperature difference
varies directly with the load. The other
system components are the same as the
previous example. The difficulty with
this parallel arrangement is the system
part load performance.
Consider the system operating at 50%. From a chiller performance aspect, turning off one
chiller and operating the other at full capacity is desirable. However, this will not happen.
At 50% capacity, the return water will be 49F. The chiller that is turned off, will let the
water pass through it unchanged. The operating chiller will only see a 50% load (49F return
water), and will cool the water down to the set point of 44F. The two chilled water streams
will then mix to 46.5F supply temperature.
If the system is operated in this manner, the warmer chilled water will cause the control
valves to open (increase flow) to meet the space requirements. The return water
temperature will rise affecting the supply system supply water temperature. An iterative
process will occur and the system can stabilize. The issue is whether the cooling coils can
meet the local loads with the higher chilled water temperature. Depending on the actual
design conditions, the building sensible load could be met but high chilled water temperature
will make it difficult to meet the latent load. Since this scenario is likely to occur during
shoulder weather, dehumidification can not be an issue. In areas where humidity is an issue,
this arrangement will result in high humidity within the space.
One solution is to operate both chillers all the time. This works and is a simple solution,
however, it is not energy efficient and causes unnecessary equipment wear.
Another possibility is to lower the operating chillers set point to offset the mixed water
temperature. This too works but has some difficulties. Lowering the chilled water set point

Application Guide AG 31-003 9

 requires the chiller to work harder lowering its efficiency. In extreme conditions, it can
cause chiller stability issues.

Figure 9, Parallel Chillers with Isolating Valves

Figure 9 shows a modified version of
parallel chillers. This concept incorporates
isolating valves for each chiller. The
chilled water pump includes a Variable
Frequency Drive (VFD). The loads now
have two-way valves.
In this design concept, as the system load
decreases, the flow is reduced until one of
the chillers can be shut down and its
isolating valve is closed. Supply water
temperature remains constant.
This design requires careful chiller
selection to provide good flow
characteristics over the required operating
range. More sophisticated controls are required to operate the system. See Variable Flow
Design for further details.

Series Chillers
Figure 10, Series Chillers
Figure 10 shows two
chillers in series. This
design concept resolves the
mixed flow issues found in
parallel chiller designs. It
is simple to design and
operate. However, it also
has some challenges to
overcome.
All the system flow goes
through both chillers. If
both chillers are the same
and the condensers are
piped in parallel, the lead
chiller will accomplish
about 45% of the system load and the lag chiller will accomplish about 55% of the system
load. This occurs because the lead chiller is supplying chiller water at the system set point
(typically 44F). The lag chiller is supplying chilled water at approximately 48.5F to the lead
chiller. The reduced lift for the lag chiller allows it to provide more cooling capacity.
A problem with series chillers is the high flow rate and the low Delta T through the chillers.
The high flow rate can result in high water pressure drops. Since the chillers are in series,
the pressure drops of the chillers must be added. If the typical 10F system temperature

10 Application Guide AG 31-003

 difference is maintained, then single pass evaporators should be considered. This will lower
the pressure drop to an acceptable level.
There is an opportunity to optimize series chillers and improve overall system performance
by connecting the condensers in series as well. Figure 10 shows the condensers connected
in series with the condenser flow counter flow to the chilled water flow.

Table 1, System Efficiency Comparison

EVAP EVAP EVAP COND COND COND
CHILLER VESSEL CAP POWER PERF.
EWT LWT FLOW EWT LWT FLOW MODEL
PIPING
(tons) (F) (F) (GPM) (F) (F) (GPM) (kW) (kW/T)
PARALLEL CH-1 400 54 44 960 85 94.2 1200 WSC087 218.0 0.547
PARALLEL CH-2 400 54 44 960 85 94.2 1200 WSC087 218.0 0.547
SYSTEM TOTAL 800 54 44 1920 85 94.2 2400 - 436.0 0.547
SERIES OPT 1 CH-1 440 54 48.5 1920 85 95.1 1200 WSC087 205.6 0.520
SERIES OPT 1 CH-2 370 48.5 44 1920 85 93.5 1200 WSC087 228.6 0.556
SYSTEM TOTAL 810 54 44 1920 85 94.2 2400 - 434.2 0.536
SERIES OPT 2 CH-1 440 54 48.5 1920 89.1 94.1 2400 WSC087 232.7 0.529
SEREIS OPT 2 CH-2 370 48.5 44 1920 85 89.2 2400 WSC087 193.6 0.523
SYSTEM TOTAL 810 54 44 1920 85 94.1 2400 - 426.3 0.526

Table 1 compares a parallel system with two versions of series systems for an 800 ton
design load. The full load penalty for series option 1 compared to the parallel system is
negligible. Series Option 2 shows chillers with series condenser flow. It provides the best
overall system performance and either chiller can be the lead chiller. Series condensers and
series evaporators are an excellent means to provide lower temperature, high Delta-T chilled
water.
It should not be concluded that parallel systems have no value. In applications where most
of the operating hours occur above 50% load, a parallel system typically does better. A
series system does better when there lots of run hours below 50% such as an HVAC system
without air side economizers.
Series Chillers Controls
As before, the chiller controllers maintain the system supply water temperature and the load
controls maintain the system flow rate. For series chillers, the controlling sensors for both
chillers should be located downstream of the chillers and the chiller control panels digitally
linked together. With the panels linked together, either chiller can be used to meet up to
about 45% of the system load. Once both chillers are required, the amp draws can be
balanced between the two chillers.
The MicroTech Controllers on McQuay chillers can communicate directly and can load
balance based on amperage. Using the load balance feature means when both chillers
operate, the power consumption is evenly distributed between the two chillers. The load
balance feature offers about 3% savings conventional control.
Primary/Secondary Systems
For large chillers or where more than 2 chillers are anticipated, primary/secondary (also
called decoupled) piping systems are used. To reduce installation and operating costs, it is
desirable to apply diversity to system flow. With diversity applied to flow, the pumps and
piping will be smaller. To accomplish this, two-way control valves are used at the loads. At
the same time it is necessary to provide constant flow through the chillers to maintain chiller
stability. The solution is primary/secondary piping.

Application Guide AG 31-003 11

 Figure 11, Primary/Secondary Loop at Full Load

SECONDARY PUMP

VFD

PRIMARY PUMP

1920 gpm 1920 gpm

44F
C H ILL ER 44F

44F
800 TONS A LOAD
(DECOUPLER) 800 TONS
COMMON
0 gpm
PIPE 54F
B
54F
54F
1920 gpm 1920 gpm

Primary/Secondary Loop Basics

Figure 11 shows a basic primary/secondary loop operating at full load. In this example, the
system design load is 800 tons, the flow rates and temperatures are at standard ARI
conditions and the load has a two-way control valve. The loop with the chiller is called the
primary loop. The loop with the load is the secondary loop. The common pipe is sometimes
referred to as the decoupler.
At full load, the design flow of 1920 gpm passes through the chiller, the two pumps, the load,
and back to the chiller. There is no flow through the common pipe. At first, it would appear
that the flow is being pumped twice. Although this is true, the total head is split between the
two pumps. The primary pump is only sized for the primary loop of which the chiller is main
pressure drop. The secondary pump is sized for the pressure drop outside the mechanical
room. The higher pressure drops and larger piping arrangements in the secondary loop
justify the variable flow.
Figure 12, Primary/Secondary Loop at 50% Load
SECONDARY PUMP

VFD

PRIMARY PUMP

1920 gpm 960 gpm

44F
44F

1920 gpm
CHILL ER

44F
400 TONS A (DECOUPLER) LOAD
400 TONS
COMMON
960 gpm
PIPE 54F
B
49F 49F 960 gpm
54F
1920 gpm

12 Application Guide AG 31-003

 Figure 12 shows the same example operating at 50% capacity. The two-way control valve
at the load has reduced the flow in the secondary loop to 960 gpm. The Delta-T across the
load remains at 10F. The primary pump is a constant flow pump sized for the chiller design
flow. It remains constant at 1920 gpm. The additional flow not required in the secondary
loop passes through the common pipe to the chiller return line. The 44F fluid from the
common pipe mixes with the 54F return fluid to 49F. The chiller maintains its design flow
of 1920 gpm with 49F RWT and 44F LWT. The chiller sees a 50% load.
The example in Figure 12 demonstrates how diversity is applied to flow in the secondary
loop. The variable flow in the secondary loop offers excellent pump operating savings and
first cost saving in pipe sizing. The constant flow in the primary loop provides the chiller with
stable operating conditions.

Figure 13, Primary/Secondary Loop at Low Delta-T

SECONDARY PUMP

VFD

PRIMARY PUMP

1920 gpm 3200 gpm

44F
44F
1920 gpm (DECOUPLER)
CHILLER

44F COMMON
480 TONS A PIPE LOAD
800 TONS
1280 gpm
50F
B
50F 1920 gpm 3200 gpm
50F
50F

It is important to understand what happens if design temperature range is not maintained.

This is known as a low Delta-T syndrome. Figure 13 shows the previous example with an
800 ton load but only a 6F Delta-T. This could be caused by several factors including poor
valve selection or dirty coils.
To meet the 800-ton load requirement, the control valve will respond by opening and allowing
more flow through the load. The secondary pump will respond in turn by increasing the
secondary loop flow to 3200 gpm to meet the load. The primary pump is only supplying 1920
gpm so 1280 gpm will flow backward through the common pipe to meet the 3200 gpm
requirement. Two problems now occur. The supply fluid temperature in the secondary loop
will rise when the primary fluid and the return fluid mix. The higher fluid temperature will
cause the control valve to open further, making the problem worse. The second problem is
the return water to the chiller is only 50F so the chiller only sees a 480-ton load. This
system will not function well under these conditions.

Application Guide AG 31-003 13

 Figure 14, Primary/Secondary Loop with Low Delta-T Reality
SECONDARY PUMP

VFD

PRIMARY PUMP
1920 gpm

PRIMARY PUMP 3200 gpm

1920 gpm

44F 44F
44F
3840 gpm
CHILLER

CHILLER
44F
400 400 A (DECOUPLER) LOAD
TONS TONS 800 TONS
640 gpm COMMON
44F PIPE
50F
B
49F 49F 3840 gpm 3200 gpm
50F
49F

Obviously the above example cant occur. Figure 14 shows what does happen. A second
chiller has to be started to balance the flow in the primary loop with the flow in the
secondary loop.
Although running two chillers provides a working solution, many of the features of the
primary/secondary approach are lost. The flow in the secondary is high, wasting pumping
energy. Two primary pumps have to operate when only one should be doubling the primary
pump horsepower. Finally, two chillers are operating (and their condenser water pumps)
when only one should be.
Primary Loop Details
Figure 15, Standard Primary Loop Layout
The most common arrangement
is to have dedicated pumps for
each chiller. In addition, each
chiller requires an isolating valve.
It is also possible to have a main
primary pump outfitted either with
multiple speeds or a variable
frequency drive. The issue with
the latter is there is minimal to no
redundancy available.
The chillers can have different
capacities and be manufactured
by different vendors. However,
they must have the same supply
water set point and the same
chilled water Delta-T.

14 Application Guide AG 31-003

 Decoupler Location
The location of the decoupler line will change how the chillers are loaded. Figure 15 shows
the typical layout. In this situation, each chiller sees the same return water temperature even
at part load conditions.
Figure 16 shows the decoupler line in a different location. Locating the chillers between the
secondary loop and the decoupler line causes the return water temperature to each chiller to
vary. Chiller 2 in Figure 16 will see close to the secondary loop return water temperature.
Chiller 1 will see a mixture of supply water and return water. The result is Chiller 2 is more
heavily loaded than Chiller 1.

Figure 16, Optional Primary Loop Layout

Relocating the decoupler can make sense if one or more of the chillers is a dual compressor
model. The dual compressor chiller has very good part load performance. Single
compressor chillers typically work best when fully loaded. By locating the dual compressor
chiller close to the decoupler line and the single compressor chiller furthest away, the
strengths of each chiller can be maximized. Table 2 shows the chiller plant performance for
Figures 15 and 16. By base loading the single compressor chiller and taking advantage of
the duals part load performance, the power input can be cut by up to 10 percent.

Application Guide AG 31-003 15

 Table 2, Table 2 Chiller Plant Performance vs. Decoupler Location
Figure 15 Cap. (tons) RWT (F) SWT (F) Power (kw)
CH-1 300 51.5 44 124.6
CH-2 300 51.5 44 124.6
Total 600 51.5 44 249.2
Figure 16
CH-1 200 49 44 73.2
CH-2 400 54 44 151.7
Total 600 44 224.9

Secondary Loop Details

Figure 17, Basic Secondary Loop

The secondary loop must be variable flow.

Traditionally, multiple pumps were staged on to vary
the flow. More recently, variable frequency drives
are used. The primary/secondary arrangement
allows the engineer a great deal of flexibility when
designing the distribution piping. Figure 17 shows the
basic design. Multiple secondary pumps are used to
provide some redundancy.

Figure 18, Multiple Secondary Loops

Figure 18 shows dedicated pumps for various loops.

Multiple loops can serve areas with different
operating schedules or widely different fluid
pressure drops (such as a building on the far side of
a campus). The individual loops can be scheduled
off when not required.
Controlling the secondary pumps is a subject of
some debate. Most systems today use some
method of pressure differential across the
secondary loop. The location for the pressure
sensors is critical. Proper system operation requires
that the load control valves be properly sized and
the pressure sensors properly located. This is a
discussion in itself and is beyond the scope of this manual.

16 Application Guide AG 31-003

 Reverse Return/Direct Return Piping
The examples used in this manual show reverse return piping. The secondary piping is
designed such that any path through any load is the same length and therefore has
approximately the same fluid pressure drop. Reverse return piping is inherently self-
balancing. It also requires more piping and consequently is more expensive.
Direct return piping results in the load closest to the chiller plant to have the shortest path
and therefore the lowest fluid pressure drop. Depending on the piping design, the difference
in pressure drops between a load near the chiller plant and a load at the end of the piping run
can be substantial. Balancing the system can be difficult. The advantage of direct return
piping is the pipe savings.
The decision whether to use direct or reverse return piping should be based on system
operability vs. first cost. Where direct return piping is used, flow-balancing valves should be
carefully located so that the system can be balanced.
Varying Chiller Sizes
One advantage of primary/secondary systems is varying the chiller sizes. As long as the
supply water temperature and the design Delta-T are the same, the chillers can have
different capacities.
Varying the chiller sizes allows chillers to be selected so the chiller plant is at maximum
performance when the run-hours are highest. For example, consider a chiller plant where
two chillers can be used. However, the bulk of the run-hours will be at 50% to 70% of
design capacity. This will require the two chillers to operate between 50% and 70% of their
design capacity. By varying the chiller sizes to one at 800 tons and one at 400 tons. The
system load can be met with one chiller for the bulk of the operating time.
System Expansion
Figure 19, Expanding the System
Primary/secondary piping allows
easy expansion both in the chiller
plant (primary loop) and the building
(secondary loop). To expand the
chiller plant capacity, another chiller
can be added to the loop as shown
in Figure 19. By strategically
locating the decoupler and the new
chiller (see Figure 16), it is possible
to apply a greater load on the new
chiller. This can be advantageous if
the new chiller is more efficient
than the rest of the plant.
If the building load is increased, a
new loop can be added. The pump
for the new loop can be sized to
meet the new loops pressure drop
requirements.

Application Guide AG 31-003 17

Water-Side Free Cooling
Some HVAC systems (fan coils) can require chilled water year round. Where the weather
allows, water-side free cooling can avoid the need for mechanical cooling. Figure 20 shows
a heat exchanger in parallel with the chiller. During free cooling the chiller is off and isolated
by valves. The heat exchanger rejects heat into the condenser water loop. For this to
happen the condenser loop must be colder than the chilled water loop (the reverse of chiller
operation).

Figure 20, Water-Side Free Cooling

The actual winter chilled
water supply temperature
requires careful
consideration. Since the
cooling load is lower in the
winter particularly, the
latent load, the chilled
water supply temperature
can be higher than in the
summer, 50F to 55F are
common. The higher
chilled water temperature
allows the condenser
water temperature to
remain further away from
the freezing point. With a
3F to 5F approach on the heat exchanger, the condenser supply water temperature can be
around 45F.
A key issue is the transition from free cooling to mechanical cooling. Once the building load
cannot be met by free cooling, the chiller will need to be started. At that point, the
condenser loop will be cooler than the chilled water loop, which is backwards from the
chiller point of view. To allow the chiller to operate, a cooling tower bypass line and valve is
required. The bypass valve will allow the chiller to raise the condenser loop temperature.

Figure 21, Free Cooling in Series with Chillers

18 Application Guide AG 31-003

 Figure 21 shows a different free cooling arrangement with the chiller in series with the heat
exchanger. Since the heat exchanger operates with a higher chilled water temperature, the
operating season is longer, offering more annual savings. The chiller trims the chilled water
temperature and operates with significant condenser water relief. This arrangement works
very well with process loads.

Hybrid Plants
Mixing and matching different chiller types increases the designers option in chiller plant
design. To meet small winter chilled water loads, an air cooled chiller might be included in
the chiller plant. The operator does not have to run the cooling towers in winter and the
chiller is properly sized for the winter load. This is common in health care applications with
water cooled equipment (MRIs, linear accelerators, etc.) The air-cooled chiller must be
properly selected for winter operation.
To diversify the chiller plant on energy sources, an absorption chiller is often incorporated
into the chiller plant design. The absorption chiller can operate on either plant steam or
directly on natural gas. Either allows the operator to shave demand peaks for the electrical
load. The absorption chiller can be in series or parallel (primary/secondary) with the ele ctric
chiller.
In a series application, the absorption chiller can be upstream of the electric chiller. The
warmer return chilled water improves the efficiency of the absorption chiller by as much as
30%. This arrangement automatically base loads the electric chiller. Until the return water
reaches 49F, the absorption chiller wont operate. Once the building load climbs above
50%, the electrical demand is avoided, by using the absorption chiller. In shoulder weather,
either chiller can be operated. (reset the absorption chiller set point to 44F).
The condenser water needs of the absorption chiller are different from the electric chiller.
Whereas electric chiller typically operates with 3 gpm/ton on the condenser side, an
absorption chiller operates with 4.5 gpm/ton. Condenser water temperature stability and
reset are also more critical with an absorption chiller. Care must be taken to properly
integrate an absorption chiller into the chiller plant design.

Application Guide AG 31-003 19

Variable Flow Design
Modern DDC controllers on chillers allow the possibility of variable flow design. Traditional
thinking has been that the chiller should see constant flow and then the load will vary directly
with the return fluid temperature. Allowing variable flow means the cooling load can vary
either with the return fluid temperature or a change in the chilled water flow. It requires
modern controllers to deal with two variables and provide stable chiller operation.
Variable flow allows the designer the option to use two-way control valves at the loads and
apply diversity to flow while at the same time avoiding the complication of primary/
secondary systems. This is particularly advantageous with small single chiller installations or
where a dual compressor chiller is being considered instead of two single compressor
chillers.
The range of flow rates in the chiller is limited at the low end by laminar flow in the tubes (3
fps tube velocity) and at the high end by tube erosion and vibration (10 fps tube velocity).
Chiller selection software typically tries to pick a tube velocity of around 6 fps. When a
chiller is intended for variable flow, the tube velocity should be picked closer to 10 fps. The
chiller will only see high tube velocities at full load, which seldom occurs.

Figure 22, Variable Flow

Selecting the chiller with tube velocities near 10 fps allows the system flow to be turned
down to 30% of design flow. The designer should work with the actual minimum and
maximum flow rates for the chiller selected on the project. The chiller manufacturer can
provide this information.
If all the control valves are two-way, a bypass will be required and sized for the chillers
minimum flow rate (approximately 30% of design flow). Alternatively, some three-way
valves can be used to provide minimum flow rate is maintained. However, the three-way
valves will consume their design flow whether the fluid goes through the load or around it.
This will reduce the overall pump savings potential. From an energy point of view, the pump

20 Application Guide AG 31-003

 motor savings below 30% are minimal due to VFD losses and reduced motor efficiency.
Operating at frequencies below 20 hz (33%) also puts unnecessary wear on the motors.

Figure 23, Variable Flow with Parallel Chillers

Variable flow can also be applied to chillers in parallel. Figure 23 shows two chillers in
parallel with VFDs on the primary pumps. Variable flow allows the option of operating only
one chiller when the system load is within the range of one chiller. The second chiller can be
shut down and all the flow directed through the remaining chiller. Variable flow resolves
most of the issues of parallel chiller design.
The bypass should be sized for the highest minimum flow rate of the chillers being used.
The critical issue for variable flow with parallel chillers is controlling the cycling of the
chillers. This is best accomplished by measuring system flow. When the system load and
flow rate can be met by a single chiller, the other chiller can be shut down. With one
pump/chiller combination off line, the other pump will increase speed/flow until the required
chilled water loop pressure differential is obtained. If the single chiller minimum flow cannot
be met (the two valves are all nearly closed) the bypass line control valve can be opened to
provide minimum chiller flow. Chiller/pump cycling should be controlled with anti-cycle time
delays.
Even with modern chiller controllers, care should be taken that the system flow changes are
slow. Slow flow changes will allow the chiller controller time to respond and provide stable
system operation. Although each project is different, a good rule of thumb is to limit the rate
of change to 10% of design flow per minute.

Application Guide AG 31-003 21

22 Application Guide AG 31-003
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