FUNDAMENTAL OPERATION

ROHM PROJECT BUILDING FACILITIES TRAINING MODULE

OVERVIEW

 ROHM Building-H Chilled Water Distribution

system is designed to operate at variable pump
speed
 Motorized actuated valves are installed at AHU
units and FCU units to control the required
volume flow rate to meet the specific set-point
of air temperature on each separate rooms.
Surely, if AHU/FCU stop, this valve will shut-off.
OVERVIEW
 Gross capacity of 1 unit chiller is 2109.6 kW or 600
TR x 4-units with a total cooling capacity of
8,438.4kW or 2,400 tons of refrigeration. with lowest
unloading part load of 632.88 kW or 180 TR
 Modulating By-pass valve, also called as decoupler,
is installed to regulate pressure cause by opening
and closing of motorize valves at AHUs and FCUs
by diverting the excess flow at supply header back
to return header. This means, header pressure is
always constantly maintain.
FUNDAMENTAL FORMULA
Cooling Load = Flow x delta T x constant factor
Tons of Refrigeration(TR) = cubic meter per hour (CMH) x delta T (°C) x 0.33036

Sample Computation :

1. What is the cooling load of chiller if the chilled water flow is 363.24 CMH and ΔT=5°C?
Load = 363.24 CMH x 5°C x 0.33036
Load = 599.99 or 600 TR

Note: a. This 599.99 computation is the gross capacity of the ROHM chiller/ 1-unit
b. 1 TR = 3.516 kW
FUNDAMENTAL FORMULA
 COP – Coefficient of Performance
 It is the measurement of system efficiency in Air
Conditioning
 The higher the COP means the higher the efficiency

COP = Cooling Energy Produced ( kW) divided by Power Input (kW)

Example:
Compute Chiller COP with gross capacity of 2,109.6 kW and absorbed power of 351.6 kW
Answer: COP = 2,109.6 kW/ 351.6kW = 6
 HEAT TRANSFER FLOW
EXAMPLE if ROHM Building - H is in maximum load that chiller units can only handle.

AIR WATER REFRIGERANT WATER AIR

convection convection convection conduction
BUILDING
AHU, COOLING COOLING
-H HEAT FCU HEAT CHILLER HEAT WATER HEAT TOWER
LOAD

1,906 TR 1,906 TR 2,400 TR 2,800 TR HEAT DESIPATE

+400TR
COMPRESSOR
HEAT
CHILLED WATER AND COOLING
WATER SYSTEM DIAGRAM
AIR CONDITIONING EQUIPMENT
LAYOUT (1F)
AIR CONDITIONING EQUIPMENT
LAYOUT (2F)
AIR CONDITIONING EQUIPMENT
LAYOUT (ROOF DECK)
 THEORETICAL EXAMPLE CASE NO. 1

Constant Volume Chilled Water Distribution System – Full Load at Design Condition ( ΔT=5°C)

( ΔT=5°C)
CHWS = 1,452.96 CMH 100% SYSTEM LOAD ( ΔT=5°C)
14°C 363.24CMH 600 TR
9°C

9°C 9°C 9°C

CP-1-1
CH-1-1

363.24CMH 600 TR
14°C 600 TR 9°C

CP-1-2
CH-1-2
14°C 600 TR
363.24CMH 9°C

OAC x 4 units AHU x 9 units FCU x 45 units

CP-1-3
CH-1-3

14°C 600 TR MV=100% MV=100% MV=100%

363.24CMH 9°C
14°C 14°C 14°C
By-Pass
CP-1-4 CH-1-3 MV=0%
CH-1-4
14°C
CHWR = 1,452.96 CMH Temperature CHWR = 1,452.96 CMH
Mixing Point
CASE no. 1
 This case is practically have a very small chance to
occur. Four chiller running is more than enough for the
whole building load, so it will always be part loading the
whole season.
 Total chiller gross capacity is greater than AHUs &
FCUs capacity combined.
 Possible to occur only when starting to cool the chilled
water again after a long shut down of chiller. It is when
the water temperature is to be cooled from normal
temperature (27°C) to chilled water temp ( 9°C)
 THEORETICAL EXAMPLE CASE NO. 2

Constant Volume Chilled Water Distribution System – Part Load at Design Condition

( ΔT=3.5°C)
CHWS = 1089.72 CMH 85% CHILLER LOAD ( ΔT=5°C)
12.5°C 363.24CMH 600 TR
9°C

9°C 9°C 9°C

CP-1-1
CH-1-1

12.5°C 363.24CMH 600 TR

600 TR 9°C

CP-1-2
CH-1-2
12.5°C 600 TR
363.24CMH 9°C

OAC x 4 units AHU x 9 units FCU x 45 units

CP-1-3
CH-1-3
MV IS MV IS MV IS
12.5°C 600 TR MODULATED MODULATED MODULATED
363.24CMH 9°C
14°C 14°C 14°C
By-Pass
CP-1-4 CH-1-3 MV=15%
STAND-BY CH-1-4 163.46CMH
12.5°C
CHWR = 926.26CMH Temperature CHWR =1089.72CMH
Mixing Point
CASE no. 2
 This is the operation scheme when the system is
running with system delta T of 5°C at load side. and
with chiller load of 85%.
 Chiller will not be same delta T with the AHU’s
since there is mixing of hot and cold water because
of by-pass opening.
 In this condition chiller will surely experience part
loading.
 THEORETICAL EXAMPLE CASE NO. 3

Constant Volume Chilled Water Distribution System – Part Load at ΔT=2.5°C- Valves Manually Open

( ΔT=2.5°C)
CHWS = 1089.72 CMH 50% CHILLER LOAD ( ΔT=2.5°C)
11.5°C 363.24CMH 600 TR
9°C

9°C 9°C 9°C

CP-1-1
CH-1-1

11.5°C 363.24CMH 600 TR

600 TR 9°C

CP-1-2
CH-1-2
11.5°C 600 TR
363.24CMH 9°C

OAC x 4 units AHU x 9 units FCU x 45 units

CP-1-3
CH-1-3
MV IS MV IS MV IS
11.5°C 600 TR MANUAL OPEN MANUAL OPEN MANUAL OPEN
363.24CMH 9°C
11.5°C 11.5°C 11.5°C
By-Pass
CP-1-4 CH-1-3 MV=0%
STAND-BY CH-1-4
11.5°C
CHWR = 1089.72 CMH Temperature CHWR = 1089.72 CMH
Mixing Point
CASE no. 3
 This is the operation scheme when the system is running with
all valves are constantly open (manually open)
 By-pass valve is always close.
 Delta T will become lower and continue to become low without
control
 Chiller load also becomes lower and lower if continue running.
 Usually depend on chiller setting, lower than 40% load, the
chiller will automatically shutdown.
 always consider running chillers & valves in auto mode
 COOLING WATER SYSTEM
1-CHILLER CAPACITY 600 TR

700 TR HEAT
COMPRESSOR HEAT
ABSORBED BY
100 TR
CONDENSING
WATER

CHILLER 600 TR COOLING TOWER 700TR

COOLING WATER SYSTEM Entering = 37°C
Leaving = 32 °C
700TR CWP-1-1
426.24 CMH 600TR 32°C 426.24 CMH ( ΔT=5°C)
37°C

CH-1-1 CT-1-1 426.24 CMH

600TR 700TR CWP-1-2

9°C
426.24 CMH 32°C 426.24 CMH
37°C

CH-1-2 CT-1-2 426.24 CMH

700TR CWP-1-3
600TR 37°C
426.24 CMH 32°C 426.24 CMH

CH-1-3 CT-1-3 426.24 CMH

700TR CWP-1-4
426.24 CMH 600TR 426.24 CMH
32°C 37°C

CH-1-4 CT-1-4 426.24 CMH

CHILLED WATER & DUCTING DISTRIBUTION SYSTEM
AIR HANDLING UNIT CONTROL DIAGRAM
PROCESS CHILLED WATER SYSTEM
CONTROL DIAGRAM
COOLING WATER CONTROL DIAGRAM
START-UP SERIES

 Ensure first that there will be cooling load. This is necessary so that
chiller unit can load-up
 Run AHUs, OACs, FCUs, supply fan
 Run exhaust fans, for good air balance
 Check the chilled/cooling water pumps
 Check pressure and valve position
 Run the system thru paramatrix control and ensure that cp & cwp are
running.
 isolate valve of the stand-by chillers if necessary.
 Observe if chiller runs according to the control system sequence.
FLOW CHART
Start in BMS Mode

Check all Circuit breakers of

Check valve Ensure Cooling Water Supply
S positions is in stable and in normal level
equipment like Chiller, OAC’s,
AHU’s, FCU, Pumps, Fans

Paramatrix will automatically

OAC’s, AHU’s, FCU, Pumps
Chiller select available Chiller
E starts - Pumps will automatically run
on electrical panel
Select Auto
first
FLOW CHART
Start in Manual Mode

Check all Circuit breakers of

Check valve Ensure Cooling Water Supply
S positions is in stable and in normal level
equipment like Chiller, OAC,
AHU, FCU, Pumps, Fans

Turn On OAC’s, AHU’s,

Run pumps first then Check
FCU’s,, Pumps on Electrical
E Start Chiller Chiller Status select Local
Panel
mode
Select Manual
TOTAL SHUT-DOWN SERIES
 In manual shutdown, chiller will be in local mode – stop
first chiller
 Circulate the chilled waterline for minimum of 3~5
minutes before shut-down the chilled water pump
 Cooling water valve is allowable not to close because
water is free flowing
 Last turn off OAC’s, AHU’s, FCU’s

In BMS mode, starting down and shutting-down are made on computer’s Graphic
User Interface which will be broadly discussed on December 3 & 4.
 REGULAR CHECK
 Check all valves position in proper order,
 Check circuit breakers and panels, check the torque marks.
 Monitor pressure and temperature conditions of chilled and cooling water,
 Monitor cooling space parameters like temperature and humidity, including outdoor
condition
 Check pump vibrations, unusual vibration and noise means something wrong
 Check routine maintenance schedule of equipment like chillers
 Check all filters of OAC’s, AHU’s and FCU’s if they need cleaning or replacement
 Any alarm on BMS should be acknowledged and make action
 Make record and report any incident immediately, big or small
 Once a day, make a routine check on all system piping for any possible condensation
someday, leak on drain valves, irregularity and etc.
 LOW ΔT SYNDROME
 If the system is in Automatic Mode and delta -
T is low, probable cause is:
 Dirty chilled water coils
 Reduces system efficiency
 Less Heat Transfer
 Area may hard to reach desired temperature
 Malfunctioned motorized valve or mis-calibration
SAFETY
AS OPERATOR, THINK SAFE TY ALL THE TIME

1. When dealing with valves like opening, adjusting and closing it, make it slowly to
avoid sudden increase and decrease in pressure. Sudden change in pressure
and flow, depend on situation, will result cavitations in the piping system.
Cavitations will reduce the life of the system.
2. Keep distance from unprotected parts of rotating equipment like fan or pump.
Thus, always check its condition
3. Maintain cleanliness everywhere
4. Always follow check list
5. When encountered trouble and not sure what to do, call for help of
knowledgeable person or trained personnel for their advice.
 Questions?
 What is condenser and evaporator approach?
 It is the variation between the refrigerant temp and water temp on
evaporator or condenser
 condenser approach 3°C and below is good
 above 4 °C means dirty coils
 Why motorized valve needs to close when one AHU unit is
shutdown?
 To avoid mixing of supply temp back to return temp
 delta T will become low and cooling energy is wasted
 Questions?
 What is the use of open-type expansion tank?
 when chilled water temperature changes for example from 7°C to
25°C, due to long shutdown there will be a thermal expansion. It means
water volume will increase – that’s why it is called expansion tank
 it also serves as make-up water should in case system piping is drained
because of maintenance
 Any more questions?

END OF PART 2 – FUNDAMENTAL OPERATIONS