UNIT-4

HVAC Water System

HarisH Patil
HVAC Water System

Chilled Water System

 Refrigeration Cycle
Refrigeration is the removal of heat from a material or
space, so that it’s temperature is lower than that of it’s
surroundings.

When refrigerant absorbs the unwanted heat, this raises

the refrigerant’s temperature (“Saturation Temperature”) so
that it changes from a liquid to a gas — it evaporates.
The system then uses condensation to release the heat and
change the refrigerant back into a liquid. This is called
“Latent Heat”.

This cycle is based on the physical principle, that a liquid

extracts heat from the surrounding area as it expands (boils)
in to a gas.
 To accomplish this, the refrigerant is pumped through a
closed looped pipe system.
 Refrigeration Cycle
►Most common refrigeration cycle in use today
►There are four principal
control volumes involving
these components:
►Evaporator
►Compressor
►Condenser
►Expansion valve Two-phase
liquid-vapor mixture

All energy transfers by work and heat are taken as positive in

the directions of the arrows on the schematic and energy
balances are written accordingly.
 Refrigeration Cycle
►The processes of this cycle are:
Process 4-1: two-phase liquid-vapor
mixture of refrigerant is evaporated
through heat transfer from the
refrigerated space.
Process 1-2: vapor refrigerant is
compressed to a relatively high
temperature and pressure requiring
work input.
Process 2-3: vapor refrigerant Two-phase
liquid-vapor mixture
condenses to liquid through heat
transfer to the cooler surroundings.
Process 3-4: liquid refrigerant
expands to the evaporator pressure.
 Refrigeration Cycle
►P-H Diagram:

►Refrigerant temperature in
evaporator is less than TC.
►Irreversible heat transfers
have negative effect on
Two-phase performance.
-vapor mixture
 Refrigeration Cycle
►Heat transfers between refrigerant and cold and warm
regions are not reversible.
►Refrigerant temperature in
evaporator is less than TC.
►Refrigerant temperature in
condenser is greater than
TH.
►Irreversible heat transfers
have negative effect on
performance.
The Vapor Compression Refrigeration Cycle
Coefficient of Performance

TH

R
TL
The Vapor Compression Refrigeration Cycle
Coefficient of Performance

energy sought Qout

ηE = = = COPH
TH energy that costs Wcycle

A refrigeration system that is used for cooling is called

R a heat pump.

The conversion efficiency for a heat pump is called the

Heating Coefficient of Performance (COPH).
TL
The Vapor Compression Refrigeration Cycle
Coefficient of Performance

energy sought Q
ηE = = in = COPC
TH energy that costs Wcycle

A refrigeration system that is used for cooling is called

R a refrigerator.

The conversion efficiency for a refrigerator is called the

Cooling Coefficient of Performance (COPC).
TL
The Vapor Compression Refrigeration Cycle
Coefficient of Performance
For the Refrigeration cycle …
Qin Qin 1
ηth = COPR = = =
Wcycle Qout − Qin Qout / Qin − 1
TH
1 1 TL
COPR,Carnot = = COPR,Carnot =
( Qout / Qin ) rev − 1 TH / TL − 1 TH − TL

R For the Heat Pump cycle …

Qout Qout 1
ηth = COPH = = =
TL Wcycle Qout − Qin 1 − Qin / Qout
1 1 TH
COPH,Carnot = = COPH,Carnot =
1 − ( Qin / Qout ) rev 1 − TL / TH TH − TL
The Vapor Compression Refrigeration Cycle
Coefficient of Performance
►P-H Diagram:
 Selecting Refrigerants
►Refrigerant selection is based on several
factors:
►Performance: provides adequate cooling
capacity cost-effectively.
►Safety: avoids hazards (i.e., toxicity).
►Environmental impact: minimizes harm to
stratospheric ozone layer and reduces
negative impact to global climate change.
 Refrigerant Types and Characteristics

Global Warming Potential (GWP) is a simplified index that estimates the potential
future influence on global warming associated with different gases when released
to the atmosphere.
 Refrigerant Types and Characteristics
►Chlorofluorocarbons (CFCs) and Hydrochlorofluorocarbons
(HCFCs) are early synthetic refrigerants each containing chlorine.
Because of the adverse effect of chlorine on Earth’s stratospheric
ozone layer, use of these refrigerants is regulated by international
agreement.
►Hydrofluorocarbons (HFCs) and HFC blends are chlorine-free
refrigerants. Blends combine two or more HFCs. While these
chlorine-free refrigerants do not contribute to ozone depletion, with
the exception of R-1234yf, they have high GWP levels.
►Natural refrigerants are nonsynthetic, naturally occurring
substances which serve as refrigerants. These include carbon
dioxide, ammonia, and hydrocarbons. These refrigerants feature
low GWP values; still, concerns have been raised over the toxicity
of NH3 and the safety of the hydrocarbons.
 Refrigerant Types and Characteristics
An ideal refrigerant should have the following properties:
1. low viscosity
2. low freezing point
3. low boiling point
4. low heat capacity
5. low specific volume
6. low saturation pressure
7. odorless
8. High latent heat of vaporization.
9. good thermal conductivity
10. high COP
11. Non inflammable and non explosive.
12. high critical pressure and temperature.
 Refrigerant Types and Characteristics
Uses of Refrigerants:
Ammonia: Ice plants, large cold storages, etc.

Carbon dioxide: Marine refrigerators, dry ice making and air

conditioning.

Methyl chloride: domestic and industrial refrigerators

Fluorocarbon refrigerants: Freon-11, 12, 13, 22,113,114, etc.

These are used in domestic refrigerators, water coolers, air
conditioning plants cold storages etc.

Sulphur dioxide: Domestic refrigerators.

 Refrigeration System Components

►Four principal components:

►Evaporator
►Compressor
►Condenser
►Expansion valve
Refrigeration System Components
Expansion Valve


Capillary tube


Thermal expansion valve (TXV)


Electronic expansion valve
 Refrigeration System Components
Expansion Valve

Capillary tube

A capillary tube is long, wound up copper tube

with a tiny opening that passes hot, high
pressure liquid refrigerant.
 Refrigeration System Components
Expansion Valve

Thermal Expansion Valve

Unlike the stationary capillary tube, the

thermal expansion valve (TXV)actually
varies the amount of refrigerant
flowing through based on what the
HVAC system needs.
 Refrigeration System Components
Expansion Valve

Electronic Expansion Valve
 Chillers

Cooling
tower

Chiller AHU
Plant
Chillers

AHU
Chillers
 Chillers
What is a Chiller?
The refrigeration machine that produces chilled water is referred to as a “Chiller”.
A chiller is a water-cooled air conditioning system that cools inside air, creating a more
comfortable and productive environment.

Basically, there are two types of chillers based upon the refrigeration cycle:
1. Vapour Compression Chiller
2. Absorption Refrigeration Chiller

Based upon the condensation process of working fluid , there are two types of chiller:
1. Air-Cooled Chiller
2. Water Cooled Chiller
 Working of Chillers
1. Chillers circulate chilled water to air-handlers(AHU’s) in order to transfer heat from air
to water.
2. This water then returns to the evaporator side of the chiller where the heat is
passed from the water to a liquid (LP) refrigerant .
3. The refrigerant leaves the evaporator as a cold vapor (LP) and enters the
compressor where it is compressed into a hot vapor (HP).
4. Upon leaving the compressor, the vapor enters the condenser side of the chiller
where heat is transferred from the refrigerant to the air/water side of the
condenser where it is circulated to an ACC/open cooling tower for the final
removal of heat from the refrigerant as a liquid (HP).

(Water Cycle) (Refrigerant Cycle) (Air/Water Cycle)

AHU Evaporator Compressor Condenser C.Tower

 Chillers Basics: Refrigeration Cycle

55ºF 170ºF
COMPRESSOR
68.5PSIG 226PSIG
Low Pressure, High Pressure,
High Temp Vapor High Temp Vapor

EVAPORATOR CONDENSER

Low Pressure, High Pressure,

Low Temp Liquid Low Temp Liquid
40ºF EXPANSION 60ºF

68.5PSIG VALVE 226PSIG

R-22 refrigerant with, Evaporating Temp 4.4ºC & Condensing Temp 43.3ºC
 Chillers Basics: Refrigeration Cycle

 Pressure Enthalpy Diagram (PH Diagram

or Mollier Diagram)

 Enthalpy is a thermodynamic quantity

equivalent to the total heat content of a
system. It is equal to the internal
energy of the system plus the product
of pressure and volume
 Enthalpy is the scientific term for Heat
and is the measurement of Heat
Content within the refrigeration cycle
as the refrigerant is circulated.
Expressed as KJ/Kg

29
 COP of chiller

 Coefficient of Performance
 Each Kg of refrigerant entering the evaporator will contain a
certain amount of heat and each Kg of refrigerant leaving the
evaporator will have a certain amount of heat. (Heat absorbed
in evaporator) Pressure

 The difference in Heat Content is the Net Refrigeration

Effect. Heat Rejection
 Each Kg of refrigerant entering the compressor will contain a
certain amount of heat and each Kg of refrigerant leaving the
compressor will have a certain amount of heat.
 The difference is the “Work Done” or energy used to
pump the refrigerant
Wo
Note: The heat rejected from the condenser is the sum of the Refrigeration rk
Net Refrigeration Effect + the Work Done Effect Do
ne
Enthalpy (h) KJ/Kg

COP COOLING = Refrigeration Effect Work Done per unit time can be
Work Done expressed in kW
 Chillers Components
EVAPORATOR COMPRESSOR :
Uses Refrigerant to absorb i. Centrifugal
Heat from Water . ii. Reciprocating
Types : iii. Screw
1. Shell and Tube : iv. Scroll
i. Direct Expansion
ii. Flooded Type
2. Plate Type EXPANSION VALVE :
i. Thermostatic Expansion
CONDENSER Valve
Uses Refrigerant reject Heat to ii. Electronic Expansion Valve
Water .
Cooling Towers:
i. Water Cooled
i. Water Cooling Towers
ii. Air Cooled
ii. Air Cooling Towers
iii. Evaporative

Chilled and condenser-water distribution systems include

water pumps, piping, control valve, check valves,
strainers etc.
Evaporator: Shell & Tube type
Evaporator: Direct Expansion type
Evaporator: Plate type
Condensor:
Air Cooled Condensor Water Cooled Condensor
Available from 7.5 to 500tons (25 to Available from 10 to 3000tons (35 to
1580kW) 10500kW)

Packaged System - Reduced design

time , simplified installation, higher Additional requirement of condenser-
reliability & single source water piping, pump, and associated
responsibility. controls.

Cooling tower require special control

sequences, basin heaters or even an
Better low-ambient operation (i.e. indoor sump for safe operatin in
below frezing weather conditions) freezing weather

Elimination of cooling tower Cooling tower in the system

Mainteance requirements associated
with water treatment, chiller
condensor-tube cleaning, tower
Lower Maintenace - Eliminates mechanical maintenance , freeze
concers & maintenance requirements protection & availability of make up
related to cooling tower water with its quality

Reduce Operating Costs of cooling Additional Costs of cooling tower &

tower condensor pumps
Centrifugal Compressors
Reciprocating Compressors
Screw Compressor
Scroll Compressor
Expansion Valve
Expansion Valve: Orifice
Cooling tower
Cooling tower

Types of Cooling Towers:

Natural draft cooling towers:

Natural draft spray type, and

Natural draft splash deck type,

Mechanical draft cooling towers:

Forced draft cooling towers, and

Induced draft cooling towers.

Cooling tower
Natural draft cooling towers:

Natural draft spray and

splash deck type:

Cooling tower: Mechanical draft cooling towers

a. c.
a. Induced Draft Counter flow
b. Forced Draft Counter Flow
c. Induced Draft Cross Flow
(Single Flow Tower)
d. Induced Draft Cross Flow
(Double Air Entry)

b.
d.
Chiller Plant Configurations

1. Single chiller
2. Parallel chiller
3. Series chiller
4. Primary/Secondary system (Primary pump without VFD)
5. Primary/Secondary system (Primary pump with VFD)
Single Chiller System
Single Chiller System (Constant Flow)

For constant flow, chilled water temp range varies directly with the
load
Chiller is sized to meet load
1. Fewer % of time – 100%
2. Balance time = 50 to 60%
Advantages:
1. Easiest design
2. Require smaller mechanical room
Disadvantages
1. Least efficient
2. Provide no redundancy
Parallel Chiller System
Parallel Chiller System


Advantages

Provide a redundancy

Improve overall system load performance.

Reduce energy consumption

Disadvantage

1. Mixed flow issues
Series Chiller System
 Series Chiller System


Sequence of Operation

As the chiller plant load increases, the lead chiller will load from 0 to 100%
capacity to meet it. Once the lead chiller is loaded (which is likely to be about
45% of plant capacity) the lag chiller is started.

Here are three ways to operate the lag chiller:
1. Set the upstream chiller chilled water setpoint to bring on the chiller once the
downstream chiller is fully loaded. This will preferentially load the downstream
chiller. The downstream chiller will operate at full load while the upstream chiller
will ramp up as the chiller plant load goes from about 45% to 100%. If the
downstream chiller is offline for any reason, the upstream chiller will not be able
to assume its role unless the chilled water setpoint is changed, either manually or
remotely.
2. Move the upstream chiller sensor downstream of both chillers. This will
preferentially load the upstream chiller. Once the upstream chiller cannot
maintain the chilled water supply temperature, the downstream chiller will start
and provide the balance of the load.
3. Modern chiller controllers can allow two chillers to communicate. In this
arrangement. Either chiller can be the first chiller on. Once the first chiller is fully
loaded, the second chiller will start and the load will be evenly balanced between
the two chillers. This can result in about a 2% improvement in annual chiller
energy usage. Where possible, this method is recommended
Series Chiller System

Advantages
1.No mixing issues
2.Optimize chiller performance

Disadvantages
1. Pressure drop through evaporates are additive
Primary/Secondary (Decoupled) Chiller System
(Constant flow)
Primary/Secondary (Decoupled) Chiller System
(Constant flow)

Decoupled Loop
The additional flow from the two primary pumps bypasses the building
through the decoupler. The bypassed water mixes with the return
water from the building and is returned to the chillers.
The decoupler allows the pumps to operate at different flow rates. This
is necessary because the primary pumps are fixed speed and the
secondary pumps are variable speed. Only on special occasions will
the primary pump flow and the secondary flow be equal.
Isolation Valve:
An automatic isolating valve is required for each chiller to stop short-
circuiting when the chiller and pump are off.
Primary/ Secondary Chiller System (Variable flow)

* The chiller must have a unit controller capable of dealing with

both a change in flow and a change in return temperature. In most
cases, the controller should be a modern digital type using PID
control loops.
Primary/ Secondary Chiller System (Variable flow)


Bypass Line:

There is a bypass line to Maintain minimum flow through The chillers
only. Whenever the Chilled water flow is above Minimum, the bypass
is closed. Usually, the minimum flow rate of a chiller is 50% of the
design flow rate.

Bypass Line Valve Control:

It is recommended that each chiller should have a flow meter. The
meter can be used to recognize both minimum and maximum flow
constraints.

The bypass line control valve is controlled by a signal from the flow
meter of the operating chiller.

The control system should recognize the chiller and know the
minimum flow rate for that chiller.

The bypass line control valve is modulated to maintain the minimum
chiller flow. This must be done slowly. Fast changes in the bypass
line flow may cause the primary pump control loop to hunt as it
recognizes a change in total chilled water flow.
 Waterside free cooling

1. Direct Water-Side Free Cooling

2. Parallel Water-Side Free Cooling
3. Series Water-Side Free Cooling
Direct waterside free cooling

The chilled water loop can

be connected by means of
three-way valves, directly
to the cooling tower in a
“strainer cycle” method.

This method is not

preferred
because the chilled water
loop is then exposed to
atmosphere introducing dirt
and creating water
treatment difficulties.
Parallel Waterside free cooling

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).
This is “Non Integrated”
System
Series Waterside free cooling
Heat Pump


Heat pump is essentially an air conditioner with a few additions. A heat pump
has a reversing valve, two metering devices and two bypass valves. This
allows the unit to provide both cooling and Heating.
Heat pump in Cooling mode

a) The compressor (1) pumps the refrigerant to the reversing valve (2).
b)The reversing valve directs the flow to the outside coil (condenser) where the fan (3)
cools and condenses the refrigerant to liquid.
c)The air flowing across the coil removes heat (4) from the refrigerant
d)The liquid refrigerant bypasses the first metering device and flows to the second
metering device (6) at the inside coil (evaporator) where it is metered.
e)Here it picks up heat energy from the air blowing (3) across the inside coil (evaporator)
and the air comes out cooler (7). This is the air that blows into the home.
f)The refrigerant vapor (8) then travels back to the reversing valve (9) to be directed to the
compressor to start the cycle all over again (1).
Heat pump in Heating mode

The diagram above shows the heat pump in heat mode. The difference in the two
diagrams is the reversing valve (2) directs the compressed refrigerant to the inside coil
first. This makes the inside coil the condenser and releases the heat energy (3-4). This
heated air is ducted to the home. The outside coil is used to collect the heat energy (3-7).
This now becomes the evaporator.
Absorption Chiller