Chiller System Sequences

Chilled Water System Sequence of Operations

Original 10/2/96 Sequence 6, CHWST Reset Revised 11/2/96
Overview
The chiller system is comprised of three chillers: two larger centrifugals (CH-1 and 2) with good part load
efficiency down to 25% and one reciprocating chiller (CH-3) about 1/3 the size of the centrifugals which
has excellent part load efficiencies with eight stages of unloading.1 There is no automatic chiller
staging/selection optimization controls. The preferred sequence of chiller staging may vary by season. The
primary pumps and condenser pumps run at constant flow. There is a secondary chilled water supply loop
with variable speed drives on the pumps controlled from differential pressure, which is reset incrementally
to operate at the lowest speed and pressure possible to satisfy the current load. There are three cooling
towers, each assigned to one chiller. There is also a heat exchanger in the condenser water loop that rejects
heat from ACU-1-10 and CRU-1, which requires the lead cooling tower to operate year-round. The
building automation system (BAS) controls many of the chiller functions and setpoints and just enables
others, and monitors a number of points through the chiller interface. BAS in brackets denotes where the
BAS has control over the setting or parameter, rather than the local chiller packaged control panel.
1
Including pump energy, at high loads (75% - 100% of chiller capacity) the centrifugals are more
efficient, at 50% the centrifugals and reciprocating chillers are about equal and at 25% load the
reciprocating chiller is more efficient. Since 25% load on the small CH-3 is expected to rarely be
encountered for any period of time, CH-1 and 2 should primarily be used.
Chillers (CH-1, 2; 3)
1. Software [BAS] lead lag selector to allow any of the chillers to act as the lead machine.
2. Chiller will only be enabled to operate in AUTO upon the following conditions:
a) Chiller scheduled ON [by BAS]
b) OSAT > 56F [BAS]
c) There are no active alarms that initiate a shutdown (reported to BAS and chiller panel)
d) The chiller sump temperature is above its minimum [BAS and chiller panel]
e) There is a call for cooling [BAS]
f) Chilled and condenser water flows are verified [BAS and chiller panel]
3. Upon a call for cooling2, the lead primary CHW pump starts and the pump status is confirmed ON via
a current sensor in the BAS and flow is confirmed through a flow switch . Then the assigned lead
chiller oil pump starts, then the lead condenser water pump starts and the pump status is confirmed ON
via a current sensor in the BAS and flow is confirmed through a flow switch. There are 30-60 second
delays between these pumps, per the chiller integral programmed settings (adjustable). The lead
secondary CHWP then starts, ramping up from the minimum RPM of ___________ via the variable
frequency drive (VFD), [per BAS or VFD??]
2
A call for cooling is when a cooling coil valve (CCV) on one of the ON AHUs (AHU 1, 2, 3 or 4) is at
least 15% open for at least 10 minutes. It is noted that the chiller packaged controls designate a call
for cooling to be when the CHWST SPt is xx degrees lower than actual CHWT. This is inactive by
being set to 0.
4. The lead chiller then starts with the prerotation vanes closed, which begin to open (closed to full open
in ~ 3 minutes and full open to closed in ~1 minute).
5. The chiller maintains the CHW supply temperature at the setpoint [BAS] which ranges from 42F to
48F, based on a reset schedule, by modulating chiller capacity. CH-1 and CH-2 utilize prerotation
vanes for capacity control, while the reciprocating chiller, CH-3, utilizes 8 stages of unloading.
6. Chilled water supply temperature (CHWST) reset [BAS]. The CHWST will have a default of 44F.
The chilled water temperature will be reset only when the secondary pumps speeds are at their

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minimum (as described in sequence 33). This is because, lowering pump speed with the differential
pressure reset strategy (sequence 33) will save more energy than resetting the chilled water temperature
up, per ton of cooling. When the pump speed is at its minimum allowed, start the CHWST reset routine
and continue it until one or more pumps are above their minimum speed, then hold the CHWST
setpoint where it is until the pumps are at their minimums. Include a differential or time delay to
prevent hunting. When enabled, the CHWST reset sequence is: when all CCVs are less than 90%
open, the CHWST setpoint (SPt) is at its highest value of a proportional range (48F). When three or
more CCVs are 90% or more open, the CHWS SPt is at its lowest value (42F).
50 F

48 F

CHWST
Set
Point
and
Temp

42 F
0 1 2 3 4
Number of CCVs >= 90% Open

7. The CHWST reset will not increase when the return air relative humidity rises above 50% [BAS].
8. Chiller Staging. [All in BAS] There is no automatic chiller staging/selection optimization controls.
The first lag chiller will be called for whenever the secondary CHW flow exceeds the primary CHW
flow for 20 minutes (adjustable) as determined by flow meters AND the lead chiller is 95% loaded (by
% of rated current).1 For reference, each secondary CHW pump is design rated at 765 gpm. After a
call has been maintained for the 20 minutes, the first lag chiller and pump sequence start as described
above for the lead chiller. The second lag chiller will start under the same conditions and sequences.
Whenever a lag chiller starts, all running chillers load and unload as necessary to be running within 5%
of the same % load (based on rated current).
1
This 95% load parameter will allow CH-3 to operate as the lead chiller, if desired, up to its full load before the
much larger chillers (CH-1 and 2) start, since there is such a difference in primary CHW flow between CH-1 or
2 and CH-3, but no difference in the secondary CHW pump flows for the different chillers.
9. The last selected lag chiller and associated pumps stage OFF when the total primary CHW flow
exceeds the total secondary CHW flow by the capacity (flow) of the last selected chillers primary
CHW pump for a 20 minute duration (adjustable).
10. All chillers and pumps will turn OFF when OSAT is < 55F for ______ minutes [BAS], OR when all
CCVs are less than 15% open for 10 minutes [BAS], OR when all air handlers are OFF [BAS], OR
when an unoccupied schedule occurs (subject to night low limit conditions not being met) [BAS], OR
when failure alarms are registered (BAS and chiller controls).

Misc. Chiller Features

11. Chillers will not cycle ON and OFF more than three times in a one hour period (chiller controls).
12. Alarm on chiller failure. Failure alarms must be manually reset. See other alarm modes in chiller
operators manual [alarms created by chiller controls, shutdown by chiller controls, message sent to
BAS].

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13. Demand limiting. [BAS] Demand limiting setpoint adjustment may be made through building
automation system [BAS]. The demand limit (in sum of all chillers kW), when met will delay the start
of the next chiller for one hour (adjustable). This sequence is different than the disabled stock sequence
in the chiller packaged controls.
14. The BAS will monitor kW and calculate the load on the chiller using evaporator CHW flow and
temperature differentials [BAS].
15. Provide emergency stop switch located adjacent to chiller room mandoor exit to stop all equipment in
chiller room, except ventilation system. Ventilation fan to automatically operate on purge mode with
activation of emergency stop switch.

Primary Chilled Water Pumps (CHWP 1`, 2, 3 for CH-1 & 2 and CHWP 4; 5 for CH-3)
16. Each primary CHW pump is assigned to one chiller [BAS]. Lead primary CHW pump starts upon a
call for cooling per above chiller sequences. Lag primary CHW pump starts upon a call for the lag
chiller per above chiller sequences [BAS]
17. Primary CHW pumps to operate continuously when their associated chiller is running. Primary CHW
pumps provide constant flow through the chiller according to the manufacturers recommendations:
675 gpm for CH-1 and CH-2 and 180 gpm for CH-3. Check balancing report for finals.
18. A standby (redundant) primary CHW pump is provided for CH-1 and 2 together and can be operated
as active pumps after opening manual valves. A standby primary CHW pump for CH-3 will
automatically change over [detected by BAS and chiller controller; pump control by BAS].
19. a) CHWP 1, 2; 3: Alarm on pump failure detected via a motor current switch and flow switch. Upon
failure of lead pump, chiller shuts down and lag chiller should start automatically to meet load [BAS].
b) CHWP 4; 5: Alarm on pump failure detected via a motor current switch and flow switch. Upon
failure of lead pump, standby pump automatically starts [detected by BAS and chiller controller; pump
control by BAS].

Chiller Condenser Water Pumps (CDP 1, 2, 3, 4; 5)

20. CD pumps CDP 1, 2, 3 for CH-1 and CH-2 and CDP 4, and 5 for CH-3 to operate continuously when
their associated chiller is running. CD pumps provide constant flow through the chiller condenser
according to the manufacturers recommendations: 1350 gpm for CH-1 and CH-2 and 360 gpm for
CH-3.
21. A standby (redundant) CD pump is provided for CH-1 and 2 together. The pumps can be operated as
active pumps after opening manual valves. A standby pump is provided for CH-3 and will
automatically changeover [BAS].
22. a) CDP 1, 2; 3 (CH-1; 2): Alarm on pump failure detected via a motor current switch and flow
switch. Upon failure of lead pump, chiller shuts down and lag chiller should start automatically to meet
load [detected by BAS and chiller controller; pump control by BAS].
b) CDP 4; 5 (CH-3): Alarm on pump failure detected via a motor current switch and flow switch.
Upon failure of lead pump, standby pump automatically starts [detected by BAS and chiller controller;
pump control by BAS].

Cooling Tower (CT-1, 2; 3)

21. Cooling towers operate with operation of their associated condenser water pump. With operation of a
pump, open selected tower supply valve and allow tower temperature control to function [BAS].
22. Software selector to allow any tower to be the lead tower, second tower or third tower [BAS].

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23. CT Sequences. [All BAS] The CT during the normal cooling season rejects heat from the chillers and
returns as cool of water as possible to the chillers condenser, down to 65F. The CT will try and
maintain a 65F return temperature (ECDWT) by first modulating the normally open bypass valve,
with no water going over the top of the tower. When the valve is full open AND the ECDWT is greater
than the ECDWT setpoint (65F), the bypass valve begins to close and the normally closed CT control
valve associated with the respective CT and CDW pump, opens 100% and water goes over the
respective CT. The bypass valve continues to modulate open to try and maintain the ECDWT setpoint
without the CT fans. When the ECDWT reaches 69F, the bypass valve will be fully closed and the
pony motor CT fan turns ON. When the ECDWT reaches 73F, the main CT fan turns ON. As the
ECDWT decreases, the main fan turns OFF at 69F and the pony motor fan turns OFF at ECDWT of
65F. All parameters are adjustable. There is an eight minute delay between each stage.

ECDWT
Fan Spd ON (F) OFF (F)
OFF <69 ----
(modulation of bypass valve)
*Low 69 65
*High 73 69
* Bypass valve should be closed.
24. When a lag chiller comes on line, its condenser water pump and associated CT come on line [BAS].
25. A multiple position CT sump or basin level sensor provides the following information to the BAS:
a) High water alarm
b) Low water alarm
c) Open make up water valve
d) Closed make up water valve
e) System shutdown
Alarm on heater stage failure detected via current sensing switch.
26. Cooling tower sump two stage heaters shall be controlled to maintain a sump temperature of 45F with
the following schedule [BAS]:
ON (F) OFF (F)
Stage 1 45 43
Stage 2 47 45
Each CT basin has a temperature sensor and separate??? heaters.
27. Cooling tower makeup valve (one for all three CTs) to maintain sump water level. Upon sensing a
drop in water level, slowly open makeup valve in industrial cold water line [level sensor by BAS].
28. Alarm on pony and main motor upon motor failure detected via current sensing relay. Upon failure of
fan motor, lag CT starts automatically [BAS].
29. Alarm on excessive vibration detected via vibration limit switch. Upon failure of fan, lag CT starts
automatically [BAS].
30. The lead cooling tower operate during periods, when the chillers are OFF (even during winter) to
maintain a heat rejection source for the heat exchanger HE-1, which serves approximately 40 tons of
cooling from ACU-1 thru 10 and CRU-1. See sequences for CDP 6, 7, 8; 9.

Secondary Chilled Water Pumps (CHWP 6, 7; 8)

31. Software lead/lag function allows any of the secondary pumps to act as the lead pump [BAS].

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32. Lead secondary CHW pump starts upon a call for cooling per above chiller sequences. Lag secondary
CHW pump starts upon a call for the lag chiller per above chiller sequences [BAS].
33. Differential pressure control. [All BAS] The objective is to always have one CCV 80% open so the
pumps operate at the lowest speed and pressure possible to satisfy the current load. Every 5 minutes
the CCVs are polled. A PI loop that changes the secondary pump discharge differential pressure
setpoint to maintain the remote (local on 8th floor) DP setpoint to maintain the most open CCV at 80%
open (with a deadband of +/-_________). For example: When the most open CCV is more than 80%
open, a PI signal is calculated and changes the local DP setpoint upward. When the local DP setpoint
is not being met, a PI signal is calculated and sent to the pump discharge pressure setpoint and it is
raised accordingly. Through another PI loop, the variable speed (frequency) drive (VFD) increases the
pump motor speed to meet the raised pump differential (discharge) pressure setpoint.

The remote DP setpoint will be maintained between maximum and minimum pressures. The maximum
pressure limit is the pressure required to provide full flow to all CCVs simultaneously (per TAB). The
minimum pressure limit is the pressure correlating to the lowest speed the pump motor is allowed to be
operated at (per motor manuf. and TAB). Maximum pressure limit:__________psi. Mininum
pressure limit:__________psi.
The VFD internal settings will allow the VFD to run the pumps to their minimums.
Number of remote DP sensors: _______. Locations: ________________________________
___________________________________________________________________________
34. Pump Staging. [BAS] With one secondary CHW pump running, when the total secondary CHW gpm
exceeds the lead secondary CHW pump design gpm AND the discharge differential pressure drops
more than 2 psi below the setpoint for 10 minutes (all adjustable), start the first lag pump. Both pumps
converge and run at similar speeds and gpm to maintain the common discharge pressure differential
setpoint and the remote DP setpoints. If the total secondary gpm exceeds the total design gpm of the
running pumps (lead and 1st lag) AND the discharge differential pressure drops more than 2 psi below
the setpoint for 10 minutes, start the second lag pump. All three pumps converge and run at similar
speeds and gpm to maintain the common discharge pressure differential setpoint and the remote DP
setpoints.
35. During reducing load as the DP increases: when the total secondary CHW gpm has reduced to be
equal to or less than the sum of the first two selected pumps gpm for 10 minutes (adjustable), the
second lag secondary CHW pump shuts OFF. Similarly, when the total secondary CHW gpm, with
two pumps ON, has reduced to be equal to or less than the gpm of the lead CHW pump for 10 minutes,
the first lag pump shuts OFF.
36. The controller shall monitor rpm and gpm of the pumps and shall not allow operation of the pumps at
or beyond their published End of Curve [BAS].
37. Alarm on pump failure detected via current sensing switch. Upon failure of pump, next lag pump
starts automatically (BAS and chiller controller).
38. Alarm on failure of VFD [BAS].
39. The rpm of secondary CHW pumps to be monitored by BAS.
40. For coil freeze protection during smoke exhaust system operation, pumps CHWP-6, 7; 8 to run under
NORMAL control and all cooling coil valves to open with operation of respective AHU when smoke
exhaust system (EF-10) is in operation AND outside air temperature is below 40F [BAS].

ACU Condenser Water Pumps (CDP 6, 7 and 8; 9) and HE-1

41. The lead cooling tower operates during periods, when the chillers are OFF (even during winter) to
maintain a heat rejection source for the heat exchanger HE-1, which serves approximately 40 tons of
cooling from ACU-1 thru 10 and CRU-1. CDP 6 or 7 (one is redundant) provides water from the heat

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exchanger to the cooling towers. CDP 8 or 9 (one is redundant) services the ACUs and CRU-1 from
HE-1. The selected CD pump for each loop (CDP 6 or 7 AND 8 or 9) operate continuously [BAS].
42. During chiller OFF periods, the ECDWT setpoint and CT bypass valve and fan staging parameters
remain the same as during chiller ON periods (see above).
43. Alarm on pump failure detected via current sensing switch. Upon failure of any pump, standby pump
automatically starts [BAS].

General Chiller Operation During Unoccupied Periods

44. Unoccupied Operation. During scheduled unoccupied hours at night or weekends, the chiller system is
in standby, except the cooling tower operates as required to maintain 65F condenser water to the heat
exchanger HE-1 for heat rejection of ACU-1 thru 10 and CRU-1.
45. Winter Operation. During winter, the chiller system is in standby, except the cooling tower operates as
required to maintain 65F condenser water to the heat exchanger HE-1 for heat rejection of ACU-1 thru
10 and CRU-1.

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