HYDRONICS
Chilled Water System
اعداد
المهندس أحمد عبده أبوالعال
(ماجستير العلوم الهندسية في هندسة القوي الميكانيكة)
االصدار االول
) المحاضرة الثالثة )
Eng. Ahmed Abdou +2 01116142613 [email protected]
وعرفنا عيوبها وعلشان3 way و محابس الconstant volume chilled water system اتكلمنا في المحاضرة الثانية عن
. فضال عنها2-way كدة تم التفكير في محابس استخدام محابس ال
2-way valve which response with the load by limit the flow to the coil depend on the load in control
zone
constant chilled water pumping في2-way دلوقتي هنحاول نستخدم محابس ال
three مع مضخات ثابتة السرعة عن طريق استخدام محابس2-way دة اتعمل كمحاولة مبدئية الستخدام محابس الsystem ال
. في خروج كل شيلرway
still operates at its full flow ولكن المضخاتcooling coil خالل الVariable flow تم تحقق ال
Meaning that no power is saved, and No benefit has been added which three-way is still in the
system with its bypass balance valve, the same disadvantages were mentioned before due to using
the three-way valve still working.
Primary-Secondary Chilled Water System Pumping Method
Law of Tee (Gil Carlson law)
The law of Tee state that whenever flow enters
the tee must exit the tee.
. هي اللي هتخرج منهTee بكل بساطة كمية المية اللي هتدخل ال
فاصل بينهمTees طبق القانون دة عند استخدام اتنينGil Carlson
: مسافة صغيرة الحظ االتي
Two Tees are located next to each other, therefore there
is a very small pressure drop between the two Tees and
maintain Hydraulic separation if the pressure drop
remains very small.
مشTee 1 يعني المياة اللي هتمر من خاللHydraulic separation
. Tee 2 هتختلط بالمياة اللي هتمر من خالل
)Bell & Gossett`s and Gil Carlson( Pioneers Engineers علي يدPrimary – Secondary loops ومن هنا ظهرت فكرة
.. ونصت علي ذلك0591 وتم استخدام الطريقة حيث اثبت فعليتها في منظومات ضح المياة المثلجة عام0591 عام
Primary – Secondary pumping used two tees which are hydraulically located very close to
each other .The tees are used as supply and return connections to a branch circuit, the branch
circuit is the secondary. This connection
is hydraulically close enough that the
pressure drop between the two tees is
nearly zero, even if there is a length of
the pipe between them. By Minimizing
the pressure drop between the two tees
the piping system connected to the two
tee become hydraulically separated or
decoupled.
The hydraulic separation between the
two piping segments permit the two
piping loops to work independently of
each other
The piping shared between the two tees is called (Common pipe- De-coupler pipe- Bridge).
الكالم لسة مخلصش عن خط.. جاية منينPrimary Secondary pumping methodكدة احنا عرفنا الفكرة الخاصة بي
. هنرجع له تاني قريبDe-coupler ال
constant volume primary –secondary تم عمل منظومةHydraulic separation محاولة الستفادة من مبدأ ال
pumping method (Primary Pump constant & Secondary Pump constant).
في المنظومة علي المضخات االولوية والثانوية وال يوجد ايpressure drop وجد ان الفائدة الوحيدة للدائرة دية هو تقسيم ال
حيث المضخات االولوية مسؤولة عن التغلب علي الفقد في الضغط في منطقةPower consumption توفير في
والمضخات الثانوية. ) اللي هي المواسير و الشيلرات بالمحابس الخاصة بها ومحابس المضخات االولويةProduction loop(
+ cooling coils + ( في المواسيرDistribution loop) مسؤولة عن التغلب علي الفقد في الضغط في باقي المنظومة
. المحابس وخالفة
. Primary + Secondary المضخات الhead هنبقي ناخد شرح مفصل علي حساب
Constant Volume Primary – Secondary pumping Method
In constant-flow systems, flow rate ( GPM) is estimated for peak design condition and
Delta-T (the difference between the chiller supply and return) varies in response to the load
(BTU/hr).
In air-conditioning applications, since the design conditions occur only during 1% of the
operational hours in a year [i.e. 99% of the time the system runs on part load], some of the
chilled water will always bypass through the three-way valve for most of coil’s operational
life.
Higher quantities of bypassed chilled water mixes with leaving water from the cooling
coil yielding lower chilled water return temperature to the plant.
The lower return water temperature reduces the operating temperature differential (∆T) across the
chiller as the supply water temperature is fixed to a set point. This phenomenon is termed “Low delta –
T syndrome” in HVAC industry.()هنتكلم عن الظاهرة بالتفصيل بعد كدة
Remember that the chillers are able to control only the temperature at which chilled
water is sent out, while cooling loads control the temperature at which it is returned
and, ultimately, Delta-T.
انما الحمل التبريد هو اللي بيتحكم في... الشيلرات بتتحكم فقط في درجة حرارة المياة اللي بتخرج منها
. درجة حرارة المياة الراجعة للشيلرات بالتالي 𝑻∆ متوقفه علي الحمل التبريدي المستهدف
No Power Saving in constant flow pumping chilled water at all-time even in partial load operation.
Low Return water Temperature (3-way problem).
Rob chilled water from other coils at part load conditions (3-way problem).
Increase flow in circuit lead to Over pumping (3-way problem).
By lowering Return water temperature lead to chillers performance is reduced (3-way problem).
Constant Primary – Variable Secondary pumping Method
)Primary Constant and Secondary Variable (في هذة الطريقة من منظومات ضح المياة المثلجة
. 3-WAY بدال من2-WAY تم استخدام محابس ال
. تم استخدام مضخات ثانوية متغيرة السرعة بدال من ثابتة السرعة
لتغير سرعتها طبقا للحمل التبريديVSD لقياس فرق الضغط في الشبكة وارسال اشارة اليDPS/DPT تم استخدام
تم التحكم في كمية التدفق طبقا للحمل التبريدي داخل المكان المراد تكييفة باالضافة لذلك2-way باستخدام محابس ال
. المطلوبةGPM المضخات الثانوية ستغير سرعتها طبقا للحمل حيث ستزيد او تقلل سرعتها طبقا لكمية ال
With two way valves controlling the volume of flow to the coil depends on the load
requirements in the zone, the flow produced with secondary pump depends on the load.
Secondary pump produce flow based on the system resistance.
Sequence of operation (SOP) >>>
Scenario 1 as load increase in the space, the two-way valve modulates further open, the
more open the valve position, the smaller the pressure drop through the valve, and a
signal is sent from the Differential Pressure sensor (DPS OR DPT) to the pump
controller (VSD) to increase its speed resulting on that the flow will increase.
Scenario 2 as load decrease in the space, the two-way valve modulates further close, the
closer the valve position, the greater the pressure drop through the valve, and a signal is
sent from the Differential Pressure sensor (DPS OR DPT) to the pump controller (VFD)
to lower its speed resulting on the flow will increase.
Variable Frequency Drive Control (VFD)
The advantages are:
It’s good for systems with high levels of
modulation;
It’s among the most energy-efficient
pump control methods;
Hydronic system pressure does not
increase during partial load conditions;
It offers long bearing and seal life; and
It has lower electrical load during soft
startup.
The disadvantages are:
It has a higher construction cost.
ASHRAE 90.1-2010/2013/2016/2019 make variable speed pumping a requirement in most commercial
chilled water systems
Hydronic heat pumps and water-cooled unitary air conditioners having a total pump system
power exceeding 3.7 kW (5Hp) shall have controls and/or devices (such as variable-speed control)
that will result in pump motor demand of no more than 30% of design wattage at 50% of
design water flow.
Pump controls can operate as a function of either the desired flow or the minimum required
differential pressure at the heat exchanger requiring the greatest differential pressure, e.g. the most
remote coil.
If differential pressure control is used and the building has a DDC operated BMS (building
management system), then the controller must continually change or “reset” the differential set point
downward until one 2-way valve is nearly wide open.
لذلك اختيار مكان الDPS بيعتمد اعتماد كلي علي االشارة اللي جاية منGPM ان تغير سرعة دوران المضخات وثم تغير كميات الSOP زي مشوفنا في ال
DCC لanalog بتدي اشارة ضغطDPS ال. Power consumption في عملVSD هام جدا جدا في المنظومة لكي تعمل بكفائة ونستفاد من مبدأDPS
اللي جاي منControl head يقلل او يزود سرعة ماتور المضخة طبقا لVFD فاVFD فيحولها من ضغط لي فولت ثم الفولت يدخل الControl panel
. وانسب مكان له في المنظومةDPS هنعرف دلوقتي كيفية ضبط الDPS
Differential Pressure Sensor Setpoint And Location
It begins with a fundamental understanding of the two basic types of variable speed control, curve control and
area control.
Now, before we start painting in the detail of these two control strategies, we need to review some hydronic
fundamentals.
Pump Affinity Laws.
These laws define the mathematical relationships between flows (GPM), pump speed (RPM/change in
impeller diameter), head and brake horsepower (BHP).
They are:
Pump GPM capacity varies DIRECTLY as the speed (RPM) or impeller diameter ratio change.
Total pump head varies directly as the SQUARE of the speed (RPM) or impeller ratio change.
BHP varies directly as the CUBE of the speed (RPM) or impeller diameter ratio change.
These relationships provide the basis for variable speed pump control, because if we know a couple of
the values, we can always determine the others.
Keep in mind that a variable speed pump drive is the magical
equivalent of switching out various size impellers on the same pump.
. ثابتimpeller (D) ) عند قطرN) impeller (عند تغير سرعة دوران الHead-Flow-Power) تحدد العالقة بينAffinity Laws
New Pump Curve لعمل الimpeller لقطر الtrimming ثابت و عملN او عند
فقطcentrifugal pump وهي خاصة بال
At constant impeller diameter but change in rpm (VFD)
𝒇𝒍𝒐𝒘𝟏 𝒓𝒑𝒎𝟏
=
𝒇𝒍𝒐𝒘𝟐 𝒓𝒑𝒎𝟐
𝒉𝒆𝒂𝒅𝟏 𝒓𝒑𝒎𝟏 𝟐
=( )
𝒉𝒆𝒂𝒅𝟐 𝒓𝒑𝒎𝟐
𝑷𝒐𝒘𝒆𝒓𝟏 𝒓𝒑𝒎𝟏 𝟑
=( )
𝑷𝒐𝒘𝒆𝒓𝟐 𝒓𝒑𝒎𝟐
At constant rpm but change in
impeller diameter
𝒇𝒍𝒐𝒘𝟏 𝑫𝟏
=
𝒇𝒍𝒐𝒘𝟐 𝑫𝟐
𝒉𝒆𝒂𝒅𝟏 𝑫𝟏
=( )𝟐
𝒉𝒆𝒂𝒅𝟐 𝑫𝟐
𝑷𝒐𝒘𝒆𝒓𝟏 𝑫𝟏
=( )𝟑
𝑷𝒐𝒘𝒆𝒓𝟐 𝑫𝟐
Pump وان نقدر نعمل اكتر من. كدة عرفنا ازي اقدر احصل علي تدفق متغير من خالل تغيير سرعة دوران المضخةAffinity laws من خالل
. طبقا لسرعة دوران المضخة للحصول علي ضغط وتدفق معين طبقا الحتياجات المنظومةcurve
System Curve. This is a simple curve that represents the friction loss in a system as the flow changes. Because
of the quadratic relationship between flow and friction loss, if we know the head and flow for our system at
any point in time, we can calculate the head for each corresponding flow point and draw a curve. In a closed
loop system this curve takes us all the way from design flow to zero flow and zero head.
عند تغير التدفق اوsystem curve للتذكير اخدنا قبل كدة ازي احسب ال
الضغط في الشبكة
For same pipe length and diameter
𝒉𝟐 𝑭𝑳𝑶𝑾𝟐𝟐
=
𝒉𝟏 𝑭𝑳𝑶𝑾𝟏𝟐
Control Curve. The control curve is similar to the system
curve except for one very important detail. It begins with a
minimum head at zero flow. Why? Because in distributed
HVAC flow there are coils and a certain amount of head
must be present in order to establish Minimum flow.
The control curve represents a theoretical calculation of
where a variable speed pump will operate at part load.
Keep in mind that there are constant head
losses and variable head losses.
System head loss = Control Head loss+ Variable Head
Control Head loss. This is the minimum amount of head
that must be present in the system at all times to establish
full flow through the critical coil(s). A variable-speed pump
will produce in a closed loop. It can be calculated
differently depending on whether we are using curve or
area control
Variable Head. Variable head, as the term suggest, is
indeed variable. It is the piping head loss in the system, and
because of the pump affinity laws, it will vary as we reduce
system flow.
It is calculated by subtracting control head from design pump head.
The higher the variable head is compared to the control head, the more energy we will save.
set point ft Required
system Distribution piping ft control curve
Flow Gpm Controlled zone ∆P ft
curve ft (Variable head) ft
head
1000 100 20 80 20 100
800 64 20 51.2 12.8 71.2
500 25 20 20 5 40
300 9 20 7.2 1.8 27.2
0 0 20 0 0 20
150
the area between control curve
125
and system curve represents the
100 wasted energy . the larger the set
point the greater the difference between set point
Head, ft
75 the control curve and system curve
50 Distribution piping head
loss curve
Control Curve
25
system curve
0
0 250 500 750 1000 1250 1500
Flow GPM
In a differential pressure controlled system the system
curve represent the head of the pump must produce to
overcome the distribution piping head losses and
maintained differential pressure at the load which is being
control (20ft in this example) ,this maintained differential
pressure called Set point, must be maintained to ensure
full flow at the controlled load .
The DPT is placed across both the valves and the coil to
maximize the pressure drop seen by the sensor.
The DPT could be placed across the valve alone, but at
full load the differential pressure across the sensor would
be very small , reducing its accuracy .
Sequence of operation (SOP) For DPT.
Scenario 1 when the two way valve starts to modulate closed, in response to the load the differential head
(called process variable head) starts to rise , the DPT signal the pump controller to slow the pump down
because the process variable head is greater than the control head (set point) .
Scenario 2 when the two way valve starts to modulate open, in response to the load the process variable head is
less than the setpoint and the pump controller calls for an increase in pump speed.
Signal usually from 4 to 20 ma to the pump controller to indicate the process variable head is above or less
than setpoint .
Eng. Ahmed Abdou +2 01116142613 [email protected]
System head loss = Control Head loss+ Variable Head
To maximize the energy saving in the system, we must maximize the Variable Head loss in the system piping
and reduce Control Head loss.
This is done by locating the DPT at the most remote zone (Hydraulically) in the system
Pumps flow rates = 2000 GPM
Total dynamic head = (AB+GH+BC+FG+CD+EF+ZONE3)=150 FT
احنا دلوقتي عايزين نرسم ال Control curveو نحدد ال setpointالخاصة بي DPTونعرف هل القيمة اللي هنحددها كافية عند ظروف التشغيل
المختلفة وال ال .
اول قاعدة هروح لي ابعد زونه (ابعد مسار عن المضخة واكبر كمية )GPMو اطلع ال Pressure dropلكل من
( )cooling coil+2-way+B.V+piping frictionفي المثال دة انا اعتبرته 30 FTوهعتبر دية ال Setpointالخاصة بالشبكة بتاعتي .يعني
مهما قل الحمل وقل ال GPMضغط المضخة مش هينزل عن . FT 30محتاج دلوقتي اختبر واشوف ان ال FT01كافين لتوصيل المياة بالكمية
المناسبة عند سيناريوهات مختلفة من ال GPMلكل زونة ( .الحسابات بالجداول).
(جرب انت واعمل سيناريو لو غيرت مكان ال DPTمن عند زونة 0وحطيته عند زونة .. 2هل لو زونه 2قفلت مش محتاجة حمل تبريدي المضخة
هتقدر توصل المياة بال GPMالمطلوب الي زونه 0و زونه 0وال ال)
Eng. Ahmed Abdou +2 01116142613 [email protected]
كدة احنا عرفنا ازي نحدد LOCTIONالخاص بال DPTوقدرنا نعمل له Setpointمناسبة لتشغيل جميع ال . zones
في بعض الشبكات الكبيرة اللي فيها كذا مبني بيتم وضع اكتر من DPTعلي كل زونه وبيتجمعوا علي DCC Controllerوبياخد ال worst
. case sensorبس دة بيكون مكلف جدا .
الموضوع دسم انا عارف بس مهم جدا جدا في اي منظومة Variable secondary chilled waterفمش خسارة فيه المجهود اللي هتبذله
لفهمه.
يتبع ........
Eng. Ahmed Abdou +2 01116142613 [email protected]
