District Cooling plant-Maroun-Khoury

District Cooling System
Design Parameters
District Cooling System Table of Contents
Table of Contents
1. Why District Cooling?
2. Design Parameters
– District Served
– Identifying a Feasible FAR of District Served
– Cooling Load Estimation
– Thermal Energy Storage
– Availability of Potable Water, TSE & Treatment and Sea Water
– Space Limitations and choice of location
– Design of Plants & Networks
– Chilled Water Temperatures
– Power Demand & Combination with Power Generation
– Opex and Capex Analysis
3. Creating Fit-for Purpose Plants to Suit End-User Parameters
– End User Parameters

– Optimal Plant Capacity
– Plant Configurations
4. District Cooling Plants – Designed by Dar Al-Handasah

District Cooling System Introduction
Why District Cooling?
• District Cooling rapid growth is due to:
– Increasing demand for comfort cooling, flexibility and reliability.
– A growing trend toward outsourcing operations to specialist companies that can provide the
service more efficiently.
– Reductions in peak electricity demand provided by district cooling.
– Cost-effectiveness.
– Environmental consideration.
– Costumer value provided by district cooling service.
– Centralized system reduces the use of usable land area compared to an ordinary
Decentralized system.
District
District Cooling SystemCooling Systems
– Design Parameters Introduction
District Served
District Served
• District cooling serves a variety of district types:
– Residential
– Hospitality Complexes
– Office parks
– Commercial developments
– Airports
– Community Facilities
– Medical Facilities
– Educational Facilities
– Sports Facilities
– Etc …
District
– Design Parameters Identifying a Feasible FARIntroduction
of District Served
Identifying a Feasible FAR of District Served
• Quick steps for identifying a feasible Floor to Area Ratio (FAR) of District served, which is a major factor in
assessing the feasibility of a District Cooling system.
– Estimate the FAR for each District type i.e. Residential, Commercial …
– Estimate the capital cost of the district cooling plant (DCP) for each FAR/District type at different cooling
capacities.
Note that the district cooling plant cost rate decreases with higher FAR and larger capacity plants.
– Based on the cost rate computed and local financing parameters, estimate the DCP charging rate for each
FAR and cooling capacity.
– Estimate the de-centralized system charging rate.
– Compare the DCP charging rate to the de-centralized operating cost and identify the feasible FAR for the
specific project.
District
– Design Parameters Cooling Load Estimation Introduction
Cooling Load Estimation
• Proper cooling load demand estimation affects the design, operation and cost-effectiveness of the
district cooling system.
• Peak district cooling demands for buildings in the Middle East range from 20 to 52 m2/ton
depending on the building usage type.
– Residential: 25 m2/ton
– Commercial: 20 m2/ton
– Office: 17 m2/ton
– Hotel: 22 m2/ton
– Warehouse: 35 m2/ton
• Diversity factor in range of 70-90% depending on the building usage type is used as step between
the peak and actual cooling load. A diversity factor of 75% is usually used in the Middle East
region.
• A peak-day load profile should be modeled based on building usage type, occupancy schedule,
weather, HVAC system characteristics and other case-specific variables.
District
– Design Parameters Cooling Load Estimation Introduction
Cooling Load Estimation

• Below is an illustrative district cooling system peak-day load profile for a sample mix of building
usage types in the Middle East.
• Such difference between the average daily load and the hourly peak load provides an opportunity
for thermal storage to be used.
District
Thermal Energy Storage
• Thermal Energy Storage is a viable technology that can improve the DCP economic feasibility by:
– Shifting electrical demand to off-peak hours and to take advantage of low-cost off peak
electric rates.
– Reducing the DCP capacity and thus reducing the equipment requirements which offer
energy cost savings where energy costs are based on time-of-day or real-time pricing.
– Improving chillers efficiency allowing more continuous operation at outputs closer to full
capacity, thus, minimizing part load losses.
• The following Thermal Energy Storage can be adopted:
– Stratified chilled water storage system
– Ice storage
– Eutectic storage system (Phase Change Materials – PCM)

District
Stratified chilled water storage system
• Advantages:
– Most common system type used.
– Simplest concept.
– More efficient refrigeration
equipment can be used (higher chilled
water temperatures).
– The system gets more economical as
the size of the storage tank increases.
– Simpler to interface with other
building chilled water systems.
• Disadvantages:
– Laminar flow in storage tanks can
promote increased organic growth,
therefore the treatment of the water
requires additional attention.
– Requires a large volume and footprint
for storage capacity.
Thermal storage tank - PNU

District
Ice Storage
• Advantages:
– The volume of ice storage vessel is typically 15 to 20 percent that of water TES (water stores Energy
at 20 Btu/lb. and ice can store at 144 Btu/lb.).
– Packaged equipment usually used.
– Ability to increase the system ΔTs (reducing pipe and pump sizes, pump horsepower, etc.). This
reduces the initial costs as well as the operating costs.
• Disadvantages:
– The lower evaporator temperatures produce higher electrical consumption since the Compressors are
not as efficient as conventional discharge temperatures.
– More complex concept.
District
Eutectic Storage System
• Two or more substances mixed in a way to provide a desired melting/freezing

point.
• Advantages:
– Larger thermal energy storage capacity relative to its physical size.
– Utilizing the latent heat capacity of eutectic mixtures without the need
for minus circulation temperatures.
– Offers wide range of operating temperature (between 4°C and 89°C),
covering the majority of the chilled water application. Eutectic Beams
– The positive temperatures offered allow the designers to utilize
conventional chilled water equipments.
– Lower stand-by losses.
• Disadvantages:
– Many PCMs have poor thermal conductivity and therefore require large
heat exchange area.
– Some PCMs are corrosive and require special containers.
– Higher system cost. Eutectic Storage Tank
– More complex concept.
District
Comparison between thermal energy storage systems

District
Availability of Potable Water, TSE & Treatment and Sea Water
• Makeup water is required to replace water lost during cooling tower operation, due to:
– Evaporation.
– Blow down.
– Drift (negligible with drift eliminators).
• Make up water for the cooling tower could be supplied from different sources:
– Potable water
– Treated Sewage Effluent (TSE)
– Sea water
District
Potable Water
• Potable water requirement: 0.08 m3/TR/day
• Advantages:
– Usage of potable water for make-up water will increase the cycle of concentration within
the system, and thus decreasing the volume of make-up water needed.
– No need for special fabricated chilled water equipments.
• Limitations:
– The availability of potable water in GCC countries.
– If available, potable water may be charged at high rates which will affect the economical
feasibility of the district cooling system.
District
Treated Sewage Effluent (TSE)
• TSE requirement: 0.12 m3/TR/day
• Advantages:
– Relatively low cost compared to potable water.
– Presents a sustainability measure in terms of recycling water.
– It is available for industrial usage.
• Limitations:
– TSE may require polishing and further treatment; poor quality TSE may result in Fungi growth in
cooling tower basin.
– TSE water may contain percentage of dissolved ammonia which react with copper causing corrosion.
– Condenser piping should be fabricated with copper-nickel alloys, the alloys’ composition percentage
is according to the amount of ammonia and chlorides content.
– During early development, fresh water should be provided to substitute TSE.
– Higher volume of make-up water is needed due to the lower number of cycles of concentration.
District
Haram Central Utility Complex – TSE Polishing System
TSE Polishing System

District
Sea Water
• Advantages:
– Present no concern for the cost of water.
– Present no concern for the availability of water.
• Limitations:
– Water should be taken from a considerable depth since the Gulf seashore is shallow and
water temperature may go above 30 °C in summer time.
– Piping and condenser-tube materials must be capable of withstanding the aggressive nature
of seawater.
– The biological activity of the sea must be controlled.
– Higher volume of make-up water is needed due to the lower number of cycles of
concentration.
– Salt lowers the water vapor pressure, and thus making the seawater a less effective coolant.
District
Pearl Island – Desalination Plant

• Lakes
• Water Reservoirs
• TSE
• RO Plant
• Blow Down
District
• Plant capacity is 35,000 m3/day able to feed make up water at 400 ppm TDS to cooling towers and it
contributes to potable water supply and irrigation system as back up.
• The irrigation system is partially served from CT blow down with the remaining irrigation needs from
treated sewage effluent when becomes available.
• Treated water from plant at 400 ppm with Post Treatment supplying cooling tower make up water.
• CT blow-down and treated water from plant at 400 ppm with post treatment supplying the irrigation
system.
• Alternative of using 800 ppm without post treatment for irrigation is possible thru a set of valves.
• Potable water from the plant feeding partially the Island potable water tank.
District
Diagrammatic Control
Scheme for Water
Networks and Lakes
Filling
District
Space Limitations & choice of location
• Area availability for the DCP
• Road accessibility for each heavy truck maneuverability
• Location should be with minimal environmental impact on the surroundings.
• Noise impact must be considered
• Low emissions to the buildings
• Choosing location to be as near as possible from buildings being served to minimize pipe work
District

• Some indicative District Cooling System plot requirements
DCP Load (ton) Installed Chiller Modules Cooling Plant Dimensions Plot Requirements
20,000 4 37 m x 61 m 110 m x 105 m
25,000 5 49 m x 61 m 120 m x 105 m
30,000 5 49 m x 61 m 120 m x 105 m
35,000 6 49 m x 61 m 125 m x 105 m
40,000 7 61 m x 61 m 140 m x 105 m
45,000 8 61 m x 61 m 140 m x 105 m
50,000 9 73 m x 61 m 150 m x 105 m
55,000 10 73 m x 61 m 160 m x 105 m
60,000 11 85 m x 61 m 170 m x 105 m
65,000 11 85 m x 61 m 175 m x 105 m
70,000 12 85 m x 61 m 175 m x 105 m
75,000 13 97 m x 61 m 190 m x 105 m
80,000 14 97 m x 61 m 190 m x 105 m
85,000 15 110 m x 61 m 200 m x 105 m
90,000 16 110 m x 61 m 200 m x 105 m
95,000 17 121 m x 61 m 220 m x 105 m
100,000 18 121 m x 61 m 220 m x 105 m
• The plot requirements include space for the cooling plant building, thermal storage tank and make-up
water tanks.
District
Design of Plants & Networks
Design of Plants and Networks
• The main equipments in the chilled water plant are as follows:
– Air-Cooled or Water-Cooled chillers, commonly used capacities: 2000 TR, 2500 TR and 5000
TR
– Primary pumps, commonly used as constant speed, circulate the chilled water through the
chillers within the plant
– Variable speed secondary pumps circulate the chilled water from the primary system
through the chilled water distribution network to and from each building location
– Cooling towers: field erected induced draft, counter-flow, FRP & mounted on concrete
basin
– Condenser water system including pumps, side-stream filtration
– Control system
District
Design of Plants and Networks
• The network layout is to be selected to feed all facilities through loop networks, to insure system
redundancy.
• Piping corridor (directly buried pipe) or tunnel shall be used for chilled water pipes.
• Maximum water velocity in forced mains shall be the lesser of 4.6 m/s.
• The earthwork requires that the backfill above the top of the pipe is at least 0.90m.
• Separation between chilled water pipes and any other adjacent utilities are at minimum 0.50m in
vertical and horizontal directions.
• ETS are located in buildings basements or in dedicated outdoor chambers.

District
Princess Nora Bint Abdul Rahman University - Piping Tunnel
Piping Tunnel Design Piping Tunnel As-built

District
Chilled Water Temperatures
Chilled Water Temperatures
• The difference in chilled water supply and return temperatures (Delta T) is a key parameter in the
design and operation of district cooling systems.
• The higher the Delta T, the less flow, pump energy and equipment capacity need to satisfy cooling
requirements.
• Delta T should be assessed in order for the system elements (buildings HVAC systems, ETS,
distribution system, DCP) operate together without compromising performance.
– Normal Delta T of 6.7 Deg °C; high piping & pumping cost
– Medium Delta T of 8.9 Deg °C; optimized piping & pumping cost but special arrangements
at consumers side
– Large Delta T of 13.3 °C; highly optimized piping & pumping cost but very special
arrangements at consumer side
District
Power Demand & Combination with Power Generation
• The power consumption rate reaches 1 kW/TR for all related water-cooled plant equipments,
while 1.7 kW/TR for all related air-cooled plant equipments.
• Power generation can be used to decrease the demand of direct electric power; Gas turbines
present an efficient technology for central station power generation.
• The high quality waste heat can be recovered to generate:
– Additional power using steam turbines in a combined cycle scheme

– Refrigeration via steam turbine driven chillers in a combined heat and power (CHP)
application.
District

• Heat recovered from the turbine exhaust used to generate steam that powers steam turbines
producing additional electrical output.
District

• The turbine exhaust is utilized via heat recovery steam generators which produce steam serving
steam driven centrifugal chillers.
District
Opex and Capex Analysis
• CAPEX items:
– Chillers
– Primary chilled water pumps
– Secondary pumps
– Tertiary pumps
– Cooling towers
– Heat exchangers
– Expansion tanks
– Piping
– Electrical substations
– Medium voltage cables
• OPEX items:
– Annual running costs:

• Make-up water
• Electricity
– Annual maintenance costs:
• Preventive maintenance
• Predictive maintenance
• Overhauling
District
CAPEX
Initial costs comparison between centralized and decentralized systems.
*Based on Jabal Omar Project

District
OPEX – Running cost

Annual running costs comparison between centralized and decentralized systems.

District
OPEX – Maintenance Cost

Annual maintenance costs comparison between centralized and decentralized systems.

District
Present Worth Comparison

Present Worth comparison between centralized and decentralized systems.

District
Pay-Back Period
Pay-back Period when choosing centralized system over the decentralized one.
1.75

District
– Creating Fit-for Purpose Plants to Suit End-User Parameters End Introduction
User Parameters
Creating Fit-for Purpose Plants to Suit End-User Parameters
• For a district cooling system to be successful, it is essential that all elements of the system are
integrated without compromising performance.
– District cooling plant

– Chilled water distribution system
– Building HVAC systems.
– Energy transfer stations
• Supply water temperature is limited by the district cooling plant and distribution system
performance.
• Return water temperature is limited by cooling coil performance in customer buildings.
• For district cooling systems serving old facilities, service providers are penalizing consumers in
case of un-match between the air handling equipments low DT and the plant optimized high DT.
• Service providers shall involve in reviewing buildings design and ensure systems are done to match
the essential requirements.
District
– Creating Fit-for Purpose Plants to Suit End-User Parameters Introduction
Optimal Plant Capacity
Optimal Plant Capacity
• Optimal plant capacity is based on several parameters:
– Plant construction cost.

– Space allocation
– Project phasing
• Based on previous experience, recent studies in the Middle East region showed that for residential
& commercial developments the most economical plant capacities fall in the range of 15,000 -
60,000 TR.
District
– Creating Fit-for Purpose Plants to Suit End-User Parameters Plant Introduction
Configurations
Plant Configurations – Alternative 1
• Cooling towers are located above the

chiller building
• Above ground thermal storage tank
• Above ground water tanks
• Stand alone electrical substation

District
Configurations
• All facilities are included in one building including pump, chiller, cooling towers, electrical
substation and administration.
• The thermal storage tank is provided underground.

District
Configurations
• Such alternative offers a more compact design, providing major savings in terms of plot area.
• Suitable for District Cooling Plants located in residential areas.

District
Configurations
• The chillers are provided with sea water

cooling instead of cooling tower.
• Provides major savings in terms of plot

area.
• Reduces noise problems from cooling

towers fans.
• No consumption of potable or treated

sewage water for cooling tower make up.
• Roof of plant can be used as car park,

sports facilities or garden.
District
District Cooling SystemCooling Systems Introduction
District Cooling Plants – Designed by Dar Al-Handasah
Princess Nora Bint Abdul Rahman University
• Project total built-up area =

2,000,000 m²
• Chiller plant built-up area =

26,250 m²
• Current chiller plant capacity =

65,000 T.R.
• Total plant capacity = 90,000

T.R.
District
Utility Area
Chiller Plant
Utility tunnel
District
Chillers installed in PNU DCP

District
Radiators installed in PNU DCP

District
Makkah (Misfala) DCP
• Chiller plant capacity = 45,000

T.R.
• Centrifugal water cooled

chillers.
• Water cooling by air radiator.

District
Dubai International Airport
• Cooling Load = 110,000 T.R.
• Cooling load served by 6 Central

Utility Complexes (CUCs)
• Cooling towers located on the

roof.
District


roof.
District


roof.
District


roof.
District
Pearl Island
• One DCP located at the

center of the Pearl Island
Water Treatment Plant

Plant Power
(For CT water make up
Substation, 3 no
and potable water), 6 TR
TR each 50 to 60
with total of 19.8 MVA
MVA
District
Pearl Island
Garbage
Collection
• Plant cooling capacity Building
= 130,000 T.R.
Water
Treatment
Plant
District
Pearl Island
• 26 site erected cooling

towers each at 5,000 TR
District
Dubai Airport
• 16 sets of twin chillers

each set of 5,000 TR
| DCP Design Challenges EIA | CT Transmissions
CT Emissions
Need for CFD simulation tools

| DCP Design Challenges
CFD
District Cooling Systems
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District Cooling System

1. Why District Cooling?

3. Creating Fit-for Purpose Plants to Suit End-User Parameters

– End User Parameters

4. District Cooling Plants – Designed by Dar Al-Handasah

Why District Cooling?

• District Cooling rapid growth is due to:

– Increasing demand for comfort cooling, flexibility and reliability.

– Reductions in peak electricity demand provided by district cooling.

– Costumer value provided by district cooling service.

• District cooling serves a variety of district types:

Identifying a Feasible FAR of District Served

– Estimate the de-centralized system charging rate.

Cooling Load Estimation

Cooling Load Estimation

Thermal Energy Storage

• The following Thermal Energy Storage can be adopted:

– Stratified chilled water storage system

– Eutectic storage system (Phase Change Materials – PCM)

Stratified chilled water storage system

Thermal storage tank - PNU

Eutectic Storage System

• Two or more substances mixed in a way to provide a desired melting/freezing

Thermal Energy Storage

Comparison between thermal energy storage systems

Availability of Potable Water, TSE & Treatment and Sea Water

• Potable water requirement: 0.08 m3/TR/day

– No need for special fabricated chilled water equipments.

– The availability of potable water in GCC countries.

Treated Sewage Effluent (TSE)

• TSE requirement: 0.12 m3/TR/day

– Relatively low cost compared to potable water.

– Presents a sustainability measure in terms of recycling water.

– It is available for industrial usage.

– During early development, fresh water should be provided to substitute TSE.

Haram Central Utility Complex – TSE Polishing System

TSE Polishing System

– Present no concern for the cost of water.

– Present no concern for the availability of water.

– The biological activity of the sea must be controlled.

Pearl Island – Desalination Plant

Pearl Island – Desalination Plant

Pearl Island – Desalination Plant

Space Limitations & choice of location

• Area availability for the DCP

• Road accessibility for each heavy truck maneuverability

• Location should be with minimal environmental impact on the surroundings.

• Noise impact must be considered

• Low emissions to the buildings

Space Limitations & choice of location

Design of Plants and Networks

• The main equipments in the chilled water plant are as follows:

– Condenser water system including pumps, side-stream filtration

Design of Plants and Networks

• ETS are located in buildings basements or in dedicated outdoor chambers.

Princess Nora Bint Abdul Rahman University - Piping Tunnel

Piping Tunnel Design Piping Tunnel As-built

Chilled Water Temperatures

Power Demand & Combination with Power Generation