•Central AC plant

What is Refrigeration & Air conditioning?

• Refrigeration may be defined as the process of achieving and maintaining
a temperature below that of the surroundings, the aim being to cool some
product or space to the required temperature. One of the most important
applications of refrigeration has been the preservation of perishable food
products by storing them at low temperatures. Refrigeration systems are
also used extensively for providing thermal comfort to human beings by
means of air conditioning.
• Air Conditioning refers to the treatment of air so as to simultaneously
control its temperature, moisture content, cleanliness, odour and
circulation, as required by occupants, a process, or products in the space.
The subject of refrigeration and air conditioning has evolved out of human
need for food and comfort, and its history dates back to centuries
 Vapour compression refrigeration cycle
The Vapor Compression Refrigeration Cycle involves four
components: compressor, condenser, expansion valve/throttle valve
and evaporator. It is a compression process, whose aim is to raise the
refrigerant pressure, as it flows from an evaporator. The high-pressure
refrigerant flows through a condenser/heat exchanger before attaining
the initial low pressure and going back to the evaporator. A more
detailed explanation of the steps is as explained below
• Step 1: Compression
• The refrigerant (for example R-717) enters the compressor at low
temperature and low pressure. It is in a gaseous state.
Here, compression takes place to raise the temperature and
refrigerant pressure. The refrigerant leaves the compressor and
enters to the condenser. Since this process requires work, an electric
motor may be used. Compressors themselves can be scroll, screw,
centrifugal or reciprocating types.
• Step 2: Condensation
• The condenser is essentially a heat exchanger. Heat is transferred
from the refrigerant to a flow of air . Outside warm air absorbs the
heat from refrigerant As the refrigerant flows through the
condenser, it is in a constant pressure. When passing through the
condenser, the refrigerant releases its heat to the surrounding condensing
medium, usually air or water.
• Step 3: Throttling and Expansion
• When the refrigerant enters the throttling valve, it
expands and releases pressure. Consequently, the
temperature drops at this stage. Because of these
changes, the refrigerant leaves the throttle valve as a
liquid vapor mixture, typically in proportions of around
75 % and 25 % respectively. Throttling valves play two
crucial roles in the vapor compression cycle. First, they
maintain a pressure differential between low- and
high-pressure sides. Second, they control the amount
of liquid refrigerant entering the evaporator.
• Step 4: Evaporation
• At this stage of the Vapor Compression Refrigeration
Cycle, the refrigerant is at a lower temperature than its
surroundings. Therefore, it evaporates and absorbs
latent heat of vaporization. Heat extraction from the
refrigerant happens at low pressure and temperature.
Compressor suction effect helps maintain the low
pressure. There are different evaporator versions in
the market, but the major classifications are liquid
cooling and air cooling, depending whether they cool
liquid or air respectively.
• What is a Refrigerant?
• In a refrigerating system, the medium of heat transfer which picks up heat by evaporating at a low
temperature and pressure, and gives up heat on condensing at a higher temperature & pressure.
• (Refrigerating fluid) fluid used for heat transfer in a refrigerating system which absorbs heat at a low
temperature and low pressure of the fluid and transfers heat at a higher temperature and higher pressure of
the fluid, usually involving changes of state of the fluid.
• Desirable Properties of a Refrigerant
1. Boiling Point’ of the refrigerant should be low. : The liquid has to vapourise at the evaporator coil to cause
cooling. The liquid at the evaporator coil should therefore vapourised easily, otherwise the compressor will
have to create too much of vacuum to cause the liquid to vapourised. Thus, ‘Boiling Point’ of the refrigerant
should be low.
2. Low pressure : Pressure to which compressor has to compress the drawn gases, to convert them back into
liquid at the condenser, should be low. Therefore the refrigerant vapors should be easily condensable.
3. low ‘Specific Volume’.: Vapor produced after vaporisation of the liquid at the evaporator coil should occupy
minimum volume, to keep pipeline diameter, compressor size, etc. small and compact.
4. High dielectric strength : In hermetically sealed compressor , refrigerant vapour contact with motor windings &
may cause short circuit , so to avoid short circuit dielectric strength should be high
• R 22 , R 410A , R 134 , R 30
 Refrigeration
• Refrigeration is a process of removing heat from a low-
temperature medium and transferring it to a high-
temperature medium . The work of heat transfer is
traditionally driven by mechanical means.
• Refrigeration has many applications, including, but
not limited to: household refrigerators, industrial
freezers, cryogenics, and air conditioning. Heat pumps
may use the heat output of the refrigeration process,
and also may be designed to be reversible, but are
otherwise similar to air conditioning units.
• All Refrigeration units must have the five basic
components to work:
• The compressor
• The condenser
• The expansion device
• The evaporator
• The copper refrigerant tube
 Component of Refrigeration AC system .Evaporator
• The Evaporator
• The air conditioning evaporator is a heat
exchanger that absorbs heat into the
central air conditioner. The evaporator
does not exactly absorb heat! It’s the
cooled refrigerant fed from the bottom of
the evaporator coils absorb the heat.
• The liquid refrigerant usually flows from
the bottom of the evaporator coils and
boils as it moves to the top of the
evaporator coils.
• The reason it’s fed from the bottom is to
ensure the liquid refrigerant boils before it
leave the evaporator coils.
• Compressor
• The compressor absorbs vapor refrigerant
from the suction line and compresses that
heat to high superheat vapor.
• As the refrigerant flows across the
compressor, it also removes heat of
compression, motor winding heat, mechanical
friction, and other heat absorbs in the suction
line.
• The air conditioner compressor produce the
pressure different, it’s the compressors that
cause the refrigerant to flow in a cycle.
• The compressor inlet lines are known as:
• Suction pressure
• Back pressure
• Low side pressure
• The compressor outlet lines are known as:
• high side pressure
• Discharge pressure
• Head pressure
• Condenser
• In this refrigeration cycle diagram, the air
conditioner condenser is air cooled
condenser. It functions the same way as
the evaporator but it does the opposite.
• The condenser units are located outdoor
with the compressor. It purposes is to
reject both sensible and latent heat of
vapor absorb by the air conditioner units.
• The condenser receives high pressure and
high temperature superheats vapor from
the compressor and rejects that heat to the
low temperature air. After rejected all the
vapor heat, it turns back to liquid
refrigerant.
• The condenser has three important steps:
• Its remove sensible heat or (de-superheat)
• Remove latent heat or (condense)
• Remove more sensible heat or (subcooled)
 Expansion valve
Expansion Valve .
• All expansion device or metering device has
similar function (to some extent); it’s
responsible for providing the correct amount of
refrigerant to the evaporator.
• This is done by creating a restriction within the
thermostatic expansion valve. The restriction
causes the pressure and temperature of the
refrigerant entering the Evaporator to reduce.
• provides the correct amount of refrigerant to
the evaporator by using a remote sensing bulb
as a regulator. The remote sensing bulb and
capillary tube has a refrigerant inside.
HVAC central chilled water system
• 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:
• Vapour Compression Chiller
• Absorption Refrigeration Chiller
• Based upon the condensation process of working fluid , there
are two types of chiller:
• Air-Cooled Chiller
• Water Cooled Chiller
Chiller system
How does a water-cooled chiller work?
• The cycle of water-cooled chillers, like any other chiller, consists of
four main members: evaporator, compressor, condenser and expansion
valve, in each of which a thermodynamic process takes place.
• The first step in chiller operation:
• The starting point of this cycle is where the water in the AHU process
enters the evaporator to enter the chiller cycle.
• In this part of the cycle, the heat absorbed by the refrigerant first shows
itself in the form of a liquid-to-gas phase change. As the refrigerant
absorbs the heat of the water, the environment in contact with this part
drops in temperature, so the water leaves at a lower temperature. This
water enters the fan coils and brings cold air to the desired spaces.
• second stage:
• The gas refrigerant, which had reached the gas phase in the pre-liquid
state, then enters the compressor. In the compressor, the gas condenses
and the temperature and pressure increase so that it can enter the next
stage with high pressure. This increase in pressure and temperature as it
exits the compressor is important because the refrigerant needs to
release heat from inside the condenser, so it must carry enough heat to
the condenser.
• Another key function of the compressor is to draw refrigerant into the
evaporator at the appropriate time so that the pressure inside the
evaporator remains high enough to absorb heat again.
• third level:
• The third step takes place inside the condenser. High-
temperature gas enters the condenser. In the
condenser, the gas refrigerant is converted to a high-
pressure liquid that is saturated. This is a constant
pressure process.
• On the other hand, since the condenser is present in
another cycle between the cooling towers, water enters
the cooling tower after the temperature rises for the
water. Because cooling towers in water-cooled chillers
have the main task of cooling the consumed water and
the condenser uses this water as its driving material.
• This is where the unwanted heat of the water disappears
and the water temperature is brought back to the
desired low temperature. The heating process that we
mentioned earlier takes place in the condenser to
release the gas refrigerant from the heat itself, the heat
source that is now being talked about and needs to be
eliminated by the cooling tower. In this way, the water
coming from the condenser to the chiller cooling tower
is in contact with the airflow and transfers its heat to the
air, then goes back to the condenser
• The fourth and final step:
• The expansion valve is the last stage that the refrigerant
goes through. This milk, as its name implies, expands
and reduces the refrigerant. These processes that take
place on the refrigerant in the expansion valve cause the
refrigerant to become a mixture of liquid and gas.
Eventually, the same compound re-enters the
evaporator to resume the cycle with hot water re-
entering the evaporator from another direction.
• Advantages and disadvantages of water-cooled chiller
• One of the advantages of water-cooled chillers over cold air chillers is that they
take up less space and can be installed indoors. This can reduce the maintenance
and repair costs of the chiller to some extent and increase its useful life. The next
item goes back to the longer useful life of the water-cooled chiller. Water-cooled
chillers are known for their high stability and useful life compared to other types
of chillers.
• One of the reasons why it is said that water-cooled chillers have better
performance and higher efficiency than other types of chillers is their higher
bubble temperature. Since the temperature of a wet bubble is always lower than
that of a dry bubble, there is a large difference between the activity of a water-
cooled chiller at a certain temperature and pressure and the activity of a cold air
chiller at the same temperature and pressure; Therefore, the refrigerant is active
with significant pressure and temperature difference, and this gives the chiller a
more useful performance. Of course, it should not be forgotten that the positive
performance of the chiller goes back to other criteria.
• In terms of the mere use of water-cooled chillers, if we ignore the costs of water
supply and the initial installation costs of water-cooled chillers, this chiller
• They seem to be more economical, otherwise, it is better to use cool air chillers if
the initial costs are important for the consumer and are limited for them.
• One of the main disadvantages of water-cooled chillers is the need for a large
amount of water. Also, despite the maintenance of water-cooled chillers in closed
environments, these chillers still have many different parts in them, which
increases the total cost of maintaining the chiller.
Air cooled & water cooled chiller
Working of chiller system
• Chillers circulate chilled water to air-handlers(AHU’s) in
order to transfer heat from air to water.
• This water then returns to the evaporator side of the chiller
where the heat is passed from the water to a liquid (LP)
refrigerant .
• The refrigerant leaves the evaporator as a cold vapor (LP) and
enters the compressor where it is compressed into a hot
vapor (HP).
• 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).
 Chiller calculation basic formula
Water side BTU /Hr.
• BTU/ Hr = 500 x GPM XΔT
• Where GPM water flow in the system
• Δ T is temperature difference between entering & leaving water
GPM evaporator = (TONS X 24) /Δ T or 2.4 GPM per TR
GPM CONDENSER = (TONS X 30) /Δ T or 3 GPM per TR

air side Btu / hr = 1.08 X CFM X ΔT (For AHU calculations )

For calculating AHU CFM as per dehumidification then select the
CFM as per r heat load calculation
Calculation of pump flow rate for given TR capacity.
• Example: The building cooling load is 500 TR
• For Condensed Water System, the pump flow rate required is
• = 500 TR x 3 GPM/ton = 1500 GPM
• For Chilled Water System, the pump flow rate required is
• = 500-ton x 2.5 GPM /ton= 1250 GPM
• Piping sizing calculation based on water velocity (approximate 8 FPS)
• Some approximate velocity at various stages
• A. Pump Discharge 8-12 FPS
• B. Pump Suction 4-7 FPS
• C. Header 4-15 FPS
• D. Riser 3-10 FPS
• E. Drain Line 4-7 FPS
Chiller system component
Water cooled Chiller machine layout
Components of chilled water system
• Chiller (Evaporator)
• Compressors
• Chilled Water Pumps
• Air Cooled Condenser in Air Cooled Chiller
• Cooling Tower in Water-cooled Chiller
• Condensate water pumps in water-cooled chiller
• Load Terminals (chilled water cooling coils)
• Chilled and condenser-water distribution systems
include piping, expansion valve, control valve,
check valves, strainers etc.
Components of chiller system
• Compressor : The compressor is the
prime mover, it creates a pressure
difference to move the refrigerant
around the system. There are various
designs of refrigerant compressors, the
most common being the centrifugal,
screw, scroll and reciprocating type
compressors. It is always located
between the evaporator and the
condenser. It’s usually partly insulated
and will have an electrical motor
attached as the driving force, this will
be either mounted internally or
externally.
Chiller parts
 Chiller condenser
• Condenser: The condenser is located after the
compressor and before the expansion valve.
The purpose of the condenser is to remove
heat from the refrigerant which was picked up
in the evaporator. There are two main types of
condensers, Air cooled and Water cooled.
• Water cooled condensers will repetitively
cycle “Condenser water” between the cooling
tower and the condenser, the hot refrigerant
which enters the condenser from the
compressor, will transfer its heat into this
water which is transported up to the cooling
tower and rejected from the building. The
refrigerant and the water do not mix they are
kept separated by a pipe wall, the water flows
inside the pipe and the refrigerant flows on the
outside.
Condensers on air cooled chillers work
slightly differently, they do not use a cooling
tower but instead blow air across the exposed
condenser pipes with the refrigerant flowing
this time on the inside of the tube.
 What is the condenser approach?
• A condenser approach is a difference between liquid refrigerant
temperature as measured on the liquid line, and leaving condenser
water temperature. Generally, the condenser approach for a water-
cooled chiller will be in the range of 0 to 4 degrees.
• High chiller approach temperatures usually mean reduced heat
transfer, increased energy consumptions, and a reduction in
refrigeration capacity.
• Condenser TR Capacity can be calculated as per below formula
• BTUH = 500 x ΔT x flow(GPM) X [specific gravity]
• if using water as a fluid with no additives, you can neglect specific gravity. The
formula then just becomes:
• BTUH = 500 x ΔT x flow (gpm)
• If you desire answer is tons of refrigeration, just divide answer by 12000
(#btus in 1 Ton)
Water cooled condenser
Air cooled condenser
Air cooled condenser GA drawing
• Evaporator:
• The evaporator is located between the expansion
valve and the compressor, its purpose is to
collect the unwanted heat from the building and
move this into the refrigerant so that it can be
sent to the cooling tower and rejected. The water
cools as the heat is extracted by the refrigerant,
this “chilled water” is then pumped around the
building to provide air conditioning, This
“Chilled water” then returns to the evaporator
bringing with it any unwanted heat from the
building.
• Evaporator Approach = Leaving Chilled Water
Temperature – Saturated Refrigerant
Evaporating Temperature, Approch is too high,
the capacity of the chiller will be negatively
affected, as the compressor may not be able to
deliver as much capacity, or must work much
harder to achieve the same capacity
• evaporator, approach should be 7° to 10°
Evaporator design
Chiller expansion valve
• Expansion valve:
• The expansion valve is located between
the condenser and the evaporator. It’s
purpose is to expand the refrigerant
reducing its pressure and increase it’s
volume which will allow it to pick up the
unwanted heat in the evaporator. There
are many different types of expansion
valve, the most common at the thermal
expansion vale, the pilot operated
thermal expansion valve, the electronic
expansion valve and the fixed orifice
expansion valve.
AIR COOLED v/s WATER COOLED CONDENSER
Chiller selection criteria
• Indoor areas:
• Both air-cooled and water-cooled chillers are installable indoors. However, the chiller type will dictate the
room’s arrangement. Indoor air-cooled chillers need ventilation to the outside. Sufficient fresh make-up air
allows for the maintenance of a suitable temperature within the space. Water-cooled chillers do not require
ventilation or fresh make-up air. They are almost exclusively installed indoors. Since they use water for
cooling, the water conducts the heat out of the room, eventually exhausted to ambient, often via a cooling
tower.
• Outdoor Areas:
• Almost all outdoor installations will be air-cooled chillers . In these installations, the heat rejected at the
condenser simply dissipates into the ambient air. Outdoor installations require properly configured electrical
control panels, based on the expected range of environmental conditions.
• High Temperature Environments:
• Water-cooled chillers work great in high temperature environments since they do not rely on ambient air for
cooling. Thus, they can be placed in hot mechanical rooms or in spaces with minimal ventilation.
• Small Spaces:
• The condenser on water-cooled chillers is more compact than an equivalently sized air-cooled unit. This can
result in an overall smaller unit, especially in the case of high capacity chillers. However, the entire
refrigeration system will still require sufficient space.
• Water-scarce areas:
• Use an air-cooled unit. The cooling medium, ambient air, does not require any connections. Nor does a chiller
with an air-cooled condenser need a cooling tower. These installations have lower overall environmental
concerns surrounding water treatment and removal. An air-cooled chiller should be the best choice for water
conservation.
Typical chiller control panel
Chiller piping arrangement
Typical water piping details for water cooled
Open loop water system
Piping details for air cooled
Typical AHU piping details
Water pipe colour identification
Pump piping details
Chilled water return water arrangement
Direct return horizontal system

1. Water enters Unit-1 from supply

2. Water leaves Unit-1 and returns directly to source
3. The first unit supplied is the first returned
4. Unequal circuit pressure drops result
5. Circuit pressure drop through
6. Unit-1 < Unit-2 < Unit-3 < Unit-4 < Unit-5
7. Balancing valves are a necessity
8. Fan coils close to pump receive great flow and coils away from the pump less flow so balancing valve is must
Direct return vertical distribution
Reverse Return Horizontal Distribution

1. Return header flow is same direction as supply flow

2. Water leaves Unit-1 and goes all the way around in returning to source
3. The first unit supplied is the last returned
4. Circuit pressure drop through
5. Unit-1 = Unit-2 = Unit-3 = Unit-4 = Unit-5
6. Balancing valves may be eliminated
Reverse return vertical distribution
Variable distribution flow
• Variable distribution flow:
• The distribution pump is typically
equipped with a variable-speed drive
that is controlled to maintain a certain
pressure difference between the
supply- and return-water piping. In
response to a reduced cooling load, the
two-way valve modulates closed,
restricting the flow of water through
the coil. This causes an increase in
system differential pressure, which can
be measured and used to signal a
reduction in the speed of the
distribution pump.
• primary- secondary pumping scheme : divides the chilled water system into two
distinct circuits (loops) that are hydraulically separated by a neutral bridge (de-
coupler).
• 1. Primary circuit is the place where chilled water is produced and its principal
components are the chiller and pumps. The primary pumps are typically constant
volume, low head pumps intended to provide a constant flow through the
evaporator of the chiller. These are usually placed in tandem with each chiller
though can also be arranged in common header.
• 2. The secondary circuit is responsible for the distribution of the chilled water to
the terminal units. Among the components of the secondary circuits are pumps,
terminal units such as fan-coils and air handling units (AHU) and control valves. The
secondary pumps can be constant speed or variable speed and are sized to move
the flow rate and head intended to overcome the pressure drop of secondary
circuit only.
• 3. The neutral bridge consists of two tees that are typically located at the suction
header of the secondary pumps and at the suction header of the primary pumps
and connected by a de- coupling pipe. This de-coupler separates the primary and
secondary loops. This common pipe is designed for negligible pressure drop at
design flow. A well designed, low-pressure- drop common pipe is the heart of prim
Primary & secondary pumps

•
Constant flow primary/secondary chilled water system
• Constant flow primary/secondary chilled water system
• Primary pumps are lower horsepower than the secondary pumps because
they only have to overcome the friction loss associated with the chiller,
pipes, and valves in the primary loop. The secondary pumps, in contrast, are
higher horsepower because they must overcome the friction loss associated
with the secondary loop: the distribution piping, fittings, valves, coils, etc.
The secondary loop contains 3-way valves to vary chilled water quantity
through the coil in response to load but the total quantity of flow in
secondary loop remains the same.
• One of the salient features of a primary/secondary pumping schemes is to
allow different chilled water flow rates as well delta-T on the two loops.
 CONSTANT PRIMARY/ VARIABLE SECONDARY SYSTEM
• In primary/secondary systems, water flows through the chiller primary loop at a
constant rate, and water flows through the secondary loop, which serves air
handlers or fan coils, at a variable rate. The constant speed pumps in secondary
circuit are replaced with “variable speed” pumps. The speed of the secondary
pumps is determined by a controller measuring differential pressure (DP) across
the supply-return mains or across the selected critical zones. The decoupled
section isolates the two systems hydraulically.
• Also the system uses two-way valves in the air handlers that modulate secondary
loop flow rate with load requirements. During light load condition, the 2-way
control valves will close (partially or fully) in response to load conditions, resulting
in pressure rise in the secondary chilled water loop. A differential pressure sensor
measures the pressure rise in the secondary loop and signals variable frequency
drive of secondary pumps to alter the speed (flow).
• Primary-secondary variable-flow systems are more energy efficient than constant-
flow systems, because they allow the secondary variable-speed pump to use only
as much energy as necessary to meet the system demand. Refer to the schematic
below.
Constant flow primary and variable secondary
 Water Flow rate = BTH/HR / 500 X Delta T
• How many tons of cooling is served by a 6,000 GPM operating at 42°F supply
water temperature and 54°F return water?
• GPM = 6,000
• Supply water temperature = 42°F
• Return water temperature = 54°F
• ΔT in distribution system = 12 degrees ----- [ 54°F – 42°F]
• Flow Rate per TR = 24/ ΔT = 24/12 = 2 GPM/Ton
• Tons Cooling = Total GPM / Flow rate per TR
• GPM / (24/Delta T) = 6,000/2 = 3,000 tons
• For a given design load, the chiller is selected for fixed temperature range ΔT and
the associated chilled water pumps are selected for calculated flow rate. The
chilled water supply temperature usually has a fixed set point and the only
variable that affects the output capacity of chiller is the return water
temperature.
Chilled water piping material
• The materials most commonly used in piping systems are the following:
1. Steel – black and galvanized
2. Wrought iron – black and galvanized
3. Copper – soft and hard
Typical pipe joints
Mechanical Groove Joint
Piping support
• All piping should be supported with
hangers that can withstand the combined
weight of pipe, pipe fittings, valves, fluid in
the pipe, and the insulation.
• They must also be capable of keeping the
pipe in proper alignment when necessary.
Where extreme expansion or contraction
exists, roll – type hangers or saddles
should be used.
• The pipe supports must have a smooth,
flat bearing surface, free from burrs or
other sharp projections which would wear
or cut the pipe.
• The controlling factor in the spacing of
supports for horizontal pipe lines is the
deflection of piping due to its own weight,
weight of the fluid, piping accessories, and
the insulation.
Pipe vibration management
• Vibration isolators can also be used to minimize the intensity of vibration.
• The piping must be supported securely at the proper places. The supports
should have a relatively wide bearing surface to avoid a swivel action and to
prevent cutting action on the pipe.
• The support closest to the source of vibration should be an isolation hanger and
the succeeding hangers should have isolation sheaths as illustrated in Fig. 2,
• The piping must not touch any part of the building when passing thru walls,
floors, of furring. Sleeves which contain isolation material should be used
wherever this is anticipated. Isolation hangers should be used to suspend the
piping from walls and ceilings to prevent transmission of vibration to the
building Isolation hangers are also used where access to piping is difficult after
installation..
• Flexible hose is often of value in absorbing vibration on smaller sizes of pipe.
Tobe effective, these flexible connectors are installed at right angles to the
direction of the vibration.
 Pipe fittings
1. Elbows are responsible for a large
percentage of the pressure drop in the
piping system. With equal velocities the
magnitude of this pressure drop depends
upon the sharpness of the turn. Long radius
rather than short radius elbows are
recommended wherever possible.
2. When laying out offsets, 45 ells are
recommended over 90 ells wherever
possible. If more than one tee is installed
in the line, a straight length of 10 pipe
diameters between tees is recommended.
This is done to reduce unnecessary
turbulence.
3. To facilitate erection and servicing,
unions and flanges are included in the
piping system. They are installed where
equipment and piping accessories must be
removed for servicing.
Selection of valves for chilled water system
• Butterfly valve :
• Butterfly valves are generally used
for large system and usually used
for shut off duty , throttling duty
and where there is frequent
operation .
• They have good flow control
relation ship between full open
and partial open system
• These valves have low cost , high
capacity and low pressure drop .
• these valves are in bigger sizes , so
used for 2.5 “ and above pipe sizes
Selection of valves for chilled water system
• Gate valve shut off duty :
• A gate valve is intended for use as a
stop valve. It gives the best service
when used in the fully open or
closed position.
• An important feature of the gate
valve is that there is less
obstruction and turbulence within
the valve and , therefore, a
correspondingly lower pressure
drop than other valves. With the
valve wide open, the wedge or disc
is lifted entirely out of the fluid
stream, thus providing a straigth
flow area thru the valve
Selection of valves for chilled water system
• Globe valve balancing duty :
• They are primarily intended for
throttling service and give close
regulation of flow. The method of
valve seating reduces wire drawing
and seat erosion which is prevalent in
gate valves when used for throttling
service.
• Globe valves can be opened or closed
substantially faster than a gate valve
because of the shorter lift of the disc.
When the valves are to be operated
frequently of continuously , the globe
valve provides the more convenient
operation. The seating surfaces of the
globe valve is less subject to wear
and the discs and seats are more
easily replaced than on the gate valve
Globe valves can be arranged in such a way that the disk closes against the flow or in the same
direction of flow. When the disk closes in the direction of flow, the kinetic energy of the fluid
helps closing but obstructs the opening. This characteristic is preferable when a quick-acting stop
is required.
Selection of valves for chilled water system
• Y type valve balancing duty :
• The Y-type design is a solution
to reduce pressure drop problem
in valves. In this type, seat and
stem are angled at
approximately 45° to the pipe
axis. Y-body valves are used in
high pressure and other critical
services where pressure drop is
concerned.
• Angle globe valve turns the flow
direction by 90 degrees without
using an elbow and one extra
pipe weld. Disk open against the
flow. This type of globe valve
can be used in the fluctuating
flow condition also, as they are
capable of handling the slugging
effect
Y type globe valve
Z type globe valve
• Application of Globe valve
• Globe Valves are used in the systems where flow control is required and
leak tightness is also important.
• It used in high-point vents and low-point drains when leak tightness and
safety are major concerns. Otherwise, you can use a gate valve for drain
and vent.
• It can be used in Feed-water, chemical, air, lube oil and almost all
services where pressure drop is not an issue
• This valve is also used as an automatic control valve, but in that case,
the stem of the valve is a smooth stem rather than threaded and is
opened and closed by lifting action of an actuator assembly.
• Advantages
• Better shut off as compared to gate valve
• Good for frequent operation as no fear of wear of seat and disk
• Easy to repair, as seat and disk can be accessed from the valve top
• Fast operation compares to gate valve due to shorter stroke length
• Usually operated by an automatic actuator
• Disadvantages of globe valve
• High head loss from two or more right-
angle turns of flowing fluid within the
valve body.
• Obstructions and discontinuities in the
flow path lead to a high head loss.
• In a large high-pressure line, pulsations
and impacts can damage internal trim
parts.
• A large valve require considerable power
to open and create noise while in
operation.
• It is heavier than other valves of the same
pressure rating.
• Costlier compared to the gate valve.
 Plug valves
• PLUG Valves :
• Plug cocks are primarily used for
balancing in a piping system not
subject to frequent changes in
flow. They are normally less
expensive than globe type valves
and the setting cannot be
tampered with as easily as a globe
valve.
• Plug valves have approximately
the same line loss as a gate valve
when in the fully open position.
When partially closed for
balancing, thus line loss increases
substantially.
 Plug valves
• Ball Valves :
• A Ball valve is a quarter-turn rotary
motion valve that uses a ball-shaped
disk to stop or start the flow. It
resembles a plug valve in many ways.
When a port in the ball is in line, it
allows flow whereas when you rotate
the valve 90 degrees, solid part of
the ball stop the flow.
• Most ball valves are of the quick-
acting type, which requires a 90°
turn of the valve handle to operate
the valve. But in case large size valve
which required considerable force to
open or close the valve, the gear-
operated actuator is used. With this
arrangement, a small handwheel is
enough to operate a fairly large
valve.
• Applications of the ball Valve
• It can be used in different types of fluid services as an on-off stop valve that provides
bubble-tight shutoff.
• It can be used in air, gaseous, and vapor services as well as hydrocarbon services.
• Metal seated valves can be used in high-pressure & temperature applications.
• it is widely used with instrument tubing to connect instruments.
• Advantages
• It is quick to open and close type that provides bubble-tight reliable sealing in high-
pressure temperature applications.
• It is smaller and lighter than a gate valve of the same size and rating.
• Several designs of ball valves offer the flexibility of selection so that you can choose
the valve that suits your requirements.
• Easy to operate and Cost-effective maintenance.
• Disadvantages
• It cannot be used in service that required throttling.
• In slurry or other similar applications, the suspended particles can settle and become
trapped in body cavities causing wear, leakage, or valve failure.
• Due to rapid opening and closing, surge pressures may arise which could damage
downstream equipment.
Swing check valve
• The swing check valve may be
used in a horizontal or a vertical
line for upward flow. The flow thru
the swing check is in a straight line
and without restriction at the seat.
Swing checks are generally used in
combination with gate valves
• The swing type valve allows
full, unobstructed flow and
automatically closes as
pressure decreases. Usually
installed in combination with
gate valves because they
provide relatively free flow
combinations.
Lift check valve
• The lift check operates in a manner
similar to that of a globe valve and,
like the globe valve, its flow is
restricted as illustrated in Fig. The
disc is seated by backflow or by
gravity when there is no flow, and
is free to rise and fall depending on
the pressure under it. The lift check
should only be installed in
horizontal pipe lines and usually in
combination with globe, angle and
“Y” valves.
 Flow control valve
• Control valves may be either two-way
(one pipe in and one pipe out) which
act as a variable resistance to flow or
three-way (two pipes in and one out
for mixing valves – one pipe in and
two out for diverting valves) .
• Three-way valves may be either
mixing (two flow streams are merged
into one) or diverting (a single flow
stream is broken into two), as shown
in the figure. With all three
configurations shown, the valves
modulate flow through the cooling or
heating coil to vary the capacity of the
coil.
 Selection of Two way & three way valve
• In Chilled water line Criteria to use2 or3-way valve depends on the
application type:
• 1. 2-way valves are recommended in Chilled water piping with
primary const. flow and secondary Variable speed pump. 3-way
valves are not suitable for this system.
• 2. 2-way valves are recommended in Primary only Variable speed
pump. to maintain a minimum flow across chiller, a motorised
bypass valve is used across the headers in this system
• 3. When there is a primary only constant speed pumping system is
used,3-way valve is recommended. for this application2-way valves
are not best suitable.
 PICV valve
Pressure independent control valves are an automatic
temperature control valve and an automatic flow regulating
valve packaged in one valve body. A ball valve with a
characterized insert performs as a regular actuated
temperature control valve, and a pressure control cartridge
provides automatic flow regulation to maintain a constant flow
of hot or chilled water regardless of system
pressure changes.
They are used in many closed loop HVAC applications

These valve is both a control valve and automatic balancing

valve in one, the installation is easier. There is no need to
purchase and install a balancing valve and a control valve. This,
in addition to no system balancing and re-balancing, saves
installation costs.
In addition, if the pump speed is controlled with a remote
differential pressure sensor, the greatest savings will achieved
by placing the sensor at the pressure independent control
valve located furthest from the pump. This way the pump is
driven to develop only the head required to support the most
remote valve and coil in the system.
 Benefit of placing the balancing valve on return side
• there is not a right or wrong order to place the balancing valves
because both location have been proven to be effective. Placing a
balancing valve on the supply side will give you satisfactory
results, but choosing the return side can be more effective because
it can reduce air and noise problems while achieving better heat
transfer across the coils. Moreover, the coils can remain fully
flooded and there will be less turbulence due to less free air
trapped in the coils. Due to several above benefits, Hays highly
recommends to install the Balancing Valves on the Return side of
the coil whenever possible.
• At a given temperature, the amount of air in water depends on
pressure. If the, water pressure is reduced, air is released, Flow balance
valves placed on the return side will result in higher water pressures
within the coil, which means that more air will remain in the solution
and out of the coil
Y strainer
 Location of expansion tank open type
What are Expansion Tanks?
Expansion tanks are required in a closed loop heating or chilled
water HVAC system to absorb the expanding fluid and limit the
pressure within a heating or cooling system. A properly sized
tank will accommodate the expansion of the system fluid during
the heating or cooling cycle without allowing the system to
exceed critical pressure limits. The expansion tank uses
compressed air to maintain system pressures by accepting and
expelling the changing volume of water as it heats and cools.
Some tank designs incorporate a diaphragm or bladder to
isolate the expanded water from the pressure controlling air
cushion. As water is expanded, it is contained in the bladder to
prevent tank corrosion and water logging potentials. The
pressure controlling air cushion is pre-charged at the factory
and can be adjusted in the field to meet critical system
requirements. This design and operation of this style of
expansion tank allows the designer or specifying engineer to
reduce tank sizes up to 80%.
A bladder expansion tank is a system which is used for heating
and cooling purposes by absorbing the expansion force. It uses
compressed air to adjust with the pressure changes by eliminating
or accepting the water volume changes as it expands or contracts
Typical expansion tank and air separate piping
Expansion tank
Air vent
Air vent
Pumps in chilled water system
• Understand pumping head
Pumps selection
• In chilled water HVAC plant, the pumps’ role is to provide
sufficient pressure to move the fluid through the chiller and
condenser water distribution system at the desired flow rate.
The pumps are broadly classified in two types: 1) centrifugal
pump and 2) positive displacement pump. In HVAC services,
centrifugal pumps are popular because of its design simplicity,
high efficiency, wide range of capacity and head, smooth flow
rate, low operating costs, varied sizes, and ease of operation
and maintenance. The positive displacement pumps are only
used for chemical dosing in cooling water system.
Pump cross-sectional area
Centrifugal pump
• Centrifugal pumps in
chilled water HVAC plants
are used for circulating
chilled water through
chillers and air handling
units in closed loop and
for circulating cooling
water through condensers
and cooling tower in open
loop. All centrifugal
pumps use an impeller,
which is basically a
rotating wheel, to add
energy to a fluid. Fig
illustrates a cross-section
of a typical centrifugal
pump.
Single suction pump:
pump with single
suction impeller
(suction eye on one
side of the impeller
only). This design is
subject to higher axial
thrust imbalances
due to flow coming in
on one side of
impeller only
Double suction vertical split case
Understand NPSH
• Net Positive Suction Head or
NPSH for pumps can be
defined as the difference
between liquid pressure at
pump suction and liquid vapor
pressure, expressed in terms of
height of liquid column.
Suction head is the term used
to describe liquid pressure at
pump suction in terms of
height of liquid column. When
vapour pressure is also
expressed in terms of
equivalent height of liquid
column, and subtracted from
the suction head, the
difference is npsh available at
the pump suction.
• NPSH a must be higher then
NPSH r to avoid cavitation at
pump suction.
Pump NPSH
• NPSH = 2.31 X ( Pa – Pvp ) + ( Hs – Hf) for water
• NPSH = (2.31 X ( Pa – Pvp )/ sp. Garvity ) +( Hs – Hf ) for other fluide

• Pa = Atmospheric pressure , absolute pressure psig( 32 feet at 1000 feet )

• Pvp = Vapour pressure corresponding to water temperature at the pump
suction , for water at 85 degree F it is 0.59648
• Hs = Elevation head, static head above or below pump suction , of above
static positive head or if below negative static head
• Hf = friction head , loss in suction line .
• 2.13 = conversion factor to change 1 Psig to pressure head in feet
Chilled water AHU piping with Automatic control
Chilled water AHU piping with Manual control
AHU piping for multiple AHU
AHU drain line connection
Condenser piping
Multiple chiller
Multiple pump connection
Cooling towers
Cooling towers
• General operation
Air water contact
Counter flow
Cross flow
• Heat Transfer
Principles
Evaporation
Sensible heat
Latent heat
 Cooling tower basics
• cooling towers are rated in terms of tonnage – specifically how many BTU/Hr
they can disperse through the heat of vaporization.
• refrigeration ton differs somewhat from what is known as a “cooling tower
ton”. A refrigeration ton is equal to 12,000 BTU/hr. A cooling tower ton is
15,000 BTU/hour. The extra 3000 BTUHs is carried over from the refrigeration
cycle.
• the refrigerant entering the compressor during the refrigerant cycle carries
with it the BTUs transferred to it from the chilled water loop. As it enters the
compressor this refrigerant is in a low pressure/low temperature gaseous
state. The compressor “pumps up” the refrigerant into a high pressure/high
temperature state. This process requires energy, basically adding (on average)
3,000 BTU/hr of compressor heat to cooling tower load. Thus cooling tower
ton is 15,000 BTU/hr or 12,000 BTU/hr (Refrigeration Ton) + 3000 BTU/hr
(Compressor Heat).
• This means that the operating parameters at which cooling towers are rated
are based 3 GPM of condenser water entering the cooling tower at 95°F and
leaving the cooling tower at 85°F under 78°F degree wet bulb conditions.
Cooling tower basic
Cooling tower approach
• Approach is the temperature of the water leaving the cooling tower (in
this case, 85°F nominal) minus the ambient web bulb temperature (78°F
wet bulb) or 7°F. This value represents how close the cooling tower gets
the water to the wet bulb temperature of the surrounding air.
• the higher the approach, the smaller the cooling tower can be; the lower
the approach, the larger the cooling tower will be. So first cost budgets
may also impact your decision.
• if the approach of cooling tower increases there is increase in
the TR capacity (Rejection capacity) of cooling tower subject to
hydraulic load bearing capacity. It shows if cooling tower is
selected at lower approach can give higher heat rejection at
higher approach. Also the cost of cooling tower will increase if
the approach of the cooling tower is selected at lower. Based on
the process requirement and life cycle cost approach of cooling
tower needs to be decided.
Cooling tower approach
Cooling tower range
• The “range” is very simply the difference between the entering water
temperature and leaving water temperature. Remember, ambient wet
bulb is the lowest temperature under which evaporation can occur under
a given set of conditions. Thus, cooling towers are sized based on the
design wet bulb of a region – not the sensible (dry bulb) temperature.
• Increasing the range, say from 10° to 15° will reduce the GPM from 3 to 2
GPM per cooling tower ton which means less pump
horsepower. However, if the entering water temperature is 100°F and the
leaving water temperature is 85°F, that yields an average condensing
water temperature of 92.5°F, versus an average 90°F if you designed it to
operate at 95°F/85°F. The higher the condensing water temperature is,
the harder the chiller has to work, which increases kW consumption at
the compressor.
Cooling tower range
Cooling tower water evaporation
Cooling tower blow down
Cooling tower make up water
Cooling tower placement
Cooling tower bypass arrangement
Cooling tower fan
Effect of reduce cooling tower water temperature
Effect of condenser entering water temperature
Cooling tower piping
Cooling tower piping
Multiple cooling tower piping
Classification of cooling tower
 TYPES OF COOLING TOWERS
• Mechanical draft water-cooling tower:
• Mechanical draft cooling towers are more commonly
used for cooling of water. These mechanical draft
cooling towers utilize large fans to force air through
circulated water. The water falls downward over surface
of fills, which help increase the contact time between the
air and water. This helps maximize heat transfer
between the air and water.
• Mechanical draft water-cooling tower consists mainly two
types
• a) Forced draft – In this cooling tower fans located at the
air inlet
• b) Induced draft – In this cooling tower fans located at
the air exhaust.
• Forced draught cooling tower
• These take the form of a large rectangular concrete
structure. The water is pumped to the top and broken up
into sprays. It falls as rain on to successive stages of
boards in the form of louvres of wood, polystyrene or
metal, with notches and ribs to break up the flow. The
water flows from one stage to the next and finally arrives
at the pond which forms the base of the structure, from
which it is taken by the cold water pump. In a forced
draught cooling tower, as shown in figure. The circulation
of air in forced draft cooling tower is produced by means
of fans placed at the base of the tower
•
• Induced draught cooling tower
• In an induced draught cooling
tower, as shown in below
figure. The circulation of air is
provided by means of fans
placed at the top of the tower.
• They are generally induced
draft cooling tower classified
as counter current or cross
flow tower, descriptive of the
direction of air flows relative to
that of the water.
• The counter current tower is
expected to be more efficient,
but the cross flow tower can be
operated with lower power
requirement or higher vapour
velocities.
Choice between forced draft and induced draft
• Weigh the options when deciding between forceddraft or induced-
draft cooling towers. Forced draft cooling towers are advantageous
when you need to overcome static pressure caused by ductwork on
installations inside buildings or full enclosures. However, forced-draft
cooling towers consume significantly more power than induceddraft
cooling towers and are relatively more prone to recirculation if not
ducted. Historically, forceddraft cooling towers have had a significant
install base within the cooling tower market. However, with society’s
focus on energy conservation, new forced-draft cooling tower
applications have mostly phased out, making forced-draft cooling
towers more suitable for replacement than for projects requiring new
cooling towers
• Induced Draft Cooling Tower
Components
• Spray nozzles. These provide the
water sprays to wet the fill. Uniform
water distribution at the top of the fill is
essential to achieve proper wetting of
the entire fill surface.
• Fill. Most towers employ fills (made of
plastic or wood) to facilitate heat
transfer by maximising water and air
contact. Fill can either be splash or film
• Basin. The cold water basin, located at
or near the bottom of the tower,
receives the cooled water that flows
down through the tower and fill
• Fan. Both axial (propeller type) and
centrifugal fans are used in towers.
Generally, propeller fans are used in
induced draft towers and both propeller
and centrifugal fans are found in forced
draft towers
• Drift eliminator. These capture water
droplets entrapped in the air stream
that otherwise would be lost to the
atmosphere.
 Types of cooling tower Cross flow cooling tower
Cross flow is a design in which the air flow
is directed perpendicular to the water flow
(see image ).
Space Requirements The method by which air
interacts with the process water creates two
different styles of plenum areas as illustrated in
Figure 1 and Figure 2, which has a direct effect on
the footprint of the cooling tower. Up to about 750
tons (3295 kW), a counterflow cooling tower requires
less plan area than a crossflow cooling tower, which
makes counterflow cooling towers advantageous in
densely populated metro areas with limited space. At
about the 750 ton mark, counterflow towers offer
little to no advantage in footprint relative to a
crossflow tower. Furthermore, it is critical to realize
not all available real estate can be treated the same.
Depending on the application, a crossflow cooling
tower may require less total area than a counterflow
tower even at heat loads less than 750 tons. This is
because of the air inlets on each style of tower. A
crossflow tower only has two air inlets compared to
four on a counterflow cooling tower,
Types of cooling tower Counter flow cooling tower
Maintenance
Another direct consequence of the
different plenum areas is maintenance
access. the large plenum area in the
center of a crossflow tower is large
enough to stand, making it very easy to
access equipment for inspection and
maintenance.
A counterflow tower by nature has very
limited space to access its components
which makes maintenance and repair
more complicated and time consuming
Cooling tower classification

Mechanical draft tower

Atmospheric spray tower Natural draft tower
Five types of cooling tower water problems
• Scale formation
Little dose of HCl for alkaline water, this problem is not
common in acidic water of pH(6-6.5)
• Corrosion
Chromates of sodium and zinc are most common
• Growth of organics
Direct chlorine shock and chlorinated organic compounds
• Suspended solids
Pre-treatment of water reduces this problem
• Oil leakage
Proper monitoring and maintenance of process
equipment
Cooling tower selection
AHU
 AHU
• Air Handling Unit
AHU is a device used to
condition and circulate air as
part of a heating ventilating
and air-conditioning (HVAC)
system.
• It is a large metal box
containing a blower, heating
or cooling elements, filter
racks or chambers, humidity
& temperature control
loops.
AHU
AHU layout
 Function of AHU
1) Change the temperature of the room air
----- Heating or Cooling

2) Clean the air

----- filter the dust of the air
----- wash away the chemical particle of the air
----- kill the virus, bacteria etc

3) Bring in the fresh air

4) Maintain the pressure of the room

----- positive pressure or negative pressure
Types of AHU
• DX AHU : This AHU is coupled with a
condensing unit. It is using the
refrigerant to cool or to heat the air
directly.
• Thermal AHU : This AHU is connecting
to a chiller or boiler. It is using the
chilled water to cool the air and the
hot water (or steam) to heat the air.
• Types based on Insulation :
• Single SKIN AHU
• Double skin AHU
Single skin and double skin AHU
Coil Rows
Coil arrangement
Coils size calculation formula
• FACE AREA OF COIL = CFM/VELOCITY
Example :
• AHU CFM 12525CFM
• Cooling capacity is 58TR.(chilled water system)
• cooling coil velocity is 500fpm.
• Coil area = 12525/500= 25 SQFeet
• weather coil should be of 4 row or 6 row?.
Delta T ( dF ) = (Capacity( TRX12000)) / 1.08 x CFM
= 696000/ 1.08 x 12525 = 51 Df
Selecting AHU
• The basic relationship between the space heat load and the conditioned air required
to satisfy this load can be expressed as :
• Q = 1.1 × CFM × DT
• Where Q, in Btuh, is the sensible load of a conditioned space at a given time that must
be met by supplying a certain volume of conditioned air at a temperature that is
below, for cooling, or above, for heating, the space temperature.
• 1.1 is a conversion factor for air at sea level and DT is the temperature difference
between room air and supply air . You can select dehumidified CFM as per heat load
calculation to select AHU CFM
• Selecting the Proper Fan Static Pressure
• Manufacturers of AHU’s generally furnish data of their standard units showing, for
each model, supply fan size, coil size, volume flow rate, air velocity at fan outlet, fan
static pressure, revolutions per minute of fan impeller and brake horsepower input to
fan shaft.
• The fan total pressure can be obtained by adding fan velocity pressure to the fan static
pressure. Velocity pressure, in inches WG, can be calculated by the equation :
• Velocity pressure = ((outlet velocity)2)/4005
• where outlet velocity is expressed in fpm
• Selecting the Proper Fan Static Pressure
• Manufacturers of AHU’s generally furnish data of their standard units
showing, for each model, supply fan size, coil size, volume flow rate, air
velocity at fan outlet, fan static pressure, revolutions per minute of fan
impeller and brake horsepower input to fan shaft.
• The fan total pressure can be obtained by adding fan velocity pressure to
the fan static pressure. Velocity pressure, in inches WG, can be calculated
by the equation :
• Velocity pressure = ((outlet velocity)2)/4005
• where outlet velocity is expressed in fpm
Horizontal and vertical AHU
AHU blower centrifugal fan
 AHU filter selection
• Selecting Air Filters : The air handling
unit is expected not only to cool and
dehumidfy the air but also to remove
impurities suspended in the air with
the help of efficient air filters.
• dust particles less than 0.1 micron
behave like gases and have no rate of
fall. Those in the range of 0.1 to 1.0
microns have negligible settling
velocities while those in the range of
1.0 to 10 microns have constant and
appreciable settling rates but are
kept in suspension by air currents.
Particles larger than 10 microns will
normally settle out of the
atmosphere.
• ISHARAE table 1.82( Page 105 ) gives
the selection guidelines for filter
HEPA : high efficiency particulate air ULPA (Ultra-Low Particulate Air)
 Flexible connector
• Flexible Connections A flexible connection is
required between the fan outlet and the supply
air duct to prevent fan vibrations being
transmitted to the ductwork with consequent
noise in the conditioned space. The length of the
flexible connection should be between 7.5 to 10
cms (3 to 4 inches) minimum
• for best results Heavy canvas cloth commonly
used will serve the purpose but is not the best
material for the job since it becomes wet after
use, causing fungus to grow on it, discolor the
cloth, generate unpleasant odours and in course
of time to tear. Importe synthetic material which
retains its flexibility for a long time is used by
many companies in their air handling units as a
standard and the flexible connection itself is
factory provided inside each unit, as shown
Heat recovery wheel
• Wherever a high percentage of outside air is introduced into an air
conditioned area for improved ventilation and reduced pollution, a Heat
Recovery Wheel is used as an integral part of the AHU for heat recovery
and energy conservation.
• The Heat Recovery Wheel can recover both sensible (temperature) and
latent (moisture) energy. As the wheel or rotor slowly rotates
(approximately 20 rpm) between the outdoor and return air streams,
the warm outdoor air is cooled by the return air before it is exhausted
and simultaneously the high moisture content in the outdoor air is
reduced by the lower moisture content in the exhaust air.
• Typical installations involve hospitals, hotels, theatres, auditoriums,
laboratories and other high occupancy areas or industrial process areas
which produce contaminants
Heat recovery wheel
Chilled water AHU piping with Automatic control
Chilled water AHU piping with Manual control
AHU piping for multiple AHU
AHU drain line connection
Condenser piping
Multiple chiller
Multiple pump connection
• Load Control
• The purpose of load-terminal control is to modulate the flow of air or water
through the coil to
maintain building space comfort. This is accomplished by measuring the
temperature of the supply air or space. The temperature is then converted to an
electronic signal that modulate the capacity of the cooling coil to match the
changing load in the space. Three methods of load-terminal control are commonly
used in chilled-water systems.
Three-way modulating valve control
• A. Constant water flow
• B. Variable return-water temperature
Two-way modulating valve control
• A. Variable water flow (pump energy savings)
• B. Constant return-water temperature
Pressure Independent Control Valves and Actuators
• Each of these methods has a different effect on the operation of the system
 Flow control valve
• Control valves may be either two-way
(one pipe in and one pipe out) which
act as a variable resistance to flow or
three-way (two pipes in and one out
for mixing valves – one pipe in and
two out for diverting valves) .
• Three-way valves may be either
mixing (two flow streams are merged
into one) or diverting (a single flow
stream is broken into two), as shown
in the figure. With all three
configurations shown, the valves
modulate flow through the cooling or
heating coil to vary the capacity of the
coil.
 Three way valve control
• A three-way control valve is one
method used to regulate the flow of
chilled water through a
• cooling coil. As the space cooling load
decreases, the modulating valve
directs less water
• through the coil, decreasing its
capacity. The excess water bypasses
the coil and mixes
• downstream with the water that
flows through the coil. As a result,
the temperature of the
• water returning from the system
decreases as the space cooling load
decreases
 Two way valve control
• A two-way modulating valve is
similar to a three-way valve in that
the water flow through the coil is
modulated proportionately to the
load. The primary difference is
that the two-way valve does not
bypass any unused water, it simply
throttles the amount of water
passing through the coil
 Pressure independent control valve
• Pressure Independent Control
Valves and Actuators

• Pressure Independent Control

Valves (PICV) make a significant
contribution to efficient energy
usage and offer cost savings by
preventing over- or under-supply of
heating or cooling energy. They also
improve the control accuracy and,
therefore, enhance room comfort.
 PICV valve
Pressure independent control valves are an automatic
temperature control valve and an automatic flow regulating
valve packaged in one valve body. A ball valve with a
characterized insert performs as a regular actuated
temperature control valve, and a pressure control cartridge
provides automatic flow regulation to maintain a constant flow
of hot or chilled water regardless of system
pressure changes.
They are used in many closed loop HVAC applications

These valve is both a control valve and automatic balancing

valve in one, the installation is easier. There is no need to
purchase and install a balancing valve and a control valve. This,
in addition to no system balancing and re-balancing, saves
installation costs.
In addition, if the pump speed is controlled with a remote
differential pressure sensor, the greatest savings will achieved
by placing the sensor at the pressure independent control
valve located furthest from the pump. This way the pump is
driven to develop only the head required to support the most
remote valve and coil in the system.
 Selection of Two way & three way valve
• In Chilled water line Criteria to use2 or3-way valve depends on the
application type:
• 1. 2-way valves are recommended in Chilled water piping with
primary const. flow and secondary Variable speed pump. 3-way
valves are not suitable for this system.
• 2. 2-way valves are recommended in Primary only Variable speed
pump. to maintain a minimum flow across chiller, a motorised
bypass valve is used across the headers in this system
• 3. When there is a primary only constant speed pumping system is
used,3-way valve is recommended. for this application2-way valves
are not best suitable.
 Benefit of placing the balancing valve on return side
• there is not a right or wrong order to place the balancing valves
because both location have been proven to be effective. Placing a
balancing valve on the supply side will give you satisfactory
results, but choosing the return side can be more effective because
it can reduce air and noise problems while achieving better heat
transfer across the coils. Moreover, the coils can remain fully
flooded and there will be less turbulence due to less free air
trapped in the coils. Due to several above benefits, Hays highly
recommends to install the Balancing Valves on the Return side of
the coil whenever possible.
• At a given temperature, the amount of air in water depends on
pressure. If the, water pressure is reduced, air is released, Flow balance
valves placed on the return side will result in higher water pressures
within the coil, which means that more air will remain in the solution
and out of the coil
• Typical HVAC processes - VAV
• Variable air volume systems are used for controlling
• the air flow of constant temperature in different parts
• of the building
• Dampers inside ducts regulate the flow of air to
• different serving areas
• Pressure difference measurements accross supply
• and exhaust fans are used for maintaining a constant
• pressure inside ducts
• Thermostats inside serving areas are used for local
• setpoint adjustments that affect the air flow through
• dampers
VAV Box
VAV arrangement
Heat recovery wheel
• Wherever a high percentage of outside air is introduced into an air
conditioned area for improved ventilation and reduced pollution, a Heat
Recovery Wheel is used as an integral part of the AHU for heat recovery
and energy conservation.
• The Heat Recovery Wheel can recover both sensible (temperature) and
latent (moisture) energy. As the wheel or rotor slowly rotates
(approximately 20 rpm) between the outdoor and return air streams,
the warm outdoor air is cooled by the return air before it is exhausted
and simultaneously the high moisture content in the outdoor air is
reduced by the lower moisture content in the exhaust air.
• Typical installations involve hospitals, hotels, theatres, auditoriums,
laboratories and other high occupancy areas or industrial process areas
which produce contaminants
Heat recovery wheel
Chiller temperature control
• Chiller control:
• 1.Start–stop
• 2.Chilled-water temperature control
• 3.Monitor and protect
• Key Issues for Chiller-Plant Control
When to turn a chiller on or off
Which chiller to turn on or off
How to recover from an equipment failure
How to optimize system efficiency
How to communicate with the operator

• Chiller Sequencing strategy:

• Turning on an additional chiller
• Turning off a chiller
• Which chiller to turn on or off?
•VRF AC system
VRF AC system:
• Variable refrigerant flow (VRF), also
known as variable refrigerant
volume (VRV), is an HVAC
technology invented in 1982.VRFs
use refrigerant as the cooling and
heating medium. This refrigerant is
conditioned by a single outdoor
condensing unit and is circulated
within the building to multiple fan-
coil units (FCUs).
• IN VRF system 1 TR = 1.21 HP
because VRF capacity mentioned in
HP unit
Typical layout for VRF system
VRF along with fresh air arrangement
VRF heating and cooling
VRF AC layout
• VRF System types
• Cooling only systems (less popular) – those systems can only
cool. Heating is not available. Fan and Dry modes are available
for each indoor unit independently.
• Heat Pump systems (most popular) – all the indoor units can
either heat, or cool (not at the same time). Fan and Dry modes
are available for each indoor unit independently.
• Heat Recovery systems (less popular) – those systems are
the most sophisticated ones, where cooling and heating may
be available by each indoor unit, independently, at the same
time.
Typical VRF system
VRF system arrangement
VRF indoor junction
VRF design flexibility
Comparison with normal split ac