Optimizing Pumping Solutions For HVAC

Applications
Topics for this module
• Hydronic chilled water system for air conditioning

• Law of the T

• Constant flow (constant primary) system

• Constant primary/variable flow secondary system

• Primary/secondary/tertiary pumping systems

• Mixing loop

• Variable primary flow systems

• Differential pressure sensor

Central (hydronic) air conditioning system

A central system overall consists of the following five sub-systems, which work
together to form a hydronic air-conditioning system
Five Sub Systems Of A Central Air Conditioning
System

2.
3. HEAT
1. CHILLED
4.
5. AIRREJECTION
WATER
SIDE LOOP
REFRIGERATION
CONTROLS LOOP
LOOP
LOOP
Chilled water loop
• Chilled water loop - Consists of circulation pumps, which carries the cool water from the chiller to the
various distribution systems like Fan Coil Units (FCU) or Ceiling Suspended Units (CSU) or Air Handling Units
(AHU) or Radiant Cooling Panels (RCP)

• Various distribution methods, piping/pumping schemes are employed to carry the chilled water to these
distribution systems based on load demand
Topics for this module

• Hydronic chilled water system for air conditioning

• Law of the T

• Constant flow (constant primary) system

• Constant primary/variable flow secondary system

• Primary/secondary/tertiary pumping systems

• Mixing loop

• Variable primary flow systems

• Differential pressure sensor

Law of the T

5 Amp

1 Amp 4 Amp

1Ω
Gustav Kirchhoff 4Ω
(1824-1887)
Kirchhoff's current law states that the sum of the currents
flowing into a node equals the sum of the currents flowing
out of the node.
Law of the T

Resistors for electric circuits

Valves = resistors for flow circuits

Topics for this module
• Hydronic chilled water system for air conditioning

• Law of the T

• Constant flow (constant primary) system

• Constant primary/variable flow secondary system

• Primary/secondary/tertiary pumping systems

• Mixing loop

• Variable primary flow systems

• Differential pressure sensor

Constant flow (constant primary) system
3-way
control valves
Chiller - 3
Chiller - 2
Chiller - 1

• High pump power

Cooling Loads consumption

• Loss of cooling
Primary Pumps performance

Constant
Low delta-T syndrome
Topics for this module
• Hydronic chilled water system for air conditioning

• Law of the T

• Constant flow (constant primary) system

• Constant primary/variable flow secondary system

• Primary/secondary/tertiary pumping systems

• Mixing loop

• Variable primary flow systems

• Differential pressure sensor

 Constant primary/variable flow secondary system

Secondary
Chiller - 3 Pumps
Chiller - 2
Chiller - 1

• Constant primary flow

DP • Variable secondary flow

Secondary Control

Primary
Panel
2way control • More energy efficient
De-coupler

Pumps valves

Constant Variable
De-coupler sizing
Topics for this module
• Hydronic chilled water system for air conditioning

• Law of the T

• Constant flow (constant primary) system

• Constant primary/variable flow secondary system

• Primary/secondary/tertiary pumping systems

• Mixing loop

• Variable primary flow systems

• Differential pressure sensor

Primary/secondary/tertiary pumping systems
Chiller Plant Room Tertiary
Pump
Room

Secondary

Building 1
Pumps
Chiller - 3
Chiller - 2
Chiller - 1

Tertiary
Pump

• Zone divided

Building 2
De-coupler

Primary
Pumps
• Increased energy
efficiency

Tertiary Tertiary
Pump Pump

Building 4 Building 3
Constant Variable Variable
Primary/secondary/tertiary pumping systems
△P
Cooling Loads

Pump
Controller

• Proportional pressure
control based on P
Tertiary
Pump
Tertiary
pump

Supply 7 oC

△P
Return 13 oC

Constant Variable Variable

Signal to secondary pump controller
Topics for this module
• Hydronic chilled water system for air conditioning

• Law of the T

• Constant flow (constant primary) system

• Constant primary/variable flow secondary system

• Primary/secondary/tertiary pumping systems

• Mixing loop

• Variable primary flow systems

• Differential pressure sensor

Mixing loop

Tertiary
pump
Topics for this module
• Hydronic chilled water system for air conditioning

• Law of the T

• Constant flow (constant primary) system

• Constant primary/variable flow secondary system

• Primary/secondary/tertiary pumping systems

• Mixing loop

• Variable primary flow systems

• Differential pressure sensor

Variable primary flow (VPF) systems

Flow
meters

Cooling
Loads
Chiller - 1

Chiller - 2

Chiller - 3
Minimum flow
bypass valve
normally closed

2way control
valves
Primary
Pumps

Variable
Minimum flow bypass valve
20 M3/H 12 M3/H

Controller 8 M3/H
Cooling
Loads
Chiller

Minimum Flow Bypass

Valve Normally Closed

2 Way Control
Valves

20 M3/H 12 M3/H
Variable
Topics for this module
• Hydronic chilled water system for air conditioning

• Law of the T

• Constant flow (constant primary) system

• Constant primary/variable flow secondary system

• Primary/secondary/tertiary pumping systems

• Mixing loop

• Variable primary flow systems

• Differential pressure sensor

Differential pressure sensor – direct return piping
• Location of differential pressure sensor is critical in the performance of variable volume pumping system be it
primary/secondary or variable primary flow system.

• Only if the DP sensor is located at the most critical zones, it can sense the load changes effectively to modulate the
distribution pumps.

• For direct return piping scheme like the one shown below, load closest to the plant having the shortest path will
experience entire pump head. Pressure drop is minimal near to the plant and it is substantial at the end of the piping. Here
balancing valves are required to ensure right flow to each circuit.
Differential pressure sensor – reverse return piping
• For reverse return piping scheme, pressure drop is theoretically the same across all load points due to equal
length of piping from the chiller plant to the cooling loads. Pressure drop is nearly the same from the plant
to the end of the piping.

• Decision to use direct return or reverse return piping is based on system operability vs fi rst cost, and it is left
to the designer and the owner to decide.
Single delta-P sensor or multiple?
• There is always a question on whether to use single sensor in
the system or need to use multiple sensor to ascertain the
load changes

• One DP sensor is good enough for closed loop application as

change in load affects complete piping system and if the DP
sensor is located correctly then it can sense the load changes

• When a larger number of sensors are used unnecessarily in

the smaller piping system, too many sensing points increase
the scan time and at any point of time, if one or the other
sensor is having a deviation from the set point, the pump
controller will try to respond – making the system unstable

• Key is to avoid too many sensors, have either one or

maximum two in the system and locate it properly in the
piping network
Thank you