Preaictive System Curve Contro! di ; q Secondary Chilled V\ ve aL aelee EMSDA central air conditioning system usually consists of the refrigeration plant (chillers), chilled water distribution system, air side equipment and air distribution ductwork. The chilled water distribution system is a pipework system connecting the air side equipment to the refrigeration equipment and distributes the chilled water between the chillers and air side equipment. A typical chilled water distribution system consists of pumps, chilled water pipework and a number of control valves. This pamphlet aims to introduce a new algorithm for controlling the secondary chilled water pumps and to discuss its energy saving potential -Secondary Chilled Water Distribution System Ina large central air conditioning system, the chilled water distribution is usually designed with Primary-Secondary configuration (see Fig. 1). The constant speed primary chilled water pumps keep sufficient chilled water flow through chillers while the secondary chilled water pumps distribute the chilled water to/from air side equipment. The air side equipment units are usually installed with flow controlling valves which control the amount of chilled water passing through their cooling coils according to the demand. The secondary chilled water pumps therefore have to be designed to handle variable flow. This requirement gives rise to the need of a control system for the secondary chilled water pumps operation. Colm c] PRE RARBF LENA RA (248) PRKAMRAR AM Se HALE RA RKB RRS RAM RAS) RS Ri HIER FR BEADS HR 7K 3D A BAK LS a HAAS RK DAR BB IAKR > Bk SA — He He Bo HEM) HF BT — ER RI RIK RY Hl FRA at HT BOM REE ° DA+KRRRKAR RR | E-AAD PRE RAR: ORKD RATADR+ KAUARH (BS Bo1) - MRARKRAE RET tA dE 35 7B OS ROK Tt a Re Me TR ALIS RAK RAD BR 2 Rk RLS a A > A Sa A 5) OAR AE OR A $8 A HS 7 BR ak EE + lite WR LY BR ak FR 8 Bt A BT SE it re ARR EO #2 RR Ie RicanChiller Bust Chilled Water Chiller Supply To ase Air Side Equipment Chiller atten alee RK Primary Chilled Water Pumps ee ix DAE BOR os ass me Chilled Water penne Return from ke Air Side Equipment HALLE EAT AR IRIK Fig 1 - Conventional Primary-Secondary Chilled Water Distribution System 1 - DR+RBEARA OL RAD RR Control strategies are employed to adjust the flow of secondary chilled water pumps to match with the demand, The commonly adopted control strategies are constant differential pressure by-pass control, and constant differential pressure variable speed drive control Constant Differential Pressure By-pass Control In constant differential pressure by-pass control, the secondary chilled water circuit is fitted with a by-pass valve modulating to balance the pressure difference between the RAKE BERRA RKR BM RABX RRRN HHT ALE ERAS KNEE Re SRE Hie Hl - HERESH 2H EER AE BRAD RMA RA 5s Oe HO i Pa Sk A Lh Sa H¥ chilled water, supply and return pipes (see Fig.2). The secondary pumps are operating in constant speed, Excessive flow is returned via the by-pass valve to the pump suction side. This configuration is not widely used now because of its low energy efficiency. BY 7k Wis SS 1 HB 1 PS LB 2K M7 Foe Re Ay Re RK RR GR BRT FEW TH iB ° Chiller Ra Chiller Ba Chiller adi) Primary Chilled Water Pumps DRQRAR CHWS To Air Side Equipment ea AD Bk Secondary Chilled ater CHWR from Air Side Equipment RBS elt BURAK Fig 2- Conventional Primary-Secondary Chilled Water Distribution System with Constant Differential Pressure By-pass Valve B2- SEBS BHR RRUARTN RABE Constant Differential Pressure Variable Speed Drive Control With the advancement of power electronic technology and a reduction in price, variable speed drives (VSD) have now been commonly adopted in variable flow pump applications. In addition to the differential pressure by- pass valve, the pumps are driven by VSDs (see Fig.3) to achieve variable flow operation. The differential pressure by-pass valve is HERET SEO H 2 ARS AEF Sih ea RT fe RS) SS (VSD) OR BRBKRRS Pe RE 2S BAZ OKREVSDS HT (@#83) BR Te fe B ZF RADRASEH: CHERstill required: (1) to balance the system 2: (1) EBRRRR EG RAM pressure during transient condition; (2) as D: (2) RAR BR EAR IERE a safeguard to prevent overpressure when PRB A (3) WVSDSRRS A control is malfunction and (3) to allow the LAY / a ‘ 7 “ " PRK RARAAF RH AM billed bi fe | chilled water distribution system for manual 4 MAVSDHRAAD MRBB operation mode when the VSDs are disabled. : For details of VSD applications, please also USSRELHR HHS RR HS refer to "Application Guide To Variable ZHAI Speed Drive" published by the Electrical and Mechanical Services Department (EMSD) which can be accessed on EMSD website. Chiller ve (7 Pressure Sensor 4 ‘ ee \ CHWS To Chiller {air side BUSH {Equipment ' SERA ek Chiller Bett Primary Chilled Water Pumps DAR Secondary Chilled Water Pumps DAU TRARE Pressure Sensor CHWR from Air < Side Equipment CBRL ie Fig 3 -Primary-Secondary Chilled Water Distribution System with Constant Differential Pressure Variable Speed Drive Control H3- BERET KB ARTA RADE RA Compared with constant differential RHARR: ERRARKDRAR pressure by-pass control, studies show that rp a vs DsaRee 4 B#S 5s ee incorporating VSDs for secondary pump application can save about 30% of secondary pumping energy.Predictive System Curve Control is a new advanced control algorithm that can produce further saving even in comparison with constant differential pressure variable speed drive control. Unlike constant differential pressure control, predictive system curve control operates the variable speed drive by signals from a pressure sensor at the pump discharge pipe and a flow sensor at the chilled water circuit return pipe (see Fig. 4) a Al et oR HS Hil A — HY SE HEE aA: EERE SRS HE alt PR- SMA: TAR 15 A) AEF Hil» TA A Oe aa MRE EEARREKRAOKEHRAS SHGRNESRAKARET ORE PRAARPRRAHR (8S Bl 4) Chiller ie Chiller Biot Chiller Rit Primary Chilled Water Pumps DBAAKR \ CHWS To ‘pir Side 1 Equipment | ee Baa 15k Secondary Chilled Water Pumps DRI TRA ‘Flow Sensor (Ra ES CHWR from Air Side Equipment AAS RH Yeak Fig 4 -Primary-Secondary Chilled Water Distribution System with Predictive System Curve Control B4- BARRERA HMR KECARTHARKAE RRPrinciple of Operation The Predictive System Curve Control, as its name suggests, controls the operation of Variable Speed Drives (VSDs) according to a predictive system curve which describes the relationship between the pump discharge pressure and the chilled water flow rate demand of the secondary chilled water circuit. The predictive system curve must be obtained by a precise commissioning process during the control system implementation. The Energy Saving Mechanism The control algorithm saves energy mainly by: 1) The reduction of system resistance due to control valve throttling, especially during part load conditions; and 2). Avoiding delivering excessive chilled water flow through the by-pass valve. Reducing system resistance can reduce the pump head required to deliver the chilled water to fulfill the cooling demand. In the air side equipment, the contro! valve controls the amount of chilled water passing through the cooling coil of the equipment. During part load condition, the valve is closed to restrict chilled water flow through the coil. A high differential pressure is created across the valves and the pumps have to maintain sufficient discharge head to ensure sufficient chilled water flowing through the coil (see Fig.5): aera E BMARH RE: OAM: BR RE SM FRM OR) AR LIS OR 7k BER ZMH BM RRR fl BHA (VSDs) » RAMA ih ARs ZA EH tl A EH ATES ° Bi AE at 48 fil FRE BAA DR Bl AE RR: 1) RD TE RBS BBR RHA cS PT TATE EY) RGA; 2) MRRAES ARK TES A © WD ZB RAB A FT el AR 7k Re WER OR AK ARERRERHEEHRA AK AS HE tl ALS BSR AREHL RKB: EMDR RRM FOR) 42 5 DPS RL LA ia De > ARB SRAM RRR Ik Rs iH HON BH DA HEAR REARRMORRKKE (ASB 5)a% Pressure balance: BAte "| For constant differential pressure control system, AP1 is nearly constant. FE RERHARH aPl BME At full load condition, the control valve is fully opened: RRA PASM AP3 > AP2, with AP2 approximately equals to 25%-50% of API AP3 > AP2, if AP2 Af AP1HI25%-50% When cooling demand is low, control valve is closed to restrict the flow: ERERR TRH PARC BLAME ne ‘AP2 >> AP3 AP3+AP2 = AP1 Fig 5 - Typical Air Side Control of Chilled Water Flow Rate HIS RAGE Se SRA TRIE BY if the pump flow and discharge pressure can be appropriately reduced during part load conditions, the control valves can be opened more widely. This can keep the cooling demand satisfied and at the same time reduce pumping energy. Additionally, the adjustment of the pump flow and discharge pressure can prevent excessive flow returning to the pump suction through the by-pass valve under extreme part load condition. Fig. 6 shows the pump operating curve of the secondary chilled water pumps under different load conditions. At extreme part load conditions (Chart 3 in Fig.6), although the flow demand may be less than Q1, the pump VSD frequency cannot be further lowered because the pumps have to maintain the set point differential pressure. Excessive flow will still be returned to the pump suction through the by-pass valve. 38 05 20 ROK RR it BA BH FT A i hh mo RAHM RSP + TERT BL MR RK RE fEo Ab: HB KR SMBH ire AKARKE TAS ARK ES AEE KRMKOs HERRRR RAK REA FR RK EE fT eh Re EMRARRRT (Betray R3) HARSH Rtas + AA RKRKARE EERE - Ik RAY VS D $A F A] ae HE — EB OSH RS Ses MRA KR Moko «On the contrary, a well implemented Predictive System Curve Control should have no water flow through the by-pass valve under normal operation. HR — (BL 5c AA FB ea MR HE EER HZ PAR RAE Rk it Os RAH > Differential Pressure RE Sul 7 Bee e | I 2 1 eo Vv Qi Flow Chart 3 = a3 Flow Chart 2 itt WR Chart 4 -Pump set operating at full speed. (Full load) Bk - REISER) « Chart 2-Pump set operating at reduced speed due to a reduction in cooling demand. (Part load) HA2- BORER TM ARE MBET MOA i) Chart 3 -Pump set operating at very low speed due to extreme part load. BA3- RRR KREMER « Fig 6 - Typical Pump Curve Under Constant Differential Pressure VSD Control 6- SERETR ESHA HREAKRE TR Implementing The Control Strategy The system can be implemented relatively easy if the secondary chilled water pumps are already operating with VSDs. The followings are some general prerequisites for effective system implementation: * The cooling capacity of the chiller plant, ‘the chilled water distribution system and the air side system should be sufficient (or have some spare capacity) for the premises. Undersized plant or marginal plant will have fewer (or no) chances to RRA MOR RM RIkKRAMAVSDSR fe: BRAM MS) AAR A BR UR e- HAMM EA BY — BEE IR MRE © BFOMRE ORKARARAK BREN RAE (RA GRAS) eee Ee* There should be a sufficient section of Straight pipe run for installation of the flow meter sensor. Usually a straight section with length equal to about 10 - 15 diameters of the main chilled water pipe in the secondary circulation loop is required for accurate flow measurement. * The temperature control of the air side equipment should be functioning properly. * Control valves of air side equipment should be two-port valve. Three-port valves are not suitable for this control system unless they are replaced. + The scale of the chiller plant should be large enough to generate meaningful energy saving * For retrofit, if the original system is not equipped with VSDs, consideration should be taken for technical requirement of installing VSDs for the purnps. The predictive system curve control algorithm is embedded in a standalone Direct Digital Control (DDC) controller. For existing secondary chilled water pumping system, the algorithm can be implemented to co-exist with the existing secondary pump control system with a selector switch selecting the signal being fed to the analogue input of the VSDs (see Fig. 7). This ensures that the existing control system can be used in case the new control system is malfunction. A selector switch can be installed with "signal isolator” to enhance smooth switchover and to reduce risk of control system damage due to incorrect analogue signals HEGRE REMREN BREGL: BE KSHSCHES RASRE HERR BRAS MEMO 158 Ee RKS RENE BS ‘be RRL i oR HAR 7k EH He AE TE AS fre © RAR ARS ° = PRENSA ES HARE © ° FORMA NUR CARER BOT RR AAEM « * ERRLEP MRRAMRARA VSDs * AREKIFIES 4 ASK AEVSDS POH EER « KG a ARE hl BY at FFARR A AR KR-fPBULERAFRH (DDC) # BEER + TERA AD IRM ROKR A "pos 3 (Et WAS FR A] A SR AK KRW ARKAE CRRRSRR HUEVSOSHRHA MER (24 BL 7) > SB PYAAR at 20H AF ah A BE HR a MBS] eR AY HE al ABE RET AR A ERABS! Rte LER SRGARS AREER HES i S| BUR HH Hl AGN AR ° 5SAnalogue Output Signal of Control Systems Ft AAR HES Analogue Input Signal of VSDs VsDsitl Hee AES Fig 7 - Typical System Implementation Diagram for Existing Secondary Chilled Water Pumping System 7 - FRB RMARKR REA DAL RITE Compati ty With the System's Existing Staging Controller The pumps staging and de-staging control has to be checked for compatibility. Pump staging and de-staging determine how many pumps are switched on for operation. Secondary pumps operated manually (that is, the number of pump being operated is selected by site operating staff) should have no problem in implementing the control. Site operators only need to operate the pumps base on their usual practices. RRA KR KR A Bee BO ae Ste ARGRBMRRESLEKRE te BRS AR Aw th OR AE i] HARARE BORAL AFR FEAR ROKR OK RET AB hE ARB) ER i a ROR TA Be RP BR RR th PY BBR KR *ists the number of pumps to operate rder to maintain a constant differential pressure set point) is not compatible with the new control because both controls are pressure based set point control. In this case, modification will be required. If the computerised pump staging and de- staging is based on flow rate requirement (that is, a computer or a local electronic controller adjusts the number of pumps to operate in response to the water flow demand in the circuit), there is good chance for compatibility without any need for modification. Deriving the Predictive System Curve The predictive system curve control adjusts the frequency of the VSDs according to a curve describing the relationship between the discharge pressure and the chilled water flow rate. The curve is site specific and has to be determined through a precise commissioning process. The energy saving potential is hinged on accuracy of the predictive curve model. A typical predictive system curve is shown in Fig, 8 below: . BRAREMREKRARH SB 46 # tel 3S (BOA ER ok HF HS) SB BKARNRSARH-AESHRE RE) RRM R A Be ARMA ARLARKREDRER Sl ERMA RT LREERRA RM REMCHARS A Hl ASR RES (NASM REFT RWB BKROREADMKRE RK) - BRAS TH EAR A Wi fe i 1K DEBRA + Dy He RH HA He eh FAW A dh PF il EAB RA Ok RH ABAN Rk SAA oR RA BVSDs Hy sas o dh Re MA BIS BOK A RA + Ht BO eB — (EL HE HE 0 GB ot I RE Go BH AE 1 HR RRA RRM AME AA Ay AMAR ARB AEB BMT:Pump Discharge Pressure ARE OBA 0 Chilled Water Circuit Flow Rate qi RRB RE Fig 8 - Typical Predictive System Curve BIS REG EWRE BR In the above diagram, HO is the minimum pressure required at the pump discharge to pump water to the air side equipment at the farthest end of the chilled water pipe work. This is the minimum pressure that the secondary pumping system will be maintained to ensure sufficient pump head to reach the farthest end air side equipment H1 and Q1 are the pump discharge pressure and flow rate when all the control valves in the air side equipment are fully opened. The predictive system curve can then be determined by curve fitting the flow EERE P HORM RK BAS) WBE 7k Se HN) — fed OK a HB) > RABK+ BERKRRRRERA HR PEAURBARA EAE NR ND H141Q12 PFA AD A Si a HH AZ MTR ARKORA MAE > AA RRS SRAM RSM REE TRARAEHRRBARK DBR, the model equation. These coefficients are site specific. Checking of the predictive system curve is then carried out by opening and closing of air side equipment control valves floor by floor to verify against the predictive system curve conditions The process of finding the predictive system curve is much easier if the air conditioning system can be controlled by building automation system (for switching on/off of air side equipment, varying set point to fully open the control valves, etc.). For building that is not equipped with building automation system, the curve can still be determined with the air side equipment being operated manually. However, it will take much longer time and will be more labour intensive. The Predictive System Curve Control strategy enables the secondary chilled water pumps to be operated more closely with the cooling demand of the building and reduces energy wastage. It should however be noted that the energy saving achievable is site specific which depends on the load pattern and the conditions of the plant equipment. For further information, please contact the Energy Efficiency Office of The Electrical and Mechanical Services Department. WAR: BH AMAA RKRA BAH RELA REA AMY SH fe i OST A BKM KH A AR AY AD SEE WREAK TARSAL AR feo) CPR Bi a Bie Re ASE Ae HSS) Mati HUARHRANMRAL RAR - RARARSRRILARHAR: B AF 2 4F K Boe a8 8 05 FR Bt AMER Ki HH E RR AS Fi AURARMAF > FA A i oa ARE Hil 7 OK EK MLS RIK RERESKRA RN ARE RE fe SLD RE ROA FE + PR Th ARK BS BG fe MRAAARRKARATAMH MMRARARHARRAARA RH HR: Ma SRE ES RH # RELL LARA PKA >A Predictive System Curve Control system has C-RAEPARKT BARRA been implemented in a Government premises UE SIR ARBAT Al as a pilot project. Basic Information of the Case: GEHESRA Number of chilled water pump: 3 Nos. (2 duties + 1 standby) KBE: 3A (2ABT+1 AK) Rating of pump motor: 37 kW ARB: 37F Original control system: Constant differential pressure RAR: HEReS AEH A al Variable speed drive equipped: Yes. BR BB ke es: z Pump staging/destaging control: Manual AR & BE tel AF #8 fil Pump Operating Hour: According to office hours (10 hours each day) of the building Ik RRS 77 RRABRA SHR (SA10 85) Chilled Water Circuit: The chilled water circuit is serving the high zone of the building. RK HB RAMEE SA RKB A BS Result of the Pilot Project: Ret MHRR The power consumption of the original control system was recorded during January 2007. This forms the base case data in establishing a mathematical model for predicting the power consumption for the pump operation under other conditions. The energy consumption of the secondary chilled water pumps were recorded from February 2007 to July 2007 with the pumps controlled by the Predictive System Curve Control. The period covered a full range of operating conditions from cold winter to hot summer. In this pilot case the energy saving of the secondary pumps was found to be about 69% in winter, 48% in spring and 13% in hot summer, The overall saving throughout the period is about 38%. Operating staff of the premises did not receive any negative feedback about indoor environmental condition during the test period. RR PAT 20075 1H MRA Hl ARMKRE Fac Se fe OER — fF A! RB KR EH fh HB ERD 8 SFE I A RI FR 6 da RE Hi ALR TR BUS Rk RR 200742 A Bl 2007 #7 A yee RAR: MM AERRHSARAMHEK: S-ARPAHRERR- ERR BRERA KRARKRMMRRESKH69%: ERKB48% ' ERXRMNBRA a a ae RAREcece Paper EMSD AELARE KRRRSBR Energy Efficiency Office Electrical and Mechanical Services Depat Ranma oR 3 Kai Shing Street, Kowloon, Hong Kong ‘BIE To: (852) 1823, 2808 3485, {95T_ Fex (852) 2690 6081 184, Homepage: htpw.omsd.gov.hk {CH Email: eopubicgemss.govhk