AC-Training II.2 Cooling Distribution

Inspection of AC-Systems
II 2 Cooling
II.2
Distribution
Author:
Prof.(FH) DI Dr. J. Geyer
Enertec Naftz&Partner OG
Graz, Februar 2012
MOVingfromInspectiontoDomesticAdvicebyservicecompanies
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II.2 Cooling distribution
Agenda
Basics
Direct Cooling
Air-based Systems
Air/Water-based Systems
Water-based Systems
Hydraulic circuits
Checklist, Advices
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Agenda
Basics
Direct Cooling
Air-based Systems
Water-based Systems
Hydraulic circuits
Checklist, Advices
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Basics: cooling or heat transfer medium
Place of Cooling generation (Chiller) is generally not the place of

coolingg demand (room
( to be chilled))
heat must be transported from the place of cooling demand to the

pplace of Cooling
g ggeneration
Chiller
- - -
Cooling demand
- - -
Cooling demand
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Refrigerant medium: (at direct cooling systems)
+ No additional medium, no additional pumping effort
Bad controllability, refrigerant medium in living zones
Air: (ventilation and air conditioning system with air distribution)
+ Good controllability
controllability, central chilling generation,
generation air is easy to
handle (no problem with leakages), automatic ventilation
Huge volume flow,

flow huge cross-sections of air ducts
Additional energy effort for transportation of air
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Water: (indirect cooling with cold water)
+ Good controllability, small volume flow, small cross sections of

pipes
No ventilation, water damage in case of leakage, in endangered

areas frost protection required
B i (indirect
Brine: (i di cooling
li with
i h brine)
bi )
Same as with water
+ No frost protection required
Smaller heat capacity and higher pressure drop (higher viscosity)

than water
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Ethylene Propylenglycol/
medium Air Water glycol/Water Water
(30%/70%) (30%/70%)
Densiy (1bar, 10C) [kg/m] 1,19 1.000 1.052 1.034
Specific heat capacity [kJ/kgK] 1,005 4,186 3,718 3,864
Mass flow rate per kW at
[k / ]
[kg/s] 0 1658
0,1658 0 0398
0,0398 0 0448
0,0448 0 0431
0,0431
t=6K
Volume flow rate per kW at
[m/h] 501,7 0,143 0,153 0,150
t=6K
Pressure drop [Pa/m] 15
1,5 130 **) 166 **) 178 **)
*) at di=300mm, w=6m/s, t=18C
**) at di=50mm, w=0,7m/s, t=6C
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transportable heat energy (cooling energy)
Q& = m& c p T & heat capacity [kW]

Q
&
m ........mass
mass flow [kg/s]
or &
V
volume flow [m/s]
& = V& c T
Q .density [kg/m]
p
cp........specific
specific heat capacity [kJ/kgK]
DT....... temperature difference [K]
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Monoethylenglycol
concentration vol% 0 5 10 15 20 25 30 35 40 45 50 55 60
1.140
1.120
1.100
1.080
density [kg/m]]
1.060
1.040
1.020
1.000
980
960
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100
t [C]
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Monoethylenglycol
concentration vol% 0 5 10 15 20 25 30 35 40 45 50 55 60
4,50
4,30
4,10
3,90
3 70
3,70
cp [kJ/kgK]
3,50
3,30
3,10
2,90
2,70
2,50
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100
t [C]
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E
Example:
l
Cooling capacity to be transferred: 50 kW
medium: water (cp=4,186 kJ/kgK, =1000 kg/m)
temperatures: 6C/12C
asked: required mass flow rate? required volume flow rate?
from:Q& =m & c p T
Q& 50 kg
& =
m = = 1,99
c p T 4,186 (12 6) s
from:
& = V& c T
Q p
Q& 50 m m
V& = = = 0,00199 = 7,17
c p T 1000 4,186 (12 6) s h
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E
Example:
l
medium: monoethylenglycol/water30%/70% (cp=3,718 kJ/kgK, =1053 kg/m)
from:Q & =m & c p T

&
Q 50 kg
& =
m = = 2,24
c p T 3,718 (12 6) s
from:
& = V& c T
Q p
Q& 50 m m
V& = = = 0,00213 = 7,66
c p T 1053 3,718 (12 6) s h
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Example:
Medium: air (cp=1,005 kJ/kgK, =1,2 kg/m)
from:Q& =m & c p T
Q& 50 kg
& =
m = = 8,29
c p T 1,005 (24 18) s
from:
& = V& c T
Q p
Q& 50 m m
V& = = = 6,91 = 24.876
c p T 1,2 1,005 (24 18) s h
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P
Pressure D
Drop
During the flow through pipes or air ducts occurs a flow pressure drop caused by friction and
turbulence which has to be compensated by pumps or ventilators 1pressure
p dropp pipe
pp
2pressure increase Ventilator
3pressure drop pipe
4pressure drop bend
5pressure drop pipe
6pressure drop bend
7pressure drop pipe
8 ambient pressure
pressure
4
3
5 6
2 7
1
8
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P
Pressure ddrop
general:

p = w2 p.......pressure drop [Pa]
2 .. pressure loss coefficient [-]
.density [kg/m]
[kg/m ]
w.flow speed[m/s]
..friction factor of pipes [-]
llength of pipe [m]
d..inner diameter of the pipe (hydraulic
diameter) [m]
l
For pipes and air ducts: =
d
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P
Pressure llosses
friction factor of pipe from Moody-Diagram according to
Reynolds
y number ((Re)) and relative roughness
g of ppipes
p ((k))
w d Re.......Reynolds number [-]

Re = w
w..flowflow speed [m/s]

.. kinematic viscosity of the flowing
medium [m/s]
d.inner diameter of the pipe (hydraulic
di
diameter)
t ) [[m]]
kinematic viscosity of:

until Re < 2300: laminar flow
water (10C): ca. 1,3 . 10-6 m/s
ab Re > 2300: turbulent flow air (20C): ca. 15,2 . 10-6 m/s
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Moody Diagram
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P
Pressure ddrops
The Moody-Diagram is valid for all media (e.g. air, water, brine, oils etc.)
With non-circular flow-cross sections ((e.g.
g rectangular
g air duct)) the so called
hydraulic diameter has to be used in the formula
w dh 4A
Re = dh =
U dh.......hydraulic diameter [m]
A.flow cross section [m]
U.perimeter of flow cross section [m]
e.g. rectangular cross section:

h
4A 4hb 2hb
dh = = =
U 2 (h + b) (h + b) b
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P
Pressure ddrops: pipes,
i air
i ducts
d t
for fittings, armatures: according to the shape
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Determination of ppressure dropp with diagrams:

g
Nominal
diameter of
pipe
Fl
Flow speed
d
Pressure
drop
V l
Volume fl
flow
Friction diagram for cold water pipes
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P
Pressure ddrop: P
Pumping
i effort,
ff t ventilation
til ti effort
ff t
theoretical drive power:
Pth = V& p
actual drive power:
Pth V& p
P= =
Pththeoretical drive power [W]
P..actual drive power [W]
V& ..volume flow [m/s]
p
p.......pressure
pressure drop [Pa]
.......... overall efficiency [-]
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P
Pressure ddrop: P
Pumping
i effort,
ff t ventilation
til ti effort
ff t
Drive power:
Pththeoretical drive power[W]
Pth V& p P..actual drive power [W]
P= = & ..volume flow [m/s]
V

p.......pressure drop [Pa]

..........overall
overall efficiency[-]
efficiency[ ]
because: p = w2 A..flow cross section [m]
2
w..flow speed [m/s]
V& p V& ... p pressure loss coefficient [[-]]
P= = w2
2 density [kg/m]
V&
with: w=
A
V& V& V& 2
P= w =
2
= V& 3
2 2 A2 2 A 2
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P
Pressure ddrop: P
Pumping
i effort,
ff t ventilation
til ti effort
ff t
Drive power:

P= V& 3
2 A 2
P increases in a given medium and air-duct or pipe system with V
On doubling the volume flow the drive power increases eight times!
Halving the volume flow reduces the drive power to 12,5%!
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Agenda
Basics
Direct Cooling
Air-based Systems
Water-based Systems
Hydraulic circuits
Checklist, Advices
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Direct Cooling
Evaporator is situated directly at the place of cooling demand

(Small AC-Device):
Regarding the situation of the chiller (compressor of cooling

medium, condenser) you can distinguish:
AC-devices with internal chiller
p
AC-devices with separate ppositioned chiller ((split-system)
p y )
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Agenda
Basics
Direct Cooling
Air-based Systems
Water-based Systems
Hydraulic circuits
Checklist, Advices
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Air
Air--based System (solely
(solely--air
air--based system)
Air: (Ventilation and Air-Conditioning System with Air Distribution)
Central air-conditioning (heating, cooling, de-humidify, humidify)
Distribution through air-duct-system
Insertion through air inlets
Generally supply and return-ducts are required
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Air
(solely--air
air--based system)
central air-conditioning
distribution via air ducts
recommended air velocity
air duct convenience systems industrial systems
main ducts 4 to 6 m/s (to 8 m/s) 6 to 10 m/s (to 12 m/s)
distribution ducts in storeys 3 to 5 m/s 5 to 8 m/s
flexible tubes 2 to 4 m/s 4 to 6 m/s
Hi h air
Higher i velocity
l it results
lt in:
i
+ smaller cross sections of ducts
Higher pressure drops (driving power of ventilators)
Higher noise level (flow noise)
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Air
(solely--air
air--based system)
Ai (Ventilation
Air: (V til ti andd Air-Conditioning
Ai C diti i System
S t with
ith Air
Ai Distribution)
Di t ib ti )
The air flow should always be as small as possible because the effort for the
transportation can be reduced considerably (smaller pressure drops)
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Air
(solely--air
air--based system)
E
Example:
l
Which driving power is required by the following air duct system?
air flow rate = 30.000 m/h
overall pressure drop= 1.200 Pa
efficiency of fan = 75%
Efficiency of driving engine = 90%
1 1
P = p V& = p V&
ges vent eng
30.000 1
P = 900 = 11.111W = 11,1 kW
3.600 0,75 0,90
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Air
(solely--air
air--based system)
Example:
What is the driving energy demand per year at an operating time of 6000 hours per year?
W = P t = 11,1kW 6.000 h = 66.600 kWh
Which cooling capacity can be transported at a temperature difference of 6K?
& =m
Q & c p T = V& c p T with:
cp......spec.
p heat capacity1,005
p y , kJ/kgK
g
density of air ca. 1,2 kg/m
& = 30.000 1,2 1,005 6 = 60,3 kW

Q
3.600
Regarding the transported cooling capacity the required driving power is

much too high!
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Air
(solely--air
air--based system)
Ai vents
Air t
According to application and requirements many different air vents are used
Examples for ceiling vents
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Air
(solely--air
air--based system)
Ai vents
Air t
Examples for wall-vents
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Air
(solely--air
air--based system)
F
Fans
According to application and
requirements different fan-types are used
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Air
(solely--air
air--based system)
F
Fan
Different types have considerable different efficiency
Both efficiency of fan and the combination of fan and driving engine (possibly belt
transmission) are significant
a) High performance blade wheel with

6 to 12 backward-curved blades
b) Drum impeller with ca. 40 Forward-

curved blades
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Air
(solely--air
air--based system)
Fan with forward-curved blades Fan with backward-curved blades
max. max.
67% 81%
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Air
(solely--air
air--based system)
Example: performance map of fan
F
Fan
Depending on the operating point

the same fan shows different
efficiencies
The right dimensioning (close to
the highest efficiency) is very
important for efficient operating
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Air
(solely--air
air--based system)
Ai (Ventilation
Ai C diti i System
S t with
ith Air
Ai Distribution)
Di t ib ti )
Normally that mass flow of air is supplied to the conditioned room in a stationary state which
is also dissipated,
p , because otherwise there would be an over- or underpressure.
p Because of
leakages a part of the supply mass flow can run out or can flow into the room. So the mass
flow of supply and return has not to be the same.
If the supply flow is higher than the return flow the excessive air must run out through leakages.
Therefore there must be an overpressure in the room compared to the atmosphere.
atmosphere
If the mass flow of the return duct is higher than the supply flow the difference must be
recovered from outside. This means that there is an underpressure in the room .
So you ca
can depe
dependent
de t oon tthee leakages
ea ages of
o the
t e room
oo generate
ge e ate an
a overpressure
ove p essu e or
o an
a u
underpressure
de p essu e
through the difference between supply flow and return flow.
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Air
(solely--air
air--based system)
Ai (V
Air: (Ventilation
til ti andd Air-Conditioning
Ai C diti i System
S t with
ith Air
Ai Distribution)
Di t ib ti )
Thermal insulation
According to temperature differences between the air in the ducts and the ambient the ducts
have to be thermal insulated.
Beside the heat loss through not insulated ducts there could be problems due to condensing
water If the temperature at the surface of the duct falls below the dew
water. dew-point
point this can lead to
moisture penetration and corrosion.
The temperature can fall below the dew-point both at the inner and the outer surface of the
duct (but always on the warmer side). Usually the thermal insulation is mounted on the
outside
t id off the
th duct
d t due
d tot hygienic
h i i andd fluidic
fl idi reasons.
If there is a risk of shortfall of temperature below the dew-point at the side of the thermal
insulation a vapour barrier must be installed because otherwise the vapour would diffuse to
the surface of the duct and would condense there.
Because the temperature differences in ventilation and air-conditioning system are usually
small the thermal loss is very small even with very small thickness (20mm 40 mm) of the
thermal insulation .
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Air
(solely--air
air--based system)
Ai (Ventilation
Ai C diti i System
S t with
ith Air
Ai Distribution)
Di t ib ti )
System Calibration, Adjustment:

IIn air
i duct
d systems with i h more than
h one vents theh volume
l flow
fl forf every vent
must be adjusted. The pressure at Vents near the fan is higher (the pressure drop
is smaller) and therefore there is a higher volume flow. In this case the pressure
ddrop
op has
as to
o be increased
c eased (e.g. with
w a throttle
o e flap).
ap).
In each path of the air flow from the fan until behind the vent the pressure drop
must be exactly the same to get the desired amount of air. If this condition is not
met other volume flows as desired will necessarily arise to meet the physical
conditions.
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Air
(solely--air
air--based system)
30 m
B (desired: 1.000 m/h)
d=350mm
30 m
d=230mm 20 m
d=350mm
d=230mm
d 230mm d 230
d=230mm
20 m
A (desired : 1.000 m/h) C (desired : 1.000 m/h)
50m 10m
Gy_GT1_01_02_26
At these
th points
i t the
th flow
fl mustt be
b throttled
th ttl d otherwise
th i a higher
hi h flow
fl would
ld arise.
i
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Air
(solely--air
air--based system)
Ai (V
Air: (Ventilation
til ti andd Air-Conditioning
Ai C diti i System
S t with
ith Air
Ai Distribution)
Di t ib ti )
1
1. filter
2. preheater
3. air cooler
4
4. air washer with demister
5. supplementary heater
6. fan
7
7. Sound absorber
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Agenda
Basics
Direct Cooling
Air-based Systems
Water-based Systems
Hydraulic circuits
Checklist, Advices
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Air/
Air/Water
Water-based Systems
Water-
In such systems a central air-conditioning is done only for that amount of

air which is necessary for ventilation of the rooms
Generally this amount of air (external air for ventilation) is considerably

smaller than the amount which is necessary for cooling.
The necessary additional heat dissipation is carried out by additional

cooling units which are supplied with cold water.
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Air/
Air/Water
Water-based Systems
Water-
Advantages:
+ smaller amounts of air
+ smaller AC-units for and smaller air ducts
+ smaller energy effort for transportation of air
+ ggood controllability
y ((distributed))
Disadvantages:
many single units
additional cold-water piping (with required diffusion resistant thermal

insulation)
Dissipation system for condensate (in case of temperature shortfall

below dew point at the local units)
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Air/
Air/Water
Water-based Systems
Water-
Locally cooling with:
Induction units
Fan-coil-devices *)
cooling ceiling*)
Cooling of structural components *)
*) These devices are primarily used with solely water systems
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Air/Water
Air/Water--based Systems
Ai /W t b d Systems
Air/Water-based S t with
ith induction
i d ti devices
d i
1. filter
2. preheater
3
3. air cooler
4. air washer with demister
5. supplementary heater
6
6. f
fan
7. sound absorber
8. inductiojn unit
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Agenda
Basics
Direct Cooling
Air-based Systems
Water-based Systems
Hydraulic circuits
Checklist, Advices
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Water
Water--based Systems
No central conditioning (cooling) of the air
The necessary additional heat dissipation is carried out by locally installed

cooling units which are supplied with cold water.
If necessaryy additional measures for ventilation must be provided

p (e.g.
( g
natural ventilation or separate ventilation system)
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Water
Water--based Systems
Locally cooling with:
Fan
Fan-coil-devices
coil devices
cooling ceiling
Cooling of structural components
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Agenda
Basics
Direct Cooling
Air-based Systems
Water-based Systems
Hydraulic circuits
Checklist, Advices
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Hydraulic Circuits
To supply the different units with cold water a piping network and an
appropriate system to control the amount of water for the adjustment of
the capacity of the air-cooling units are required.
Depending on the purpose (cooling, dehumidifing) different hydraulic

circuits are required
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Hydraulic Circuits
Basic possibilities of control of air-cooling units
GEJO01_037
GEJO01 026
GEJO01_026
volume control: temperature control:

variable volume flow through the constant volume flow through the
cooling unit cooling unit,
unit admixing of return-flow
return flow
water
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Hydraulic Circuits
Ch
Change off air
i property
t iin a cooling
li unit
it
On volume-controlled cooler units the water at the inlet has always the
minimum temperature of the supply flow (e.g. 6C)
Even with slight opening of the control valve emerges a de-

humidification of the air!
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Hydraulic Circuits
Ch
Change off air
i property
t iin a cooling
li unit
it
On temperature
temperature-controlled
controlled cooling units the temperature of the
supply-flow at the inlet is close to the temperature of the return flow
At first no de-humidification emerges. If the control-valve is wide

opened the temperature falls below the dew point and the de-
h idifi ti begins!
humidification b i !
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Hydraulic Circuits
B i possibilities
Basic ibiliti off control
t l off air-cooling
i li units
it
If air coolingg without de-humidification is desired always

y a
temperature controlled cooling unit should be used.
If air cooling with de-humidification is desired always a volume

controlled cooling unit should be used.
Otherwise emerges particularly at part load additional cooling

energy demand!
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Hydraulic Circuits
Ch
Change off air
i property
t - cooling
li (without
( ith t desired
d i d de-humidification)
d h idifi ti )
Target value: temperature of air at vent t2
Cooling volume-controlled
t1
cooling temperature-controlled
t2
power demand
without de-humidification
additional power demand

for de-humidification
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Hydraulic Circuits
Change of air property - cooling (with desired de-humidification)

Target value: humidity of air at vent x2
de-humidificate volume controlled de-humidificate temperature-controlled

t1
power demand
volume-controlled
additional power demand

with temperature-controlled system
x2 x1
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Hydraulic Circuits
P ibiliti off control

Possibilities t l off an air-cooling-unit
i li it (temperature-controlled)
(t t t ll d)
M M M
M
GEJO01_026 GEJO01_027 GEJO01_028 GEJO01_029
3-way mixing valve 3-way deviding valve Injector Injection circuit

(throttle-valve
(throttle valve in
supply-flow)
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Hydraulic Circuits

i li it (temperature-controlled)
(t t t ll d)
M
M M
GEJO01_030 GEJO01_031 GEJO01_032
injection circuit injection circuit with 3-way- admixing cicuit

(th ttl
(throttle-valve
l ini return-flow)
t fl ) mixing-valve
i i l (
(pressure-less)
l )
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Hydraulic Circuits

i li it (volume-controlled)
( l t ll d)
M M
GEJO01_033
GEJO01_034
admixing valve deviding valve
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Hydraulic Circuits

i li it (volume-controlled)
( l t ll d)
M M M
GEJO01_035 GEJO01_036 GEJO01_037
Straight-way valve (with Straight-way valve in Straight-way valve

bypass) supply flow (with bypass)
supply-flow
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Hydraulic Circuits
I t
Interaction
ti off distribution
di t ib ti system
t andd chiller
hill (water
( t chiller)
hill )
In some circuits occurs a variable volume flow in the cold-water-

circuit
As a result the water volume at the evaporator in the chiller is
changing
g g
Reducing the water-volume at the evaporator has a great impact on
the cooling-coefficient of performance !
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Hydraulic Circuits
Schematic view on a chiller ((cold water chiller))
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Hydraulic Circuits
Performance of the evaporator at reduced cold water volume
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Hydraulic Circuits
I
Interaction
i off distribution
di ib i system andd chiller
hill (water
( chiller)
hill )
Thee reduction
educ o ofo thee water
w e volume
vo u e through
oug thee water
w e chiller
c e iss
necessarily followed by a reduction of the evaporation temperature
(except for continuously adjustable chillers)
Reduction of cooling capacity

Reduction of the cooling cop = rising of energy demand
Danger of freezing in the evaporator!
The required volume flow through the chiller must be observed
without fail!
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Hydraulic Circuits
I
Interaction
i off distribution
hill (water
( chiller)
hill )
Right volume flow through cold water chiller
safety installations
installations, measures
frost guard
Flow
Fl guardd
Installation for checking the flow rate (e.g. flow control valve)
Right dimensioning and adjustment of the cold water piping
With volume-variable consumer circuit:

Hydraulic separator for separation of cold water chiller and
cold water piping
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Hydraulic Circuits
I
Interaction
i off distribution
hill (water
( chiller)
hill )
Consumer with throttle control ((volume variable))

Connection to chiller with hydraulic separator
compensatting
water volume
M M
Constant volume flow

(cold water chiller)
Variable volume flow (consumer)
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Hydraulic Circuits
I
Interaction
i off distribution
hill (water
( chiller)
hill )
hydraulic separator
I
Important: right
i h dimensioning
di i i andd adjustment
dj off water flows
fl
If the flow rate in the distribution piping (e.g. at full load) is greater
than the flow rate through the evaporator,
evaporator the supply flow
temperature rises through the hydraulic separator
The maximum power of the cooling units will not be obtained !!
Reduced flow rate in the cold water piping ( at part load) results in a
back flow through the hydraulic separator from the outlet of the
chiller
hill tot the
th return
t flow.
fl
This results in a reduction of the return-flow temperature to the
chiller
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Hydraulic Circuits
Interaction of distribution system and chiller (water chiller)

Consumer with diverting circuit (volume constant)
Connection to chiller without hydraulic separator
M M
GEJO01_043
constant flow rate

(chiller and consumer piping)
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Hydraulic Circuits
Interaction of distribution system

y and chiller ((water chiller))
diverting circuit (diversion switching)
+ Ove
Overall flow
ow ratee ccan be kept
ep nearly
e y constant
co s
+ Piping net is used as buffer storage!
+ Cold water is ppresent at the valve even with switched off coolingg
unit
Short reaction time even with long piping systems
solid control
With diverting circuit the return flow temperature is decreasing in
partt load
l d operation
ti
Even in part load or null load operation the whole flow is pumped
through
g the net ((higher
g ppumping
p g effort compared
p with variable flow
rate!)
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Hydraulic Circuits
Operation with buffer storage (opt. stratified storage tank)

equates
q to hydraulic
y separator
p with huge
g volume
M M
GEJO01_044
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Hydraulic Circuits
I
Interaction
i off distribution
hill (water
( chiller)
hill )
cold water storage: most effective with volume variable systems
high
g return flow temperature
p (if
( combined with throttle control))
with good stratification in buffer storage:
high return flow temperature out of buffer storage to chiller
high temperature at evaporator
high COP
small energy demand
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Hydraulic Circuits
I
Interaction
i off distribution
hill (water
( chiller)
hill )
O
Operation
i with
i h buffer
b ff storage (full
(f ll load)
l d)
12C 12C
12 C
VK = VKN M M
6C
6C
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Hydraulic Circuits
I
Interaction
i off distribution
hill (water
( chiller)
hill )
O
Operation
i with
i h buffer
b ff storage (part
( load,
l d loading
l di storage))
12C 12C
12 C
VK VKN=V
VK/2
M M
loading
storage
6C
6C
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Hydraulic Circuits
Operation with buffer storage (part load, unloading storage)
12C
12 C
M M
VKN=VK/2
unloading
storage
GEJO01 044
GEJO01_044
6C
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Hydraulic Circuits
Di
Dimensioning
i i off cold
ld water
t buffer
b ff storage:
t
Dimensioning with:
a) Cooling capacity and desired running time of chiller
b) Power demand and desired running time without chiller
1) amount of energy to be stored: Q =P.t
2) Storage capacity of a defined amount of Q = V . . c .

water:
Qenergy [kJ]
P.power [kW]
Q
V= V.volume [m]
3) Required volume of storage: . c . .........density [kg/m]
...... temperature difference[K]
c..heat capacity [kJ/kgK]
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Hydraulic Circuits
E
Example:
l Dimensioning
Di i i off Buffer
B ff Storage
S
cold water piping: 6/12C
cooling capacity: 300 kW
disered running time of chiller: 15 minutes
1) amount off energy to be

b stored:
d
Q = 300 kW . (15 . 60 ) s = 270 000 kWs = 270 000 kJ
2) Required volume of storage (thermal effective volume!)
2 0 000 kJ
270
V= = 10,75 m3
kg kJ
1 000 . 4,186 . (12 6) K
m kg K
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Hydraulic Circuits
C ld water
Cold t piping
i i with
ith variable
i bl cold
ld water
t flow
fl rate
t
With variable flow rate in cold water piping the installation of a pump
with rev regulator is recommended
Better controllability of different cooling units
Energy saving (pumping)
to insure the supply of every cooling unit use of control with constant
pressure
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Hydraulic Circuits
C ld water
Cold t piping
i i with
ith variable
i bl cold
ld water
t flow
fl rate
t
Keeping constant pressure with rev regulated pump
M M
GEJO01_044

p f
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Hydraulic Circuits
Cold water piping with variable cold water flow rate
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Hydraulic Circuits
Cold water
ater piping system
s stem
The cold water chiller can only provide the planned cooling capacity
if it
i is
i operatedd with
i h the
h amount off water specified
ifi d by
b the
h producer.
d
A system can only work right if the right amount of water (through
right dimensioning and adjustment) comes to the (right dimensioned)
cooling units.
Instable controls lead to higher energy demand for the chiller and in
some cases to a dramatically reduced service life.
life
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Hydraulic Circuits
Cold water
ater piping system
s stem
The cold water piping system must have a diffusion resistant thermal
insulation.
Avoiding of thermal losses (chilling losses)
Avoiding of condensate
Avoiding of corrosion at the piping system
Damaged
D d iinsulation
l ti mustt be
b repaired
i d immediately!
i di t l !
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Hydraulic Circuits
Cold water
ater piping system
s stem
Corrosion as a consequence of damaged thermal insulation
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Hydraulic Circuits
Di
Dimensioning
i i off cold
ld water
t piping:
i i
1. Hydraulic scheme, piping plan, instruments, armatures

2. Mass flow rates in sections of the piping
3. Definition of diameter of pipes
4 Calculation of pipe friction in sections
4.
5. Calculation of different single resistances in sections
6. Calculation of ppressure dropp in each consumer circuit
7. Dimensioning of controlling armature for the worst consumer circuit
8. Dimensioning of pump
9. Dimensioning of controlling armature for all consumer circuits resp.
of adjustment resistances
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Hydraulic Circuits
Di
Dimensioning
i i off cold
ld water
t piping:
i i
Typical values:
flow speed of cold water: 0,5 ... 1,5 m/s
pressure drop: ca. 150 Pa/m
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Hydraulic Circuits
E
Example:
l dimensioning
di i i off cold
ld water
t piping
i i
Cooling capacity: 800 kW
temperature: 6/12C
Length of main line route: 350m
dimensioning of pipes?
pressure drop
p p?
Required pumping capacity ?
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Hydraulic Circuits
E
Example:
l dimensioning
di i i off cold
ld water
t piping
i i
Q&
Cold water flow rate: V& =
. c p .
kJ
800
s m m
V& = = 0,03185 = 114 ,7
kg kJ s h
1000 4,186 (12 6 ) K
m kgK
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Hydraulic Circuits
Example: dimensioning of cold water piping
DN150:
R=220 Pa/m
w = 1,8 m/s
or
DN200:
R=50 Pa/m
w=1,0 m/s
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Hydraulic Circuits
Example: dimensioning of cold water piping

version DN150:
R=220 Pa/m
w = 1,8 m/s
ptot= 220 x 2 x 350 = 154.000 Pa = 1,54 bar
note: 2 x ength of pipeline for supply- and returnflow, (only pipes without
fittings,
g instruments, armatures etc.))
version DN200:
R 50 Pa/m
R=50 P /
w=1 m/s
ptot= 50 x 2 x 350 = 35.000 Pa = 0,35 bar

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Hydraulic Circuits
E
Example:
l dimensioning
di i i off cold
ld water
t piping
i i
1
Pumping capacity: P = V& p
ges
version DN150: pptot= 154.000 Pa = 1,54 bar
m 1
P = 0,03185 154 000 Pa = 6 540 W = 6,54 kW
s 0,75
version DN200: ptot= 35.000

35 000 Pa = 00,35
35 bar
m 1
P = 0,03185 35 000 Pa = 1 468 W = 1,47 kW
s 0,75
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Agenda
Basics
Direct Cooling
Air-based Systems
Water-based Systems
Hydraulic circuits
Checklist, Advices
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Checklist,
Checklist Advices
Ai b d Systems:
Air-based S t
adequate dimensioned distribution system (pressure drops, flow

noises)
smallest possible amount of air (meeting the demands)
right adjustment of distribution system
efficient fans
run fans at optimal operating points
rev regulation (combined with need-based volume flow control)
minimize pressure drops (e.g. changing filter)
thermal insulation of cold/warm air ducts
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Checklist,
Checklist Advices
C ld Water-based
Cold W t b d Systems:
S t
adequate
q dimensioned distribution system
y (pressure
(p drops)
p)
As far as possible volume variable distribution system (meeting the

demands)
Right adjustment of distribution system
Use of highest possible cold water temperature
Right hydraulic circuit at air cooling units (cooling, de-

humidification)
Rev-regulated cold water pumps
Diffusion
iff i resistant
i thermal
h l insulation
i l i
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AC-Training II.2 Cooling Distribution

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AC-Training II.2 Cooling Distribution

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Inspection of AC-Systems

Basics: cooling or heat transfer medium

Place of Cooling generation (Chiller) is generally not the place of

heat must be transported from the place of cooling demand to the

Basics: cooling or heat transfer medium

Refrigerant medium: (at direct cooling systems)

+ No additional medium, no additional pumping effort

Bad controllability, refrigerant medium in living zones

Air: (ventilation and air conditioning system with air distribution)

Huge volume flow,

Additional energy effort for transportation of air

Basics: cooling or heat transfer medium

Water: (indirect cooling with cold water)

+ Good controllability, small volume flow, small cross sections of

No ventilation, water damage in case of leakage, in endangered

Same as with water

+ No frost protection required

Smaller heat capacity and higher pressure drop (higher viscosity)

Basics: cooling or heat transfer medium

**) at di=50mm, w=0,7m/s, t=6C

Basics: cooling or heat transfer medium

transportable heat energy (cooling energy)

Q& = m& c p T & heat capacity [kW]

Basics: cooling or heat transfer medium

Basics: cooling or heat transfer medium

Basics: cooling or heat transfer medium

Basics: cooling or heat transfer medium

from:Q & =m & c p T

Basics: cooling or heat transfer medium

Basics: cooling or heat transfer medium

Basics: cooling or heat transfer medium

Basics: cooling or heat transfer medium

w d Re.......Reynolds number [-]

kinematic viscosity of:

Basics: cooling or heat transfer medium

Basics: cooling or heat transfer medium

e.g. rectangular cross section:

Basics: cooling or heat transfer medium

for fittings, armatures: according to the shape

Basics: cooling or heat transfer medium

Determination of ppressure dropp with diagrams:

Friction diagram for cold water pipes

Basics: cooling or heat transfer medium

theoretical drive power:

actual drive power:

Basics: cooling or heat transfer medium

Basics: cooling or heat transfer medium

P increases in a given medium and air-duct or pipe system with V

Halving the volume flow reduces the drive power to 12,5%!

Evaporator is situated directly at the place of cooling demand

Regarding the situation of the chiller (compressor of cooling

AC-devices with internal chiller

Air: (Ventilation and Air-Conditioning System with Air Distribution)

Central air-conditioning (heating, cooling, de-humidify, humidify)

Distribution through air-duct-system

Insertion through air inlets

Generally supply and return-ducts are required

Air: (Ventilation and Air-Conditioning System with Air Distribution)

distribution via air ducts

recommended air velocity

air duct convenience systems industrial systems

main ducts 4 to 6 m/s (to 8 m/s) 6 to 10 m/s (to 12 m/s)

distribution ducts in storeys 3 to 5 m/s 5 to 8 m/s

flexible tubes 2 to 4 m/s 4 to 6 m/s