Professional Documents
Culture Documents
Operations Division
Engineering Services
Sequence of Operation
Campus Chilled Water Service Entrance
Without Heat Exchanger
B. FLOW METER
1. Measurement of instantaneous building tonnage will be calculated by the building BAS using the
following inputs:
a. Campus chilled water supply flow from the campus chilled water flow meter
b. Campus chilled water supply temperature sensor, T1
c. Building chilled water return temperature sensor, T2
C. PRESSURE (summary, see other sections for sequences)
1. Campus differential pressure, DP1, between the campus chilled water supply and return will be
measured. For some specific buildings this value may be used by the campus chilled water
plant(s) for campus supply pump speed control. This DP1 value is also used for enable/disable
control of the building pump. DP1 will also be used as a safety shut-off isolation trigger.
2. Building differential pressure, DP2, which is the DP between the chilled water supply and return at
a remote location in the building chilled water distribution system, will be sensed and used to
control the speed of the Duty building chilled water pump. There may be multiple remote DP
sensors required.
3. Pressure P1, campus chilled water return pressure at building entrance, will be sensed and used
as a safety shut-off isolation trigger.
4. The campus chilled water supply pressure at building entrance will be calculated from the
campus DP and the campus chilled water return pressure. The value will be used for
comparisons with required specific building chilled water system pressure to assure that static
head is sufficient to maintain the fill pressure.
5. Pressures P2 and P3 (inlet and discharge of building pumps/pump bypass) will be used by the
BAS for monitoring only.
D. CHILLED WATER SYSTEM ENABLE
1. Ideally all the building equipment provided with chilled water shall be capable of issuing cooling
requests for chilled water flow thru the BAS network. Where specific cooling requests from
equipment are impractical, then some other appropriate representative conditions for that
equipment will be used in place of specific requests to enable the system. In some applications
the system may be required to operate continuously due to process loads or other critical loads.
This issue should be resolved in the design phase and verified with PSU OPP.
2. For purposes of system enable only, if any equipment chilled water control valve in the
system is open > 20% (or other condition used as a substitute request where direct
request is not practical), or if the network connection is lost for more than 10 mins, then
the following shall occur:
a. Isolation valve (CHWV-2) shall open.
b. And Choke valve (CHWV-1) shall modulate open to maintain (with a minimum position) the
chilled water return temperature setpoint (refer to CAMPUS CHILLED WATER VALVES
FLOW AND TEMPERATURE CONTROL).
c. For conditions where equipment chilled water control valve is opened in response to chemical
treatment refer to Chemical Treatment Section of this sequence.
3. The system shall be enabled for 1 hour minimum. After 1 hour if all the equipment chilled water
control valves have closed to 10% (10% hysteresis) or if other conditions used in place of direct
requests for other equipment served then the system will be disabled.
4. After system is initially enabled and prior to starting building duty pump, system shall be operated
using only campus supply and return differential pressure to distribute chilled water to the
buildings equipment. The goal is to reduce operating time and speed of the building pumps as
much as possible.
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Sequence of Operation
Campus Chilled Water Service Entrance
Without Heat Exchanger
Sequence of Operation
Campus Chilled Water Service Entrance
Without Heat Exchanger
The maximum pump speed shall be programmed at the VFD drive for (typ. 100% or 60 hz) and
also in the software as necessary. The system should be balanced for minimal pressure drop. If
design flow requirements are met at a pump speed less than 100% there should be no effort to
create a pressure drop so this design flow occurs at 100% speed. In that case the pump may
never have to operate at 100% (saving energy) but will have the capacity for greater flow.
2. Basic VFD speed control: Once pump is enabled the pump will start at min speed. The
optimized setpoint block for the DP2 setpoint shall modulate the pump VFD to its maximum
speed as required to maintain a differential pressure setpoint that shall be automatically reset with
a Trim and Respond function as described below.
a. The pump VFD speed DP2 setpoint shall be recalculated every 5 minutes (adj.). The
incremental change per interval shall be based on the maximum cooling requests from any
one of the associated Primary or Terminal Application Controllers served by each pump
system.
b. Cooling requests are not accumulated for pump VFD speed DP2 reset until after pump has
started and the optimized setpoint block for T2 (choke valve control, see valve and
temperature control section also) has reset down to the its minimum (including override reset)
5 minutes (adj.).
c. Cooling requests are the same as described in the Building Pump Starting and Stopping
Section.
d. The pump VFD speed DP2 setpoint shall be reset between a min and max setpoint (3-10 for
example) psi. The initial differential pressure setpoint shall be 3 psig (adj.). If network
communication is lost for more than 10 minutes, the setpoint shall be reset to 0.75 x
maximum DP2 setpoint and an alarm issued. The maximum DP2 setpoint is the pressure
required to provide full pump design flow (taking into account the design diversity of all the
connected load) to all control valves simultaneously while providing full design flow to the
hydraulically most remote load (some coordination between the design engineer, BAS
engineer and the TAB is expected). For a particular building this maximum value may need
to be set greater than 10 psi. The minimum value is an arbitrarily set number representing a
low value that will likely result in pump operation at min speed for optimal energy savings but
still high enough to maintain minimal flow after enable until DP has time to reset if required.
e. As cooling requests increase, the setpoint shall incrementally respond up by 0.5 psi per
request value, limited to 3 psi (adj.) per period (see above for time period), to the maximum
reset value.
f. With no cooling requests, the setpoint shall incrementally be trimmed down by 0.5 psi (adj.)
per period to the minimum reset value.
3. VFD speed control adjust to prevent recirculation: If building CHWS temperature (T3) is 2F
greater than the campus CHWS temperature (T1) for an adjustable time, then the pump speed
will be reduced incrementally even though the actual building remote DP2 may be less than the
DP2 setpoint. The pump speed shall be reduced (with a ramp) by resetting the pump VFD
speed DP2 setpoint. This control logic is needed due to the conditions when campus pressure is
too low to support required campus chilled water supply flow into the building system. When the
controlled variable for the equipment control valves cannot be satisfied the valve will respond by
opening further and lowering the actual differential pressure at remote DP2. The basic pump
VFD speed control will respond by increasing the pump speed. The result will be over pumping
and higher building CHWS temperatures and therefore associated potential loss of
dehumidification capacity and wasted pump energy.
4. Pump (building chilled water) deadhead protection: If actual remote differential pressure at
DP2, with the Duty pump controlled to its minimum, is 3 psi > DP2 setpoint (for 15 minutes), then
pump shall be turned off (for 15 minutes) and an alarm issued. Further control logic may be
necessary to insure that pump is operating in accordance with manufacturers recommendations.
Sequence of Operation
Campus Chilled Water Service Entrance
Without Heat Exchanger
5. Pump deadhead protection further explanation: The design engineer responsible for the project
needs to design and provide for all expected low flow conditions that the system will see over the
course of a typical year. In most cases the pump will not be capable of safe operation and able to
support all expected low flow needs. In most applications an additional smaller pump or
modulating system bypass valve (preferred choice typically) may be required for flows that are
too low for safe Duty pump operation. Both flow and associated required head combination must
be considered. The flow and head do not neatly follow the max condition system curve. For
example, some buildings may have a CRAC unit whose branch DP requires 15 psi, but with a
relatively very low flow, compared to the total system flow. In summary low system flow
conditions do not always also mean low head requirements (when branch DP is a large portion of
the overall DP total). In some case the Duty pump would not meet this condition without
operating in a region of the pump curve that would cause damage to the pump based on
manufacturers recommendations. Standard recommendation is that flow should be greater than
or equal to 0.20 multiplied by the gpm at the most efficient point on that particular pump operating
curve.
G. BUILDING PUMPS OFF - CAMPUS CHILLED WATER VALVES FLOW AND TEMPERATURE
CONTROL
1. When the building cooling is OFF, the choke valve, CHWV- 1 shall be at min position and the
isolation valve, CHWV-2 will be closed completely. The decision to leave the choke valve at min
position is based on experience that when both valves are closed, the water in this closed portion
of the system can become (at some locations) warm from the ambient conditions in a warm
mechanical room. The water expands and the pressure increases without any means of relief
unless a valve is left open.
2. When the building cooling is enabled (see building system enable section above), the isolation
valve, CHWV-2, will be open and CHWV-1, the choke valve, shall modulate with the constraints of
a minimum position to maintain T2 setpoint (54F initial). A linear converter block shall reset the
minimum valve position from 20% to 10% as the campus chilled water DP ranges from 0 psi to 10
psi. These values may be adjusted during the commissioning process based on particular
building conditions. This min position is required to avoid condition where the valve closes on low
(T2) reading and the stagnant water remains cool at T2 and therefore does not allow choke valve
to open again.
3. When the building chilled water pumps are off, CWHV-1 shall modulate as required from
minimum position to 100% open to maintain chilled water return temperature, T2 setpoint. The
optimized setpoint block for the T2 setpoint shall be reset from 54F to 60F using a time ramp if
there are no cooling requests. A cooling request will cause the T2 setpoint to be reset from 60F
to 54F using a time ramp.
4. T2 setpoint shall be reset from 54F to a lower limit of 52F for buildings without critical loads or
48F for buildings with critical loads prior to starting pumps (see Building Pump Starting/Stopping
Section).
5. T2 setpoint shall be reset from 54F to a lower limit of 52F for buildings with all non-critical loads
or 48F for buildings with critical loads if:
a. There are 3 or more cooling request for 5 minute (adj.).
b. If T2 (CHWR temperature) is reset below 54F for more than 15 minutes then a non-critical
alarm shall be issued. Lower CHWR temperatures reduce the efficiency of the central plant
chilled water production and increase pumping requirements for both the central system and
the building system. New construction shall be designed so that CHWR temperatures are
always above 54F. PSU OPP has ongoing effort to increase CHWR temperatures in existing
systems. T2 reset below 54F should only be considered a temporary condition to meet
immediate required load.
5
Sequence of Operation
Campus Chilled Water Service Entrance
Without Heat Exchanger
Sequence of Operation
Campus Chilled Water Service Entrance
Without Heat Exchanger
4. Additional requirements when the building chilled water system was enabled for greater
than or equal to 1 hour during a consecutive 7 day period but pipe branches at the
equipment level did not have adequate flow. The objective of this next portion of the
sequence is to insure that the chemical treatment process administered at the central plant
locations is distributed to all the branches of the system on a timely basis. At the equipment level
controllers (for those served with chilled water from this system) the time that the chilled water
valve is open shall be accumulated. If the valve was opened for 30 minutes or greater during a
consecutive 7 day period than there is no action, if not then the valves shall be opened 50% for
15 minutes (adj). If valve already open to meet load take the higher of the PID request or the
50% value. This will enable the chilled water system (thru the network) in a chemical treatment
mode, where the duty building pump shall operate but without any campus chilled water flow. The
pump will operate under normal speed control to maintain remote DP setpoint (with exception that
the setpoint shall be at the upper range of the reset).
J. VALVE EXERCISE
1. The objective of this sequence is to exercise valves that may stay in one position for long periods
of time and then be unable to move properly when commanded.
2. CHV-1 (choke valve)
a. If CHV-1 is 0% for more 168 consecutive hrs, then cycle valve open to 30% and then
immediately return to normal operation.
b. If CHV-1 is 100% for more 168 consecutive hrs, then cycle valve to 80% open and then
immediately return to normal operation.
3. CHV-2 (isolation valve)
a. If CHV-2 is closed for more 168 consecutive hrs, then cycle valve open to 100% and then
return to normal operation. Open only after CHV-1 has closed to prevent unnecessary flow.
b. If CHV-2 is open for more 168 consecutive hrs, then cycle valve closed and then after 10
seconds (valve should not actually close with this short time period) immediately return to
normal operation. This short movement is required given that CWV-2 is 2-position type valve,
(open-closed) and preventing flow in an enabled system is to be avoided .
K. CAMPUS CHILLED WATER VALVES SAFETY SHUT-OFF
1. If the campus differential pressure, DP2, is 0 psi or less for 30 seconds, the Duty building chilled
water pump will be stopped, the choke valve, CWV-1, and the isolation valve, CWV-2 will be
closed completely and an alarm will be issued. The valves will be released to reopen when the
differential pressure is re-established at 0.5 psi or greater for 30 seconds.
2. If the pressure sensed in the campus chilled water return pipe at P1 is 5 psi below the minimum
system pressure (determined during commissioning under various operating conditions) for 30
seconds, the Duty building pump will be stopped, the choke valve, CWV-1, and the isolation
valve, CWV-2 will be closed completely. The Duty pump shall be restarted and the valves will be
released to reopen when the system pressure is re-established for 30 seconds. An alarm will be
issued.
I.
Sequence of Operation
Campus Chilled Water Service Entrance
Without Heat Exchanger
2)
Excessive Pump Speed Alarm: If the pump speed output remains above 95% for more
than 8 hours (adj.) accumulated per occupied period for at least 3 (adj.) consecutive
occupied periods.
3) Continuous Request Alarm: If one or more application controllers is sending continuous
cooling requests, and differential pressure has reset to maximum setpoint, and the
combined condition remains for more than 8 hours (adj.) continuously.
b. T2 (CHWR temperature) reset
1) If T2 (CHWR temperature) is reset below 54F for more than 15 mins then a non-critical
alarm shall be issued. Lower CHWR temperatures reduce the efficiency of the central
plant chilled water production and increase pumping requirements for both the central
system and the building system. New construction shall be designed so that CHWR
temperatures are always above 54F. PSU OPP has ongoing effort to increase CHWR
temperatures in existing systems. T2 reset below 54F should only be considered a
temporary condition to meet immediate required load.