Chiller Plant Control

CHILLER PLANT CONTROL
This case study demonstrates the control of a three stage chiller plant that
cools water in a primary loop, which feeds into a secondary loop with a
heat load.
MINING INDUSTRY
MINING INDUSTRY
CHALLENGE:
Investigate the operation and effectiveness of a three stage chiller plant that
cools water in a mine primary and secondary loop with a heat load. Develop an
effective control system in a situation where the load changes rapidly.
BENEFITS:
Transient analysis of the System
Control Optimization
Heat loads
SOLUTION:
Page
Flownex was used to simulate the control of a three stage chiller plant using a
step controller in conjunction with a controller on a bleed valve that allows
colder water from the primary circuit into the warmer secondary circuit. The
simulation shows that the control strategy is effective.
Flownex was used to simulate the control of a three stage

chiller plant using a step controller in conjunction with a
controller on a bleed valve that allows colder water from
the primary sales@flownex.com
circuit into the warmer secondary circuit.
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CONTROL OF A CHILLER PLANT
SYSTEM DESCRIPTION
The lay-out of the system is shown in Figure 1.
Figure 1: Layout of three-step chiller plant.
The water in the primary and secondary loops is circulated at nearly

constant rates by two independent pumps. A varying heat load
heats the water in the secondary loop. Controller C1 senses the
temperature in the primary loop and attempts to keep the
temperature constant by switching chiller stages on or off.
Controller C2 senses the temperature just before the heat load and
opens or closes the control valve in an attempt to keep the
temperature at the inlet to the load constant.
OBJECTIVE OF SIMULATION
Page
The objective of the simulation is to investigate the operation and

effectiveness of the control system in a situation where the load
changes rapidly.
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The objective of
the simulation is to
investigate the
operation and
effectiveness of the
control system in a
situation where the
load changes
rapidly
FLOWNEX MODEL
The Flownex model of the system is shown in Figure 2. The threestage chiller is modeled by three pipes, each with a negative heat
load of 1100 kW that can individually be switched on or off by
separate PID controllers. The control valve is also controlled with a
PID controller.
Primary loop
Secondary
loop
Load
Valve
Control valve
Three-stage chiller
Pump
Stage 1
Controller
Step
Controller
Figure 2: Flownex model of the three stage chiller plant with control system.
DESCRIPTION OF SIMULATION
A transient simulation is done where the load in the secondary loop
is varied as shown in Figure 3.
3500
3000
Load [kW]
2500
2000
1500
1000
500
0
200
400
600
Page
Time [s]
Figure 3: Variation of load with time.
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800
1000
Stage 2
Stage 3
The initial condition or the simulation is the steady-state solution

with a fixed temperature of 45 C at node 13.
The settings of the three step controllers for the chiller are as
follows:
Stage Setpoint
Deadband
1
2
3
1 C
1 C
1 C
5 C
6 C
7 C
Minimum
heat
-1.1 MW
-1.1 MW
-1.1 MW
10 MW/C 0
10 MW/C 0
10 MW/C 0
Figure 4 shows how the different stages will be switched on and off
on rising and decreasing temperatures.
Step
Off
On
On
Off
On
Step
Off
Step
Cooling
Combined effect
5
6
7
9
Temperature [C]
Figure 4: Settings of step controller.
RESULTS
Page
Figure 5 shows the variation of temperature at the inlet to the load

for the case where the chiller step controller is on while the control
valve controller is switched off.
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25.0
Temperature [C]
20.0
15.0
10.0
5.0
0.0
200
400
600
800
1000
Time [s]
Figure 5: Temperature at inlet to the load with the control valve controller switched
off.
Figure 6 shows the variation of temperature at the inlet to the load

with both controllers switched on. Apart from the initial transient
the control valve controller succeeds in keeping the temperature at
the inlet of the load within a narrow range.
18.0
Temperature [C]
16.0
14.0
12.0
10.0
8.0
6.0
4.0
2.0
0.0
200
400
600
800
1000
Time [s]
Page
Figure 6: Temperature at inlet to the load with the control valve controller switched
on.
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Figure 7 shows the variation of control valve diameter with time.

0.12
Diameter [m]
0.10
0.08
0.06
0.04
0.02
0.00
200
400
600
800
1000
Time [s]
Figure 7: Variation in valve diameter with time.
CONCLUSION
Page
Flownex was used to simulate the control of a three stage chiller

plant using a step controller in conjunction with a controller on a
bleed valve that allows colder water from the primary circuit into
the warmer secondary circuit. The simulation shows that the control
strategy is effective.
www.flownex.com
sales@flownex.com
The objective of
the simulation is to
investigate the
operation and
effectiveness of the
control system in a
situation where the
load changes
rapidly

Chiller Plant Control

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Chiller Plant Control

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CHILLER PLANT CONTROL

Transient analysis of the System

Flownex was used to simulate the control of a three stage

CONTROL OF A CHILLER PLANT

The lay-out of the system is shown in Figure 1.

Figure 1: Layout of three-step chiller plant.

The water in the primary and secondary loops is circulated at nearly

The objective of the simulation is to investigate the operation and

The initial condition or the simulation is the steady-state solution

Figure 4: Settings of step controller.

Figure 5 shows the variation of temperature at the inlet to the load

Figure 6 shows the variation of temperature at the inlet to the load

Figure 7 shows the variation of control valve diameter with time.

Figure 7: Variation in valve diameter with time.

Flownex was used to simulate the control of a three stage chiller

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