Chilled-water supply stays at constant design

temperature

Introduction
Some chilled-water systems have a reset logic based on outside-air temperature (OSAT). This conserves
energy when the cooling load is less than the design load. The reset logic allows the chilled-water supply
temperature (CHWST) to rise above the design temperature and increases the chiller efficiency by
reducing the amount of work it has to do. The air-handling-unit (AHU) fans will compensate for the
corresponding elevated supply-air temperature (SAT) as needed, but using less energy.

How This Wastes Energy

Keeping the CHWST lower than necessary causes the chiller to operate in a less efficient region of its
performance curve. The rule of thumb is that raising the CHWST one degree Fahrenheit reduces chiller
energy consumption roughly 2%. Lower CHWST can also cause higher heating bills because of reheating
at terminal units.

Possible Causes of This Symptom

The table below shows some of the possible causes of this symptom. The cause of a symptom can be an
energy-performance problem that can be fixed, or it may be explained by an unavoidable aspect of your
current system that would probably require a capital project to change. Follow the steps described after
the table to determine the possible cause of this symptom. If you find a problem, perform the suggested
trend logging to confirm that the problem exists and, later, that you have solved the problem.

Inspection
Checked Type Description
Step
1 Explanation A small process load (e.g., server room) is connected to the
system and requires a constant chilled-water temperature.
2 Explanation Control over chiller setpoints (either local or via the direct digital
control system) is absent.
3 Problem Temperature-reset schedule is not programmed, or is
overridden.
4 Problem Temperature sensor is miscalibrated or improperly located.
5 Problem HVAC zone may require low supply-air temperature to
compensate for a lack of airflow.
6 Problem Lack of insulation or long piping runs cause excessive heat
gains in the piping distribution system.
7 Problem Distribution system is undersized.
8 Problem Chilled-water system is improperly balanced.

How to Find the Problem(s) by Inspection

Inspection Step 1
Review the design documents for your chilled-water system to see if a process load is served by the
system. Possible loads include a fan coil serving a small data room, an elevator machinery room, or a

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lighting-control room. Any one of these would force the chilled-water system to maintain a steady CHWST
since the process load is constant.

Inspection Step 2
Familiarize yourself with your chiller’s capabilities. Can it reset the CHWST through the direct-digital-
control (DDC) system? If it has an OSAT sensor installed, can it do it using control logic integral to the
chiller controls, Can it reset CHWST based on the AHU that requires the most cooling? Older chillers
often have no temperature-reset capability. Your system will operate at a set chilled water temperature if
reset logic is not included in the stand-alone software running the unit, or if there is no control from the
DDC system.
If you have no automatic-reset capability, you may want to consider adjusting the temperature manually
for seasonal conditions. This will require that a detailed record be kept showing occupant complaints as
compared to OSAT and CHWST. Always operate the CHWST as high as possible without causing tenant
complaints. Be aware, though, that allowing the AHU cooling-coil temperature to rise too high may allow
humidity to become unacceptably high.

Inspection Step 3
Inspect the override logs of the DDC system to verify that the reset-schedule setpoints have not been
altered. Verify the original setpoints as commissioned or in the operating plan. If the setpoints have been
overridden, find out why before correcting the problem. Some reasons for override may be:
ƒ A process load connected to the system requires constant chilled-water temperatures.
ƒ An AHU that can’t meet its loads with a higher chilled-water temperature due to a water- or air-
balance problem.

Inspection Step 4
Check sensor location and calibration:
ƒ See if the CHWST probe is correctly installed and calibrated. If the probe is not located properly in the
water stream, it will provide elevated temperatures to the DDC system, forcing the chiller to drop the
supply-water temperature.
ƒ Inspect the OSAT sensor location and installation. Is it located where it provides an accurate reading?
Check to see if it shares a DDC system point from another controller. If communication was lost
between controllers, the reset logic may be using the last OSAT value transmitted.

Inspection Step 5
Check the trouble log of the HVAC system. A zone may lack airflow and require supply air at a
temperature below its normal setpoint to meet its load. If this is the case, resolve the airflow problem
before addressing the reset logic.

Inspection Step 6
Review your chilled-water piping. You may have excessive heat gain in the piping due to very long runs
or inadequate insulation. Wet insulation, due to a break in the vapor barrier or a leak can increase
temperature rise dramatically.

Inspection Step 7
Review the design drawings for flow and piping size. The piping may be undersized such that the chilled
water must be cooled below its design setpoint due to a lack of adequate flow.

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Inspection Step 8
Review the latest test-and-balance report.
ƒ Verify that the system was properly balanced at the time the report was prepared. Compare those
readings to the current conditions. Inspect your system for possible bypassing through 3-way valves.
Check balancing valves for proper position. Passing too much water through a coil can actually
reduce the heat transfer rate by not allowing the water enough time in the coil. (More flow is not
always a good thing.)
ƒ Sometimes water flow at the far end of the system is inadequate due to poor balancing. The pump
may be at the design rate but most of the flow is passing through the units closest to the pumps due
to the higher pressure differential. The most common response to this is to turn on another pump,
which only makes the problem worse.

How to Confirm the Problem(s) by Trend Logging

Trend log the following:
ƒ Outside-air temperature (OSAT)
ƒ Chilled-water supply temperature (CHWST)
ƒ Chilled-water return temperature (CHWRT)
ƒ Cooling-coil valve positions—feedback if possible, and not output from the DDC system
ƒ Secondary pump speed—feedback from the variable speed drive (VSD) if possible, and not output
from the DDC system

Graph the CHWST with respect to the other four points. If the OSAT line is flat, then the OSAT sensor is
the problem. If a cooling-coil valve is always 100% open, then that unit may be undercooling (or over-
flowing). If the secondary pump speed is constant at 100%, the system demand may exceed the chiller
capacity. (The return-water temperature can also be above design in this case.)

Normal Operation
The graph below illustrates normal, efficient operation of the system. The system starts at 09:00 (based
on an OSAT of 60 degrees) with the CHWST at 50 degrees, and the cooling valve 20% open. As the
OSAT rises, the CHWST starts to drop to its design point of 45 degrees. The CHWRT starts to rise at the
same time, showing that the chilled water is bringing back more heat to the chiller. The pump speed
increases as the load increases. The chiller is operating at maximum differential temperature at 14:00.
The AHU-cooling-coil valve continues to open as the zone load increases until it is open 100%. If your
graph looks like this then the problem should be solved.

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Normal system operation

Abnormal Operation – Absence of Reset Sechedule

The graph below illustrates abnormal operation of the system. The system starts at 09:00 (when the
OSAT reaches 60 degrees) with the CHWST at 45 degrees, and the cooling valve 20% open. As the
OSAT rises, the CHWST stays constant at its design point of 45 degrees. The CHWRT starts to rise,
showing that the chilled water is bringing back more heat to the chiller. The pump speed increases as the
load increases. The chiller is operating at maximum differential temperature at 14:00. The AHU-cooling-
coil valve continues to open as the zone load increases, until it is 100% open. If your graph looks like this,
the problem is a lack of reset.

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Abnormal operation: reset problem

Abnormal Operation – Water Flow or Balance

The graph below illustrates abnormal operation of the system. The system starts at 09:00 (when the
OSAT reaches 60 degrees) with the CHWST at 45 degrees. As the OSAT rises, the CHWST stays
constant at its design point of 45 degrees, trying to satisfy the AHU demand. The CHWRT starts to rise,
showing that the chilled water is bringing back more heat to the chiller from the entire system. The chiller
is operating at maximum differential temperature at 14:00. If your graph looks like this, then the problem
is either an airflow or water-flow issue. If you have trended the chilled-water pump speed and it is
constant at 100%, you may have a water-flow or water-balance problem. In either case, go back to
Inspection Step 5 and re-investigate. Continue trending to verify your new findings.

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Abnormal operation: chilled-water valve and VFD at 100%

Labor Skills Required to Find and Resolve the Problem

ƒ DDC system operator/programmer
ƒ Service mechanic
ƒ Test-and-balance technician

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