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HVAC Water Chillers and Cooling Towers Fundamentals, Application, and Operation Herbert W. Stanford Stanford White Associates Consulting Engineers, Inc. Raleigh, North Carolina, U.S.A. m MARCEL MARCEL DEKKER, INC. NEW YORK • BASEL LibraryofCongressCataloging-in-PublicationData AcatalogrecordforthisbookisavailablefromtheLibraryofCongress ISBN:0-8247-0992-6 Thisbookisprintedonacid-freepaper. Headquarters MarcelDekker,Inc. 270MadisonAvenue,NewYork,NY10016 tel:212-696-9000;fax:212-685-4540 EasternHemisphereDistribution MarcelDekkerAG Hutgasse4,Postfach812,CH-4001Basel,Switzerland tel:41-61-260-6300;fax:41-61-260-6333 WorldWideWeb http://www.dekker.com The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/Professional Marketing at the headquarters address above. Copyrightq2003byMarcelDekker,Inc.AllRightsReserved. Neitherthisbooknoranypartmaybereproducedortransmittedinanyformorbyany means,electronicormechanical,includingphotocopying,microfilming,andrecording,or byanyinformationstorageandretrievalsystem,withoutpermissioninwritingfromthe publisher. Currentprinting(lastdigit): 10987654321 PRINTEDINTHEUNITEDSTATESOFAMERICA MECHANICAL ENGINEERING A Series of Textbooks and Reference Books Founding Editor L. L. Faulkner Columbus Division Battelle Memorial Institute and Department of Mechanical Engineering The Ohio State University Columbus Ohio 1 Spring Designer's Handbook, Harold Carlson 2 Computer-Aided Graphics and Design, Daniel L Ryan 3 Lubncation Fundamentals, J George Wills 4 Solar Engmeennr Dogf omestic Buildings, WilliamA Himmelman 5 Applied Engmeenng Mechanics Static dnsaD ynamicsG , Boothroyddna C Poh 6 Centnfugal Pump Clinic, Igor J Karassik 7 Computer-Aided Kinetics rof Machine Design, DanielL Ryan 8 Plastics Products Design Handbook, Part A Matenals and Components, Part B Processes and Design for Processes, edited by Edward Miller 9 Turbomachmery Basic Theor dnAya pplications, Earl Loganr,J 10 Vibrations of Shells and Plates, Wemer Soedel 11 Flat and Corrugated Diaphragm Design Handbook, Mario Di Giovanni 12 Practical Stress Analysis in Engineering Design, Alexander Blake 13 An Introduction to the Design and Behavior of Bolted Joints, John H Bickford 14 Optimal Engmeenng Design Pnnciples and Applications, James N Siddall 15 Spnng Manufacturing Handbook Harold Carlson 16 Industnal Noise Control Fundamentals and Applications, edited by Lewis H Bell 17 Gears and Their Vibration A Basic Approach to Understanding Gear Noise, J Derek Smith 18 Chains for Power Transmission and Material Handling Design and Appli- cations Handbook, American Chain Association 19 Corrosion and Corrosion Protection Handbook, edited by Philip A Schweitzer 20 Gear Dnve Systems Design and Application, Peter Lynwander 21 Controlling In-Plant Airborne Contaminants Systems Design and Cal- culations, JohnD Constance 2 2CAD/CAM Systems Plannd iInnmag plementation, CharleS sK nox 23 Probabilistic Engmeenng Design Pnnciples and Applications, James N Siddall 24 Traction Dnves Seld eAcnptaiopnl ication, FreddeW nricaHk e iIliIcIh Eugene E Shube 25 Finite Element Methods An Introduction, Ronald L Huston and Chris E Passerello . 6M2echanical Fastenif nPog lastin cEAsn: gineering Handbook, Brayton Lincoln, Kenn. eGJthd o Jmanme. aBFser ,as den 27. Lubrication in Practice: Second Edition, edited by W. S. Robertson . 8P2rincipf lAoesu tomated Drafting, Dan. iLRe lyan . 92Practical Seal Design, editedy bL eonard. J Martini . 03 Engineering Documentation rof CAD/CAM Applications, Charles. S Knox 31. Design Dimensioning with Computer Graphics Applications, Jerome C. Lange 32. Mechanism Analysis- Simplified Graphical and Analytical Techniques, Lyndon O. Barton 33. CAD/CAM Systems: Justification, Implementation, Productivity Measurement, Edward J. Preston, George W. Crawford, and Mark E. Coticchia 34. Steam Plant Calculations Manual, V. Ganapathy . 5D3esign Assurr Eaonn dcgfMei nnaenaeargs ers, J. oBAhun rgess 36. Heat Transfer Fluids and Systems for Process and Energy Applications, Jasbir Singh 37. Potential Flows: Computer Graphic Solutions, Robert H. Kirchhoff 38. Computer-Aided Graphics and Design: Second Edition, Daniel L. Ryan 39. Electronically Controlled Proportional Valves: Selection and Application, Michael J. Tonyan, edited by Tobi Goldoftas 40. Pressure Gauge Handbook, AMETEK, U.S. Gauge Division, edited by Philip W. Harland 41. Fabric Filtrr aoCtifoonm bustion Sources: Fundame dBnntaaaslsi c Tech- no .lPDo go.Ryn, ovan 42. Design of Mechanical Joints, Alexander Blake 43. CAD/CAM Dictionary, Edward J. Preston, George W. Crawford, and Mark E. Coticchia 44. Machinery Adhesives for Locking, Retaining, and Sealing, Girard S. Haviland . 54 Couplingsd na Joints. Design, Selection,d na Application. R, noJ Mancuso 46. Shaft Alignment Handbook, John Piotrowski 47. BASIC Programs for Steam Plant Engineers: Boilers, Combustion, Fluid Flow, and Heat Transfer, V. Ganapathy 48. Solving Mechanical Design Problems with Computer Graphics, Jerome C. Lange . 94Plastics Gearing: Selecd tAinopanp lication, Cliffo. rEAd dams . 05Clutched nsBa rakes: Desigd nnSa election, William. CO rthwein 51. Transducn eMris echad nEnilceaac ltronic Design, Ha. rTLryr ietley 52. Metallurgical Applications of Shock-Wave and High-Strain-Rate Phenom- ena, ey dLibtaewd r. eEMncue rr, . PKSatar ludhad mM.nAmaarec r , Meyers 53. Magnesium Products Design, Robert S. Busk 54. How to Integrate CAD/CAM Systems. Management and Technology, William D. Engelke m aCD .55esignd na Manufacture: Second Edition; withm ac design software d cnoam CpaPti bMleBsI, edifhsotkr included, Preb. JWeenn sen .65Solid-StaC tMAe otor Controls: Selectid Aonanp plication, Sylvester Campbell . 75Fundamentaf olRs obotics, Dav. iADd rdayfio 58. Belt Selection and Application for Engineers, edited by Wallace D. Erickson 59. Developing Three-Dimensional CAD Software with the IBM PC, C. Stan Wei 60. Organizing Data for CIM Applications, Charles S. Knox, with contributions by Thoma. CsB oos, RosS s Culverhousd ePna,a u. FMl uchnicki 61. Computer-Aided Simulation in Railway Dynamics, by Rao V. Dukkipati and Josep. RAh myot 62. Fiber-Reinforced Composites: Materials, Manufacturing, and Design, P. K. Mallick 63. Photoelectric Sensors and Controls Selection and Application, Scott M. Juds . 46Finite Element Analysis with Personal Computers, Edwa. RrCd hampion, Jr., and J. Michael Ensminger .56 Ultrasonics: Fundamentals, Technology, Applications: Second Edition, Revisedd naE xpanded, Dale Ensminger 66. Applied Finite Element Modeling: Practical Problem Solving for Engineers, Jeffrey M. Steele . 76Measurem dnIenanst trumentati noiEn ngineering. Princd ipnBlaeass ic Laboratory Experiments, Francis S. Tse and Ivan E. Morse 68. Centrifugal Pump Clinic: Second Edition, Revised and Expanded, Igor J Karassik 69. Practical Stress Analysis in Engineenng Design- Second Edition, Revised and Expanded, Alexander Blake nAI 0n7troducte ihotD onte sig dnnaB ehaviof or Bolted Joints. Second Edition, Revd Eisnxeapd anded, Jo .hHBni ckford 71. High Vacuum Technology.A Practical Guide, Marsbed. H Hablanian . 27Pressure Sensors. Selectiod Annap plication, Duane Tandeske . 37Zinc Handbook' Properties, Processn i DiesnUe gdnsa, ign, Frank Porter 74. Thermal Fatigue of Metals, Andrzej Weronski and Tadeusz Hejwowski 57Classd iMcnaao ldem Mechanism roEfsn gined Iennravs entors, Preb.eWn Jensen 76. Handbook of Electronic Package Design, edited by Michael Pecht 77. Shock-Wave and High-Strain-Rate Phenomena in Materials, edited by Marc . AMeyers, Lawren. ME dcKe. nu SPaarrtr al ,udhammer . 87 Industrial Refrigeration: Principles, Designd na Applications,C .P Koelet 79. Applied Combustion, Eugene L. Keating 80 Engine Oils and Automotive Lubncation, edited by Wilfried J. Bartz 81. Mechanism Analysis: Simplified and Graphical Techniques, Second Edition, Revised and Expanded, Lyndon O. Barton . 28 Fundamental Fluid Mechanicse ht rof Practicing Engineer, JamesW Murdock 83. Fiber-Reinforced Composites: Materials, Manufacturing, and Design, Second Edition, Revd iEsnexadp a. nKMd ae.Pldlic ,k . 4N8umencal Methor Eodnfs gineenng Applications, Edwa .CRrdh ampio.rnJ, 85 Turbomachmery. Basic Theory and Applications, Second Edition, Revised and Expanded, Earl Logan.r,J 86. Vibrations of Shells and Plates: Second Edition, Revised and Expanded, Wemer Soedel . 7S8team Plant Calculations Manual: Second Editiox npE,a nR ddeevndis,aed V. Ganapathy 88. Industrial Noise Control: Fundamentals and Applications, Second Edition, Revisd Eenaxd panded, Lew. HiBsd Dnealol ugla. HBs ell 89. Finite Elements- Their Design and Performance, Richard H MacNeal 90. Mechanical Properties of Polymers and Composites: Second Edition, Re- vised and Expanded, Lawrence E. Nielsen and Robert F. Landel 91. Mechanical Wear Predictid oPnanr evention, Raymon. GdB ayer . 29Mechanical Power Transmission Components, editey dbD av. iWdS outh and Jon R. Mancuso .39 Handbook fo Turbomachinery, edited yb Earl Logan,.rJ 94. Engineering Documentation Control Practices and Procedures, Ray E. Monahan 95. Refractory Linings Thermomechanical Design and Applications, Charles A. Schacht 96. Geometric Dimensioning and Tolerancing: Applications and Techniques for Usen i Design, Manufacturingd n,aI nspection, James. D Meadows 97. An Introduction to the Design and Behavior of Bolted Joints: Third Edition, Revised and Expanded, John H. Bickford 98. Shaft Alignment Handbook: Second Edition, Revised and Expanded, John Piotrowski 99. Computer-Aided Design of Polymer-Matrix Composite Structures, edited by Suong Van Hoa 100. Friction Science and Technology, Peter J. Blau 101. Introduction to Plastics and Composites: Mechanical Properties and Engi- neering Applications, Edward Miller 102. Practical Fracture Mechanicn sDi esign, Alexander Blake 103. Pump Characteristics and Applications, Michael W. Volk 104. Optical Prind cTinpelacehs nor lEoongfgy ineers, Jam. SEetse wart 105. Optimize iSnhtgh apf oMe echanical Elemed Snnattsr uctu. ASr ee.Asir, eg and Jorge Rodriguez 106. Kinematics and Dynamics of Machinery, Vladimir Stejskal and Michael Valasek 107. Shaft Sear loDsf ynamic Application sesHL, orve 108. Reliability-Based Mechanical Design, edited by Thomas A. Cruse 109. Mechanical Fastening, Joining, and Assembly, James A. Speck 110. Turbomachinery Fluid Dynamics and Heat Transfer, edited by Chunill Hah 111. High-Vacuum TechnologyA :P ractical Guide, Second Edition, Revisdenda Expanded, Marsbed H. Hablanian 112. Geometric Dimensioning and Tolerancing: Workbook and Answerbook, James D. Meadows 113. Handboof oMk aterials Selectior oEnf ngineering Applications, ed.Gite ybd T. Murray 114. Handbook of Thermoplastic Piping System Design, Thomas Sixsmith and Reinhard Hanselka 115. Practical Guide to Finite Elements: A Solid Mechanics Approach, Steven M. Lepi 116. Applied Computational Fluid Dynamics, edited by Vijay K. Garg 117. Fluid Sealing Technology, Heinz .K Mullerd na BernarudaN .S 118. Fd rLicnutbiaorni catn iMoine chanical D. SAees i.irgeAng , 119. Influence Funcd Mtnioaantrsi ces, Y. MAure ilnikov 120. Mechanical Analysis of Electronic Packaging Systems, Stephen A. McKeown 121. Couplings and Joints: Design, Selection, and Application, Second Edition, Revised and Expanded, Jon R. Mancuso 122. Thermodynamics: Proces dAsnepasp lications, Earl Loga.rnJ, 123. Gear Noisd nVea ibration, J. Derek Smith 124. Practical Fluid Mechanics for Engineering Applications, John J. Bloomer 125. Handbook of Hydraulic Fluid Technology, edited by George E. Totten 126. Heat Exchanger Design Handbook. T, Kuppan 127. Designinr oPgf roduct Sound Quality, Richar. HdL yon 128. Probability Applications in Mechanical Design, Franklin E. Fisher and Joy R. Fisher 129. Nickel Alloys, edited by Ulnch Heubner 03R1otating Machinery Vibration: Problem And anlTyasroisu bleshooting, Maurice L. Adams, Jr. 131. Formulas for Dynamic Analysis, Ronald L. Huston and C. Q. Liu 132. Handbof oMok achinery Dynamics, Lyn. LFn aulkd Enneaarr l Loga.rnJ, 133. Rapid Prototyping Technology. Selection and Application, Kenneth G. Cooper 134. Reciprocating Machinery Dynamics Design and Analysis, Abdulla S. Rangwala 135. Maintenance Excellence: Optimizing Equipment Life-Cycle Decisions, edi- ted by John D. Campbell and Andrew K. S. Jardine 136. Practical Guio dInte dustrial Boiler Systems, Ralp. VLh andagriff 137. Lubrication Fundamentals' Second Edition, Red vEinsxaep.dM an d.Ded , Pirro and A. A. Wessol 138 Mechanical Life Cycle Handbook: Good Environmental Design and Manu- facturing, edited by Mahendra S. Hundal 139. Micromachinf iEonng gineering Matenals, edy itJebods eph McGeough 140. Control Strategiesr of Dynamic Systems. Designd naI mplementation, John H. Lumkes, Jr. 141. Practical Guo Pidtre essure Vessel Manufacturing, Sunil Pullarcot 142. Nondestructive Evaluation- Theory, Techniqud Aensap, plications, editeybd Peter J.Shull 143. Diesel Engine Engineering: Thermodynamics, Dynamics, Desdignan, Control, Andrei Makartchouk 144 Handbof oMok achine Tool Analysis, loD aMn arinescu, Constantin Ispas, n BoaboDc dna 145. Implementing Concurrent Engineenng in Small Companies, Susan Carlson Skalak 146. Practicale PhGatu coikdtae gf inoEg lectronics: Thed rMnmaeac lhanical De dsAningaan lysis, Ali Jamnia 147. Bearing Design in Machinery Engineering Tribology and Lubrication, Avraham Hamoy 148 Mechanical Reliability Improvement Probability and Statistics for Experi- mental TestinE g R,L ittle 149. Industnal Boild enraHs eat Recovery Steam Generators: Desig-pnA, plicatd iConnaaslc ,ulatio. nVGs ,anapathy D GAuCide beohA oBTk .as1i5c0 .Mar noUufnad lerstd anInmdaipnrgo ving Computer-Aided Design, Stephen J. Schoonmaker 151. Industnal Noise Control and Acoustics, Randall F. Barren 152. Mechanical Properties of Engineered Materials, Wole Soboyejo 153. Reliability Verification, Testing, and Analysis in Engineenng Design, Gary S. Wasserman 154. Fundamental Mechanics of Fluids. Third Edition, I. G. Cume 155. Intermediate Heat Transfer, Kau-Fui Vincent Wong 156. HVAC Water Chillers and Cooling Towers- Fundamentals, Application, and Operation, He. rSWbtearn tfIoIrId Additional Volumes in Preparation Handbook of Turbomachinery Second Edition, Revised and Expanded, Earl Logan, Jr., and Ramendra Roy Progressing Cavity Pumps, Downhole Pumpsd nM,a udmotorsv eNL, elik Gear Noise and Vibration: Second Edition, Revised and Expanded, J. Derek Smith Piping and Pipeline Engineering: Design, Construction, Maintenance, Inted gRnreiatpy ,air, Geor. gAAen taki Turbomachinery: Designd na Theory. Rama. S Gorlad na Aijaz Ahmed Khan Mechanical Engineering Software Spring Design with an IBM PC, Al Dietrich Mechanical Design Failure Analysis. With Failure Analysis System Software for the IBM PC, David G. Ullman Preface TherearetwofundamentaltypesofHVACsystemsdesignedtosatisfybuilding cooling requirements: direct expansion (DX) systems, in which there is direct heat exchange between the building air and the refrigerant, and secondary refrigerant systems that utilize chilled water as an intermediate heat exchange medium totransfer heat from the building air tothe refrigerant. Chilled water systems are the heart of central HVAC cooling, providing coolingthroughoutabuildingorgroupofbuildingsfromonesource.Centralized cooling offers numerous operating, reliability, and efficiency advantages over individual DX systems and, on a life-cycle basis, can have significantly lower total cost. Every central HVAC cooling system is made up of one or more refrigeration machines, or water chillers, designed to collect excess heat from buildings and reject that heat to the outdoor air. The water chiller may use the vapor compression refrigeration cycle or the absorption refrigeration cycle. Vapor compression refrigeration compressors may be of the reciprocating, helicalscrew,orcentrifugaltypewithelectricorgas-firedengineprimemovers. Theheatcollectedbythewaterchillermustberejectedtotheatmosphere.This wasteheatcanberejectedbyair-cooling,inaprocessthattransfersheatdirectly from the refrigerant to the ambient air, or by water-cooling, a process that uses water to collect the heat from the refrigerant and then to reject that heat to iii

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