Chiller System Design
Chillers are an important component of any HVAC system, being a part of various facilities including restaurants, hotels, hospitals, manufacturing plants, and more. They’ve been widely used in a number of establishments, making them one of the largest electrical consumers with more than 50% of the entire electrical usage in the US during seasonal periods.
Statistics from the US Department of Energy revealed that all chillers throughout the country combined can use up to 20% of the entire electric power which is generated in North America. Such massive consumption can be caused by poorly performing chillers with inefficient designs.
We at NY Engineers aim to solve that problem by addressing cost-inefficiency and even outdated designs through our detailed and cost-effective chiller design solutions.
If you need a custom chiller design for your HVAC system, our professional and experienced team of designers and engineers can help you. With our custom chiller design solutions, you will be able to create a healthier indoor environment, cut down on energy consumption, and reduce your facility’s carbon footprint.
Our solid MEP engineering design expertise is what you need to turn your Chiller design project into a huge success. We can deliver designs in BIM format and create spatially coordinated 2D and 3D models that your contracting and installation teams can access. In every stage of the design process, we provide the best level of support we can render. We help you in every step of the way—from the concept, schematic, and design phase all the way to the construction stages.
Considerations for a Proper Chiller Design
Thinking of a chiller design can be challenging, especially if you don’t know where and how to start. That said, it certainly helps if you know what you should consider for the overall design of your chiller.
Here at NY Engineers, we always consider several factors in order to come up with a foolproof chiller design. Alternatively, if you already have a specific design in mind, we’ll help you review and visualize it through 3D modeling, so you’ll know what it looks like once it’s manufactured.
- Chiller Type
A chiller can come in several types (more details discussed further below). Depending on your preference, you can either have an air-cooled design if you have limited indoor space or a water-cooled design if you have a lot of space to spare indoors.
- Temperature
Chilled water systems will have delta Ts ranging from 10 to 16 degrees while supply temperatures normally range from 38 to 44 degrees Fahrenheit.
Higher delta Ts combined with lower supply temperatures will result in smaller coils at both terminal and air handling units; however, they will cause your chiller to consume a higher amount of energy.
- Pumping
Large systems will typically use a variable primary flow piping system due to their lower energy consumption and upfront cost. However, for modular chillers, a primary-secondary system is preferred since it is required to maintain minimum flow via the chiller during low load days. This is to prevent cycling the chiller because of low flow. On modular chillers with a constant load profile, a primary-secondary pumping system will be a good option.
- Operation
Another vital component of an effective chiller design is the way the chiller will operate. That said, you need to determine when you want your chiller to operate. Do you need constant cooling inside your facility 24/7? Or do you prefer space cooling which will only operate during summer seasons? By providing us with such information, we’ll be able to come up with a design which can meet such conditions.
- Pressures
The standard pressure rating for a chiller is 125 PSI although you can have a chiller manufactured with a higher rating at additional costs. Facilities located inside a tall building higher than 280 feet can have issues with the pressure, especially if the chiller plant is at the bottom.
It will be our responsibilities as designers to look at locating the chiller plant to a central location or perhaps use heat exchangers for providing pressure breaks.
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As mentioned earlier, chillers can be classified into several types. The type of chiller you preferred is essential, so we can come up with the right design that will cater to your needs. Primarily, chillers are categorized into two: air-cooled and water-cooled.
Air-cooled chillers look just like the radiators in cars which are used to cool their engines. They use a motorized blower to remove heat and force air across the tubes of the condenser. Compared to water-cooled variants, air-cooled systems require more energy although they’re an excellent option in terms of stationary cooling.
Since air-cooled chillers rely on a condenser which is being cooled by the surrounding air, they’re mostly found in smaller or medium installations with limited space. They’re also very easy to install and can even be installed outside without any extra space requirements.
Air-cooled chillers hold the advantage of having lower installation costs than water-cooled chillers. Additionally, they require less maintenance compared to their water-cooled counterparts. However, as they’re mostly installed outside, they will become more prone to recirculation, blockage, and other issues caused by outdoor elements.
Water-cooled chillers, on the other hand, have a water-cooled condenser which is connected with a cooling tower. Compared to air-cooled versions, they are more ideal for medium and large installations with a sufficient water supply. Additionally, they offer more constant performance for both industrial and commercial cooling.
As opposed to air-cooled chillers, water-cooled chillers are normally installed in an indoor environment, thereby protecting it from the outdoor elements. As a result, they can last way longer. However, since they will require a cooling water system, the installation expenses are way higher than air-cooled chillers. Routine maintenance is also necessary to keep them in good working condition at all times.
While chillers are categorized into two, air-cooled and water-cooled chillers can be further categorized based on the compressor technology they’re using. These are as follows:
- Centrifugal chiller – most water chillers are centrifugal chillers. They are mostly used for medium and large cooling loads and offer high cooling capacity despite a compact design. Chillers that are in this category use rotating impellers for compressing the refrigerant and forcing it around the chiller.
- Scroll compressor chiller – this type of technology can be used in either air and water coolers. They operate with the help of two spiral plates which are responsible for compressing the refrigerant.
- Reciprocating chiller – this technology uses a chamber and piston for compressing the refrigerant.
- Screw driven chiller – designed to handle small and medium cooling loads, a screw driven chiller uses two interlocking helical rotors for compressing the refrigerant. It can be used in both air and water-cooled chillers.
Why a Chiller Design Matters
Earlier, we mentioned that poorly designed chillers are among the biggest consumers of electricity throughout North America. However, apart from that, they’re also the reason why lots of buildings and facilities ended up losing billions of dollars every year.
With a well-designed chiller, however, you will be able to avoid such expenses. So why exactly does a chiller design matter?
- First, a well-designed chiller lets you avoid any heavy expenses which you could have spent when using an inefficient chiller with a poor design.
- Second, you’ll be able to visualize the chiller in advance before you even have it manufactured. This way, you’ll have an idea on how it will look like, how it will work, and how you can have it installed in your facility. You’ll also be able to figure out if it can fit inside your facility's space or not.
- Third, it will be possible to spot any potential issues before they even happen. Our team will work with you throughout the design process, so you can know the progress of the design and pinpoint any possible issues.
- Lastly, you’ll be able to provide powerful and efficient cooling to your building. While this is what chillers are supposed to do, a properly designed chiller will deliver even more efficient cooling in a more cost-effective means.
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Our team here at NY Engineers consist of passionate and skilled professionals who can create designs, come up with concepts, and visualize your chiller through 3D modeling and rendering.
To ensure a smooth and complete process, we normally follow these procedures:
- Once you have contacted us for a chiller design service, our representative will attend to you and answer any of your queries. We can also provide you with an estimate, so you will be able to allocate enough budget for the project.
- After you’re set to have a chiller design, the next step is to provide us with your design brief. As much as possible, include everything you would like to incorporate in your chiller system. Mention all the components you want to be included in the design. We can also recommend several components and other specifications, but if you can provide us with your own custom specifications, it will help us visualize what you need and complete the design as soon as possible.
- We’ll then send some of our staff to your facility, so they can obtain accurate measurements of your building. This way, we’ll be able to confirm the size of your chiller and also get an idea of your building’s design which we’ll use later for visualization.
- As soon as we have the information we need, our team of designers will then start working on your design. We will also collaborate with you throughout the designing process. We would appreciate if you can provide initial feedback as we go; this way we’ll be able to address any issues which we might have overlooked and even make minor or major changes depending on your preferences.
- During the final phase, we will visualize your chiller design and give you a 3D representation of your chiller and how it will look like once installed in your facility. This way, you can ascertain that the chiller is of the right dimensions before you have it manufactured.
- Once everything is completed and agreed upon, with all the necessary revisions and changes implemented, we’ll then give you the design in a single file. The file will be ready for manufacturing, so you are guaranteed that everything will go smoothly from the designing to the manufacturing process.
Our Chiller Design Service
Our 3D BIM design service makes sure that you can have a fully functional and highly efficient chiller design for your facility.
- By using several advanced tools designed for 3D BIM modeling and design, such as AutoCAD, Revit, and more, our designers are capable of creating 3D models of your chiller and facility at a 1:1 scale.
- One interesting aspect of our 3D chiller design service is that our designers can also create sections, floor plans, and elevations of your building from various perspective.
- With BIM modeling, we’ll be able to create detailed 3D representations of your facility and even create color fill and render limited animation.
- We make sure our 3D design and modeling services are hassle-free. This is to ensure that your contractors will be able to avoid rework, allowing both of you to save time and money.
- Through 3D visualization and rendering, you’ll be able to know how your chiller system will look like once it’s manufactured and installed within your building. You’ll also be able to “explore” the different sections of your building.
- Our modeling service is aimed at bringing collaboration between the disciplines of structural, MEP, and architectural.
We at NY Engineers help construction firms transform projects into BIM environments while at the same time empower site managers for cost and risk reduction for their construction project’s entire cycle.
By working with us, you are guaranteed:
- On-time project completion and delivery
- Cost-effective chiller design solutions for your project
- Precise and detailed model of your systems
- 100% adherence to local and international standards
- Strict compliance with HVAC-related regulations
- Quality and comprehensive designs
- Friendly and cooperative team
For all your BIM modeling and design needs, NY Engineers will be your best go-to team. Get in touch with us now so we can cater to your request immediately. We’ll also be glad to provide you with a FREE estimate.
