Sequence of Operation-Dubai Marina

SEQUENCE OF OPERATION

CHILLER CONTROLS
 Sequence of Operation-Dubai Marina

EQUIPMENTS CONTROLLED & MONITORED BY THE DDC

SUPPLIED BY HONEYWELL/WOTEK.

 Chillers- 3 Nos.
 Chilled Water Primary Pumps- 4 Nos.
 Chilled Water Secondary Pumps- 4 Nos
 Cooling Tower- 3 Nos.
 Condenser Water Pump- 4 Nos.
 Pressurization Unit

Control Philosophy
It shall be noted that any BMS, gives only an enable/disable (and
monitors chiller HOA, run, trip status), volt free command to the
chillers and does not interfere in any manner, whatsoever, with the
internal operation, factory logic, control of compressors, internal
capacity control, or control of any other component in the chiller.

All chillers operate with their internal factory programmed sequence,

from their own microprocessor, to give a constant leaving chilled
water temperature, as per chiller selection and design. The
compressors in the chiller stage up/down, the capacity control and
even the individual compressor lead/lag sequence, is done by the
chiller microprocessor and not through the BMS or any controls by
BMS.

The BMS system shall be programmed such that it shall provide auto
lead lag control of each piece of equipment. This shall be configured
for both the chillers and all the pumps such that the units with the
least number of run hours, shall be the first to start, which gives
EVEN operation, for each unit.

The primary pumps, condenser pumps, and the cooling towers are
controlled and monitored by the BMS/DDC, and the chillers are
monitored and enabled/disabled based on the building load (main
return header chilled water temperature).
Sequence of Operation-Dubai Marina
 Sequence of Operation-Dubai Marina

Starting Sequence of Chillers, Pumps, and Cooling towers.

On initial startup of the system, the DDC will verify the selector
switches of (pumps, chillers, cooling towers) set to auto mode. (The
trip status will be verified of all equipment’s), then the DDC Controller
will initiate the following based on the return header temperature
(which will decide the load requirement of the Building):

a. The butterfly valves for the Lead cooling towers (In & Out)
shall be Switched ON and the open status shall be
verified.

b. The lead condenser pump shall be commanded to start

and condenser water will start circulating. The operational
status of the pump is confirmed by the DPS installed to
monitor the run status of the pump. If the flow DPS is not
activated the pump flow failure signal will be given by the
BMS, and the next duty pump will be sequenced
accordingly.

c. The lead cooling tower fans shall be commanded to start,

based on demand (based on the delta T between CDW
Supply & Return Header). The CT fans will come ON if the
entering water temperature is higher than the set point.
The cooling tower fans are commanded to start/stop
based on the entering condenser water temperature,
which is settable, and this temp can be set as per the
chiller supplier’s requirements. CT FAN VFD will be
operated based on Delta T between Entering & Leaving
Temperature.

d. Once the condenser water circuit initiates, the evaporator

circuit will be sequenced to turn on.
 Sequence of Operation-Dubai Marina

e. The Chiller Motorized Butterfly Valves of Lead Chiller set

to start. After the valve is fully open the open signal is sent
to the DDC Controller confirms the fully open status of the
Motorized Butterfly Valves.

f. After receiving confirmation of the Motorized Butterfly

Valves, lead primary pump shall be commanded to start
and chilled water will start circulating. The operational
status of the pump is confirmed by the Volt Free contact
from MCC to monitor the run status of the pump. If the run
status is not activated the pump flow failure signal will be
given by the BMS, and the next duty pump will be
sequenced accordingly.

g. Once the primary pump has started, and monitored by

BMS, the lead secondary pump will be commanded to
start. It will start ramping up and the further demand and
speed of the secondary pump is decided based on
AVERAGE of the differential pressure sensed by the
differential pressure transmitter installed across the chilled
water riser. (A) – Tower 1 at Level 13, (B) Tower 2 at Level
12, (C) At Chiller Plant Room. For Tertiary – Tower 1 at
Level 41 and Tower 2 at Level 30.

h. Further, the command for the lead chiller to start is

provided by the DDC controller, based on and comparing
the return CHW header temperature, with the desired set
point. The chiller internal operation will be sequenced by
its own chiller microprocessor panel and BMS will only
provide enable/ disable command to chiller. The supplied
chiller has its own, internal, flow switch, which will stop the
chiller if the flow varies abnormally.(Both condenser and
evaporator sides)
 Sequence of Operation-Dubai Marina

i. If there is persisting flow demand, decided by the set value

for the differential pressure, then the DDC Controller will
command other secondary pump to start and fulfill the
demand, once the lead pump has ramped up to full speed.
Both secondary pumps, with VFD, will ramp up & down
(modulate) based on this DPT reading and set value.

j. Bypass Butterfly Valve is Installed at both Tower 1 &

Tower 2. In case of less demand and VFD is lowered to
minimum, the bypass valve will fully open and allow
maximum water to bypass to return line.

k. Similarly, the demand for cooling and operation of the

chillers is sensed by immersion water temperature sensors
situated in the main supply and return chilled water
header. The DDC controller compares this return header
CHW temp with the user defined set point (settable as per
project requirement) and on receiving a signal higher than
its set point the DDC controller commands the chiller to
start (enable). All the above sequence will repeat before
giving enable command to 2nd & 3rd Chiller to start
operation, in case of an increasing cooling demand and
rise in the return CHW header temperature.

l. On weekly basis, equipment sequencing will be changed

automatically to maintain equal number of run hours for all
the chillers/pumps/cooling towers, etc.

m. Pressurization units are designed to replace water that

has been lost through system leakage and to maintain the
system design fill pressure in chilled water systems
automatically. BMS/DDC controls only monitor Run Status
& Alarm Status with the volt free contact provided in their
control panel.
 Sequence of Operation-Dubai Marina

n. Heat Exchanger & Tertiary Pumps are located Level 27 at

Tower 1 and Level 21 at Tower 2. Tertiary Pumps are VFD
driven (Ramp up and Ramp Down) control via DPT
installed Level 41 at Tower 1 and Level 30 at Tower 2.
PICV Valves are installed at HEX Primary Return and shall
modulate to control the constant supply temperature at
Heat Exchanger secondary.
o.

Our proposal for Chiller requirement shall be follows:

(Set Points can be changed / modified by user or operator)

Pri
SN Description Chiller SCWP CDWP CT Remarks
CHWP
Return Header Temp is greater
1 1-2-3 1-2-3 1-2-3 1-2-3 1-2-3
than 21.3 Deg
Week#1
Return Header Temp is greater
2 1-2 1-2 1-2 1-2 1-2
than 17.3 Deg

Return Header Temp is greater

3 1 1 1 1 1
than 13.3 Deg

If any
Pri
SN Description Chiller
CHWP
SCWP CDWP CT equipment
1
Return Header Temp is greater
2-3-1 2-3-1 2-3-1 2-3-1 2-3-1
fails, then
than 21.3 Deg
Week#2
next duty
2
Return Header Temp is greater
than 17.3 Deg
2-3 2-3 2-3 2-3 2-3 equipment
will take
Return Header Temp is greater
3
than 13.3 Deg
2 2 2 2 2 over, by
generating
Pri
SN Description Chiller
CHWP
SCWP CDWP CT alarm to
Return Header Temp is greater
operator.
1 3-2-1 3-2-1 3-2-1 3-2-1 3-2-1
than 21.3 Deg
Week#3
Return Header Temp is greater
2 3-2 3-2 3-2 3-2 3-2
than 17.3 Deg

Return Header Temp is greater

3 3 3 3 3 3
than 13.3 Deg
 Sequence of Operation-Dubai Marina

Stop Sequence of Chillers, Pumps, and Cooling towers.

a. When the return CHW header temperature sensed is lower

than the set point, the BMS shall signal the 1st chiller to stop
(disable). The BMS gives a disable command to the chiller and
once this is given to the chiller, the chiller starts its own ramp
down sequence, and logic, and comes to rest after its internal
sequence is completed. Unless the DDC gives an enable
command, based on increase in return CHW temp, to the
chiller, as explained above, the chiller will remain at rest.

b. The chilled water primary pumps shall continue to run for a

preset time [5 to 10 min] to dissipate any load still within the
chiller therefore preventing freezing or damage to the chiller.
This time delay is settable as required by the chiller
manufacturer.

c. After the desired time delay is over, the off command is given to
the primary pump.

d. Once the pump off status is received by BMS, the PICV in the
evaporator side are then commanded to switch OFF.

e. Once all the operating primary pumps are switched off, and off
status received, the operating secondary pump are
commanded to stop.

f. The cooling tower fan is then commanded to switch off, based

on its operating status.

g. The condenser water pumps are commanded to stop, and once

the pump off status is received by BMS, the butterfly valves in
the condenser and the cooling towers are commanded to close.
 Sequence of Operation-Dubai Marina

h. In the event of any failure or trip of any chiller, during operation,

the DDC controller shall disable this chiller, and command to
close its associated PICV valves. Once the fault is reset, the
DDC again enables the chiller, after commanding the next
chiller PICV Valve to open fully, and assume the position of the
lead chiller. The similar control logic will prevail on the pumps
and cooling towers, in case of failure/trip of this equipment.

i. Start and stop time delays, for all equipment, will be

programmed and set as discussed with consultant/client at site.
 Sequence of Operation-Dubai Marina

Following Points & Alarms shall be generated and recorded in the system:

S.No Point Description S.No Point Description

Primary Chilled Water
A Chillers B
Pump
Chiller Supply & Return
1 1 Unit - Trip Status / HOA / Run
Temperature Sensor
Secondary Chilled Water
2 CHW Return line BTU meter C
Pump
Unit - Trip Status/ / HOA /
3 Common Fault on Chiller 1
Run / VFD Feedbk
4 Chiller RUN Status D Cooling Tower (2D+1S)
5 Gas Leak Detection 1 Trip Status
Chiller Supply Main Header Cooling Tower IN/Out
6 2
Temperature Temperature
Chiller Return Main Header Bvf Valve Control &
7 3
Temperature Feedback
Differential Pressure Monitoring Condensing Water Pump
8 E
(Riser wise) (2D+1S)
Unit - Trip Status HOA / Run /
9 Bvf Valve Control & Feedback 1
Line Pressure