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Transcript of 10092012 System Diagrams
Instructor:Instructor:Instructor:Instructor:
System Diagram WorkshopIntroduction
Introduction and Overview
David Sellers
Senior Engineer
Facility Dynamics Engineering
October 9, 2012
Disclaimer
The information in this document is believed to accurately describe the
technologies described herein and are meant to clarify and illustrate typical
situations, which must be appropriately adapted to individual circumstances.
These materials were prepared to be used in conjunction with a free, educational
program and are not intended to provide legal advice or establish legal standards
of reasonable behavior. Neither Pacific Gas and Electric Company (PG&E) nor any
of its employees and agents:
(1) Makes any written or oral warranty, expressed or implied, including, but not
limited to, those concerning merchantability or fitness for a particular purpose;
(2) Assumes any legal liability or responsibility for the accuracy or completeness
of any information, apparatus, product, process, method, or policy contained
herein; or
(3) Represents that its use would not infringe any privately owned rights,
including, but not limited to, patents, trademarks, or copyrights.
Disclaimer
The information in this document is believed to accurately describe the
technologies described herein and are meant to clarify and illustrate typical
situations, which must be appropriately adapted to individual circumstances.
These materials were prepared to be used in conjunction with a free, educational
program and are not intended to provide legal advice or establish legal standards
of reasonable behavior. Neither Pacific Gas and Electric Company (PG&E) nor any
of its employees and agents:
(1) Makes any written or oral warranty, expressed or implied, including, but not
limited to, those concerning merchantability or fitness for a particular purpose;
(2) Assumes any legal liability or responsibility for the accuracy or completeness
of any information, apparatus, product, process, method, or policy contained
herein; or
(3) Represents that its use would not infringe any privately owned rights,
including, but not limited to, patents, trademarks, or copyrights.
Disclaimer
The information in this document is believed to accurately describe the
technologies described herein and are meant to clarify and illustrate typical
situations, which must be appropriately adapted to individual circumstances.
These materials were prepared to be used in conjunction with a free, educational
program and are not intended to provide legal advice or establish legal standards
of reasonable behavior. Neither Pacific Gas and Electric Company (PG&E) nor any
of its employees and agents:
(1) Makes any written or oral warranty, expressed or implied, including, but not
limited to, those concerning merchantability or fitness for a particular purpose;
(2) Assumes any legal liability or responsibility for the accuracy or completeness
of any information, apparatus, product, process, method, or policy contained
herein; or
(3) Represents that its use would not infringe any privately owned rights,
including, but not limited to, patents, trademarks, or copyrights.
Disclaimer
The information in this document is believed to accurately describe the
technologies described herein and are meant to clarify and illustrate typical
situations, which must be appropriately adapted to individual circumstances.
These materials were prepared to be used in conjunction with a free, educational
program and are not intended to provide legal advice or establish legal standards
of reasonable behavior. Neither Pacific Gas and Electric Company (PG&E) nor any
of its employees and agents:
(1) Makes any written or oral warranty, expressed or implied, including, but not
limited to, those concerning merchantability or fitness for a particular purpose;
(2) Assumes any legal liability or responsibility for the accuracy or completeness
of any information, apparatus, product, process, method, or policy contained
herein; or
(3) Represents that its use would not infringe any privately owned rights,
including, but not limited to, patents, trademarks, or copyrights.
INTRODUCTION 2
Copyright Materials
Some or all of this presentation may be protected by US and
International Copyright laws. Reproduction, distribution,
display and use of the presentation without written permission
of the copyright holder is prohibited.
Copyright Materials
Some or all of this presentation may be protected by US and
International Copyright laws. Reproduction, distribution,
display and use of the presentation without written permission
of the copyright holder is prohibited.
Copyright Materials
Some or all of this presentation may be protected by US and
International Copyright laws. Reproduction, distribution,
display and use of the presentation without written permission
of the copyright holder is prohibited.
Copyright Materials
Some or all of this presentation may be protected by US and
International Copyright laws. Reproduction, distribution,
display and use of the presentation without written permission
of the copyright holder is prohibited.
INTRODUCTION 3
Learning Objectives
After completing this course you should be able to:
Learning Objectives
After completing this course you should be able to:
Learning Objectives
After completing this course you should be able to:
Learning Objectives
After completing this course you should be able to:
• Explain and embrace the system concept
• Understand the key concepts behind a system diagram
• Understand the similarities and difference between air
and water system diagrams
• Understand how to apply system diagrams to support
design, commissioning, and ongoing operation
• Be familiar with the tool available to you to develop
system diagrams
INTRODUCTION 4
AgendaAgendaAgendaAgenda
• Introduction and Overview to the System Concept
• System Diagram Concepts
‒ Key Characteristics
‒ Tools and Development Resources
‒ Water System Diagrams
‒ Air System Diagrams
• Case Studies
• Lab Session
‒ Identifying System Components
‒ Organizing Components into a Diagram
‒ Using a System Diagram for Design, Analysis and
Diagnostics
INTRODUCTION 5
The System Concept
Key to design and commissioning success �
INTRODUCTION 6
The Chilled Water System
7
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Not just the chiller �
The Chilled Water System
8
Load
Not just the loads �
The Chilled Water System
9
Piping
Network
Pump
Expansion tank and make
up water
Not just the pumps and piping �
The Chilled Water System
10
Piping
Network
Load
Pump
Expansion tank and make
up water
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Rather, the integrated, interactive assembly of chiller, pumps,
piping and coils and all of their related control elements
The Same Thing is True on the
Condenser Side of the Chiller
11
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Not just the chiller �
The Same Thing is True on the
Condenser Side of the Chiller
12
Cooling
Tower
Not just the cooling tower �
The Chilled Water System
13
Make-up, Blow-
down, and Water
Treatment
Pump
Piping
Network
Piping
Network
Not just the pumps and piping �
The Chilled Water System
14
Make-up, Blow-
down, and Water
Treatment
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Pump
Piping
Network
Piping
Network
Cooling
Tower
Rather, the integrated, interactive assembly of chiller, pumps,
piping and cooling towers and all of their related control elements
What Happens to the Condenser Water
System if we Shut Down the Chiller?
INTRODUCTION
The Chilled Water System
16
Make-up, Blow-
down, and Water
Treatment
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Pump
Piping
Network
Piping
Network
Cooling
Tower
What Happens to the Cooling Basin when
we Restart the Condenser Pump?
INTRODUCTION
Lack of system integration
can waste energy and
other resources
Lack of system integration
can trigger nuisance (or
worse) problems
Problems in one system
can ripple out to other
systems
What Happens if the Discharge Temperature
Control Loop on a Load Becomes Unstable?
18
Piping
Network
Load
Pump
Expansion tank and make
up waterMake-up, Blow-
down, and Water
Treatment
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Pump
Piping
Network
Piping
Network
Cooling
Tower
The Problem
Persistent chiller trips
�and related issues
Proposed causes
• Someone else
• System design will
not support the
operation of only the
small units
• Chiller adjustments
• Control issues
INTRODUCTION
Chillers trip off on freeze
protection safety
Set point
Low suction
temperature
safety set
point
INTRODUCTION 20
Major secondary flow swings
occur right before a trip �
Flow never drops below
about 110 gpm (chillers
rated for 194 gpm)
� but big swings don’t
always produce a trip
INTRODUCTION 21
Note strong correlation
between flow swings and
temperature swings
Flow swings seem to
lead/trigger the
temperature swings
Supply temperatures “flirt”
with the freeze protection
setting on some swings
Low suction
temperature
safety set
point
INTRODUCTION 22
70% travel in 4 – 5 minutes
for the chilled water valve in
AHU-C causes major
secondary flow swings
The valve swings are
traced to an economizer
change-over control
algorithm with a dead-band
that is too tight
INTRODUCTION 23
A similar problem seems to exist
on the previous chiller trip
INTRODUCTION 24
Resolution at Last! (Maybe)
INTRODUCTION 25
AH-B seems to be driving
the pattern on June 2, not
AH-C. Maybe there is
something else going on!
INTRODUCTION 26
The other major AHUs are
not doing much of anything
relative to AH-B and the
flow variation seems to be
following AH-B
INTRODUCTION 27
This has been going on for
a while!
INTRODUCTION 28
Secondary temperature
and flow both seem to
follow AH-B
INTRODUCTION 29
The Issues at This Point
Identifying and solving the economizer integration issue
was a big step
AH-B-1 chilled water valve related hunting:
• Seems linked to secondary flow variations
• Seems to cause CHWS temperature swings that “flirt”
with low temperature safety settings
• Could cause 150,000 or so actuator cycles a year
INTRODUCTION 30
VFD tuning and speed
control is not the issue
INTRODUCTION 31
Contractor Focus has Moved To Other Areas
INTRODUCTION 32
Substantial
Completion
“Locking down” the AH-B
control valve so it can’t
move provides proof
positive of the impact of the
valve on secondary flow
and temperature control
INTRODUCTION 33
A Picture is Worth 1,000 Words (or e-mails)
Graphic evidence catches
peoples attention
• Control system lead
programmer connects the dots
‒ AH-B-1 chilled water valve
is controlled by two different
loops
‒ The loops are in conflict
‒ The ongoing conflict
generates the saw-tooth
valve control pattern
INTRODUCTION
Our Bottom Lines
• Lack of system integration can waste energy and other
resources
• Lack of system integration can trigger nuisance (or
worse) problems
• Problems in one system can ripple out to other systems
INTRODUCTION 35
Our Bottom Lines
• Lack of system integration can waste energy and other
resources
• Lack of system integration can trigger nuisance (or
worse) problems
• Problems in one system can ripple out to other systems
and cause really big problems
• We need a tool that can help us see the big picture and
understand system level and system to system
interactions
INTRODUCTION 36
Floor Plans
Common Construction
Document Mechanism
• Depict real world
dimensional relationships
• (Can) show if things will fit
• (Can) show fittings required
to make things fit and imply
related pressure drops
• Three dimensional reality
portrayed in two
dimensions
• Not intended to convey the
design in a schematic
arrangement
INTRODUCTION 37
Piping Isometrics
Less Common Construction
Document Mechanism
• Bring a three
dimensional perspective
• Constructed on isometric
projection lines
• Not a true 3D model
• Not intended to convey
the design in a
schematic arrangement
INTRODUCTION 38
System Diagrams Convey the System
Concept
39
Piping
Network
Load
Pump
Expansion tank and make
up waterMake-up, Blow-
down, and Water
Treatment
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Pump
Piping
Network
Piping
Network
Cooling
Tower
Conveying the system concept is a powerful design tool
What Set the AHU Flow Rate?
INTRODUCTION
System Diagrams Convey the System
Concept
41
Piping
Network
Load
Expansion tank
and make up
water
Make-up, Blow-
down, and Water
Treatment
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Piping
Network
Piping
Network
Cooling
Tower
Conveying the system concept is a powerful design tool
1,500 gpm from 95°F to
85°F with an 75°F ambient
wet bulb
30 hp motor
8” Mains
2 Pumps; 1,500 gpm at 40 ft.w.c. each
hPump = 80%, 18.9 bhp, 20 hp motor; hMotor
= 93%; PFMotor= .90
2 Pumps; 400 gpm at 45 ft.w.c. each
hPump = 75%, 6.1 bhp, 7-1/2 hp motor;
hMotor = 91%; PFMotor= .88
8” Mains
800 gpm
42°F EWT
57°F LWT
∆p = 12 ft.w.c.
Are the Chilled Water Pumps Redundant?
INTRODUCTION
Are the Chilled Water Pumps Redundant?
43
Piping
Network
Load
Expansion tank
and make up
water
Make-up, Blow-
down, and Water
Treatment
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Piping
Network
Piping
Network
Cooling
Tower
1,500 gpm from 95°F to
85°F with an 75°F ambient
wet bulb
30 hp motor
8” Mains
2 Pumps; 1,500 gpm at 40 ft.w.c. each
hPump = 80%, 18.9 bhp, 20 hp motor; hMotor
= 93%; PFMotor= .90
2 Pumps; 400 gpm at 45 ft.w.c. each
hPump = 75%, 6.1 bhp, 7-1/2 hp motor;
hMotor = 91%; PFMotor= .88
8” Mains
800 gpm
42°F EWT
57°F LWT
∆p = 12 ft.w.c.
Are the Condenser Water Pumps
Redundant?
INTRODUCTION
Are the Condenser Water Pumps
Redundant?
45
Piping
Network
Load
Expansion tank
and make up
water
Make-up, Blow-
down, and Water
Treatment
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Piping
Network
Piping
Network
Cooling
Tower
1,500 gpm from 95°F to
85°F with an 75°F ambient
wet bulb
30 hp motor
8” Mains
2 Pumps; 1,500 gpm at 40 ft.w.c. each
hPump = 80%, 18.9 bhp, 20 hp motor; hMotor
= 93%; PFMotor= .90
2 Pumps; 400 gpm at 45 ft.w.c. each
hPump = 75%, 6.1 bhp, 7-1/2 hp motor;
hMotor = 91%; PFMotor= .88
8” Mains
800 gpm
42°F EWT
57°F LWT
∆p = 12 ft.w.c.
Are the Condenser Water Pumps
Redundant?
46
Piping
Network
Load
Expansion tank
and make up
water
Make-up, Blow-
down, and Water
Treatment
Evaporator
Condenser
Expansion
Device
Compressor
Water Chiller
Piping
Network
Piping
Network
Cooling
Tower
1,500 gpm from 95°F to
85°F with an 75°F ambient
wet bulb
30 hp motor
8” Mains
2 Pumps; 1,500 gpm at 40 ft.w.c. each
hPump = 80%, 18.9 bhp, 20 hp motor; hMotor
= 93%; PFMotor= .90
2 Pumps; 400 gpm at 45 ft.w.c. each
hPump = 75%, 6.1 bhp, 7-1/2 hp motor;
hMotor = 91%; PFMotor= .88
8” Mains
800 gpm
42°F EWT
57°F LWT
∆p = 12 ft.w.c.
Conveying the system concept is a powerful
commissioning tool
System Diagrams Convey the System
Concept
Design Tool
Allows the entire system to be seen at
once in an orderly, untangled arrangement
• Ensures persistence of intent as plans
evolve
• Provides a framework for locating
control elements
Allows critical design parameters to be
conveyed
• Most engineering decisions can be
made at the system diagram stage
• Facilitates inter-discipline
communication
Allows configuration details to be
conveyed
Cx and Operations Tool
Allows the entire system to be seen at
once in an orderly, untangled arrangement
• Allows interactions and integration to
be assessed
• Allows trouble-spots to be quickly
identified
Allows critical design and performance
parameters to be documented
Facilitates:
• Training
• Persistence
• Commissioning
• Troubleshooting
INTRODUCTION 47
Instructor:Instructor:Instructor:Instructor:
System Diagram WorkshopBasic Concepts
Tools and Techniques for Developing your System
Diagrams
David Sellers
Senior Engineer
Facility Dynamics Engineering
October 9, 2012
Resource for Details Behind this Content
www.Av8rdas.Wordpress.com
Posts with the heading “System Diagrams: �” (Your Pre-
class Reading Assignment)
BASIC CONCEPTS 49
There is No Real Standard
P&ID (Process and Instrumentation Diagrams) are a
similar concept as is a PFD (Process Flow Diagram)
http://en.wikipedia.org/wiki/Piping_and_instrumentation_diagram - From the author’s own work - Creative Commons Share Alike
BASIC CONCEPTS 50
Starting Points for Symbols
ISA-5.1-1984 Instrumentation
Symbols and Identification
BASIC CONCEPTS
Starting Points for Symbols
2009 (or earlier) ASHRAE
Handbook of Fundamentals,
Chapter 37
BASIC CONCEPTS
Starting Points for Symbols
Your Own Creativity
BASIC CONCEPTS
Starting Points for Symbols
Drawing program symbol
libraries
BASIC CONCEPTS
Physically Complex,
Schematically Simple
BASIC CONCEPTS
“Like a Ladder on its Side”Chuck McClure
BASIC CONCEPTS 56
A Ladder On Its Side “On Drugs”
BASIC CONCEPTS 57
Dealing With a Ladder On Its Side “On
Drugs”
BASIC CONCEPTS 58
Show the entire system at a small scale on the lead sheet …
Dealing With a Ladder On Its Side “On
Drugs”
BASIC CONCEPTS 59
… and provide larger scale drawings of portions of the system
Dealing With a Ladder On Its Side “On
Drugs”
BASIC CONCEPTS 60
BASIC CONCEPTS 61
What’s on the Ladder Rungs and What’s on
the Ladder Rails Can Vary
“What’s using up the pump
head?” focus
“What’s making and using cold
glycol?” focus
BASIC CONCEPTS
“Untangled” versus “Tangled”
tangled adj
1. existing in or giving the appearance of a state of utter
disorder
2. very involved : exceedingly complex
BASIC CONCEPTS 63
“Untangled” versus “Tangled”
Tangled Untangled
BASIC CONCEPTS
“Untangled” versus “Tangled”
Keep simplifying things to minimize line crossings and head towards a
“ladder on its side”
But remember:
Things should be made as simple as possible, but not any simpler.Albert Einstein
That means for a system diagram, order of connection “trumps”
untangled
BASIC CONCEPTS 65
Floor Plans; A Common
Tool Targeted at the Big
Picture
INTRODUCTION 66
Schematics; Another
Common Tool
INTRODUCTION 67
An Exercise Applying What You’ve Learned
So Far
Half the class take the piping
plan in the next slide and
make a system diagram from
it
The other half of the class take
the schematic in the previous
slide and make a system
diagram from it
See if there are any problems
that jump out at you from your
system diagrams
Did you recognize/understand
them before you did the
system diagram?
INTRODUCTION
Chillers Wet Economizer
(Free Cooling) Plate
and Frame Heat
Exchanger
Chilled Water
Distribution Pumps
Typical Chiller/Heat
Exchanger Pump
Three-Way
Control Valve
INTRODUCTION 69
See Any Problems
INTRODUCTION
Order of Connection Matters in Action
Bypass is “Inside” the plant Bypass is “Outside” the plant
BASIC CONCEPTS
Order of Connection Matters;An Exercise
BASIC CONCEPTS
Getting Ready to Go Out in the Field
Study existing drawings if they
exist
• May include a schematic
• May reveal issues
• Provides a first draft
Be ready for reality
• Clipboard
• Paper
• Flashlight
• Camera
BASIC CONCEPTS73
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
BASIC CONCEPTS74
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
BASIC CONCEPTS75
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
BASIC CONCEPTS76
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
BASIC CONCEPTS77
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
BASIC CONCEPTS78
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
BASIC CONCEPTS79
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
BASIC CONCEPTS80
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
BASIC CONCEPTS81
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
• Make decisions at tees
BASIC CONCEPTS82
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
• Make decisions at tees
BASIC CONCEPTS83
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
• Make decisions at tees
BASIC CONCEPTS84
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
• Make decisions at tees
BASIC CONCEPTS85
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
• Make decisions at tees
BASIC CONCEPTS86
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
• Make decisions at tees
BASIC CONCEPTS87
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
• Make decisions at tees
BASIC CONCEPTS88
Getting Started
Find something you can identify
• Nameplate data
• Labels
• Past experience
Start following the system of
interest
• Your first effort will likely not be
your last effort
• “Follow your nose”
• Make decisions at tees
BASIC CONCEPTS89
Getting Off the Roof
Identify a Point of Reference
BASIC CONCEPTS90
Getting Off the Roof
• Identify a Point of Reference
• Identify Your “Pace”
• Use Your “Pace” to Develop
Coordinates Relative to the
Point of Reference
• Apply Your Coordinates on a
Different Floor
• Leverage Existing Labels
(Maybe)
• Cutting a hole in the wall or
pipe may or may not be
warranted
• Leverage other clues
• Some of them may be
misleadingBASIC CONCEPTS91
What About Drawing Programs?
AutoCAD and AutoCAD LT
• Quasi-standard in the industry
• Full version $3 – $4K
• Factor of 4 price difference between full and LT version
• LT probably sufficient for most Cxproviders
• Steep learning curve
• Can do more than diagrams
‒ Drafting
‒ Some 3-D
‒ Automation
Visio
• Microsoft family
• Full version about $1K
• Factor of 4 price difference between low end and high end versions
• Geared toward diagrams
‒ Not as universally applicable
‒ Faster to pick up
• Basic wire-frame capabilities in higher end products
• Interfaces with other Microsoft products directly
BASIC CONCEPTS
What About Drawing Programs?
Draw – OpenOffice.org
• Free
• Limited page size (about 12” x
12”)
• Basic diagramming features
• 3D capabilities
Word/PowerPoint Drawing Utilities
• Part of the Office package
• Difficult to use for complex
drawings
• Relatively easy to pick up for
basic shapes
• Some issues with alignment in
2007 versions
• Most programs can exchange files all though the content may not be editable
once imported and some information may be lost
• Most programs have free viewers available (e.g. Acrobat reader vs. full
Acrobat)
BASIC CONCEPTS
What About Drawing Programs?
Sketch-up
• Google/Trimble
• Free
• Using 3D model to convey 2D
information
• Most programs can exchange files all though the content may not be editable
once imported and some information may be lost
• Most programs have free viewers available (e.g. Acrobat reader vs. full
Acrobat)
BASIC CONCEPTS
Diagram Drawing
101Get in the habit of drawing on a grid
• “Electronic graph paper”
• Orderly drawings
• Alignment is easier
• Can be “on” or “off” for printing
BASIC CONCEPTS
Diagram Drawing
101
• Distinguish different types of fluids
(chilled water, hot water,
condenser water)
• Distinguish hot from cold, warmer
from cooler, supply from return
BASIC CONCEPTS
Diagram Drawing
101
• Distinguish different types of fluids
(chilled water, hot water,
condenser water)
• Distinguish hot from cold, warmer
from cooler, supply from return
• Enhance understanding
Outside Air mixing with Return
Air makes Mixed Air
BASIC CONCEPTS
Diagram Drawing
101
BASIC CONCEPTS
Diagram Drawing
101
BASIC CONCEPTS
Diagram Drawing
101
BASIC CONCEPTS
Diagram Drawing
101Line weights can be important
BASIC CONCEPTS
Diagram Drawing
101Line weights can be important
• Heavier lines draw the eye towards
the major system elements
• Lighter line weights show related
equipment that is auxiliary to the
main system elements
BASIC CONCEPTS
Diagram Drawing
101Points where lines cross vs. connect
should be clear
BASIC CONCEPTS
Diagram Drawing
101Points where lines cross vs. connect
should be clear
• Gaps where lines cross need to
consider the plot scale relative to
the line weight
BASIC CONCEPTS
Diagram Drawing
101Points where lines cross vs. connect
should be clear
• Gaps where lines cross need to
consider the plot scale relative to
the line weight
• “Bumps” can be used to clarify line
crossings but can become tedious
to draw
BASIC CONCEPTS
Diagram Drawing
101Create symbols
• Most programs allow you to take
collections of objects, given them a
name, and save them as a more
complex object
• AutoCAD blocks are an example
BASIC CONCEPTS
Diagram Drawing
101Create symbols
• Most programs allow you to take
collections of objects, given them a
name, and save them as a more
complex object
• AutoCAD blocks are an example
• AutoCAD allows you to assign “fill
in the blank” field for data
associated with the block
• This data can then be extrapolated
to generate equipment schedules,
point lists, etc.
BASIC CONCEPTS
Diagram Drawing
101Create symbols
• Most programs allow you to take
collections of objects, given them a
name, and save them as a more
complex object
• AutoCAD blocks are an example
• AutoCAD allows you to assign “fill
in the blank” field for data
associated with the block
• This data can then be extrapolated
to generate equipment schedules,
point lists, etc.
• You can also edit blocks after they
are inserted
BASIC CONCEPTS
Diagram Drawing
101Desirable habits/features
• Frequent “saves”
• Enable “auto-save”
• Regular back-ups
BASIC CONCEPTS
Tee’s are Important
For both the physical system and the
system diagram:
• Divergence or convergence of
flow
• An opportunity to introduce a
problem if the order of connection
is not correct
For the physical system, they
represent a pressure drop
• Significant
• Highly variable with configuration
BASIC CONCEPTS
Elbows; Not So Much Maybe
From the perspective of the system
diagram:
• Just a bent piece of straight pipe
• Water in = Water out
One way to think of elbow resistance is
to consider it as composed of:
• Resistance due to interaction with
the pipe wall
BASIC CONCEPTS
Elbows; Not So Much Maybe
From the perspective of the system
diagram:
• Just a bent piece of straight pipe
• Water in = Water out
One way to think of elbow resistance is
to consider it as composed of:
• Resistance due to interaction with
the pipe wall
• Resistance due to a change in
direction
BASIC CONCEPTS
Elbows; Not So Much Maybe
From the perspective of the system
diagram:
• Just a bent piece of straight pipe
• Water in = Water out
One way to think of elbow resistance is
to consider it as composed of:
• Resistance due to interaction with
the pipe wall
• Resistance due to a change in
direction
BASIC CONCEPTS
Elbows; Not So Much Maybe
From the perspective of the physical
system:
• Pump energy required
• Short radius = optimized loss =
energy savings
One way to think of elbow resistance is
to consider it as composed of:
• Resistance due to interaction with
the pipe wall
• Resistance due to a change in
direction
BASIC CONCEPTS
System Diagram Rules for Elbows and Tees
Show all tees
• Verify order of connection
• Order of connection “trumps” drawing organization
• Drawing organization “trumps” matching branch and main configuration in the field
Don’t show elbows
• Turns on the system diagram should be made for drawing organization purposes, not to reflect real elbows
BASIC CONCEPTS 115
Sometimes Rules are Made to be Broken
Elbows that form traps or inverted
traps in open systems
Pipes that run above basin level
in open systems
Pipe runs with an relatively
excessive number of elbows
Tees where the pressure drop
created by the installed
configuration could cause an
operational issue
BASIC CONCEPTS
So Far, Our Focus Has Been Hydronic
Systems; What About Air Systems?
BASIC CONCEPTS 117
Can You Identify the HVAC/Air Handling
System Elements in this Picture?
BASIC CONCEPTS 118
Air Handling Systems and System Diagrams
The same general rules apply
Significant differences from piping systems
• Envelope is a part of the system
• Mass (air and water vapor) are actively moved across
the system boundary by the operation of the system
• The water vapor can change state in the system
• People move around inside the systems
• Building processes occur inside the system
BASIC CONCEPTS 119
Envelope Integrity = HVAC Duct Integrity
BASIC CONCEPTS 120
Envelope Integrity = Process Integrity =
Cash Flow Integrity
Smoke cycle outdoor air intake
Attenuator
Attenuator
Cooling only AHU
Recirc. Fan
Production Tool
Make up AHU
Smoke exhaust fan
Scrubbers
exhaust fans
Cooling/ Recirc. AHU
Reheat coils
BASIC CONCEPTS 121
A Demonstration of Fundamental Principles
Smoke cycle outdoor air intake
Attenuator
Attenuator
Cooling only AHU
Recirc. Fan
Production Tool
Make up AHU
Smoke exhaust fan
Scrubbers
exhaust fans
Cooling/ Recirc. AHU
Reheat coils
5,000 cfm in
6,000 cfm out
1,000 cfm in
BASIC CONCEPTS 122
Conservation of Mass;A.K.A The Goes Intas gotta equal the Goes Outa’s
Smoke cycle outdoor air intake
Attenuator
Attenuator
Cooling only AHU
Recirc. Fan
Production Tool
Make up AHU
Smoke exhaust fan
Scrubbers
exhaust fans
Cooling/ Recirc. AHU
Reheat coils
5,000 cfm in
6,000 cfm out
1,000 cfm in
5,000 cfm in
BASIC CONCEPTS 123
The Envelope is Significant(ly Complex)
Sump Sump SumpSump
Sump
Atriums interconnect floors
BASIC CONCEPTS 124
The Envelope is Significantly Complex
Sump Sump SumpSump
Sump
Atriums interconnect floors
Stair and elevator shafts act
like chimneys
BASIC CONCEPTS 125
The Envelope is Significantly Complex
Sump Sump SumpSump
Sump
Atriums interconnect floors
Stair and elevator shafts act
like chimneys
Smoke shafts act like
chimneys and interconnect
floors
BASIC CONCEPTS 126
The Envelope is Significantly Complex
Sump Sump SumpSump
Sump
Atriums interconnect floors
Stair and elevator shafts act
like chimneys
Smoke shafts act like
chimneys and interconnect
floors
Return and relief plenums
interconnect floors and shafts
BASIC CONCEPTS 127
The Envelope as the Framework for the Air
Handling System Diagram
AHU1
AHU3
AHU2
AHU4 AHU 8
BASIC CONCEPTS 128
The Envelope as the Framework for the Air
Handling System Diagram
Direct/Indirect Evaporative
Cooling AHUs 1 and 3 (2 and 4
Similar)
BASIC CONCEPTS
The Envelope as the Framework for the Air
Handling System Diagram
Low temperature air VAV reheat
AHU 8 (Typical of 9 other systems
on L20 and 2 systems in the 8 story
office tower on L8)BASIC CONCEPTS 130
The Envelope as the Framework for the Air
Handling System Diagram
Typical Public Lobby Area (Served Direct/Indirect
Evaporatively Cooled AHU)BASIC CONCEPTS 131
The Envelope as the Framework for the Air
Handling System Diagram
Entry Lobby and Core at
Lower Levels (Served by
both evaporatively cooled
systems and low
temperature air VAV
systems)
BASIC CONCEPTS 132
The Envelope as the Framework for the Air
Handling System Diagram
Typical Non-lobby Lower
Levels (Served by both
evaporatively cooled
systems and low
temperature air VAV
systems)
BASIC CONCEPTS 133
The Envelope as the Framework for the Air
Handling System Diagnostics
AHU1
AHU3
AHU2
AHU4 AHU 8
Flow Arrow Color Codes
• AHU1
• AHU2
• AHU3
• AHU8 (Note AHU7 is not
shown but serves a similar
area and function for the
other half of the building)
• Return air (all systems)
• Transferred air
• Outdoor air infiltration
• Garage exhaust
BASIC CONCEPTS 134
The Envelope as the Framework for the Air
Handling System Diagnostics
AHU1
AHU3
AHU2
AHU4 AHU 8
BASIC CONCEPTS 135
Air Handling System Diagram Characteristics
BASIC CONCEPTS 136
Reflect the Building Physical Arrangement
BASIC CONCEPTS 137
Include Examples of Each Zone Type
BASIC CONCEPTS 138
Include the Impacts of Other Systems
BASIC CONCEPTS 139
Document Conservation of Mass and Energy
BASIC CONCEPTS 140
Instructor:Instructor:Instructor:Instructor:
System Diagram WorkshopCase Studies
Applying System Diagrams to Address Real World
Challenges and Issues
David Sellers
Senior Engineer
Facility Dynamics Engineering
October 9, 2012
System Diagram Examples
• Birge Hall
• Unusual Systems
• MHC Central Plant
• San Diego Marriott
• Seattle Courthouse Condenser Water System
• Doe Library DH3
• Seattle Courthouse Cross Section
• Seattle Courthouse Air Flow
• Seattle Courthouse Heating Hot Water
INTRODUCTION 142
"PG&E" refers to Pacific Gas and Electric Company, a subsidiary of PG&E Corporation. ©2012 Pacific Gas and Electric Company. All rights reserved.
System Diagram Workshop Fall 2012 These links are provided as information only and are not in any way to be considered a comprehensive listing or as an endorsement by PG&E. All links were current at time of list creation. An electronic version of this list is available at www.pge.com/energyclasses/ Related Online Resources: Advanced Variable Air Volume System Design Guide This comprehensive design guide was developed as part of the California Energy Commission’s PIER program, Integrated Energy Systems: Productivity and Building Science. http://www.energy.ca.gov/title24/2008standards/prerulemaking/documents/2006-07-12_workshop/reviewdocs/2006-12-07_ADVANCED_VAV_SYSTEM.PDF Air-Conditioning Heating and Refrigeration Institute (AHRI) ARI is a national trade association representing manufacturers of air-conditioning and commercial refrigeration equipment. It develops and publishes technical standards; supports and assists training; and certifies performance ratings of products. Many of its guidelines and standards for systems and equipment are available for download. http://www.ahrinet.org/ American Society of Heating Refrigerating and Air-Conditioning Engineers (ASHRAE) ASHRAE is a professional organization dedicated to the creation and promotion of quality-based standard practices in the HVAC&R industry. Members have access to ASHRAE technical articles and conference papers. Anyone can browse abstracts of ASHRAE’s numerous books, journal articles and other technical publications that are available for purchase. http://www.ashrae.org Consortium for Energy Efficiency (CEE). Commercial HVAC Installation Guidelines Both the Guidelines for Energy-Efficient Commercial Unitary HVAC Systems and the accompanying White Paper can be downloaded from CEE’s site. The Guidelines provide best practices, selection criteria, and details of components and systems. HVAC commissioning is also outlined and discussed. http://www.cee1.org/com/hecac/hecac-spec.php3 CoolTools™ Chilled Water Plants Design Guide This design guide from the CoolTools chilled water plants project can be downloaded from the publications section of the Taylor Engineering site. http://www.taylor-engineering.com/publications/design_guides.shtml DDC Online. Iowa Energy Center The Iowa Energy Center provides unbiased information on Direct Digital Controls. This site includes a guide to controls manufacturers and their products, an Introduction to Digital Control Systems, an Input/Output tutorial that also covers analog devices, and advanced technical information on DDC Systems. http://www.ddc-online.org
Energy Efficiency Class Resources Page 2 of 5
Energy Design Resources (EDR). Design Briefs EDR contains many useful Design Briefs useful to the system design process. Titles include Design Review, Design Details, and Centrifugal Pump Application and Optimization. http://www.energydesignresources.com/Resources/Publications/DesignBriefs.aspx Energy Design Resources (EDR). HVAC Design EDR provides access to many useful tools and resources related to the design and operation of energy efficient buildings. The HVAC Design category includes design briefs, guidelines, and design software tools that cover a variety of efficient HVAC design techniques and technologies. Titles include Design Guidelines for Chilled Water Plants and Chiller Plant Efficiency. http://www.energydesignresources.com/technology/hvac-design.aspx Functional Testing and Design Guides The Functional Testing Guide: Fundamentals to the Field, Checklist Tool and Test Directory, and Control System Design Guide can be viewed and downloaded from the PECI Web site. The Guideline includes instructions on how to use the FTG and modules on air handlers, chillers, boilers, condensers, and pumping. http://www.peci.org/ftguide/ Industrial Energy Analysis. Lawrence Berkeley National Laboratory. This system optimization site provides links to several useful publications on pump performance. http://industrial-energy.lbl.gov/node/171 Industries and Technologies. Motors, Fans, and Pumps This Department of Energy site leads users to technical information about Motors, Fans, or Pumps. Click on the technology you want to find tools, training information, technology assessments, case studies and related technical publications. http://www1.eere.energy.gov/manufacturing/industries_technologies/index.html Motor Decisions MatterSM (MDM) MDM offers several useful tools and resources to help one improve the performance and efficiency of motor systems. Resources include software tools, guides, and case studies organized by industry segment. http://www.motorsmatter.org/index.asp MotorMaster MotorMaster+ 4.01.01 is a software tool that analyzes motors and motor system efficiency for thousands of motors. It can be downloaded from the Industrial Technologies Program’s software tools site. http://www1.eere.energy.gov/manufacturing/tech_deployment/software_motormaster.html National Building Controls Information Program (NBCIP) NBCIP was established by the Iowa Energy Center and provides unbiased information on building control system products and strategies, including reports that describe the actual performance of products tested by the program. All publications on the site can be downloaded free of charge. http://www.iowaenergycenter.org/energy-efficiency/projects-partnerships/national-building-controls-information-program/ Pumping System Assessment Tool This free software tool form the DOE’s Industrial Technologies Program helps users assess the efficiency of pumping systems operations. A fact sheet and User Manual is included. http://www1.eere.energy.gov/manufacturing/tech_deployment/software_psat.html Pump Systems Matter™ This pump system site contains a variety of useful tools for optimizing pumping systems and achieving better energy efficiency. Among the available resources are energy saving presentations, an assessment guide, case studies, white papers, and modeling tools. http://www.pumpsystemsmatter.org/default.aspx
Energy Efficiency Class Resources Page 3 of 5
Tool Lending Library at the Pacific Energy Center The Tool Lending Library (TLL) site contains images and descriptions for its data collecting devices from over 100 vendors. Application Notes describe measurement techniques and provide step-by-step instructions for using specific tools. The TLL has a search feature to help you select the right tools for your project. A tool request form and contact information is also provided. http://www.pge.com/pec/tll/ Commissioning Building Commissioning Association (BCA) The Building Commissioning Association is a professional organization dedicated to “promoting building commissioning practices that maintain high professional standards”. Case studies, information about commissioning-related events, membership information, Best Practices in Commissioning Exiting Buildings, and other useful commissioning publications are available on this site. https://netforum.avectra.com/eweb/StartPage.aspx?Site=BCA&WebCode=HomePage California Commissioning Collaborative The California Commissioning Collaborative is a group of government, utility, and building service professionals organized to develop and promote commissioning practices in the California. The CCC site includes over 40 case studies, and a Library of information under its Resources heading that contains articles, white papers, guides, and sample commissioning documents. http://www.cacx.org PG&E Resources: Business Tools PG&E Business Tools include Energy Usage, Billing History and Rate Comparison Tools. http://www.pge.com/mybusiness/myaccount/analysis/ Demand Response Incentives Information on the various Demand Response incentives offered by PG&E can be found here. http://www.pge.com/mybusiness/energysavingsrebates/demandresponse/ Energy Use Audit Services. Energy Analyzer Here are quick on-line tools for identifying and analyzing business energy use. Tools include an Online Energy Analyzer. http://www.pge.com/mybusiness/energysavingsrebates/analyzer/ Money-Back Solutions for your Business by Industry Here you will find information about cash rebates and incentives for replacing existing equipment with new energy efficient technologies or purchasing new equipment. Design assistance for a new facility and system process is also available. http://www.pge.com/mybusiness/energysavingsrebates/incentivesbyindustry/ Money-Back Tool Use the Money-Back Tool to instantly get a list of rebates that fit your needs—and see how much you could be saving each year. http://www.pge.com/mybusiness/energysavingsrebates/moneybacksolutions/moneybacktool/index.html
Energy Efficiency Class Resources Page 4 of 5
PG&E PowerPathway™ PowerPathway offers a Portfolio of programs aimed at building capacity within the state of California to produce the skilled workers needed by PG&E and the energy and utility industry. The PowerPathway Portfolio includes four separate but interconnected efforts: Career preparation, Industry workforce challenges, Education, and Green communities. http://www.pge.com/about/careers/powerpathway/ Partners and Trade Professionals PG&E program partners, local contractors and trade professionals offer special assistance in implementing energy efficiency measures for your business. http://www.pge.com/mybusiness/energysavingsrebates/partnersandtradepros/ Rebates, Incentives, and Resources Information about current rebates, incentives, money-back programs and resources. http://www.pge.com/mybusiness/energysavingsrebates/rebatesincentives/ Self-Generation Incentive Program at Pacific Gas and Electric Financial incentive information, description of eligible technologies, forms, resources, and program contact information can all be accessed here. http://www.pge.com/mybusiness/energysavingsrebates/selfgenerationincentive/ Solar Energy PG&E provides information on how a photovoltaic system works; steps to take before installing solar in your home or business; solar schools; and requirements and applications for the California Solar Initiative Program. http://www.pge.com/solar/ Tariff Book This site contains all current gas and electric rate schedules. http://www.pge.com/tariffs/ Third Party Incentive Programs and Fact Sheets PG&E has partnered with energy efficiency specialists in order to extend the reach and effectiveness of energy efficiency, demand response, renewable energy, and self-generation programs. A fact sheet describing all of the specialists and their energy efficiency programs can be downloaded here. Use the search function to find information about all of the programs that are available for your market segment. http://www.pge.com/thirdparty/ Understanding Your Bill Sample business class bills with explanations for each bill item. http://www.pge.com/mybusiness/myaccount/explanationofbill/smallbiz/index.shtml Print Resources Available in the PEC’s Resource Center:
ASHRAE Handbook. Fundamentals. ASHRAE, 2009 ASHRAE Handbook: HVAC Systems and Equipment. ASHRAE, 2008 ASHRAE Handbook on HVAC Applications, ASHRAE, 2011 Heating, Cooling, Lighting: Sustainable Design Methods for Architects. Norbert Lechner. John Wiley &
Sons, 2008 HVAC Equations, Data, and Rules of Thumb, 2nd ed. Arthur Bell. McGraw-Hill, 2008 Mechanical and Electrical Equipment for Buildings, 11th edition. Walter Grondzik. Wiley, 2011
Energy Efficiency Class Resources Page 5 of 5
Journals:
ASHRAE Journal HPAC Engineering
Other Print Resources:
Air Handling Systems. Tseng-Yao Sun. McGraw-Hill, 1994 Electric Motors and their Applications. Tom Cox Lloyd. Wiley, 1969 HVAC Control Systems Design Diagrams. John Levenhagen. McGraw-Hill, 1998 HVAC Pump Handbook, 2nd ed. James B. Rishel, McGraw-Hill, 2006 HVAC Systems Design Handbook, 4th ed. Roger W. Haines, McGraw-Hill, 2003