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