While pump life is a primary consideration when configuring an industrial cooling system, pressure loss across the system and the necessary flow rate must first be determined by the pump size and performance.
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Pressure: An undersized pump will reduce the fluid flow rate through the entire cooling loop. If the chiller has been equipped with internal pressure relief, the flow will be diverted around the process and back into the chiller. If there is no internal pressure relief, the pump will attempt to provide the necessary pressure and run at what is referred to as dead-head pressure, or limit. When this state occurs, the pump&#;s life can be drastically reduced; liquid ceases to flow and the liquid in the pump becomes hot, eventually vaporising and disrupting the pump&#;s ability to cool leading to excessive wear to bearings, seals, and impellers.
Determining the pressure loss across a system requires siting pressure gauges at the process&#;s inlet and outlet, then applying pump pressure to obtain values at the desired flow rate.
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Flow rate: Inadequate flow through the process will yield inadequate heat transfer so the flow will not remove the heat necessary for safe operation of the process. As the fluid temperature increases beyond the setpoint, the surface/component temperatures also will continue to rise until a steady-state temperature that is greater than the initial setpoint is reached.
Most chiller systems will detail the pressure and flow requirements. When specifying the necessary heat load removal as part of the design, it is important to account for all hoses, fittings, connections, and elevation changes integral to the system. These ancillary features can significantly increase pressure requirements if not sized appropriately.
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