In large-scale commercial HVAC systems, a Secondary Chilled Water Loop is the distribution network responsible for delivering cooling to every corner of a building. While the Primary Loop focuses on keeping the chiller itself safe and cold, the Secondary Loop is designed for flexibility. It uses dedicated pumps to push chilled water through Air Handling Units (AHUs) and Fan Coil Units (FCUs) based on the actual cooling demand of the tenants.
EKG (Malaysia) Sdn Bhd specializes in the design, balancing, and smart control of secondary loops to ensure maximum comfort with minimum energy consumption.
These are typically larger pumps equipped with Variable Frequency Drives (VFDs). Unlike primary pumps that run at a constant speed, secondary pumps speed up or slow down depending on how many cooling valves are open in the building.
This is a critical pipe that connects the primary and secondary loops. It allows the two systems to operate at different flow rates without interfering with each other. A properly sized decoupler ensures that the chiller always receives the correct flow, even if the building demand is low.
In a secondary loop, AHUs use 2-way valves to regulate flow. When a room reaches its set temperature, the valve closes. This increases the pressure in the loop, signaling the secondary pumps to slow down and save energy.
These sensors are the "eyes" of the system. Usually placed at the furthest point in the piping network, they tell the VFD exactly how much pressure is needed to ensure the top floor stays as cool as the ground floor.
Low Delta-T Syndrome: This occurs when water moves too fast through the building, returning to the chiller still cold. This forces the plant to run more pumps and chillers than necessary, wasting massive amounts of electricity.
Hydronic Imbalance: Without proper balancing, the AHUs closest to the pump get too much water, while the "remote" units struggle to cool their zones.
Pump Hunting: Poorly tuned VFDs can cause pumps to rapidly ramp up and down, leading to mechanical stress and noisy pipes.
We help facilities transition from inefficient constant-flow systems to variable-flow secondary loops. We precisely tune the PID loops in your controllers to ensure smooth, stable pressure management.
Using digital ultrasonic flow meters and pressure gauges, we balance the entire secondary network. This ensures every AHU receives its "Design Flow," eliminating hot spots and reducing pump energy.
We verify that your decoupler pipe is correctly positioned and that your pressure sensors are placed at the "Hydronically Most Remote" location for optimal pump control.
Because secondary pumps often operate under varying loads and pressures, their seals and bearings face unique stresses. We provide ISO-certified maintenance to prevent leaks and ensure silent operation.
At EKG (Malaysia) Sdn Bhd, we understand that a secondary loop is a complex ecosystem. Our integrated MEP approach ensures that the mechanical pumps, electrical VFDs, and plumbing valves are all synchronized for peak efficiency. Based in Selangor, we provide technical support that helps Klang Valley businesses lower their operational costs and improve tenant satisfaction.
Is your building experiencing uneven cooling or high energy bills? Contact us now for a free site assessment and a technical quote on our secondary chilled water loop services!
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