Building services · plain English and engineering detail

Chiller Plant Anatomy

Six ways a building gets cooled, from the box outside a flat to a thousand-ton central plant, drawn as working schematics. Hover or tap anything to see what it is and what it does.

Detail

Start here

Air-conditioning moves heat. Nothing in a building makes cold.

Nothing in a building creates cold. Every system on this page does the same single job: pick up heat where people don't want it, carry it somewhere else, and dump it outside. The differences are all about what carries the heat, and how far.

Your fridge does this to your kitchen. Put your hand behind it and you feel the heat it took out of the milk. A building works the same way, the heat comes out on the roof instead, which is why plant rooms and rooftops are hot places.

There are only two families. In the refrigerant family, a special fluid is piped straight to the room, boils inside a coil right there, and carries the heat back out to a box outside. That is your home air-conditioner, and the office version of it, VRF. In the chilled water family, that same boiling happens once, in a big machine in the basement, and water is pumped around the building instead. Water is heavy and slow, but it is safe in a ceiling and it scales to a whole tower.

The six drawings below run from the simplest to the largest. Hover or tap anything, every pump, valve, vessel and pipe explains itself. Switch Detail to Engineer if you want the design and operational notes instead of the plain-English version.

Reading the drawings

Colour is the fluid

Teal is chilled water going to the building and coming back. Green is condenser water going to and from the roof. Amber is refrigerant. Grey is air. The key sits under each drawing.

The moving dashes

Motion is flow rate

The dashes and dots travel at the speed the water is actually moving. Drag the Building load slider and watch what speeds up, what slows down, and what stubbornly doesn't.

The run button

Order matters

Run start-up walks through how a plant is actually brought online, and it is not the order most people guess. Nothing is allowed to start until the thing before it has proven it is really working.

Steady state

Scroll the drawing sideways to follow the whole system →

85%

Line key

Comparison

Six systems, one job, so how do you choose?

The honest answer is that the choice is mostly about how many rooms share one machine, and how far the heat has to travel. Everything else, cost, efficiency, maintenance, who you call when it breaks, follows from those two things.

A single split serves one room with one outdoor box. A multi-split, Singapore's familiar System 2, 3 or 4, lets several rooms share one box, which saves ledge space but means the rooms also share the compressor's capacity. VRF is the same idea again, much larger: one outdoor unit feeding dozens of indoor units across a floor or a building. A chilled water plant goes further still and stops piping refrigerant altogether, boiling it once in a basement machine and sending water out instead.

That last step is the real dividing line. Refrigerant is efficient and compact, but it can only travel so far. Daikin's VRV 5 allows about 165 m of actual pipe run and a 90 m level difference, roughly 20 to 25 storeys from one outdoor unit. Above that, you are putting plant on multiple levels, and at some point a water riser is simply the easier answer. No standard sets the crossover, and the consultancy rules of thumb you will find (10,000–15,000 m² is one published figure) are one firm's opinion, not an industry threshold. The pipe envelope is the constraint that actually bites.

The thing almost everyone gets wrong

A ceiling cassette is a shape, not a system. The square four-way grille you see in an office or shop ceiling tells you nothing about what is inside it. Daikin sells the identical form factor both ways: the FXFQ Round Flow cassette is a refrigerant (DX) unit for a VRV system, while the FWF and FWC cassettes are chilled-water fan coils rated at 7 °C in and 12 °C out. Same ceiling, same grille, completely different building services above it.

The distinction is not academic. One has two copper refrigerant lines and a condensate drain in the void; the other has insulated flow-and-return water pipes with valves, strainers and air vents. One leaks refrigerant, the other floods a ceiling. One is governed by refrigerant concentration limits in the room below; the other is not. If you are reading a tender and it says "cassette", you still do not know what system you are buying.

Why you cannot compare the efficiency numbers

Every system type is rated by a different standard, at different conditions, with a different boundary around what counts. Room air-conditioners in Singapore are rated on weighted COP under ISO 5151, not SEER, and not the CSPF used by most of our neighbours. VRF is rated on IEER under AHRI 1230. Chillers are rated on kW/RT and IPLV under AHRI 550/590, and that figure is the compressor alone, not the pumps and towers around it. Putting "IEER 15.5", "SEER 20" and "0.55 kW/RT" side by side is meaningless.

There is one clean way through it, and Singapore has already built it. BCA Green Mark 2021 assesses VRF and chilled water on the same yardstick, total system kW/RT, including outdoor units or chillers, pumps and air distribution, with VRF converted as 3.517 ÷ IEER. A new building has to reach 0.8 kW/RT whichever technology it uses. The regulator refuses to give either one a handicap, which is the most useful answer anyone is going to give you.

The Singapore complication: humidity

In a temperate climate, cooling means lowering the temperature. Here, most of the work is removing moisture, and the two are not the same job. Direct-expansion fan coils, whether split or VRF, typically run a sensible heat ratio of 0.70–0.85, meaning limited capacity to dehumidify. They also condition only the air already in the room; they bring in no outdoor air at all. Introducing raw outdoor air at an indoor unit is usually limited to about 10% of supply volume before it overwhelms the coil.

So a VRF building in Singapore still needs a separate unit to bring in fresh air and dry it first. That unit is not optional, it is not cheap, and leaving it out is why some buildings feel clammy at 23 °C. A chilled water system gives the designer a second lever, the water temperature and the depth of the coil, to set how dry the air leaves. That is the strongest technical argument for water in this climate, and it is rarely the one used in the sales meeting.

And one that is backwards

Refrigerant safety is usually assumed to be a chiller problem. It is the opposite. A chiller keeps its entire refrigerant charge inside a plant room. A VRF or split system puts refrigerant inside occupied rooms, which is why it falls under the ASHRAE 15 charge-versus-room-volume check, and the smallest room on the circuit governs the whole system. It is one of the most commonly overlooked items in VRF design.

Comparison of air-conditioning system types
SystemHeat carried byTypical scale ProsCons
Single splitWALL / CASSETTE / DUCTED Refrigerant, direct to the room (DX) 2.5–7 kW · one room
  • Cheapest to buy and install
  • No plant space at all
  • One failure affects one room
  • Any aircon technician can fix it
  • One outdoor box per indoor unit, ledge and façade clutter
  • No central control or monitoring
  • No fresh air
  • Poorest efficiency per unit of cooling at scale
Multi-splitSYSTEM 2 / 3 / 4 Refrigerant, direct to the room (DX) 6–12 kW · one flat or small office
  • One outdoor unit for several rooms
  • Must be 5-tick to be legally sold here, so efficiency is guaranteed
  • Familiar, cheap to maintain
  • Outdoor unit is deliberately undersized, all rooms cannot run flat out at once
  • One outdoor failure takes out every room
  • Longer refrigerant runs, more joints, more leak risk
  • No fresh air
VRF / VRVVARIABLE REFRIGERANT FLOW Refrigerant, piped through the building (DX) 22–56 kW per module · up to 64 indoor units
  • No plant room, no water in ceilings
  • Excellent part-load behaviour, quiet rooms cost almost nothing
  • Room-by-room control and metering
  • Phased installation suits fit-out by tenant
  • Hard piping limits: ~165 m run, 90 m height
  • Needs a separate fresh-air unit in the tropics
  • Refrigerant in occupied rooms, ASHRAE 15 applies
  • Large charge across many joints; leaks are costly and carbon-intensive
  • Specialist, often single-brand, maintenance
Air-cooled chilled waterCONFIG 01 Water to the coils; heat to outdoor air 100 kW–2 MW · medium buildings
  • No cooling tower, no water treatment, no water bill
  • Simpler and cheaper to install than water-cooled
  • Water in the building, refrigerant confined to the machine
  • Good for sites with no water supply or no roof space for towers
  • Roughly twice the electricity per unit of cooling: 1.0–1.4 vs 0.50–0.61 kW/RT
  • Performance falls exactly when it is hottest
  • Noise and heat rejection at ground or roof level
Water-cooled chilled waterCONFIG 02–04 Water to the coils; heat to a cooling tower 350 kW–20 MW+ · large buildings
  • Best large-scale efficiency, 0.6–0.8 kW/RT achievable for the whole plant
  • Real redundancy: N+1 chillers, standby pumps, staged operation
  • Full dehumidification control via water temperature and coil selection
  • 20–25 year equipment life; all refrigerant confined to the plant room
  • Needs a plant room, risers, towers and space
  • Consumes water, roughly 1.2–1.5% of circulated flow as make-up
  • Cooling towers need treatment and carry a Legionella duty of care
  • Highest capital cost; specialist operations and maintenance
District coolinge.g. MARINA BAY Chilled water from a shared central plant Precinct scale · many buildings
  • No chillers or towers in the building at all
  • Frees roof and basement space for lettable or amenity use
  • Operator carries the plant risk and the efficiency obligation
  • Long-term commitment to a single supplier and tariff
  • Only exists where a network has been built
  • Building still owns its own airside performance

Three claims worth checking before you repeat them

"VRF saves 30–55% energy." Most published savings compare operating regimes, not equipment. The most-cited field study found VRF buildings running part-time and part-space at 26 °C against VAV buildings running full-time at 24 °C, the biggest single driver of the saving was that the VRF buildings were run warmer and switched off. Bonneville Power Administration, reviewing the literature, settled on 5–20% for regional planning and warned that real performance "may not be as good as" manufacturer claims.

"VRV and VRF are different technologies." They are the same technology. Daikin says so itself: VRV is its 1982 trademark, so everyone else calls it VRF. What varies is refrigerant mass flow rate, not the amount of refrigerant in the system.

"Heat recovery VRF is always more efficient." US DOE's own minimum standards require a lower IEER of heat-recovery models than of standard ones in every capacity band, the branch selector costs efficiency in cooling-only operation. Heat recovery pays only where heating and cooling genuinely happen at the same time, which in Singapore is rare enough to need a specific justification.

Glossary

The words on the drawings

RT, refrigeration ton
A unit of cooling capacity. One RT is about 3.5 kW of cooling, historically the rate that melts a ton of ice in a day.
kW/RT
Electricity in, divided by cooling out. Lower is better. Under 0.6 is excellent, 0.6–0.8 good, 0.8–1.0 typical, over 1.0 poor.
ΔT, delta-T
How much the water warms up on its trip round the building. A big ΔT means you delivered a lot of cooling with a little water, which is what you want.
Wet-bulb vs dry-bulb
Dry-bulb is what a thermometer reads. Wet-bulb is what a wet thermometer reads, and it is lower because evaporation cools. Cooling towers work against wet-bulb; air-cooled machines work against dry-bulb, which is why they lose.
DX, direct expansion
Refrigerant boils in a coil in the room itself, rather than cooling water that is then pumped to the room.
Latent vs sensible
Sensible cooling lowers temperature; latent cooling removes moisture. In the tropics most of the work is latent, which is why an air-conditioner drips.
Index load
The coil furthest from the plant hydraulically. If it is satisfied, everything nearer is too, so it is where you put the pressure sensor.
Approach
How close a cooling tower gets the water to the outdoor wet-bulb. A rising approach is the first sign the tower needs cleaning.
COP, EER, SEER, IEER, IPLV
Different efficiency ratings from different standards at different conditions. They are not interchangeable, and comparing across them is the most common technical error in this field.
Tick rating
Singapore's NEA energy label. Since April 2025 a split must be at least 4 ticks and a multi-split at least 5 ticks to be sold at all.

About this page: drafted with an AI assistant at my direction, engineering content checked by me against the sources below, and restyled to this site. The load model is indicative and says so above. Views are my own, not my employer's.

Verification

What was checked, and against what

Every sequence, figure and rule of thumb on this page was checked against primary sources before publishing, and several earlier drafts were wrong. The start-up order originally showed the cooling tower fan starting with the condenser water pump, and the coil valves modulating as the final step. Both are incorrect: tower fans stage up later on rising condenser water temperature, and the coil valves' requests are what enable the plant in the first place. An earlier draft also put the air-cooled energy penalty at 30–40%; it is closer to double.

The plant model is indicative and deliberately simple. It illustrates how each arrangement behaves as load falls, it is not a selection tool, and it is not calibrated to any real installation.