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Fix #10817 - Avoid crash in FluidCooler/EvaporativeFluidCooler when Water flow rate autosized and no Sizing:Plant #10855

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Fix #10817 - Avoid crash in FluidCooler/EvaporativeFluidCooler when Water flow rate autosized and no Sizing:Plant #10855

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316d5ae
Highlight an issue in an existing test
jmarrec Dec 13, 2024
a003e07
Fix problem in existing test: the allocate after GetInput was resetti…
jmarrec Dec 13, 2024
61c4c5d
Rename test for clarity
jmarrec Dec 13, 2024
93c4e0b
Unrelated, but place the fluid coolers on the SUPPLY side of the plan…
jmarrec Dec 13, 2024
dee7e5b
Add tests for #10817
jmarrec Dec 13, 2024
6932358
Add test: EvaporativeFluidCooler also had the same issue as #10817
jmarrec Dec 13, 2024
9e8586b
Fix #10817 - Avoid crash in FluidCooler/EvaporativeFluidCooler when W…
jmarrec Dec 13, 2024
b02725a
Dry up code via a lambda
jmarrec Dec 13, 2024
23fa180
Rename Fluidcooler -> FluidCooler in examples files for easier grepping
jmarrec Dec 13, 2024
a179c0d
Increase num sig digits from default=2 to 6 to report the **Water** F…
jmarrec Dec 13, 2024
4aaa7c0
Calculate DesignLeavingWaterTemp in all cases, since it's reported (a…
jmarrec Dec 13, 2024
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61 changes: 31 additions & 30 deletions src/EnergyPlus/EvaporativeFluidCoolers.cc
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Original file line number Diff line number Diff line change
Expand Up @@ -1338,14 +1338,10 @@ namespace EvaporativeFluidCoolers {
Real64 constexpr Acc(0.0001); // Accuracy of result
std::string const CalledFrom("SizeEvapFluidCooler");

int SolFla; // Flag of solver
Real64 UA; // Calculated UA value [W/C]
Real64 OutWaterTempAtUA0; // Water outlet temperature at UA0
Real64 OutWaterTempAtUA1; // Water outlet temperature at UA1
Real64 DesignEnteringAirWetBulb; // Intermediate variable to check that design exit
// temperature specified in the plant:sizing object
// is higher than the design entering air wet-bulb temp
// when autosize feature is used
int SolFla; // Flag of solver
Real64 UA; // Calculated UA value [W/C]
Real64 OutWaterTempAtUA0; // Water outlet temperature at UA0
Real64 OutWaterTempAtUA1; // Water outlet temperature at UA1

Real64 DesEvapFluidCoolerLoad = 0.0; // Design evaporative fluid cooler load [W]
Real64 tmpDesignWaterFlowRate = this->DesignWaterFlowRate;
Expand All @@ -1356,6 +1352,33 @@ namespace EvaporativeFluidCoolers {

if (this->DesignWaterFlowRateWasAutoSized && this->PerformanceInputMethod_Num != PIM::StandardDesignCapacity) {
if (PltSizCondNum > 0) {

// Check when the user specified Condenser/Evaporative Fluid Cooler water design setpoint
// temperature is less than design inlet air wet bulb temperature
Real64 DesignEnteringAirWetBulb = 0;
Comment on lines 1354 to +1358
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Fix is to basically ensure the check is done INSIDE the if(PltSizCondNum > 0)

If PltSizCondNum is not > 0, it'll throw anyways

if (this->PerformanceInputMethod_Num == PIM::UFactor) {
DesignEnteringAirWetBulb = 25.6;
} else {
DesignEnteringAirWetBulb = this->DesignEnteringAirWetBulbTemp;
}
if (state.dataSize->PlantSizData(PltSizCondNum).ExitTemp <= DesignEnteringAirWetBulb) {
ShowSevereError(state, format("Error when autosizing the UA value for Evaporative Fluid Cooler = {}.", this->Name));
ShowContinueError(state,
format("Design Loop Exit Temperature ({:.2R} C) must be greater than design entering air wet-bulb temperature "
"({:.2R} C) when autosizing the Evaporative Fluid Cooler UA.",
state.dataSize->PlantSizData(PltSizCondNum).ExitTemp,
DesignEnteringAirWetBulb));
ShowContinueError(
state,
"It is recommended that the Design Loop Exit Temperature = Design Entering Air Wet-bulb Temp plus the Evaporative "
"Fluid Cooler design approach temperature (e.g., 4 C).");
ShowContinueError(
state,
"If using HVACTemplate:Plant:ChilledWaterLoop, then check that input field Condenser Water Design Setpoint must be "
"> Design Entering Air Wet-bulb Temp if autosizing the Evaporative Fluid Cooler.");
ShowFatalError(state, "Review and revise design input values as appropriate.");
}

if (state.dataSize->PlantSizData(PltSizCondNum).DesVolFlowRate >= HVAC::SmallWaterVolFlow) {
tmpDesignWaterFlowRate = state.dataSize->PlantSizData(PltSizCondNum).DesVolFlowRate * this->SizFac;
if (state.dataPlnt->PlantFirstSizesOkayToFinalize) this->DesignWaterFlowRate = tmpDesignWaterFlowRate;
Expand All @@ -1380,28 +1403,6 @@ namespace EvaporativeFluidCoolers {
ShowFatalError(state, "Autosizing of evaporative fluid cooler condenser flow rate requires a loop Sizing:Plant object.");
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Throw when PltSizCondNum is not > 0 is here.

}
}
// Check when the user specified Condenser/Evaporative Fluid Cooler water design setpoint
// temperature is less than design inlet air wet bulb temperature
if (this->PerformanceInputMethod_Num == PIM::UFactor) {
DesignEnteringAirWetBulb = 25.6;
} else {
DesignEnteringAirWetBulb = this->DesignEnteringAirWetBulbTemp;
}
if (state.dataSize->PlantSizData(PltSizCondNum).ExitTemp <= DesignEnteringAirWetBulb) {
ShowSevereError(state, format("Error when autosizing the UA value for Evaporative Fluid Cooler = {}.", this->Name));
ShowContinueError(state,
format("Design Loop Exit Temperature ({:.2R} C) must be greater than design entering air wet-bulb temperature "
"({:.2R} C) when autosizing the Evaporative Fluid Cooler UA.",
state.dataSize->PlantSizData(PltSizCondNum).ExitTemp,
DesignEnteringAirWetBulb));
ShowContinueError(state,
"It is recommended that the Design Loop Exit Temperature = Design Entering Air Wet-bulb Temp plus the Evaporative "
"Fluid Cooler design approach temperature (e.g., 4 C).");
ShowContinueError(state,
"If using HVACTemplate:Plant:ChilledWaterLoop, then check that input field Condenser Water Design Setpoint must be "
"> Design Entering Air Wet-bulb Temp if autosizing the Evaporative Fluid Cooler.");
ShowFatalError(state, "Review and revise design input values as appropriate.");
}
}

if (this->PerformanceInputMethod_Num == PIM::UFactor && !this->HighSpeedEvapFluidCoolerUAWasAutoSized) {
Expand Down
124 changes: 52 additions & 72 deletions src/EnergyPlus/FluidCoolers.cc
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Original file line number Diff line number Diff line change
Expand Up @@ -954,8 +954,31 @@ void FluidCoolerspecs::size(EnergyPlusData &state)
// Find the appropriate Plant Sizing object
int PltSizCondNum = state.dataPlnt->PlantLoop(this->plantLoc.loopNum).PlantSizNum;

// This is to trap when the user specified Condenser/Fluid Cooler water design setpoint temperature is less than design inlet air dry bulb
// temperature
auto ensureSizingPlantExitTempIsNotLessThanDesignEnteringAirTemp = [this, &state, PltSizCondNum]() {
if (state.dataSize->PlantSizData(PltSizCondNum).ExitTemp <= this->DesignEnteringAirTemp && state.dataPlnt->PlantFirstSizesOkayToFinalize) {
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I don't think it's necessary to delay until PlantFirstSizesOkayToFinalize is true, but I didn't want to change the existing behavior

ShowSevereError(state, format("Error when autosizing the UA value for fluid cooler = {}.", this->Name));
ShowContinueError(state,
format("Design Loop Exit Temperature ({:.2R} C) must be greater than design entering air dry-bulb temperature "
"({:.2R} C) when autosizing the fluid cooler UA.",
state.dataSize->PlantSizData(PltSizCondNum).ExitTemp,
this->DesignEnteringAirTemp));
ShowContinueError(state,
"It is recommended that the Design Loop Exit Temperature = design inlet air dry-bulb temp plus the Fluid Cooler "
"design approach temperature (e.g., 4 C).");
ShowContinueError(state,
"If using HVACTemplate:Plant:ChilledWaterLoop, then check that input field Condenser Water Design Setpoint must be "
"> design inlet air dry-bulb temp if autosizing the Fluid Cooler.");
ShowFatalError(state, "Review and revise design input values as appropriate.");
}
};

if (this->DesignWaterFlowRateWasAutoSized) {
if (PltSizCondNum > 0) {

ensureSizingPlantExitTempIsNotLessThanDesignEnteringAirTemp();

if (state.dataSize->PlantSizData(PltSizCondNum).DesVolFlowRate >= HVAC::SmallWaterVolFlow) {
tmpDesignWaterFlowRate = state.dataSize->PlantSizData(PltSizCondNum).DesVolFlowRate;
if (state.dataPlnt->PlantFirstSizesOkayToFinalize) this->DesignWaterFlowRate = tmpDesignWaterFlowRate;
Expand Down Expand Up @@ -986,23 +1009,6 @@ void FluidCoolerspecs::size(EnergyPlusData &state)
ShowFatalError(state, "Autosizing of fluid cooler condenser flow rate requires a loop Sizing:Plant object.");
}
}
// This conditional statement is to trap when the user specified Condenser/Fluid Cooler water design setpoint
// temperature is less than design inlet air dry bulb temperature
if (state.dataSize->PlantSizData(PltSizCondNum).ExitTemp <= this->DesignEnteringAirTemp && state.dataPlnt->PlantFirstSizesOkayToFinalize) {
ShowSevereError(state, format("Error when autosizing the UA value for fluid cooler = {}.", this->Name));
ShowContinueError(state,
format("Design Loop Exit Temperature ({:.2R} C) must be greater than design entering air dry-bulb temperature "
"({:.2R} C) when autosizing the fluid cooler UA.",
state.dataSize->PlantSizData(PltSizCondNum).ExitTemp,
this->DesignEnteringAirTemp));
ShowContinueError(state,
"It is recommended that the Design Loop Exit Temperature = design inlet air dry-bulb temp plus the Fluid Cooler "
"design approach temperature (e.g., 4 C).");
ShowContinueError(state,
"If using HVACTemplate:Plant:ChilledWaterLoop, then check that input field Condenser Water Design Setpoint must be "
"> design inlet air dry-bulb temp if autosizing the Fluid Cooler.");
ShowFatalError(state, "Review and revise design input values as appropriate.");
}
}

PlantUtilities::RegisterPlantCompDesignFlow(state, this->WaterInletNodeNum, tmpDesignWaterFlowRate);
Expand Down Expand Up @@ -1037,24 +1043,9 @@ void FluidCoolerspecs::size(EnergyPlusData &state)
if (state.dataPlnt->PlantFirstSizesOkayToFinalize) this->HighSpeedFanPower = tmpHighSpeedFanPower;
} else if (PltSizCondNum > 0) {
if (state.dataSize->PlantSizData(PltSizCondNum).DesVolFlowRate >= HVAC::SmallWaterVolFlow) {
// This conditional statement is to trap when the user specified Condenser/Fluid Cooler water design setpoint
// temperature is less than design inlet air dry bulb temperature
if (state.dataSize->PlantSizData(PltSizCondNum).ExitTemp <= this->DesignEnteringAirTemp &&
state.dataPlnt->PlantFirstSizesOkayToFinalize) {
ShowSevereError(state, format("Error when autosizing the UA value for fluid cooler = {}.", this->Name));
ShowContinueError(state,
format("Design Loop Exit Temperature ({:.2R} C) must be greater than design entering air dry-bulb "
"temperature ({:.2R} C) when autosizing the fluid cooler UA.",
state.dataSize->PlantSizData(PltSizCondNum).ExitTemp,
this->DesignEnteringAirTemp));
ShowContinueError(state,
"It is recommended that the Design Loop Exit Temperature = design inlet air dry-bulb temp plus the "
"Fluid Cooler design approach temperature (e.g., 4 C).");
ShowContinueError(state,
"If using HVACTemplate:Plant:ChilledWaterLoop, then check that input field Condenser Water Design "
"Setpoint must be > design inlet air dry-bulb temp if autosizing the Fluid Cooler.");
ShowFatalError(state, "Review and revise design input values as appropriate.");
}

ensureSizingPlantExitTempIsNotLessThanDesignEnteringAirTemp();

rho = FluidProperties::GetDensityGlycol(state,
state.dataPlnt->PlantLoop(this->plantLoc.loopNum).FluidName,
Constant::InitConvTemp,
Expand Down Expand Up @@ -1126,24 +1117,9 @@ void FluidCoolerspecs::size(EnergyPlusData &state)
if (state.dataPlnt->PlantFirstSizesOkayToFinalize) this->HighSpeedAirFlowRate = tmpHighSpeedAirFlowRate;
} else if (PltSizCondNum > 0) {
if (state.dataSize->PlantSizData(PltSizCondNum).DesVolFlowRate >= HVAC::SmallWaterVolFlow) {
// This conditional statement is to trap when the user specified Condenser/Fluid Cooler water design setpoint
// temperature is less than design inlet air dry bulb temperature
if (state.dataSize->PlantSizData(PltSizCondNum).ExitTemp <= this->DesignEnteringAirTemp &&
state.dataPlnt->PlantFirstSizesOkayToFinalize) {
ShowSevereError(state, format("Error when autosizing the UA value for fluid cooler = {}.", this->Name));
ShowContinueError(state,
format("Design Loop Exit Temperature ({:.2R} C) must be greater than design entering air dry-bulb "
"temperature ({:.2R} C) when autosizing the fluid cooler UA.",
state.dataSize->PlantSizData(PltSizCondNum).ExitTemp,
this->DesignEnteringAirTemp));
ShowContinueError(state,
"It is recommended that the Design Loop Exit Temperature = design inlet air dry-bulb temp plus the "
"Fluid Cooler design approach temperature (e.g., 4 C).");
ShowContinueError(state,
"If using HVACTemplate:Plant:ChilledWaterLoop, then check that input field Condenser Water Design "
"Setpoint must be > design inlet air dry-bulb temp if autosizing the Fluid Cooler.");
ShowFatalError(state, "Review and revise design input values as appropriate.");
}

ensureSizingPlantExitTempIsNotLessThanDesignEnteringAirTemp();

rho = FluidProperties::GetDensityGlycol(state,
state.dataPlnt->PlantLoop(this->plantLoc.loopNum).FluidName,
Constant::InitConvTemp,
Expand Down Expand Up @@ -1208,24 +1184,9 @@ void FluidCoolerspecs::size(EnergyPlusData &state)
if (this->HighSpeedFluidCoolerUAWasAutoSized && state.dataPlnt->PlantFirstSizesOkayToFinalize) {
if (PltSizCondNum > 0) {
if (state.dataSize->PlantSizData(PltSizCondNum).DesVolFlowRate >= HVAC::SmallWaterVolFlow) {
// This conditional statement is to trap when the user specified Condenser/Fluid Cooler water design setpoint
// temperature is less than design inlet air dry bulb temperature
if (state.dataSize->PlantSizData(PltSizCondNum).ExitTemp <= this->DesignEnteringAirTemp &&
state.dataPlnt->PlantFirstSizesOkayToFinalize) {
ShowSevereError(state, format("Error when autosizing the UA value for fluid cooler = {}.", this->Name));
ShowContinueError(state,
format("Design Loop Exit Temperature ({:.2R} C) must be greater than design entering air dry-bulb "
"temperature ({:.2R} C) when autosizing the fluid cooler UA.",
state.dataSize->PlantSizData(PltSizCondNum).ExitTemp,
this->DesignEnteringAirTemp));
ShowContinueError(state,
"It is recommended that the Design Loop Exit Temperature = design inlet air dry-bulb temp plus the Fluid "
"Cooler design approach temperature (e.g., 4 C).");
ShowContinueError(state,
"If using HVACTemplate:Plant:ChilledWaterLoop, then check that input field Condenser Water Design Setpoint "
"must be > design inlet air dry-bulb temp if autosizing the Fluid Cooler.");
ShowFatalError(state, "Review and revise design input values as appropriate.");
}

ensureSizingPlantExitTempIsNotLessThanDesignEnteringAirTemp();

rho = FluidProperties::GetDensityGlycol(state,
state.dataPlnt->PlantLoop(this->plantLoc.loopNum).FluidName,
Constant::InitConvTemp,
Expand Down Expand Up @@ -1611,6 +1572,24 @@ void FluidCoolerspecs::size(EnergyPlusData &state)
ErrorsFound = false;

if (state.dataPlnt->PlantFinalSizesOkayToReport) {

if (this->DesignLeavingWaterTemp <= HVAC::SmallTempDiff) {
this->WaterTemp = this->DesignEnteringWaterTemp; // design inlet water temperature
this->AirTemp = this->DesignEnteringAirTemp; // design inlet air dry-bulb temp
this->AirWetBulb = this->DesignEnteringAirWetBulbTemp; // design inlet air wet-bulb temp
this->AirPress = state.dataEnvrn->StdBaroPress;
this->AirHumRat = Psychrometrics::PsyWFnTdbTwbPb(state, this->AirTemp, this->AirWetBulb, this->AirPress);
Real64 OutletTemp = 0;
rho = FluidProperties::GetDensityGlycol(state,
state.dataPlnt->PlantLoop(this->plantLoc.loopNum).FluidName,
Constant::InitConvTemp,
state.dataPlnt->PlantLoop(this->plantLoc.loopNum).FluidIndex,
CalledFrom);
CalcFluidCoolerOutlet(
state, this->indexInArray, rho * this->DesignWaterFlowRate, this->HighSpeedAirFlowRate, this->HighSpeedFluidCoolerUA, OutletTemp);
this->DesignLeavingWaterTemp = OutletTemp;
}

// create predefined report
OutputReportPredefined::PreDefTableEntry(
state, state.dataOutRptPredefined->pdchMechType, this->Name, DataPlant::PlantEquipTypeNames[static_cast<int>(this->FluidCoolerType)]);
Expand Down Expand Up @@ -1642,7 +1621,8 @@ void FluidCoolerspecs::size(EnergyPlusData &state)
state, state.dataOutRptPredefined->pdchCTFCDesFanPwr, this->Name, this->HighSpeedFanPower); // equivalent to Design Fan Power?
OutputReportPredefined::PreDefTableEntry(
state, state.dataOutRptPredefined->pdchCTFCDesInletAirWBT, this->Name, this->DesignEnteringAirWetBulbTemp);
OutputReportPredefined::PreDefTableEntry(state, state.dataOutRptPredefined->pdchCTFCDesWaterFlowRate, this->Name, this->DesignWaterFlowRate);
OutputReportPredefined::PreDefTableEntry(
state, state.dataOutRptPredefined->pdchCTFCDesWaterFlowRate, this->Name, this->DesignWaterFlowRate, 6);
OutputReportPredefined::PreDefTableEntry(state, state.dataOutRptPredefined->pdchCTFCLevWaterSPTemp, this->Name, this->DesignLeavingWaterTemp);
}

Expand Down
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