© trane 2008 confidential eugene smithart, p.e. director, systems and solutions trane commercial...

© Trane 2008 Confidential

Eugene Smithart, P.E.Director, Systems and SolutionsTrane Commercial Sales

Chiller Killer II2 © Trane 2008Confidential

Agenda

• Highlights from EarthWise System Seminars

• A More Detailed/Advanced Look at Three Key Topics:

1. Series Chillers and VPF

2. Ice Storage

3. LAT and Controls

• Real World Examples of EachThe Goal?The Goal?


EarthWise™ Systems

EmissionsEmissions

EnergyEnergyEfficiencyEfficiency

ProductsProducts

Service/Parts/Service/Parts/SolutionsSolutions

ControlsControls


Low Flow, Low Temperature, High Efficiency Systems

+/-$+/-$air handlers

+/-$+/-$

+/-$+/-$controls

chillers+/-$+/-$piping

~/–$~/–$

ductwork

~/–$~/–$


How?

Temperature differential

Supply temperature Flow rates Fans

Ductwork

Pumps

Piping

Lessons Learned?


Chilled Water/VAV Systems

% o

f H

VA

C e

ner

gy

con

sum

pti

on

Trane EarthWise™ System

83%93%70%83%89%80%

AtlantaMinneapolisLos AngelesDenverPhiladelphiaPortland

100%100%100%100%100%100%

Conventional System

100

95

90

85

80

75

70

65

60

LEEDLEED®®

TRACETRACE


chilled water plant design...

Old “rules of thumb”

• 44°F chilled water supply

• 10°F delta T across the evaporator - that’s at 2.4 GPM/ton

• 10°F delta T across the condenser - that’s at 3.0 GPM/ton


chilled water plant design...

New “rules of thumb”

• 41°F chilled water supply

• 16°F delta T across the evaporator - that’s at 1.5 GPM/ton

• 15°F delta T across the condenser - that’s at 2.0 GPM/ton

• Potentially downsized the cooling tower


How do you know?


Key Lessons Learned …

• Cooling towers• Cooling coils• Pumps• Chillers• Air handlers• Controls


lessons learned

Cooling Tower Performance

“!Tower water should be hot!”

Towers fans should use VFDs! 2nd

1st


“Chilled water should be cold!”

lessons learned:

Cooling Coil Performance

Because of the pump energy savings

3rd

4th VFD on the CondenserWater Pump


Pump Pressure Optimization


Yes the chillers consume more energy

Factory witness testing

lessons learned

LLH Chiller Performance

“Chillers need to be efficient!”

but more than offset by the ancillaries


How can I eliminate the chiller’s kW increase for making colder water?


Ideal for use with variable primary flow:

series chillers

How can I eliminate the chiller’s kW increase for making colder water?


Chiller Killer II Seminar

Lee Cline, P.E.Senior Principal Systems EngineerTrane Commercial Systems


Series Chillers & VPF

What?

• Variable chilled water flow through the whole system



Benefits

Variable Primary Flow

• Reduces pumping costs

• Reduces first cost

• Adapts to system flow and temperature changes

• Advantages Trane chillers

• Advantages Trane controls

Series Chillers

• Increases system efficiency

• Expands system range

• Eliminate Flow Transients

• Reduces pumping costs

• Advantage Trane controls



Objections

• It looks risky!

• We’ve never done it.

• How do you control it?

• Is it reliable?


Series Chillers

Thermodynamic staging = efficiency

Average kW/Ton = 0.576 kW/ton6% better efficiency

(10% better than 90.1)

$275k list price $272k list price

10”$200/ft

8”$175/ft

parallel chillers

44°F

44°F

54°F0.611 kW/ton

0.611 kW/ton

series chillers

48°F

40°F

56°F0.605 kW/ton

0.544 kW/ton


variable primary flow systems Three Key Application Requirements:

• Chillers must be able to accommodate a change of flow of at least 10% per minute; 30% or even 50% is even better – CTV & RTWD variable flow compensation

• Chillers need to be selected with adequate flow turndown– Strive for a turn down ratio of at least 2:1 of

design to minimum flow.

• Minimum and maximum flows must not be violated– A bypass is required


Minimum flow rates – PARALLEL chillers – base system

0

500

1000

1500

2000

2500

10 20 30 40 50 60 70 80 90 100

System Load

Flo

w

System Load

1 Chiller Loading

2 Chiller Loading

2 Chiller Unloading

Chlr 1 Capacity (tons) 500

Chlr 1 Design Flow (gpm) 1000

Chlr 1 Min Flow (gpm) 400

Chiller 1 Turndown 2.5 to 1


Minimum flow rates PARALLEL chillers – less turndown

0

500

1000

1500

2000

2500

10 20 30 40 50 60 70 80 90 100

System Load

Flo

w

2 Chiller Unloading

System Load

1 Chiller Loading

2 Chiller Loading






Minimum flow rates

SERIES chillers – less turndown

0

500

1000

1500

2000

2500

10 20 30 40 50 60 70 80 90 100

System Load

Flo

w

2 Chiller Unloading

System Load

1 Chiller Loading

2 Chiller Loading






Series ChillersExpand system operating range

Chiller Pass MinFlow

(gpm)

RTHD 250std-eff

23

293196

RTHD 250hi-eff

23

450300

RTAC 300std-eff

23

339226

RTAC 300 hi-eff

23

375250

RTWD 120 std-eff

23

10167

RTWD 120hi-eff

23

12382

Flow @ 2.0 gpm/ton

[12° dt]

(gpm)

Turndownratio

500 1.712.55

500 1.111.67

558 1.652.47

574 1.532.30

230 2.283.43

244 1.982.97

Flow @ 1.5 gpm/ton

[16° dt]

(gpm)

Turndownratio

375 1.281.91

375 0.831.25

418 1.231.85

430 1.151.72

172 1.702.56

183 1.492.23


Series Chillers & VPFWhat about pumping horsepower?

RTAA110 Parallel

Load PumpFlow

Sys PD HP

100 310 70.0 5.5

90 279 60.5 4.3

80 262 52.4 3.5

70 262 45.6 3.0

60 262 39.7 2.6

50 155 36.0 1.4

40 132 30.6 1.0

30 132 27.5 0.9

20 132 25.2 0.8

10 132 23.8 0.8

RTAA100 Series

PumpFlow

Sys PD w/ CV opt. HP w/opt

310 88.4 88.4 7.0

279 75.4 74.4 5.3

248 63.8 61.4 3.9

217 53.5 50.5 2.8

186 44.6 40.6 1.9

155 37.1 32.1 1.3

124 30.9 24.9 0.8

120 27.6 20.6 0.6

120 25.3 17.3 0.5

120 24.0 15.0 0.4


VPF SystemBy-pass flow control lessons

• Size bypass line for minimum flow

• Size bypass valve for minimum flow

• Select DP transducer or flow meter for minimum flow

• Select chiller proof-of-flow device for minimum flow


VPF Proof-of-Flow

• Orange Research Model 1516 DP switch http://www.orangeresearch.com

• W.E. Anderson H3 series DP switch from Dwyerhttp://www.dwyer-inst.com

• Thermal dispersion flow sensor - IFM Effector https://eshop2.ifm-electronic.com/EShop/IfmUS/MyAccountView.do


Proof-of-Flow IFM Effector

• IFM Effector– Phone: 800-441-8246 – Website: www.ifmefector.com – Purchase online at: https://eshop2.ifm-

electronic.com/EShop/IfmUS/MyAccountView.do

• Technical resource: – Chad Mosier– HVAC Industry Specialist – Phone: 610-524-4486


Where Else Use Series?

???


series chillers Ideal application for:

Free Cooling


series chillers

Ideal application for:

One AFD


series chillers


Heat Recovery

ASHRAE 90.1 Section 6.5.6.2 requires heat recovery for…


series chillers


Series Counter-Flow


series chillers & VPF

Trane Advantages

• Chiller minimum flows– Trane chillers use less tubes for a given efficiency– Our compressors ARE more efficient !

• System flow rate-of-change– Variable Flow Compensation gives Trane chillers the

most robust control in the industry

• We know how to do it


series chillers & VPF

What did we see?

• We know what the risks are

• We done it a lot

• It is easy to make reliable

• There are many benefits

• There are may applications


Airside: What’s different?

Lowers the required air flow by 30-40%

Supply airRoom setpoint Airside delta T

55°F

75°F20°F

Common

practice

Low airtemp.system

45 – 48°F77°F32°F

• Can cut the airside fan BHP by nearly 50%• Drives the need for high efficiency chillers• Locks in the low leaving water temperature

requirements for chillers

SA

tooccupiedspace

SA

tooccupiedspace

EarthWise™

airside systemfor floor-by-floor applications

MA

MA

RA

RA

OAOA

OA CA

CDQ

SA

tooccupiedspace

SA

tooccupiedspace

EarthWise™

airside systemfor floor-by-floor applications

EA

EA

MA

MA

RA

RA

EA

OAOA

EAOA CA

CDQ

Ventilation Reset• ASHRAE 62

Fan Optimization• ASHRAE 90.1

• Floor by Floor Pressurization

• Fan Optimization


CDQ™


how it works

CDQ Desiccant Wheel

ability tohold water

vapor

high

relative humidity, %

low

0 60 1004020 80

Type III(CDQ)

Typically atmixed-air

conditions

Typically atleaving-coilconditions


Cool, Dry, Quiet (CDQ™)

OA

RA

SA

MAMA'

wate

r vap

or

50°F DB49°F DP

Trane CDQdesiccant wheel

CA

coolingcoil

55°F DB43°F DP

75°F DB63°F DP

80°F DB60°F DP


11030 40 50 60 70 80 10090dry-bulb temperature, °F

80

70

50

4030

wet-b

ulb

tem

pera

ture

, °F

60

CAreheat

180

160

140

120

100

80

60

40

20

hum

idity

ratio

, gra

ins/lb

of d

ry a

ir

RA

OA

SA

MA

MA'CA

OA 100°F DB74°F WB

RA 62°F DB50% RH

MA 80°F DB53.5°F DP

MA' 76°F DB58.5°F DP

CA 51°F DB49°F DP

SA 55°F DB42°F DP

CDQ requires:• less cooling tons• less reheat

Dryer

Wetter

WarmerCooler

CDQ


Cool, Dry, Quiet (CDQ™)

O

OA

SA

MA'

wate

r vap

or

CDQdesiccant wheel

CA

coolingcoil

100% RH

preheatcoil

RTWD

heat recovery chiller

MA

70%RH

38°–45° F

90°–140° F


10,000


9,000


0


Optimized Controls


The Four “Money” Control Strategies

• Fan Pressure Optimization

• Ventilation Reset

• Floor-by-Floor Building Pressurization

• Supply Air Reset


• Wireless Zone Sensors

• Auto-Commissioning

• Virtual Graphics

next generation VAV box control Three Capabilities That We Must Push Today!!


Auto-Commissioning

Prime Example of What We Can Do Via Intelligent Service

VAV Air System (Comm5)VAV Commissioning Report

Site: Antletam

76.666.5------32472.4 / 71.0NoVAV3-05

73.263.2------33973.3 / 73.9NoVAV3-04

73.663.6------36073.3 / 73.9NoVAV3-03

73.163.1------11673.7 / 73.0NoVAV3-02

76.266.2------27973.1 / 71.0NoVAV3-01

83.473.473.466.245170.6 / 71.0NoFP VAV3-06

81.771.771.664.739470.8 / 71.0NoFP VAV3-05

78.668.668.561.671874.6 / 73.9NoFP VAV3-04

82.272.272.162.138072.1 / 71.0NoFP VAV3-03

HWReheat

ReheatOff

Fan OnTemp

Fan OffTemp

Air Flow

Zone Temp /Zone Setpt

Alarm Present

82.372.272.263.851971.3 / 71.0NoFP VAV3-02


Virtual Graphics


Floor Plan


Chiller-Water VAV Systems


AdaptiView™Virtual Graphics on the Equipment

Trane Controls

What to talk about???

Chiller-Tower Optimization

Failure Recovery

Auto Rotation

VAS

AdaptiView

Area Control

3D Graphics

Auto Calibration

TOD Scheduling

Variable Flow

Flexible Alarming

Trend Logs

Graphical Trending

GraphICS

Soft Loading

LonTalk

ModbusAdaptive Control

Primary/Secondary

Constant Volume

Variable Primary FlowRapid Power Failure Recovery

Process Start

Operator Override Enabled

Critical Valve Reset

Ventilation Optimization

Fan Pressure Optimization

2D Graphics

Digital Page Alarms

E-Mail Alarms

Operator Manuals

Electronic Tutorials

Factory Training

MyTraneControls.Com

Demand Control Ventilation

TRAQ Dampers

Night Economizer

SAT Reset

StatiTrac

Heat Pump Control

ICE Mode

TR1 Drives

Industrial Options

Variable Flow CompensationBase Chiller

Peak Chiller

Swing Chiller

Setpoint Control

ASHRAE Std 147 Report

BacNET

Chilled Water Reset

Make Available

Make Unavailable

PPSPoints Lists

Failure Reset

V17 Demo

GeoThermal

Flow Based Subtract

Commissioning Reports


What to talk about??? Top 3 Control Sales Needs

1. Understand Trane systems’ full capabilities2. Get control of the control spec

3. Work together

“Our offering today is the “deepest” in HVACsystem insight and capability”

Mark Weldy


Top 3 Control Sales Needs

1. Know Trane full capabilities

Trane Resource Inventory Guide


Trane systems full capabilitiesTrane Resource Inventory Guide

• List of resources for:– Chilled Water– VAV System – Applied– Tracker Systems

• Info there includes– Description / Products– Value Classification– Competition– Case Studies– Presentations– Training– Seq of Op– Points Lists– Sales Tools



1. Understand Trane systems’ full capabilities

2. Get control of the control spec




Guide Specifications and Sequences of Operation




Pre-Packaged Solutions




• For New and Existing Building jobs

• Specification Information:– Sequences of operation materials – Generic input/output point lists – Sales sketches offered in Acrobat and AutoCAD formats – Generic product summaries– Sales Notes

• Technician Information:– Controller programming files – Tracer Summit custom workstation graphics – Commissioning sheets and application notes




VAV AHU WITH HYDRONIC HEATING/COOLING AND PREHEAT

AH0001





AH0001



1. Understand Trane systems’ full capabilities


3. Work together


Work Together!

Why?

Remember PPS for Existing Building and

Retrofit Work Too!

Remember PPS for Existing Building and

Retrofit Work Too!



3. Work Together

PPS Training

Trane Controls

Go talk about it!!!

Chiller-Tower Optimization

Failure Recovery

Auto Rotation

VAS

AdaptiView

Area Control

3D Graphics

Auto Calibration

TOD Scheduling

Variable Flow

Flexible Alarming

Trend Logs

Graphical Trending

GraphICS

Soft Loading

LonTalk

ModbusAdaptive Control

Primary/Secondary

Constant Volume

Variable Primary FlowRapid Power Failure Recovery

Process Start

Operator Override Enabled

Critical Valve Reset

Ventilation Optimization

Fan Pressure Optimization

2D Graphics

Digital Page Alarms

E-Mail Alarms

Operator Manuals

Electronic Tutorials

Factory Training

MyTraneControls.Com

Demand Control Ventilation

TRAQ Dampers

Night Economizer

SAT Reset

StatiTrac

Heat Pump Control

ICE Mode

TR1 Drives

Industrial Options

Variable Flow CompensationBase Chiller

Peak Chiller

Swing Chiller

Setpoint Control

ASHRAE Std 147 Report

BacNET

Chilled Water Reset

Make Available

Make Unavailable

PPSPoints Lists

Failure Reset

V17 Demo

GeoThermal

Flow Based Subtract

Commissioning Reports


Miscellaneous Musings

Creative Applications


Miscellaneous Musings

• Fan Pressure Optimization/Critical Zone Reset

• Pump Pressure Optimization

• Low temperature air distribution

• The importance of LEED®


Fan Pressure Optimization /Critical Zone Reset


VAV System with DDC Controls

Communicating BAS

Fan Speed or Inlet Vane Position

Monitors temperature and cfm

Duct Pressure Sensor


VAV System with DDC Controls

Communicating BAS

Fan Speed or Inlet Vane Position

Duct Pressure Sensor

% Damper position


Normal Operation


Reduced Load


Here is an Excellent Third Party Reference

There is a great article on Critical Zone Reset of Fan Pressure in the June 2007 Issue of the “ASHRAE Journal”


Supply air fans on variable air volume (VAV) systems are typically controlled to maintain static pressure in the duct system at a given setpoint. Since 1999, ASHRAE Standard 90.1 has required that this setpoint be reset for systems with direct digital controls (DDC) at the zone level, specifically:

Setpoint Reset. For systems with direct digital control of individual zone boxes reporting to the central control panel, static pressure setpoint shall be reset based on the zone requiring the most pressure; i.e., the setpoint is reset lower until one zone damper is nearly wide open.

.

“Nevertheless, reset can generate fan energy

supply savings on the order of 30% to 50% compared to fixed

setpoints.”

By Steven T. Taylor, P.E., Fellow ASHRAEASHRAE Journal June 2007


Pump Pressure Optimization


Low Temperature Air Distribution

• Reduced First Cost

• Reduced operating Cost

• Increased Comfort

The Proverbial Holy Grail!!


Typical Objections

• What about condensation with low temp air?

• What about cold air “dumping” from diffusers?

• What about adequate air motion in room?


Linear Slot Diffuser vs. Typical


Parallel fan powered box

primary primary airair

supplysupplyairair

terminal terminal mixing fanmixing fan

plenumplenumairair


One Unexpected Benefit For Hot and Humid Climates

When low temp air systems are designed for 45-47 degree supply air, relative humidity in the space will typically be in the 35-40% range vs. a traditional system with 55 degree supply air providing relative humidity in the space of 55-60%

This can be a huge boost to comfort in the indoor climate in the summer and an improvement to employee productivity


SYSTEM SENS ZONE COIL AHU SA OA

LOSS SENS LATENT LOAD LAT LAT CFM CFM

Cafeteria 344,292 1,247,306 75,600 1322906 53.659 55 57746 14,400

Auditorium 292,863 664,050 114,870 778920 53.766 55 30743 16410

Band/ Choir 189,109 440,997 77,430 518427 53.606 55 20417 8017

Fine Arts Rooms 196,028 647,233 90,380 737613 53.648 55 29964 8858

Administration 147,622 410,089 66,229 419,686 53.571 55 18986 4302

Ist Flr Gym Classes 132,203 322,833 57,181 380014 53.704 55 14946 5552

Gymnasium 398798 1191266 359352 1550618 53.902 55 55151 33120

2nd Flr Gym Classes 292,610 1,014,475 373,597 1388072 53.761 55 46966 19,410

AREA E 362,369 926,737 109,943 1036680 53.635 55 42904 14139

West Ed Wing 324,801 819,437 97,008 916445 53.691 55 37937 11606

East Wing 320,153 900,273 148,146 1048419 53.691 55 41679 16886

Servery 0 75,090 41,208 116298 54.118 55 3476 2483

TOTAL 3000848 8,584,696 1569736 10097800 397440 152700

ZONE GAINS

Example of Low Temp Air Unit First Cost Savings-Chicago School

397440


SYSTEM SENS ZONE COIL AHU SA OA %OA

LOSS SENS LATENT LOAD LAT LAT CFM CFM

Cafeteria 344,292 1,247,306 75,600 1322906 45.122 47 41247 14,400 0.35

Auditorium 292,863 664,050 114,870 778920 45.272 47 21959 16410 0.75

Band/ Choir 189,109 440,997 77,430 518427 45.048 47 14583 8017 0.55

Fine Arts Rooms 196,028 647,233 90,380 737613 45.108 47 21403 8858 0.41

Administration 147,622 410,089 66,229 419,686 53.571 55 18986 4302 0.23

Ist Flr Gym Classes 132,203 322,833 57,181 380014 45.186 47 10676 5552 0.52

Gymnasium 398798 1191266 359352 1550618 45.463 47 39394 33120 0.84

2nd Flr Gym Classes 292,610 1,014,475 373,597 1388072 45.266 47 33547 19,410 0.58

AREA E 362,369 926,737 109,943 1036680 45.089 47 30646 14139 0.46

West Ed Wing 324,801 819,437 97,008 916445 45.167 47 27098 11606 0.43

East Wing 320,153 900,273 148,146 1048419 45.167 47 29771 16886 0.57

Servery 0 75,090 41,208 116298 54.118 55 3476 2483 0.71

TOTAL 3000848 8,584,696 1569736 10097800 289310 152700

ZONE GAINS


289310



• Reducing Air from 55 to 47 deg

– CFM decreased from 397,439 cfm to 289,309 cfm

– Actual Installed Cost for AHU Equipment was $2.90 per cfm.

– Cost Savings excluding sheet metal and labor was $313,577 on just AHUs ($.68/sq ft).


We can often increase capacity in a building up to 20-40% by simply changing chillers and utilizing existing pumps, piping, towers, and air units.

And reduce operating costs 15%- 40%

It’s a system approach!

Great Opportunity: Existing Buildings


LEED®


LEED –What are property managers, owners, developers saying?

• Virtually all prospective tenants are asking if building is “LEED Certified”

• Tenants are willing to pay a higher rental fee in “LEED Certified” Buildings

• We need to do “Sustainable Audits” on our existing buildings to analyze potential for “LEED Existing Building” certification

• Tenants say “Our customers want to do business with “Green” companies”

• We may not be able to sell the building if it is not “LEED Certified”


So are owner’s willing to pay more to get their building “LEED Certified”?

• 25 Story office building

• Bill had commitment on SWUDs, and VAV

• Owner decided to go for LEED certification

• System was upgraded to chilled water with EarthWise design to get LEED Certification

• Owner spent an additional $1,500,000 ($2 / sq.ft.) to do this

• Trane bill of material almost doubled

• What about commission?


It gets even better!

• 6 story office building• Bill sold SWUDs and VAV• Submittal approved and equipment in production

when owner decided to go for “LEED Certification”• Owner delayed building opening for 6 months while

system was redesigned to EarthWise Chilled Water System

• Owner paid $3,000,000 ( $20 / sq. ft.) in cancellation charges, change orders and upgrade fees to get the building certified!

I think we are on to something here


Ask for the Order

• Don’t forget to ask for the order!! • It’s most important when you work with engineers.• Don’t assume

“Are you going to be able to use our stuff on your schedules?”

“I’d like to help you develop the details on this project, is this going to work for you?”


Successful People don’t necessarily have the best of everything

They just make the best of everything they have.


In Summary

• Sell the systems

• Make sure we use all the tricks we have

• Embrace LEED

• Take the Accredited Professional test now

• Ask for the order


Questions or Comments?

© trane 2008 confidential eugene smithart, p.e. director, systems and solutions trane commercial...

Documents