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Cooling Tower layout issues

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Low quality sensors lead to wrong resultsSite Seagate City

Subj Chiller Performances per Energy Audit data by Others

Description Ch 1 2 3 4 5 6 7

CHW Set Temp 5.5 5.5 5.5 - 5.5

CHWS T ( degC ) 5.8 5.8 6.3 6.1 5.8

CHWR T ( degC ) 11.2 10.8 11.1 10.9 11.3

dT 5.4 5.0 4.8 4.8 5.5

Design 30.5 30.5 30.5 30.5 30.5

CWS Temp ( degC ) 29.7 29.6 30.1 30.1 30.5

CWR Temp ( degC ) 33.8 34.2 34.6 33.8 35.3

dT 4.1 4.6 4.5 3.7 4.8

Design kW 730.0 730.0 730.0 730.0 730.0

% RLA Avg 87.0 90.3 98.0 91.7 93.7

A 85.0 89.0 95.0 89.0 88.0

B 90.0 93.0 100.0 94.0 100.0

C 86.0 89.0 99.0 92.0 93.0

Approach Temp Cond 1.0 0.9 0.9 0.0 0.4

Approach Temp Evap 1.5 2.3 2.0 2.1 1.3

IGV position % 100 100 97.1 100 86.9

Remark Limit by Vane stop Lim by I lim by I -

Flow CHW Lo 2960 2500 3150 3100 3700

Flow CHW Hi 3500 3000 3650 3350 3700

Design RTon 1,250 1,250 1,250 1,250 1,250

RTon Lo 1,199 938 1,134 1,116 1,526

RTon Hi 1,418 1,125 1,314 1,206 1,526

RTon Average measured 1,308 1,031 1,224 1,161 1,526

RTon Average at 100% 1,504 1,142 1,249 1,267 1,629

Design kW/Ton 0.58 0.58 0.58 0.58 0.58

Efficiency Lo 0.53 0.70 0.63 0.60 0.45

Efficiency Hi 0.45 0.59 0.54 0.55 0.45

Efficiency Avg 0.49 0.64 0.59 0.58 0.45

Note :

Per Others Data, all Chillers are peformance within design or better !!

Chiller efficiency too good to be true !!

Filling in other trended data revealed questionable results

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SingPost Energy Efficiency Project

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CT456

CT123

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Y 9

00 R

T

Y 9

00 R

T

Y 4

50 R

T

Y 4

50 R

T

Y 9

00 R

T

Y 9

00 R

T

Y 9

00 R

T

Decoupler

CWR

CWS

CHWS

CHWR

PCHWP

SCHWP

CWP

Cooling Tower

Baseline Monitoring Points

CH1 CH2 CH3 CH4 CH5 CH6 CH7

schwp1 schwp2 schwp3 schwp4 schwp5 schwp6

chwp1 chwp2 chwp3 chwp4 chwp5 chwp6 chwp7

cwp1

cwp2

cwp3

cwp4

cwp5

cwp6

cwp7

CT123

CT456

F F F

F

F

F

Makeup water

F

Makeup waterF Ultrasonic Flow meter

T

T

T

T T

TT

T

T

T

T

T

T

T

T

T

T

T

TT Manually Calibrated 10k/30k Thermistors

P PP

P P P

P P P

P

P

P

P

P

P

P

P P P P P P P

PP

PPPP

P Power/Current sensor

W123

W456

W Weather station

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Header CHWS (25th Nov to 19th Dec, 2006)

Header Chilled Water Supply Temperature

4.2% < 6.85 °C < 86.3%

Average: 7.626 °C

71% < 8.05 °C < 22.4%

Component’s Average

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Chiller Plant System Performance (kW/RT)

PUMPS, TOWERS, CHILLERS

SINGAPORE WEATHER CONDITIONS

~2.00 kW/RT

1.00~1.20

kW/RT

~0.90 kW/RT

~0.70 kW/RT

~0.60 kW/RT

~0.55kW/RT

POOR DESIGN,

O&M

AVERAGE

ENERGY SMART(100%)

GOOD PRACTIC

E(-22%)

EXCELLENT PRACTICE

(-33%)

BESTPRACTICE

(-39%)

NOTESNOTES

::1. Chiller plant lifetime 15 ~ 20 years

2. Fossil fuel prices increasing

3. IPCC report says Global Warming serious problem

4. Once you commit $$$ to retrofits, you are unlikely to upgrade for many years