high performance-chilled-water-systems ashrae-chicago

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© 2011 Ingersoll Rand High Performance Chilled Water Systems High Performance Chilled Water Systems Mick Schwedler, PE, LEED ® AP Manager Applications Engineering Trane

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Page 1: High performance-chilled-water-systems ashrae-chicago

© 2011 Ingersoll Rand

High Performance Chilled Water Systems

High Performance Chilled Water Systems

Mick Schwedler, PE, LEED® APManager Applications EngineeringTrane

Page 2: High performance-chilled-water-systems ashrae-chicago

Normal Performance Chilled Water Systems ASHRAE/IESNA 90.1 (LEED Prerequisite)

System configuration

Design parameters

System control

Page 3: High performance-chilled-water-systems ashrae-chicago

ASHRAE Standard 90.1-2007 Purpose

“… Provide minimum requirements for the energy-efficient design of buildings except low-rise residential buildings”

Page 4: High performance-chilled-water-systems ashrae-chicago

Purpose ofANSI/ASHRAE/IESNA Standard 90.1-2010

To establish minimum energy efficiency requirements of buildings, other than low-rise residential buildings for:

1. design, construction, and a plan for operation and maintenance, and

2. Utilization of on-site renewable energy resources.

Page 5: High performance-chilled-water-systems ashrae-chicago

Publication and Final Savings Estimates Performed by Pacific Northwest National

Laboratory (PNNL) Savings of 90.1-2010 compared to

90.1-2004

Savings shared are modeled as of January 2011

Include ventilation changes in ASHRAE 62.1 between 1999 and 2007 versions

Page 6: High performance-chilled-water-systems ashrae-chicago

90.1 Progress Indicator Including receptacle loads in modeling

Including receptacle load in % savings calculation

24.0

Energy cost savings %

25.5Ventilation rate changes

between 62.1-1999 and 62.1-2007

Energy savings %

Page 7: High performance-chilled-water-systems ashrae-chicago

90.1 Progress IndicatorExcluding receptacle loads in % savings calculation only

Including receptacle loads in modeling

Excluding receptacle load in % savings calculation

30.1

Energy cost savings %

32.6Ventilation rate changes

between 62.1-1999 and 62.1-2007

Energy savings %

Page 8: High performance-chilled-water-systems ashrae-chicago

LEED Energy and Atmosphere LEED 200910% energy cost savings beyond 90.1-2007

LEED 2012Public Review 2: September 2011 EA Prerequisite: 10% average energy cost and source

energy savings beyond 90.1-2010 (new construction) EA Credit: Credit for reductions beyond 10%

Page 9: High performance-chilled-water-systems ashrae-chicago

90.1-2010Chiller EfficienciesPaths A & B

Equipment Type Size CategoryUnits

Before 1/1/2010 As of 1/1/2010c Test Procedureb

Path A Path Bd

Full Load IPLV

Full Load IPLV

Full Load IPLV ARI 550/590

Air-cooled<150 tons EER ≥9.562 ≥10.416 ≥9.562 ≥12.50 NA NA

≥150 tons EER ≥9.562 ≥10.416 ≥9.562 ≥12.75 NA NA

Water Cooled Electrically Operated, Positive Displacement

<75 tons kW/ton≤0.790 ≤0.676

≤0.780 ≤0.630 ≤0.800 ≤0.600

≥75 tons and < 150 tons kW/ton ≤0.775 ≤0.615 ≤0.790 ≤0.586

≥150 tons and < 300 tons kW/ton ≤0.717 ≤0.627 ≤0.680 ≤0.580 ≤0.718 ≤0.540

≥300 tons kW/ton ≤0.639 ≤0.571 ≤0.620 ≤0.540 ≤0.639 ≤0.490

Water Cooled Electrically Operated,

Centrifugal

<150 tons kW/ton ≤0.703 ≤0.669≤0.634 ≤0.596 ≤0.639 ≤0.450≥150 tons and

< 300 tons kW/ton ≤0.634 ≤0.596

≥300 tons and < 600 tons kW/ton

≤0.576 ≤0.549≤0.576 ≤0.549 ≤0.600 ≤0.400

≥600 tons kW/ton ≤0.570 ≤0.539 ≤0.590 ≤0.400

Must meet both full and part load requirements

Page 10: High performance-chilled-water-systems ashrae-chicago

Heat rejection equipment Fan speed control 7.5 and

greaterCapability to operate at 2/3

fan speed or less

ExceptionsClimates > 7200 CDD50

(e.g. Miami)

1/3 of fans on multiple fan application

Page 11: High performance-chilled-water-systems ashrae-chicago

Hydronic system design and control Pump isolation

Chilled and hot water reset if >300,000 BtuhException: Variable flow systems that

reduce pumping energy

Page 12: High performance-chilled-water-systems ashrae-chicago

90.1-2007Hydronic System Design & ControlThese provisions apply if pump system power > 10 hp:

Must be variable flow unless … Pump power ≤ 75 hp ≤ 3 Control valves

Limit demand of individual variable-flow pumps to 30% of design wattage at 50% flow (e.g., use VSD) Pump head > 100 ft Motor > 50 hp

Page 13: High performance-chilled-water-systems ashrae-chicago

WatersideEnergy Recovery required Service Water Heating24 hrs per day and

Heat rejection > 6 MMBtuh and

SWH load 1 MMBtuh

Recover smaller of60% of heat rejection

Preheat water to 85°F

Page 14: High performance-chilled-water-systems ashrae-chicago

ConfigurationNormal Performance Chilled Water

productionpumps

two-way valve

distributionpump

distributionloop

productionloop

Page 15: High performance-chilled-water-systems ashrae-chicago

Design ParametersNormal Performance Chilled Water Plant ARI 550/590 Standard Conditions44°F chilled water

2.4 gpm/ton chilled water (10°F T)

3.0 gpm/ton condenser water (10°F [9.3] T)

Page 16: High performance-chilled-water-systems ashrae-chicago

ControlNormal Performance Chilled Water Plant Chilled water distribution pump

P at most remote load

Cooling tower fans55°F (as cold as possible)

Constant speed condenser water pumps

All these “normal” assumptions will be examined

Page 17: High performance-chilled-water-systems ashrae-chicago

High PerformanceChilled Water Plants Standard high performance

Reduced flow rates, increased ∆Ts

Variable primary flow

Advanced high performance Equipment capabilities

System configurations

System control

Page 18: High performance-chilled-water-systems ashrae-chicago

a history ofChiller Performance

8.0

ASHRAE Standard 90

chill

er e

ffic

ien

cy,

CO

P

6.0

4.0

2.0

0.0NBI “best”

available90-75(1977)

90-75(1980)

90.1-89 90.1-99

centrifugal>600 tons

screw150-300 tons

scroll<100 tons

reciprocating<150 tons

Page 19: High performance-chilled-water-systems ashrae-chicago

chilled water plant design …ProvocationAre our “rules of thumb” …

44 F chilled water supply

10 F T for chilled water system

3 gpm/ton condenser water flow

… in need of repair?

Page 20: High performance-chilled-water-systems ashrae-chicago

High Performance Design Parameters ASHRAE GreenGuide and CoolTools™

Chilled water T: 12°F to 20 °F

Condenser water T: 12°F to 18 °F (multi-stage)

Kelly and Chan Chilled water T: 18°F

Condenser water T: 14.2°F(3.6 - 8.3% energy savings in various climates)

Page 21: High performance-chilled-water-systems ashrae-chicago

chilled water plant …humid climateBase Design: 450 Tons 0.5% design

wet bulb: 78 F

Entering condenser water temperature (ECWT): 85 F

Evaporator and condenser temperature differences: 10 F

Coil, valve and chilled water piping pressure drop: 80 ft

Condenser water piping pressure drop: 30 ft

Pump efficiency: 75%

Pump motorefficiency: 93%

Page 22: High performance-chilled-water-systems ashrae-chicago

traditional design …humid climateSystem Energy Consumption

2.4/3.0

Chilled /Condenser Water Flows, gpm/ton

Ener

gy C

onsu

mpt

ion,

kW

TowerCondenser Water PumpChilled Water PumpChiller (100% Load)

0

50

100

150

200

250

300

350

Page 23: High performance-chilled-water-systems ashrae-chicago

traditional vs. low-flow design …System Summary At Full Load

0

50

100

150

200

250

300

350

2.4/3.0 1.5/2.0

Chilled /Condenser Water Flows, gpm/ton

Ener

gy C

onsu

mpt

ion,

kW

TowerCondenser Water PumpChilled Water PumpChiller (100% Load)

Page 24: High performance-chilled-water-systems ashrae-chicago

comparison …humid climateSystem Summary At 75% Load

0

50

100

150

200

250

300

350

2.4/3.0 1.5/2.0

Chilled /Condenser Water Flows, gpm/ton

Ener

gy C

onsu

mpt

ion,

kW

TowerCondenser Water PumpChilled Water PumpChiller (75% Load)

Page 25: High performance-chilled-water-systems ashrae-chicago

comparison …humid climateSystem Summary At 50% Load

0

50

100

150

200

250

300

350

2.4/3.0 1.5/2.0

Chilled /Condenser Water Flows, gpm/ton

Ener

gy C

onsu

mpt

ion,

kW

TowerCondenser Water PumpChilled Water PumpChiller (50% Load)

Page 26: High performance-chilled-water-systems ashrae-chicago

comparison …humid climate System Summary At 25% Load

0

50

100

150

200

250

300

350

2.4/3.0 1.5/2.0

Chilled /Condenser Water Flows, gpm/ton

Ener

gy C

onsu

mpt

ion,

kW

TowerCondenser Water PumpChilled Water PumpChiller (25% Load)

Page 27: High performance-chilled-water-systems ashrae-chicago

traditional vs. low-flow design …humid climateSavings Summary

0

10.0

20.0

25% 50% 75% 100%

Load

Ope

ratin

g C

ost S

avin

gs, %

3.8%

6.7%

10.3%

16.5%

Page 28: High performance-chilled-water-systems ashrae-chicago

High PerformanceDesign Parameters

0

200

400

600

41/16 42/14 43/12 44/10

Chilled water supply temperature/DeltaT

kWh/

ton/

year

Chilled waterpumpChiller

Page 29: High performance-chilled-water-systems ashrae-chicago

Pipe Size Example90.1-2010 Table 6.5.4.5

Past DesignPractice

ASHRAE GreenGuide

∆T (°F)

Flow(gpm)

Pipe Size

∆T (°F)

Flow(gpm)

Pipe Size

Chilled Water

10 1920 10 16 1200 8

Condenser Water

9.4 2400 14 14 1600 12

800 ton system

3,000 hours of operation

Chilled water, variable flow

Condenser water, constant flow

Page 30: High performance-chilled-water-systems ashrae-chicago

High PerformanceDesign OptionsEither …

Take full energy (operating cost) savings

Or …

Reduce piping size and costExperienced designers use pump,piping and tower savings to select aneven more efficient chiller

Page 31: High performance-chilled-water-systems ashrae-chicago

Reduced flow works for all chiller manufacturers Logan Airport - Boston:

$426,000 Construction cost savings

7.3% operating cost savings

Large Chemical Manufacturer -Greenville $45,000 Excavation and concrete savings

6.5% Operating cost savings

Computer Manufacturer - San Francisco Existing tower, pipe savings

2% Operating cost savings (tower not changed)

Page 32: High performance-chilled-water-systems ashrae-chicago

Low flow works for retrofit applications Chilled water side

Coil It’s a simple heat transfer device Reacts to colder entering water

by returning it warmer

Ideal for system expansion

Page 33: High performance-chilled-water-systems ashrae-chicago

Low flow works for retrofit applications

Condenser side retrofit opportunity Chiller needs to be

replaced

Cooling needs haveincreased by 50%

Cooling tower wasreplaced two years ago

Condenser pump and pipes are in good shape

Page 34: High performance-chilled-water-systems ashrae-chicago

Condenser side retrofit opportunity

Existing Retrofit

Capacity (tons) 500 750

Flow rate (gpm) 1500 1500

Condenser Entering WaterTemperature (F)

85 88

Condenser Leaving WaterTemperature (F)

95 103

Design Wet Bulb (F) 78 78

Page 35: High performance-chilled-water-systems ashrae-chicago

0.0

50.0

100.0

150.0

200.0

250.0

300.0

350.0

25% 50% 75% 100%

System Load

Ener

gy C

onsu

mpt

ion

(kW

h)

3.0 gpm/ton2.0 gpm/ton

Humid climatesLow flow works for short piping runs too

Condenser Water Side Only - original

Page 36: High performance-chilled-water-systems ashrae-chicago

0.0

50.0

100.0

150.0

200.0

250.0

300.0

350.0

25% 50% 75% 100%

System Load

Ener

gy C

onsu

mpt

ion

(kW

h)

3.0 gpm/ton2.0 gpm/ton

Humid climatesLow flow works for short piping runs too

Condenser Water Side OnlyZERO piping pressure drop

Page 37: High performance-chilled-water-systems ashrae-chicago

High Performance Design Parameters Low flow benefits systems - no

matter whose chiller is being used

Low flow works extremely well on existing systems

Low flow works on short piping runs

Page 38: High performance-chilled-water-systems ashrae-chicago

always, always,Always Remember …

Page 39: High performance-chilled-water-systems ashrae-chicago

Oh, by the way...

You may also do this with air

Page 40: High performance-chilled-water-systems ashrae-chicago

Variable-Primary-Flow Systems

variable-flowpumps

controlvalve

checkvalves

Page 41: High performance-chilled-water-systems ashrae-chicago

VPF Savings First cost: 4-8%

Annual energy: 3-8%

Life-cycle cost: 3-5%

http://www.arti-21cr.org/ARI/util/showdoc.aspx?doc=1085

Page 42: High performance-chilled-water-systems ashrae-chicago

Flow requirementsVPF System Limits (consult manufacturer)

Absolute flows - Minimum and maximum

Flow rate changes 2% of design flow per minute

not good enough 10% of design flow per minute borderline 30% of design flow per minute

many comfort cooling applications 50% of design flow per minute

best

Always need a way to ensure minimum flow (bypass)

Page 43: High performance-chilled-water-systems ashrae-chicago

Chiller ControlVariable W ater Flow

30

40

50

60

70

80

90

100

110

120

130

3:50:00 3:55:00 4:00:00 4:05:00 4:10:00Tim e (hour:m in:sec)

Wat

er T

emp

[deg

F]

-500

-300

-100

100

300

500

700

900

1100

1300

1500

Flow

[gpm

]Evaporator W ater F low

Evap Entering W ater Tem p

Evap Leaving W ater Tem p

Page 44: High performance-chilled-water-systems ashrae-chicago

More informationVPF System Http:/trane.com/commercial

/library/newsletters.asp (1999 and 2002)

“Primary-Only vs. Primary-Secondary Variable Flow Systems,” Taylor, ASHRAE Journal, February 2002

“Don’t Ignore Variable Flow,” Waltz, Contracting Business, July 1997

“Comparative Analysis of Variable and Constant Primary-Flow Chilled-Water-Plant Performance,” Bahnfleth and Peyer, HPAC Engineering, April 2001

“Campus Cooling: Retrofitting Systems,” Kreutzmann, HPAC Engineering, July 2002

Page 45: High performance-chilled-water-systems ashrae-chicago

High Performance Chilled Water Plants Standard high performance

Reduced flow rates, increased ∆Ts

Variable primary flow

Advanced Equipment capabilities

System configurations

System control

Page 46: High performance-chilled-water-systems ashrae-chicago

Equipment CapabilitiesHigh Performance Chilled Water Plant Constant speed0.570 FL / 0.479 IPLV

Higher efficiency “same price” optionsVariable speed (spend money on drive)

Constant speed (spend money on copper)

Purchase both a drive and more heat exchange surface

Down to 0.45 kW/ton FL available (22% reduction)

Page 47: High performance-chilled-water-systems ashrae-chicago

Same-price Chiller: Example Performance

Option Full Load(kW/ton)

IPLV(kW/ton)

VSD 0.572 0.357High Efficiency 0.501 0.430

Page 48: High performance-chilled-water-systems ashrae-chicago

Same-price Chiller: Example Performance

0

50

100

150

200

250

300

350

400

0% 20% 40% 60% 80% 100%

kW

% Load

600-ton Replacement Chiller Performance

High_efficiency_85°FVSD_85°FHigh_efficiency_75°FVSD_75°FHigh_efficiency_65°FVSD_65°F

Page 49: High performance-chilled-water-systems ashrae-chicago

Example Office building

Two 400-ton chillers

Comparisons Base system - constant speed

AFD on both chillers

High efficiency for both chillers

AFD on one chiller

High efficiency for one chiller

Page 50: High performance-chilled-water-systems ashrae-chicago

What is the actual utility rate? Utility costs ‘Combined’ utility rates ($0.10 / kWh)

Actual utility rates ($12 / kW and $0.06 / kWh)

Page 51: High performance-chilled-water-systems ashrae-chicago

Utility rate comparison

Simple paybacks, humid climate

Combined rate Actual rate

AFD 6.1 10.8on one chiller High efficiency 6.3 7.7

AFD 7.2 12.7on both chillers High efficiency 7.1 8.3

Using incorrect “combined” rate leads to incorrect decisions

Page 52: High performance-chilled-water-systems ashrae-chicago

Rule 1

Use actual utility rates

Page 53: High performance-chilled-water-systems ashrae-chicago

Temperate climatewith economizer

Annual operating cost

$20,000

$40,000

$60,000

$80,000

$100,000

Base case AFD on both chillers

High efficiency both chillers

AFD on one chiller

High efficiencyone chiller

0

5

10

15

20

25

30

Simple payback

Chiller plant operating costSimple payback

Page 54: High performance-chilled-water-systems ashrae-chicago

Temperate climate,no economizer

Annual operating cost

$20,000

$40,000

$60,000

$80,000

$100,000

Base case AFD on both chillers

High efficiency both chillers

AFD on one chiller

High efficiencyone chiller

0

2

4

6

8

10

12

Simple payback

Chiller plant operating costSimple payback

Page 55: High performance-chilled-water-systems ashrae-chicago

Humid climate,no economizer

Annual operating cost

$20,000

$40,000

$60,000

$80,000

$100,000

Base case AFD on both chillers

High efficiency both chillers

AFD on one chiller

High efficiencyone chiller

2

4

6

8

10

12

14

Simple payback

Chiller plant operating costSimple payback

Page 56: High performance-chilled-water-systems ashrae-chicago

Dry climate with economizer

Annual operating cost

$20,000

$40,000

$60,000

$80,000

$100,000

Base case AFD on both chillers

High efficiency both chillers

AFD on one chiller

High efficiencyone chiller

Simple payback

Chiller plant operating costSimple payback

024681012141618

Page 57: High performance-chilled-water-systems ashrae-chicago

Rule 2

Model ROI of each investment

Page 58: High performance-chilled-water-systems ashrae-chicago

Guidance: VSD or High Efficiency? High efficiency

Significant demand charges, especially ratchet charges

Climates where the wet bulb doesn’t vary substantially

Multiple chillers in the plant

Economizer that reduces low load/low lift operating hours

VSD Many hours at low

condenser water temperature – and low load

Perhaps only on one chiller

Factor replacement cost of VSD when performing life cycle assessment

Page 59: High performance-chilled-water-systems ashrae-chicago

High Performance Chilled Water Plants Standard high performance

Reduced flow rates, increased ∆Ts

Variable primary flow

Advanced Equipment capabilities

System configurations

System control

Page 60: High performance-chilled-water-systems ashrae-chicago

VPF System Minimum flow and bypass control

Single chiller

Retrofit

P

Controller

P

Page 61: High performance-chilled-water-systems ashrae-chicago

What may not be a good VPF application? Two packaged chillers

Limited evaporator configurations

Assume minimum flow is about 1.2 gpm/ton

In parallel

Wide ∆T (low flow) e.g 18°F ∆T is 1.33 gpm/ton

Why isn’t it a good application? Flow can only be turned down 10%

Page 62: High performance-chilled-water-systems ashrae-chicago

Variable-Volume Pumping System(series chillers)

57°F41°F

48.4°F

Bypass alternatives

Upstream chiller operating at higher temperature is more efficient

Page 63: High performance-chilled-water-systems ashrae-chicago

Series ChillersManual service bypass

Page 64: High performance-chilled-water-systems ashrae-chicago

Series Chiller Advantages Simplifies pumping and

sequencing No flow rate transitions

Makes VPF simple

Upstream chiller operates at elevated temperature Efficiency increases

Capacity increases 10% or more for

absorption

Simple preferential loading of chillers Adjust upstream

chiller’s setpoint Upward to unload Downward to load

Page 65: High performance-chilled-water-systems ashrae-chicago

High PerformanceChilled Water Plants Standard high performance

Reduced flow rates, increased ∆Ts

Variable primary flow

Advanced Equipment capabilities

System configurations

System control

Page 66: High performance-chilled-water-systems ashrae-chicago

ControlNormal Performance Chilled Water Plant Chilled water distribution pump

P at most remote sensor

Cooling tower fans55°F (as cold as possible)

Somewhere else

Constant volume condenser water pumps

Page 67: High performance-chilled-water-systems ashrae-chicago

High PerformanceChilled Water Pump Control

Valve position Pump Pressure Sensor

Communicating BAS Pump Speed

Page 68: High performance-chilled-water-systems ashrae-chicago

Position (% open)of critical valve

75%

65%

Increase pump static pressure setpoint

Reduce pump static pressure setpoint

No action

pump-pressure optimizationControl Logic 90.1-2007 Addendum ak

Page 69: High performance-chilled-water-systems ashrae-chicago

High Performance Chiller-Tower Control

Plant Power vs CWS

0.0

200.0

400.0

600.0

800.0

1,000.0

1,200.0

60 62 64 66 68 70 72 74 76 78 80 82 84 86 88

Condenser Water Setpoint (°F)

Pow

er (k

W)

Lowest condenser water temperature available from tower at this load and wet-bulb temperature

Chillers cannot meet load above this condenser water temperature

Optimal operation

1,550 tons, 65°F Wet-bulb T t

1,160 tons, 59°F Wet-bulb T

730 tons, 54°F Wet-bulb Temperature

Hydeman, et. al. Pacific Gas and Electric. Used with permission.

Page 70: High performance-chilled-water-systems ashrae-chicago

Cooling tower basicsFan energy consumption

0

20

40

60

80

100

0 20 40 60 80 100% Airflow

% Full load power

Page 71: High performance-chilled-water-systems ashrae-chicago

ambient wet bulb, °F

0.0

4.0

8.0

12.0

16.0

50 60 70 80

tow

er a

pp

roac

h,

deg

100% load

50% load

approach = 4

approach = 9

cooling tower performance factorsApproach and Wet Bulb

Page 72: High performance-chilled-water-systems ashrae-chicago

simple case: constant water flowOperating Dependencies

Wet bulb Condenser water

temperature Load Tower design

Load Condenser water

temperature Chiller design

Page 73: High performance-chilled-water-systems ashrae-chicago

condenser water control“Normal” Setpoint

Hot?e.g., 85°F, minimizes towerenergy consumption

Cold?e.g., 55°F, minimizes chillerenergy consumption

Optimized?

Page 74: High performance-chilled-water-systems ashrae-chicago

optimal condenser water controlChiller–Tower Interaction

condenser water temperature, °F

400

74

ener

gy

con

sum

pti

on,

kW

76 78 80 8272

300

200

100

084

tower

chiller

total

optimalcontrol point

Page 75: High performance-chilled-water-systems ashrae-chicago

High Performance Chiller-Tower Control Braun, Diderrich

Hydeman, Gillespie, Kammerud

Schwedler,ASHRAE Journal

Cascia

Crowther and Furlong

Page 76: High performance-chilled-water-systems ashrae-chicago

chiller–tower optimizationAn Example …

720,000 ft² hotel

2 chillers, 2 tower cells

Control strategies Make leaving-tower water cold

as possible (55F)

Optimize system operation

Entering-condenser setpoint equals design …85°F for humid climates80°F for dry climates

Page 77: High performance-chilled-water-systems ashrae-chicago

chiller–tower control strategiesNorth America

350K

ann

ual

op

erat

ing

cos

t, $

US

D

300K

250K

200K

150K

100K

50K

0Mexico City Orlando San Diego Toronto

55°F lvg toweroptimal controldesign ECWT

control strategy:

Page 78: High performance-chilled-water-systems ashrae-chicago

ann

ual

op

erat

ing

cos

t, $

US

D

500K

400K

300K

200K

100K

0Dubai Paris Sao Paulo Singapore

55°F lvg toweroptimal controldesign ECWT

control strategy:

chiller–tower control strategiesGlobal Locations

Page 79: High performance-chilled-water-systems ashrae-chicago

chiller–tower optimizationOperating Cost Savings

oper

atin

g c

ost

savi

ng

s, %

14

0

12

10

8

6

4

2

location

Du

bai

Du

bai

Par

isP

aris

Sao

Pau

loS

ao P

aulo

Sin

gap

ore

Sin

gap

ore

Mex

ico

Cit

yM

exic

o C

ity

Orl

and

oO

rlan

do

San

Die

go

San

Die

go

Toro

nto

Toro

nto

Page 80: High performance-chilled-water-systems ashrae-chicago

chiller–tower optimizationPerspective on SavingsFor centrifugal chillers ≥ 300 tons, ASHRAE 90.1 requires …

0.576 kW/ton at full load

0.549 kW/ton at IPLV

… using ARI standard rating conditions

Page 81: High performance-chilled-water-systems ashrae-chicago

chiller–tower optimizationPerspective on Savings

EquivalentSavings, % chiller efficiency

0.0 0.576

2.8 0.560

4.5 0.550

6.2 0.540

14.0 0.495

Page 82: High performance-chilled-water-systems ashrae-chicago

Where’s the Meter?On theBUILDING

Page 83: High performance-chilled-water-systems ashrae-chicago

chiller–tower optimizationFinding “Near Optimal” Tower design

(flow rate, range, approach)

Chiller design Refrigeration cycle

(vapor compression vs. absorption)

Compressor type

Capacity control (variable-speed drive)

Changing conditions(chiller load, ambient wet bulb)

Page 84: High performance-chilled-water-systems ashrae-chicago

chiller–tower optimizationNecessities

System-level controls

Variable-frequency driveon tower fans

High-quality dewpoint sensor

Page 85: High performance-chilled-water-systems ashrae-chicago

Number of chillers operating Operate one at nearly full load or two at

part load?

Examine IPLV assumptions

Page 86: High performance-chilled-water-systems ashrae-chicago

VSDs and centrifugal chillersA Closer Look at IPLV

VSDs improve part-lift performance, so running two chillers with VSDs at part load seems more efficient than one chiller at double the same load, but …is dependent on condenser water temperature

Load ECWTWeighting kW/Ton

100% 0.01 85°F 0.572

75% 0.42 75°F 0.420

50% 0.45 65°F 0.308

25% 0.12 65°F 0.372

Page 87: High performance-chilled-water-systems ashrae-chicago

Chiller power only45% Plant load

0

50

100

150

200

250

300

350

55 60 65 70 75 80 85

Available Tower Water Temperature (ºF)

Chi

ller k

W

1@90% Load2@45% Load

Operate 1 or 2 Chillers?Chiller kW Only

Page 88: High performance-chilled-water-systems ashrae-chicago

Chillers plus pumps45% Plant load

0

50

100

150

200

250

300

350

400

55 60 65 70 75 80 85Available Tower Water Temperature (ºF)

Chi

ller P

lus

Pum

p kW

1@90% Load2@45% Load

Operate 1 or 2 Chillers?Chiller Plus Pump kW

Page 89: High performance-chilled-water-systems ashrae-chicago

Operate 1 or 2 chillers?Run 1 or 2 VSD Chillers?

0

50

100

150

200

250

300

350

400

60 65 70 75 80 85Available Tower Water Temperature (ºF)

Tota

l Chi

ller P

lus

Pum

p kW

1@90% Load2@45% Load1@80% Load2@40% Load1@70% Load2@35% Load1@60% Load2@30% Load1@50% Load2@25% Load

Operate multiple chillers here,otherwise single chiller

Page 90: High performance-chilled-water-systems ashrae-chicago

Operate 1 or 2 chillers? 45% plant load: One chiller until tower

temperature is < 65°F

40% plant load: One chiller until tower temperature is < 60°F

35% plant load and below: One chiller

Page 91: High performance-chilled-water-systems ashrae-chicago

High PerformanceCondenser Water Pump Control – Variable? Pump speed limits Tower static lift

Tower nozzles (minimum flow)

Condenser minimum flow

Pump speed reductions result in Increased leaving condenser water

temperature

Decreased cooling tower effectiveness

Possible chiller surge

Page 92: High performance-chilled-water-systems ashrae-chicago

High PerformanceCondenser Water Pump Control – Variable? The condenser water pump is the hardest

place to properly utilize a variable frequency drive during operation

There are successful installations

Page 93: High performance-chilled-water-systems ashrae-chicago

variable-flow condenser waterPump Speed Determining minimum speed

Variable flow affects:Pump

Cooling tower

Chiller

Page 94: High performance-chilled-water-systems ashrae-chicago

condenser water pumpMinimum SpeedDeterminants:

Minimum condenser flow Tower static lift Minimum tower flowNozzle selection

Performance

Page 95: High performance-chilled-water-systems ashrae-chicago

reducing flow & fan speedEffect on System

100

syst

em p

ower

, kW

50

150

200

250

300

condenser water flow, %50 60 70 80 90 100

0

conditions:• 70% load• 50°F WB

fan speed

Page 96: High performance-chilled-water-systems ashrae-chicago

Varying fan and pump speed together

Page 97: High performance-chilled-water-systems ashrae-chicago

variable condenser water flowGuidance Can provide savings …Finding proper operating

points requires more time,more fine-tuning

Two-step process:1 Reduce design pump power

2 Is variable condenser-waterflow still warranted?

Page 98: High performance-chilled-water-systems ashrae-chicago

ROIHigh Performance Chilled Water Plants

EnergyPlus

Non-bin

Schematic tools that analyze in 30-45 minutes are available

Page 99: High performance-chilled-water-systems ashrae-chicago

High PerformanceChilled Water Plants Standard high performance

Reduced flow rates, increased ∆Ts

Variable primary flow

Advanced high performance Equipment capabilities

System configurations

System control

Page 100: High performance-chilled-water-systems ashrae-chicago

High performance chilled water plantWinchester Medical Center

Page 101: High performance-chilled-water-systems ashrae-chicago

Medical CenterWinchester, Virginia Five 750-ton chillers

0.571 kW/ton full load

Chilled water 58 to 42°F

Condenser water84 to 95°F(missed opportunity)

VFD’s

Variable primary flow

VFD’s on Chilled water pumps

Cooling tower fans

Condenser water pumps

Sophisticated control system with lots of Programming

Commissioning

Page 102: High performance-chilled-water-systems ashrae-chicago

Winchester Medical Center Working togetherOwner

Operators

Consulting engineer

Equipment provider

Controls provider

Service provider

Applications engineering

0.0

200.0

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1200.0

1400.0

8/8/20

03 14:3

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8/8/20

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8/8/20

03 12:3

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8/8/20

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30

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30

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03 17

:30

8/7/20

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8/7/20

03 15:3

0

Time/Date

Load

(ton

s)0.00

0.10

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0.60

0.70

0.80

Effi

cien

cy (k

W/to

n)

tonskW/ton

Page 103: High performance-chilled-water-systems ashrae-chicago

WMC - August 12Chiller plant

0.0

200.0

400.0

600.0

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1000.0

1200.0

1400.0

8/8/20

03 14:3

0

8/8/20

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8/8/20

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03 10:3

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8/8/20

03 5:30

8/8/20

03 4:30

8/8/20

03 3:30

8/8/20

03 2:30

8/8/20

03 1:30

8/8/20

03 0:30

8/7/20

03 23:3

0

8/7/20

03 22:3

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8/7/20

03 21:3

0

8/7/20

03 20:3

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8/7/20

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8/7/20

03 18:3

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8/7/20

03 17:3

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8/7/20

03 16:3

0

8/7/20

03 15:3

0

Time/Date

Load

(ton

s)

0.00

0.10

0.20

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0.40

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0.60

0.70

0.80

Effic

ienc

y (k

W/to

n)

tonskW/ton

Page 104: High performance-chilled-water-systems ashrae-chicago

WMC - Sept 1-7Chiller plant Weekly-Summary

0.0

200.0

400.0

600.0

800.0

1000.0

1200.0

1400.0

1600.01/

0/19

00 0

:00

1/0/

1900

0:0

01/

0/19

00 0

:00

1/0/

1900

0:0

01/

0/19

00 0

:00

9/1/

2003

14:

009/

1/20

03 1

9:30

9/2/

2003

1:0

09/

2/20

03 6

:30

9/2/

2003

12:

009/

2/20

03 1

7:30

9/2/

2003

23:

009/

3/20

03 4

:30

9/3/

2003

10:

009/

3/20

03 1

5:30

9/3/

2003

21:

009/

4/20

03 2

:30

9/4/

2003

8:0

09/

4/20

03 1

3:30

9/4/

2003

19:

009/

5/20

03 0

:30

9/5/

2003

6:0

09/

5/20

03 1

1:30

9/5/

2003

17:

009/

5/20

03 2

2:30

9/6/

2003

4:0

09/

6/20

03 9

:30

9/6/

2003

15:

009/

6/20

03 2

0:30

9/7/

2003

2:0

09/

7/20

03 7

:30

Time

Tons

0.00

0.10

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0.30

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0.50

0.60

0.70

0.80

kW/to

n

tonskW/ton

Page 105: High performance-chilled-water-systems ashrae-chicago

Winchester Medical Center - Mark Baker

“Please use our data, names, etc. We're proud of our facility!”

“By the way, we're now operating @ -0.20 kW/ton. The power company just sent us our 1st check. Ha..Ha…”

Page 106: High performance-chilled-water-systems ashrae-chicago

Remember...

Without controls,it’s not a system.Without controls,it’s not a system.

Page 107: High performance-chilled-water-systems ashrae-chicago

The meter is on the building!

Page 108: High performance-chilled-water-systems ashrae-chicago

It’s a great time to be in this business!