AR No. # - Refrigeration Discharge Pressure

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1 AR No. # - Refrigeration Discharge Pressure Recommendation Lower the minimum ammonia condensing (discharge) pressure on the refrigeration compressors to 100 psig (63.5 F) to decrease refrigeration system energy cost by 13%. Source Electrical Consumption Total Annual Summary Quantity Units 169,640 kwh (site) MMBtu Cost $8,482 $8,482 Implementation Cost Summary Description Cost Payback Implementation Cost $0 0.0 Facility Background The facility currently uses (insert compressor information here). During the site assessment, facility personnel explained (compressor operating conditions). (Talk about current set points). Motor information was collected for each system and is summarized in the following Motor Analysis Tool page. Technology Background Refrigeration discharge temperature is determined by the condenser's capacity to reject heat. When the condensing pressure goes below a minimum pressure setting, selected by operators, condenser fans turn off. This reduces condenser capacity and prevents the temperature and associated pressure from going below the set point. Compressors require less energy to operate against low discharge pressures, but to reduce this discharge pressure, the condenser fans must operate more frequently. As condenser fans typically use significantly less energy than the compressor, reducing compressor use can lead to significant energy savings. Reducing compressor discharge pressure saves approximately 1% of compressor energy consumption for each degree Fahrenheit reduction of condensing temperature. Proposal Adjust your minimum discharge pressure set points to 100 psig (63.5 F). Completing this procedure can be done in regular working hours by maintenance personnel so there are no implementation costs. If implemented, the recommended actions will save 169,640 kwh annually and result in an annual cost savings of $8,482 with an immediate payback. Operating Profile

2 Condensing Temperature ( F) AR No. # - Refrigeration Discharge Pressure Operating Profile Current Proposed Wet Bulb Temperature ( F) Notes Often there are specific applications that drive the need for high pressure set points. Below is a list of four common reasons for having such set points and how they can be fixed. 1. Liquid Injection Cooling typically consumes 5-15% of the compressor power to recompress injected refrigerant and is used to cool the compressor. Install thermosyphon oil cooling to avoid power and energy costs associated with liquid injection oil cooling. Thermosyphon cooling does not consume compressor power. 2. Expansion Device Design can lead to higher required discharge pressures. By looking into different designs, having your system evaluated and selecting components that operate well with lower discharge pressure, the efficiency of your refrigeration system can be improved. 3. Moving Refrigerant to Distant Endpoints can lead to a need for higher discharge pressures to ensure refrigerant can reach its destination. By installing liquid pumps in the system, discharge pressure can be reduced while still serving the entire refrigeration system. 4. Hot Gas Defrost is sometimes used to defrost evaporators as needed and requires a high discharge pressure. We suggest only raising the discharge pressure when needed for hot gas defrost and letting the discharge pressure drop lower otherwise, or using another defrost strategy such as applying warm process water. Check to make sure your facility does not require high pressure set points for special applications before making alterations to your process or equipment. Based on Data Collection Author Orange Team Review Black Team Review Unmodified Template Insert Name Insert Name Insert Name Insert Name Insert Name

3 General Data Equations Refrigeration System Data Eq. 1) Current Approach Temperature (T AC ) Refrigerant Type Ammonia (N. 1) Condenser Type Evaporative (N. 1) Condenser Fan Control Type On-Off (N. 1) Operating Hours (t h ) 8,760 hrs./yr. (N. 1) Current Set Points Minimum Discharge Pressure (p DC ) psig (N. 1) Minimum Discharge Temperature (T DC ) 84.3 F (N. 2) Notes Incremental Energy Data Incremental Electricity Cost (IC E ) $ /kwh (Rf. 1) Assumptions Proposed Set Points Minimum Discharge Pressure (p DP ) psig (N. 3) Minimum Discharge Temperature (T DP ) 63.5 F (N. 2) Proposed Condenser System Data Condenser Fan Control Type Proposed Approach Temperature (T AP ) 15.0 F (N. 4) VSD Efficiency (η VSD ) 97.0% (Rf. 2) Compressor Compressor Energy Factor (F %S ) 1.0% / F (Rf. 3) Condenser Approach Analysis Discharge Temperature Minimum Discharge Pressure (p DM ) psig (N. 5) Measured Discharge Temperature (T DM ) 78.2 F (N. 2) Weather Readings Dry Bulb Temperature (T DB ) 71.1 F (N. 6) Wet Bulb Temperature (T WB ) 57.2 F (N. 6) Approach Temperature Minimum Approach Temperature (T AC ) 21.0 F (Eq. 1) References VSD Rf. 1) Incremental energy costs developed in the Utility Analysis located in the Site Data section. Rf. 2) VSD efficiencies are assumed by analysts based on Motor Tip Sheet #11, June 2008, USDOE, Industrial Technologies Program, Energy Efficiency and Renewable Energy. Rf. 3) Compressor energy savings factor from Industrial Refrigeration Best Practices Guide, Cascade Energy Engineering, December 2004 If evaporative condenser T DM DM T WB If air cooled condenser T T DB N. 1) Refrigeration system information collected on-site during the assessment, for more details see Site Reports in the Site Data section. N. 2) Corresponding temperature for the specified pressure and refrigerant type from thermodynamic tables. N. 3) Proposed minimum discharge pressure is assumed to be the same as the measured minimum discharge pressure achieved during assessment. N. 4) Proposed approach temperature is assumed the same as current approach temperature. N. 5) Minimum discharge temperature difference determined by observing the system under typical loading conditions with all heat exchanger fans running at full-power. N. 6) Dry bulb and wet bulb temperatures measured on-site at the same time minimum discharge pressures were measured.

4 Energy Use Summary Equations Current Conditions Eq. 2) Total Energy Consumption (E TC,TP ) Compressor Energy Consumption (E CC ) 1,203,324 kwh (Rf. 4) E E Fan Energy Consumption (E FC ) 94,065 kwh (Rf. 4) Eq. 3) Total Energy (E TS ) Total Energy Consumption (E TC ) 1,297,390 kwh (Eq. 2) ETC ETP Proposed Conditions Eq. 4) Cost (C S ) Compressor Energy Consumption (E CP ) 991,721 kwh (Rf. 4) ETS ICE Fan Energy Consumption (E FP ) 136,029 kwh (Rf. 4) Eq. 5) Power Draw (P CC,FC ) Total Energy Consumption (E TP ) 1,127,750 kwh (Eq. 2) WR LF kw M 1 hp Total Energy (E TS ) 169,640 kwh (Eq. 3) Eq. 6) Energy Consumption (E CC ) PCC th UF Economic Results Eq. 7) Discharge Temperature (T DC,DP ) If evaporative condenser Cost (C S ) $8,482 /yr. (Eq. 4) Implementation Cost (C I ) $0 (N. 7) Payback (t PB ) 0.0 years Notes N. 7) There is no implementation cost associated with plant personnel adjusting the refrigeration system discharge pressure. References Rf. 4) Current and proposed energy consumption values developed analysis table on following pages. Rf. 5) Motor load factor developed in the previous Motor Analysis Tool (MAT) pages. Rf. 6) Weather bin data is processed using the DOE2 tool and TMY3 data from the National Solar Radiation Data Base. CC, CP FC, FP max T T, T WB AC, AP DC, DP If air cooled condenser max T T, T DB AC, AP DC, DP Eq. 8) Degree Hour (H S ) Eq. 9) Percent (E %S ) 1 year HS F% S 8,760 hrs Eq. 10) Compressor Energy (E CS ) Eq. 11) Energy Consumption (E FC ) P FC t Eq. 12) Fan Use Factor (U FC,FP ) Eq. 13) Fan Energy Consumption (E FC,FP ) Eq. 14) Fan Energy (E FS ) T T t DC DP BIN E E CC FT FC, FP BIN FC E % S If evaporative condenser T ( T T ) AC, AP DC, DP WB If air cooled condenser T ( T T ) AC, AP DC, DP DB If on off fan control E U t 8,760 hrs If VSD fan control E U t 8,760 hrs 3 FT FC, FP VSD BIN h E FP

5 Compressor Description Compressor #1 Compressor Energy Analysis Rated Power Efficiency Load Factor Usage Power Draw Energy Usage (W R ) (N. 1) (η M ) (N. 1) (LF) (Rf. 5) (UF) (N. 1) (P CC ) (Eq. 5) (E CC ) (Eq. 6) (hp) (kw) (kwh) % 70.0% 100.0% ,203,324 Totals ,203,324 Weather Bin Data Dry Bulb Wet Bulb Hours Compressor Summary Current Proposed Discharge Discharge Degree Hour Percent Compressor (T DB ) (Rf. 6) (T WB ) (Rf. 6) (t BIN ) (Rf. 6) (T DC ) (Eq. 7) (T DP ) (Eq. 7) (H S ) (Eq. 8) (E %S ) (Eq. 9) (E CS ) (Eq. 10) ( F) ( F) (hrs./yr.) ( F) ( F) ( F-hrs.) (kwh) % % % % % % % 1, , % 2, , % 4, , % 7, , % 14, , , % 24, , , % 38, , , % 40, , , % 33, , % 21, , % 12, , % 4, , % 1, % % % % % % 0 Totals 8, , % 211,604

6 Condenser Description Condenser # 1 Condenser Fan Energy Analysis Quantity Rated Power Efficiency Load Factor Power Draw Energy Usage (Q FM ) (N. 1) (W R ) (N. 1) (η M ) (N. 1) (LF) (Rf. 5) (P FC ) (Eq. 5) (E FT ) (Eq. 11) (hp) (kw) (kwh) % 90.0% ,713 Totals ,713 Weather Bin Data Dry Bulb Wet Bulb Hours Condenser Fan Summary Current Fan Proposed Current Fan Use Fan Use Energy Proposed Fan Energy Fan (T DB ) (Rf. 6) (T WB ) (Rf. 6) (t BIN ) (Rf. 6) (U FC ) (Eq. 12) (U FP ) (Eq. 12) (E FC ) (Eq. 13) (E FP ) (Eq. 13) (E FS ) (Eq. 14) ( F) ( F) (hrs./yr.) (kwh) (kwh) (kwh) % 100.0% % 100.0% % 100.0% % 100.0% % 100.0% % 100.0% 1,501 1, % 100.0% 2,843 2, % 100.0% 4,143 4, % 100.0% 5,574 6,646-1, % 100.0% 7,183 9,268-2, % 100.0% 10,492 14,566-4, , % 100.0% 13,164 20,210-7, , % 100.0% 14,597 25,272-10, , % 100.0% 13,244 25,527-12, , % 89.7% 9,881 15,468-5, % 76.6% 5,742 6, % 64.8% 3,100 2, % 56.1% 1, % 49.5% % 44.3% % 40.1% % 37.3% % 34.2% % 32.1% % 29.4% Totals 8,760 94, ,029-41,964

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