Chilled Water Optimization Class. Mike Smid - TEC Vice President Commercial Sales
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1 Chilled Water Optimization Class Mike Smid - TEC Vice President Commercial Sales
2 Agenda Objective Weather Determinants of Chiller Energy Consumption SPLV vs. IPLV The Life Cycle Point Questions
3 Objective Design and implement a chilled water system that reliably delivers real and verifiable energy savings, running under the operating conditions encountered in everyday life. Three Pillars: System Performance Optimize total energy (not sub components) System Reliability Under normal operating conditions Under stress Verifiable Energy Savings Accurate, appropriate metrics
4 Agenda Objective Weather Determinants of Chiller Energy Consumption SPLV vs. IPLV The Life Cycle Point Questions
5 Chicago Weather 24 x % of hours have less than 70 F entering condenser water Hours of Operation Ent. Cond Water (F) Ent Cond F F F <70 F <40 Dry Bulb (F) 0
6 Chicago Weather 12 x % of hours have less than 70 F entering condenser water Hours of Operation Ent. Cond Water (F) Ent Cond F F F <70 F <40 Dry Bulb (F) 0
7 Charlotte Weather 24 x 7 68% of hours have less than 70.4 F entering condenser water 7
8 Charlotte Weather 12 x 5 58% of hours have less than 70 F entering condenser water 8
9 Cooling Tower As the ambient wet bulb drops colder condenser water can be delivered to the chiller(s). VFD s on centrifugal chillers track the weather.
10 Agenda Objective Weather Determinants of Chiller Energy Consumption SPLV vs. IPLV The Life Cycle Point Questions
11 Chiller Efficiency Like pumps, chiller energy consumption is a function of mass flow and differential pressure. kw = Tons Lift Compressor Input kw ~ Mass Flow X Lift Compressor/Cycle Efficiency Load Chiller Cooling Tower
12 Compressor Work (Lift) 95F 85F For refrigerant to condense, it must be warmer than leaving condenser water. 95 F + 2F approach = 97F 44F 54F To boil, refrigerant must be colder than leaving chilled water. 44F 2F approach = 42F Refrigerant temperatures are based on leaving water temperatures!
13 Compressor Work (Lift) SCT SAT. LIQUID 97 Heat Rejection Pressure SST Reduced Lift Refrigerant Effect (Capacity) SAT. VAPOR 97 F / 120 PSI 82F / 90 PSI 42 F / 40 PSI Enthalpy Lower Lift = Less Work = Lower kw
14 Chiller Efficiency VFD Driven Chillers take advantage of lift and / or load reduction to reduce energy consumption. Mechanical unloading Variable speed unloading
15 Two Chiller Plant Staging Individual Chiller Load % Operating Hours 0 14% 20% 25% 31% 37% 43% 49% 56% 62% 68% 75% 81% 87% Total Building Load % Min Tower 55 F (12.8 C) ECWT 92% 100% Design Day 85 F (29.4 C) ECWT Distribution of ton-hours
16 Two Chiller Plant Efficiency VFD Driven Chillers take advantage of lift and/or load reduction to reduce energy consumption. Two chillers at 100% load each One chiller at 100% load
17 Agenda Objective Weather Determinants of Chiller Energy Consumption SPLV vs. IPLV The Life Cycle Point Questions
18 Agenda Objective Weather Determinants of Chiller Energy Consumption SPLV vs. IPLV The Life Cycle Point Questions
19 Performance Metrics Full Load, IPLV Full Load has two components: 100% load and design conditions. IPLV is a weighted average of four specific operating points. AHRI 550/590 IPLV % Load Weight Condition 100% 1% 44 F / 85 F 75% 42% 44F / 75 F 50% 45% 44F / 65F 25% 12% 44F / 65F ARI 550/590 section D2 states: The equation (IPLV) was derived to provide a representation of the average part load efficiency for a single chiller only. 19
20 Chicago Weather 24 x % of hours have less than 70 F entering condenser water Hours of Operation Ent. Cond Water (F) Ent Cond F F F <70 F <40 Dry Bulb (F) 0
21 Performance Metrics System based metrics SPLV (System Part Load Value) Actual Local Weather Load Profile Operating Hours Economizer Pump, Tower Energy Chiller Staging ARI 550/590 section D2 states: The equation (IPLV) was derived to provide a representation of the average part load efficiency for a single chiller only. However, it is best to use a comprehensive analysis that reflects the actual weather data, building load characteristics, operational hours, economizer capabilities and energy drawn by auxiliaries such as pumps and cooling towers, when calculating the chiller and system efficiency. This becomes increasingly important with multiple chiller systems because individual chillers operating within multiple chiller systems are more heavily loaded than single chillers within single chiller systems. 21
22 Chiller Staging Chicago Office Building 3 x 400 Ton Chillers: CH-1 (black), CH-2 (Yellow), CH-3 (Blue) % Bin 6 Minimum Building Load % 75% Bin 62.5% 50% Bin 37.5% 25% Bin 22
23 Performance Metrics 100% Building Load 1 Design Day Weather Fully Leased Fully Occupied Full Solar Load Full Equipment and Lighting Load Full Ventilation Rates 1 < 1% of the operating hours OR MAYBE NEVER Are the chillers sized to meet the building load exactly or were they maybe oversized just a little. 23
24 Performance Metrics 100% Chiller Load Design Leaving Chilled Water Design Entering Condenser Water No Low Delta T Syndrome! No safety factors when chillers sized Tubes fouled to AHRI selection level Assumes Chillers not oversized!!! 60F 70F 85F Far more ton-hours occur at points 3 and 5 than at point Variable speed chillers have better 100% load efficiency at points 3 and 5 due to lower lift. 24
25 Performance Metrics SPLV vs. IPLV Weighting significantly different. SPLV reflects multiple chiller plant staging SPLV reflects local condenser water temperatures 25
26 Performance Metric IPLV weighting issue (multiple chillers) IPLV (kw/ Ton) Single Chiller Plant Actual Plant Chiller A Chiller B Chiller C 100% % % % IPLV SPLV
27 75% Load The Life Cycle Point Worldwide Study 2,000 Ton Hotel, with (4) 500 Ton chillers
28 75% Load The Life Cycle Point Worldwide Study 2,000 Ton Hotel, with (4) 500 Ton chillers
29 75% Load The Life Cycle Point Carrier Worldwide Study 600 Ton Office, with (2) 300 Ton chillers
30 Back Up 30
31 System Based Decisions Chiller Staging 4 Steps to Optimize Chiller staging: Compare efficiency at the same temperatures. Compare the AHRI tolerance at the load points Compare the pump power consumption Consider the minimum evaporator flow rate 4 System Calculation (1) Chiller at 100% load, 65 F Condenser Water, no AHRI tolerance x 1.05% = (2) Chillers at 50% load, 65 F Condenser Water, no AHRI tolerance x 1.10% = Capacity (tons) 300 Chiller Savings 9 kw Condenser pump power (750 gpm x 30 ft wg) 6.8 kw Evaporator pump power (600 gpm x 20 ft wg)* 3.6 kw Extra pump power 10.4 kw Net Savings (per hour) -1.4 kw * Constant flow application, use minimum flow rate calculation for variable flow systems. Component Calculation (1) Chiller at full load * (2) Chillers at 50% load* Delta Capacity (tons) 300 Savings (per hour) 84 kw *Submittal data at 100% and 50% load is often based on two different condenser water temperatures leading to unintended calculation error. 31
32 Questions? 32
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