Chiller Optimization

POWERFUL BUSINESS
Facing a Dynamic Energy Future
CHILLED WATER SYSTEM OPTIMIZATON

Presented by David A. Rogers, P.E Harold A. Hougham, P.E.
ENGINEERING APPLIED TO OPERATIONS (Retro Commissioning)
THE CONCEPT SYSTEM FUNDAMENTALS THE PROCESS THE RESULTS
THE CONCEPT
SYSTEM FUNDAMENTALS

THE THREE RULES FOR HYDRONIC SYSTEMS OPTIMIZATION
PUMP LESS WATER PUMP LESS WATER PUMP LESS WATER
Distribution System DELTA T Drives the Plant (s)
Syllabus
Systems Concepts Simple Formulas Rules of Thumb System Configurations Hydraulic Profile System Components Delta T Flow Limited Plant How your System works Now/Optimized
Systems Concepts
A system is a group of components that when connected and operating provide a desired result.
Systems Concepts
Production Distribution Load
Systems Concepts
Pumps Chillers
Pumps Load
Cooling Tower
Systems Concepts
Chilled Water System
Secondary Pumps Chillers
Data & Controls Production System

Decoupler
Distribution System
Load
Primary Pumps
Simple Formulas
Chilled Water Delta T = T return water - T supply water GPM/TON = 24/Delta T Pump Affinity Laws = Q1/Q2=N1/N2 H1/H2=(Q1/Q2)2 BHP1/BHP2=(Q1/Q2)3 Q = Flow, N = rpm, H = Head BHP = Brake Horsepower
Simple Formulas
Chilled Water Delta T
Control Valve
CHWR T = 60oF
Cooling Coil
CHWS T = 42oF
Chilled Water Delta T = T return water T supply water Chilled Water Delta T = 60 42 = 18 degrees.
Simple Formulas
GPM/Ton = 24/Delta T
How many tons of cooling are served by a 6,000 gpm/12 degree delta T distribution system?
GPM = 6,000
Delta T = 12 degrees 24/Delta T = 24/12 = 2 GPM/Ton Tons Cooling = GPM/(24/Delta T) = 6,000/2 = 3,000 tons
HOW MANY CHILLERS DO I HAVE ON LINE TO SERVE THIS 3000 TON LOAD?
Simple Formulas
Pump Affinity Laws
Pump Affinity Laws can be used to estimate system performance but should be modified to reflect system performance. What is the approximate required pumping horsepower if I cut system flow in half while still serving the same cooling load?
10,000 GPM requires 240 BHP 5,000 GPM requires ? BHP. Q1 = 10,000 GPM, Q2 = 5,000 GPM, BHP1 = 240 BHP2 = BHP1(Q2/Q1)3 or BHP2 = 240(5,000/10,000)3 = 240/8 30 BHP
Rules of Thumb
Water Always Flows from a Higher Pressure to a Lower Pressure. Minimum Delta P for a control valve = 5 psig Minimum Delta P for a Bldg Interface = 20 psig Distribution System Delta T should always be Production System Delta T Production System Delta T should always be < Chiller Delta T
Rules of Thumb
Minimum Delta P Across a Control Valve is 5 psig
Control Valve
P3= 11 psig
P1= 18 psig
Cooling Coil
Delta P = 18 11 = 7 psig
WHAT HAPPENS IF DELTA P IS ZERO?
Rules of Thumb
Minimum Delta P Across a Building Interface is 20 psig
Pressure Compensating Control Valve
Pout= 18 psig Building Pin= 40 psig Delta P = 40 18 = 22 psig
WHAT HAPPENS IF DELTA P IS 10 PSIG?
Rules of Thumb
Distribution System Delta T should always be Production System Delta T
TPS=42oF
Chillers Secondary Pumps
TDS=42oF
Production System
TPR=56oF
Primary Pumps
Distribution System
TDR=58oF
Load
Distribution Delta T = 58 42 = 16 degrees Production Delta T = 56 42 = 14 degrees

Production System Delta T < Distribution System Delta T
Rules of Thumb
Load in Tons 2000 1800 1600 800
Chiller % Load 100 90 80 40
Production CHWR 58 56.4 54.8 48.4
Production Delta T 16 14.4 12.8 6.4
Distribution Delta T CHWR 58 58 58 58 16 16 16 16
Rules of Thumb
Production System Delta T should always be < Chiller Delta T

0.75
0.7
0.65 KW/Ton CHILLER 3 CHILLER 4&5 CHILLER 6&7 0.6
0.55
0.5 20 30 40 50 60 % Full Load 70 80 90 100
System Configurations
Primary/Secondary Constant Flow/Variable Flow Primary Only Constant Flow Variable Primary Flow (VPF) Variable Flow Multiple Plants/Common Distribution Loop Plant 1 Primary/Secondary Plant 2 Primary Only Plant 3 Primary/Secondary
Primary/Secondary
Constant Flow/Variable Flow
Production System
Distribution System
Load
Primary Pumps
Primary Only
Constant Flow
Production System
Distribution System
Load
Primary Pumps
Variable Primary Flow

Variable Flow
Chillers
Production/ Distribution System Production/ Distribution Pumps

Load
Multiple Plants on a Common Distribution Loop
Hydraulic Profile
A graphical representation of the dissipation of system head.
Ft of Head
Distance
Hydraulic Profile
Primary/Secondary System
Ft of Head
Hydraulic Profile
Two Plants Common Distribution Loop
Ft of Head
Hydraulic Profile
The Hydraulically Most Remote Point
Hydraulically most remote point & location of VFD DP sensor
Ft of Head
Physically most remote point
Distance
Hydraulic Profile
Building System/Hydraulically Most Remote Point
Ft of Head
System Components
Chillers Cooling Towers Pumps Control Valves/Cooling Coils
Chillers/Cooling Towers
Chiller Performance
COP = Output/Input COP = Q4-1/W1-2 Q2-3 = m(h2 h3) Point 3 Pressure = C Point 2
Pressure
h3 = h4 LIFT Q4-1 = m(h4 h1) Pressure = C Point 4 Temperature = C W1-2 = m(h2 h1) Point 1 Compressor Work
P-1
Enthalpy
Cooling Tower Performance

Entering Condenser Water 95 degrees Range 95 85 = 10 degrees
Leaving Condenser Water 85 degrees
Outside Air Wet Bulb Temperature 76 degrees
Approach 85 76 = 9 degrees
Cooling Tower Performance

2.5 2.0
Tower Size Factor
Constants Heat Load Range Wet Bulb
1.5
1.0
0.5 5 10 15 20 25 30
Approach
Pumps
How They Work Arrangements
Pumps How They Work
Pumps How They Work

B C A Pressure Inlet Tip of Impeller Vane Centrifugal Pump A B C Outlet Tip of Impeller Vane
Velocity
Suction Flow Path
Discharge
Pumps How They Work

NPSH = Net Positive Suction Head
B C A Pressure B C Outlet Tip of Impeller Vane
Centrifugal Pump
Collapsing Bubbles Vapor Bubbles
x x x x
Velocity
Suction Pump Impeller Blade Flow Path
Discharge
Pumps How They Work

Typical Pump Curve
Pumps How They Work

Variable Frequency Drives
Pumps How They Work

Variable Speed Pump Curves
Pumping Arrangements
Head Ft.
Head Ft.
Cooling Coil/Control Valve

Configurations How They Work

Configurations
CONTROL VALVE
CHWR 56+ degrees Leaving Air 55 degrees Delta T: 56 42 = 14 degrees COOLING COIL CHWS 42 degrees
Entering Air 70 degrees

How They Work Control Valves Waste Energy
Ft of Head

How They Work
Actuator Arm Connected to the Valve Shaft
Valve Shaft
Valve Disc Not Fixed
FLOW Valve Seat Fixed

How They Work
Delta T
Difference between CHW Return & CHW Supply and Chilled Water Supply Temperatures Delta T = TCHWR - TCHWS Q = C x GPM x Delta T For the same Q if delta T is low then GPM is high & if delta T is high then GPM is low! 5,000,000 Btuh = C x 1000 gpm x 10 F = C x 500 gpm x 20 F
CHILLED WATER SYSTEM OPTIMIZATON Low Delta T / Flow Limited Plant

2,000 Ton Chillers, 14 degree Secondary Pump P-2, delta T, 3,429 gpm each Variable Flow
Chiller
42 degree CHWS Load Typical
Chiller
Chiller
Distribution Loop Production Decoupler Loop
Pressure Compensating Valve Typical
Load in Tons 2000 2000 2000 2300
Production Gpm 3429 6858 6858 10287
On Line Tonnage (1)2000 (2)4000 (2)4000 (3)6000
Percent Loaded 100 50 50 38.3
Distribution Gpm 3429 4000 6000 6900
Distribution CHWR 56 54 50 50
Dist. Delta T 14 12 8 8
Delta T Flow Limited Plant

CENTRIFUGAL CHILLER EFFICIENCIES
0.75 0.7
0.65 KW/Ton CHILLER 3 CHILLER 4&5 CHILLER 6&7 0.6
0.55
0.5 20 30 40 50 60 % Full Load 70 80 90 100
CHILLED WATER SYSTEM OPTIMIZATON Delta T Flow Limited Plant

Estimated Annual Part Load Chiller Savings due to Increased Efficiency for non Flow Limited Operations
Flow limited average kw/ton = 0.55 Non flow limited average kw/ton = 0.523 Annual average part load = 2000 tons Annual part load hours of operation = 8,000 Cost of electricity including demand = $0.14 Estimated annual part load chiller savings due to increased efficiency of operation = (0.55-0.523)(2000)(8000)(0.14) = $60,480
CHILLED WATER SYSTEM OPTIMIZATON High Delta T / Full Load Plant

2,000 Ton Chiller, 14 degree Secondary Pump P-2, delta T, 3,429 gpm Variable Flow
Chiller
42 degree CHWS Load Typical
Production Loop Decoupler
Distribution Loop
Pressure Compensating Valve Typical
Load in Tons 2000 2000 2000
Production Gpm 3429 3429 3429
Production CHWR 56 56 56
Percent Loaded 100 100 100
Distribution Gpm 3429 3000 2667
Distrib. CHWR 56 58 60
Dist. Delta T 14 16 18
CHILLED WATER SYSTEM OPTIMIZATON High Delta T / Part Load Plant
Load in Tons 2000 1800 1800 1600
Production Gpm 3429 3429 3429 3429
Production CHWR 56 54.6 54.6 53.2
Percent Loaded 100 90 90 80
Distribution Gpm 3429 2700 2400 1920
Distrib. Gpm 56 58 60 62
Dist. Delta T 14 16 18 20
CHILLED WATER SYSTEM OPTIMIZATON Chilled Water Cost Variables

Variables Average Annual Cooling Load Electric Chiller/Tower/Condenser & Production Pumps Absorption Chiller/Tower/Condenser & Production Pumps Distribution System Delta T Cost of CHP Electrical Power Power Factor Pump Efficiency Pump Design Flow Pump Design Head Pump Hp Electric Chiller Capacity Absorption Chiller Capacity Number of Electric Chillers Number of Absorption Chillers Electric Chillers Absorption Chillers 4,500 0.9 0.3 11 $0.065 0.9 0.87 15000 155 750 2000 1385 1 2 12 16 Tons Kw/Ton Kw/Ton Degrees F $/Kwh Constants Flow 500 Ton 12000 Btuh Power 0.746 Kw/Hp Max Speed 60 Hz GPM/Ton 24 System Curve Constant 0.8 MM 1,000,000
GPM Ft Hp Tons Tons
Assumptions Absorption Chillers are always lead chillers Electrical Cost includes all byproduct burdens Building Pumping is not considered a CHP operatio
Delta T Delta T Costs not Included
Calculations Distribution Flow Distribution Pump Hp each Distribution Pumping Kw each Absorption Chillers Operating Electric Chillers Operating Number of Distribution Pumps Running Percent rpm each pump Annual Average Cost of Cooling Electric Chillers Flow Absorption Chillers Flow 9818 GPM 210 Hp 200 Kw Capital Funding Sinking Funds Administrative
Load 2 1
Flow 2 2
1 65% $5.57 $/MMBtu 4000 GPM 2078 GPM
How does your System work Now ?

Existing Distribution System Maximum Delta T = ?? degrees Existing Distribution System Average Delta T = ? degrees Chillers Staging? System Pumping Energy Optimized or not Optimized? (Control Delta P)
How should your System work when Optimized?

Optimized Maximum Delta T = ?? degrees Optimized Average Delta T = ?? degrees Chillers Staging ?? System Pumping Energy Optimized or not Optimized ??
THE PROCESS

Step #1
Chilled Water Systems Questionnaire for Initial System Evaluation
SYSTEM DATA ROI

Step #2
Pre Project Staff Training

Step #3 Pre Project Measurement & Verification (M&V)
Data Historian/Sensors Project ?
BEFORE
AFTER

Step #4
Chilled Water System Engineering Evaluation & Analysis

750 HP; 14,000 GPM; 8o T;
800 700 600 500 400 300 200 100 0
22 24 10 12 14 16 18 20 8
Pumping HP
System Delta T

Step #5 Report of Findings and Recommendations
ROI

Step #6 Implement Chilled Water System Optimization Construction Project

Step #7 Commission Chilled Water System Optimization Project

Step #8 Post Project M&V for Rebate Verification
BEFORE
AFTER

Step #9
Post Project Staff Training
THE RESULTS
The University of California Davis Medical Center, Sacramento
UCDMC
1. 3,000,000 square feet Trauma Center/Hospital/Clinic & Educational Buildings. 2. 26 MW CHP w/ Primary/Secondary 16 degree plant serving a 12 degree campus. 3. Each building was decoupled and pumped. 4. Average distribution system delta T was 8 degrees. Maximum delta T was 11 degrees.
Results
Operations
1. 18 degree distribution system delta T w/ 114 degrees outside air temperature. 2. Central plant spare distribution pump and chiller capacity. 3. Some buildings performing in excess of 20 degree delta T. 4. Average system delta T is 12 degrees.
Results
Financial
1. Financial data not available due to lack of system instrumentation.
Energy
2. Energy data not available due to lack of system instrumentation.
Lessons Learned
1. Create a system optimization sensor project to facilitate data acquisition for pre & post project M&V. 2. Provide pre project staff/management training to facilitate a coordinated effort for all parties. 3. Develop a detailed Site Acceptance Test for control valve commissioning.
BIOTECHNICAL CORPORATION
Biotechnical Corp
1. 3,000,000 square feet of R&D, Office & Production across 25 buildings. 2. Three Central Plants on common distribution loop, 14,100 ton installed capacity. 3. Delta T performance was 6 degrees part load and a maximum of 11 degrees at full load. 4. A 14 degree campus.
Results
Operations
1. Achieving distribution loop 20 degree Delta T @ full and part load. 2. Maximum flow distribution pumping requires 3 and not 4 operational pumps 3. Delayed major capital infrastructure expansion project for 3 years due to optimizing use of existing infrastructure.
Results
Financial
1. Financial data not available due to lack of system instrumentation.
Energy
1. Energy data not available due to lack of system instrumentation.
Lessons Learned
1. Discovered other system issues that were masked by poor system performance; Damper Failures, Sensor Calibration, etc. 2. Train installing controls contractor on Systems Optimization Concept and Process. 3. Verify AHU isolation valve arrangement and function prior to issuing contract requiring continued system operation during construction.
The University of Iowa Hospital and Clinics
UIHC
1. 4,000,000 square feet of contiguous hospital/clinic space between five buildings. 2. Central Plant metered and billed for each building. 3. Each building is decoupled and pumped.
Results
Operations
1. Resolved low chilled water pressure & flow to Operating Room Air handlers. 2. Resolved condensation issue on cooling panel ceilings in patient rooms. 3. Removed tertiary building pumps and reduced operation of building pumps
Results
Financial
1. Savings $2,800,000 for the last 2 cooling seasons primarily from penalty reduction. 2. Chilled Water billing based on building flow and an assumed Delta T of 16 Degrees.
Results
Energy
1. Original simple payback estimate 5 years. 2. System instrumentation was not adequate to measure actual energy reduction.
Lessons Learned
1. Building system instrumentation not adequate to provide M&V for energy consumption. 2. Building system energy savings and production/distribution billed savings are not the same number. 3. Production/distribution system billed savings represented a simple payback of less than 9 months.
dave@ra-solutions.com harold@ra-solutions.com www.ra-solutions.com

Chiller Optimization

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POWERFUL BUSINESS

Facing a Dynamic Energy Future

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

ENGINEERING APPLIED TO OPERATIONS (Retro Commissioning)

CHILLED WATER SYSTEM OPTIMIZATON

THE CONCEPT SYSTEM FUNDAMENTALS THE PROCESS THE RESULTS

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

Distribution System DELTA T Drives the Plant (s)

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

Data & Controls Production System

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

WHAT HAPPENS IF DELTA P IS ZERO?

CHILLED WATER SYSTEM OPTIMIZATON

Pout= 18 psig Building Pin= 40 psig Delta P = 40 18 = 22 psig

WHAT HAPPENS IF DELTA P IS 10 PSIG?

CHILLED WATER SYSTEM OPTIMIZATON

Distribution Delta T = 58 42 = 16 degrees Production Delta T = 56 42 = 14 degrees

CHILLED WATER SYSTEM OPTIMIZATON

Load in Tons 2000 1800 1600 800

Chiller % Load 100 90 80 40

Production CHWR 58 56.4 54.8 48.4

Production Delta T 16 14.4 12.8 6.4

Distribution Delta T CHWR 58 58 58 58 16 16 16 16

CHILLED WATER SYSTEM OPTIMIZATON

Production System Delta T should always be < Chiller Delta T

0.65 KW/Ton CHILLER 3 CHILLER 4&5 CHILLER 6&7 0.6

0.5 20 30 40 50 60 % Full Load 70 80 90 100

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

Variable Primary Flow

Production/ Distribution System Production/ Distribution Pumps

CHILLED WATER SYSTEM OPTIMIZATON

Multiple Plants on a Common Distribution Loop

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

Physically most remote point

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

CHILLED WATER SYSTEM OPTIMIZATON

Cooling Tower Performance

Leaving Condenser Water 85 degrees

Outside Air Wet Bulb Temperature 76 degrees