Chilled Water Systems

Jim Chmielewski HVAC Sales Manager

Emerson Control Techniques

Energy Opportunity Areas

Steam Generation
Steam Distribution
and Return

Compressed Air

Electric
Generation

Chilled Water

Electrical
Distribution

CW Systems General Info

In typical commercial buildings, water-cooled chilled water plants use a significant
amount of energy.
They account for between 10% and 20% of the overall facilities usage and serve
roughly one third of the commercial floor space.

Can consume more than 50% of electrical usage

Use approximately 20% of total electrical power generated in USA

US DOE estimates chillers expend up to 30% more energy through inefficiency

Chilled Water Systems

Chilled Water Systems are present in cooling
applications for air conditioning in commercial
buildings and process cooling for industrial
processes.

Chilled Water Systems

Chilled water is used in a variety of cooling
requirements:
Air conditioning
Refrigeration Systems
Process Cooling for manufacturing processes
Dehumidification systems

Chilled Water Systems

Proper control of the production and the distribution of that chilled
water presents large opportunities for savings

Chilled Water Systems

Why use water and not cool directly?
Water is an efficient medium to collect heat and is a liquid
from 32 F to 212 F (lower if mixed with a glycol solution).
Water is an inexpensive medium to use.
Water can be transported from place to place under
relatively low pressures.
Water is non-toxic and does not destroy the environment

Chilled Water Systems

-Chilled water is distributed by pumps which
follow the Affinity Laws:

Pump capacity is proportional to Pump speed

Pump head is proportional to the speed squared

Pump bhp is proportional to the speed cubed

Pump Application Desk Book

Second Edition (Paul N. Garay, PE)

Chilled Water Systems

Energy is wasted when a pump is run at full speed
and its output is modulated by using a valve.

Chilled Water Systems

Provide significant energy savings when:
Pumps are operated at low flow rates
System has low static head
Local electricity costs are high
Building codes (ASHRAE 90.1) require variable
speed chilled water pumps to meet the part load
efficiency requirements

Chilled Water Systems

Elimination of expensive valves and valve
controls
Reduces power surges and stress
associated with across the line starting
Provides accurate flow control
Longer Pump and seal life
Reduced wear
Less noise
A VSD is the BEST way to regulate flow to save
energy

Chilled Water

Air Conditioning in large

commercial buildings is
accomplished through the use
of chilled water distributed
throughout the building by
pumping systems .

Chilled Water

Air Conditioning:
In large commercial buildings the chilled water passes
through a coil that has air flowing across it and the air is
cooled as it moves across the chilled coil. Much like heat
is rejected through the radiator in your car

Chilled Water Pump

Chilled Water
In a primary/secondary chilled water pumping
system:
Refrigerant is used to cool water in a chiller. The flow of water
through the chiller is kept constant. Balancing valves are used to
optimize the flow and compensate for build up of scale on the
inside of piping and the tubes inside of the chiller.
The primary pumps produce a continuous flow and the secondary
pumps are speed controlled as space conditions call for more or
less cooling. Valves open and close to allow more or less water
to flow through cooling coils. As space temperatures become
satisfied the valves close causing the pressure to rise and the
pumps can be slowed down.

Chilled Water

HVAC primary/secondary chilled water system

Cooling Tower

Cooling Tower

Chilled Water

Control of temperature in a process is important to the

perfection of the product (Beer!)

Chilled Water
Refrigeration (food processing & cold storage)
Water or mixture of water and glycol is used to provide cooling
Some refrigerants used in food processing (such as ammonia) are toxic
and it is desirable to contain their use to non-occupied spaces. Water
is chilled by a compressor using this refrigerant to extract heat from
the water and then the water is transmitted to the space requiring
refrigeration.
Newer refrigerants that are more environmentally friendly operate
but they operate under very high pressures making it important that
they need not be transmitted all over a facility.

Chilled Water
- Process Cooling for manufacturing processes
plastic molds, die castings, semi-conductor
manufacturing
- Cooling is required to control the rate of heating or
cooling (accelerating it or decelerating it) in a
manufacturing process to maintain the integrity of the
finished product and/or to accelerate the process.

Chilled Water

Like many other processes, plastic extrusion requires a substantial amount of

cooling capacity. During processing, the plastic is heated, melted and
extruded through the die. It then must be cooled so that it will solidify into
its new shape. The faster the heat can be removed, the faster the extrusion
line can run. For this reason, rapid heat transfer is crucial to plant efficiency
and profitability.

Chilled Water Systems

A Typical Plant Operating Situation

A plastic container manufacturer has 9 plastic extrusion lines.

Chilled water is provided to each extruder from 1-75 pump.
The pressure at the extruder, the longest distance from the
pump must be maintained at 65 psi for proper operation.
The chilled water system is design for all extruders to be able to
operate.
Flow rate at each extruder is optimized to maximize production

Chilled Water Systems

A Typical Plant Operating Situation

Chilled Water

The above is an example of a facility having 16 plastic

extruders and the initial cost and operating costs of a chilled
water system versus a small portable chiller for each extruder

Chilled Water
- Dehumidification systems use chilled water to
extract moisture from the air in a conditioned
space.
- Control of humidity is important to prevent static build up,
prevent mold, maintain the integrity of the product being
stored.
- Swimming pools
- Libraries
- Plastic webs

Chilled Water

In high humidity environments such as swimming pools, control of humidity is important .

First high humidity results in condensation in or on the
structure, which can lead to rapid deterioration of structural elements
and finish materials and the way humidity is controlled can affect the amount of energy your
facility uses.
Secondly, high humidity
can result in uncomfortable conditions.

Efficiency Improvements (Cooling Tower)

Cycling
Two Speed Motors and Controls
Variable Speed

Example:
Annual Operating Cost (50 HP Cooling Tower Fan @ $0.10 kwhr, 365 days per year)
cycled on and off 20 hrs on 4 hrs off $28,752
Two speed - 12 hrs full speed, 12 hrs speed $19,714
Variable Speed (24 hrs over continuous load profile) $7,580

Efficiency Improvements (Pumps)

Pump Cycling
Pump Throttling
Variable Speed

Example:
Annual Operating Cost (50 HP Pump @ $0.10 kwhr, 365 days per year)
Pump Cycling 20 hrs on 4 hrs off - $28,752
Pump Throttling - $24,997
Variable Speed (24 hrs over continuous load profile) - $7,580

Efficiency Improvements (Chillers)

Compressor Cycling
Compressor Modulation with a slide valve
Variable Speed Compressor
Example:
Annual Operating Cost (50 HP Compressor @ $0.10 kwhr, 365 days per year)
Compressor cycled (on 20 hrs off 4 hrs) - $28,752
Constant speed compressor with slide valve 24 hrs on - $27,505
Variable Speed (24 hrs over continuous load profile averaging 75% speed) $25,786
*Variable Speed Energy Savings are minimal but optimal control of temperature and
reduced maintenance and wear due to less frequent starting and stopping are benefits

Cliff Notes for CW Energy Savings

Operate Chillers, Cooling Towers and Pumps at their peak efficiencies
Optimize temperatures and flow rates to operate equipment at peak
efficiencies.
Check refrigerant pressures to minimize leaks.
Clean chiller tubes, cooling towers and keep water free of
contaminants. Scale, corrosion and deposits can impede heat
transfer and create resistance to flow.
Consider:
Variable Speed Drives to operate equipment at lower speeds when
requirements are less than peak to optimize overall efficiencies.
Using power during off peak times if rate structures allow. Ice
storage can sometimes be justified if off peak rates are favorable.

Questions?