We hold these truths to be

self-evident, that all men are

created equal..

July 4, 1776

February 8, 2006

1
The rights of citizens of the United States
to vote shall not be denied or abridged by
the United States or by any state on
account of race, color..

15th amendment 1870

February 8, 2006

2
The rights of citizens of the United States
to vote shall not be denied or abridged by
the United States or by any state on
account of sex..

19th amendment 1920

February 8, 2006

3
Don Eppelheimer, PE
Senior Applications Engineer

The Trane Company

3600 Pammel Creek Road
La Crosse WI 54601

deppelheimer@trane.com

February 8, 2006

4
Best Practice is..

supply air temperature ?

chilled water temperature ?
water to cooling tower ?

February 8, 2006

5
Best Practice is..

supply air less than 50 F

chilled water less than 40 F
water to tower greater than 100 F
integrated control

February 8, 2006

6
 Best Practice is.. new?

cold air

February 8, 2006

7
 Best Practice is..

cold air
Electric Power Research Institute

1985

February 8, 2006

8
Best Practice is..

38 F chilled water

February 8, 2006

9
Best Practice is..

38 F chilled water
Trane Company 1972

February 8, 2006

10
Best Practice is..

2 gpm per ton cooling tower

February 8, 2006

11
Best Practice is..

2 gpm per ton cooling tower

Du Pont Chemical 1978

February 8, 2006

12
Annual Chiller Plant Energy Consumption

1972 2006

18%
26%
9% 17%

COP 4.0
73% COP 7.0
57%

Chiller
Cooling Tower
Water Pumps February 8, 2006

13
The largest energy consumer
is not the largest
energy waster.

February 8, 2006

14
Flow Rates and Temperatures

94.3F 44F

85F

54F
ARI
conditions
evaporator 2.4 gpm/ton
flow rate
condenser
flow rate 3.0 gpm/ton

February 8, 2006

15
Flow Rates and Temperatures

94.3F 44F 98.9F 41F

85F 85F

54F 57F

ARI
conditions Applied conditions
evaporator 2.4 gpm/ton evaporator 1.5 gpm/ton
flow rate flow rate
condenser condenser
3.0 gpm/ton 2.0 gpm/ton
flow rate flow rate

February 8, 2006

16
Cooling Tower Capital Cost

Cooling tower capital cost is a function

of total rejected heat

Cooling towers are sized by ton of

cooling capacity

February 8, 2006

17
1200 ton chiller
Cooling Tower Cost

4 cells
17 x 36 ft
58,800 lbs

February 8, 2006

18
1200 ton chiller
Cooling Tower Cost

4 cells
3600 gpm 17 x 36 ft
58,800 lbs

2 cells
2400 gpm
20 x 24 ft
44,500 lbs

1800 gpm 2 cells

12 x 22 ft
36,600 lbs
February 8, 2006

19
Cooling Tower Capital Cost

Cooling tower capital cost is not a

function of chiller capacity

February 8, 2006

20
Cooling Tower Capital Cost

Cooling tower capital cost is not a

function of chiller capacity

Cooling towers are sized by the

quantity of water they process

February 8, 2006

21
Cooling Tower Capital Cost

February 8, 2006

22
Cooling Tower Energy Cost

Cooling tower annual energy

consumption is a function of the total
amount of heat rejected

Cooling tower energy is a function of

chiller load

February 8, 2006

23
1200 ton chiller
Cooling Tower Cost

4 cells
120 hp

February 8, 2006

24
1200 ton chiller
Cooling Tower Cost

4 cells 95/85/78
3600 gpm 120 hp

4 cells
100 hp 100/85/78
2400 gpm

4 cells
60 hp 105/85/78
1800 gpm

February 8, 2006

25
chilled water system
Annual Energy Consumption

100
HVAC energy consumption, MWh

water
chillers
80
condenser
water pumps

60
cooling
tower fans

40

20

0
10F 15F 20F
cooling tower range
February 8, 2006

26
chilled water system
Annual Energy Consumption

100
HVAC energy consumption, MWh

water
chillers
80
condenser
water pumps

60
cooling
tower fans

40

20

0
3 2 1.5 gpm/ton
Chiller condenser flow - cooling tower flow
February 8, 2006

27
Moderate Climate
76F WB
Chiller+Tower Yearly Estimated Operating Cost OK

$44,500.00

$44,000.00

$43,500.00

$43,000.00

$42,500.00

$42,000.00

$41,500.00

$41,000.00

$40,500.00

$40,000.00

$39,500.00
Minimum Design CW WB + 5 Optimized
temperature degrees

February 8, 2006

28
 ChillerTower Optimization

400
total
optimum
300
energy consumption, kW

chiller
200

100 tower

0
72 74 76 78 80 82 84
tower supply temperature, F

February 8, 2006

29
Summary

Cooling tower capital cost and energy

cost are not a function of chiller
capacity.

Cooling tower capital cost and energy

cost are determined by cooling tower
range and control method.
February 8, 2006

30
Summary

Do not oversize cooling towers.

Increase cooling tower range.

Integrate cooling tower control method

with chiller efficiency.

February 8, 2006

31
Cooling Coil Performance

TMBH 476.5

EWT 44 F

WTR 10 F

GPM 95.3

February 8, 2006

32
Cooling Coil Physics

GPM

MBH

Delta T

February 8, 2006

33
 Cooling Coil Physics

80 1200 200

70 1050 175 GPM

60 900 150

50 750 125

40 600 100 MBH

30 450 75

20 300 50

10 150 25
Delta T
0 0 0

Delta T MBH GPM

February 8, 2006

34
 Cooling Coil Physics

80 1200 200

70 1050 175 GPM

60 900 150

50 750 125

40 600 MBH
100
30 450 75

20 300 50

10 150 25
Delta T
0 0 0

Delta T MBH GPM

February 8, 2006

35
 Cooling Coil Physics

80 1200 200

70 1050 175 GPM

60 900 150

50 750 125

40 MBH
100
30 478 75

300 50

9.6 150 25
Delta T
0 0 0

Delta T MBH GPM

February 8, 2006

36
 Cooling Coil Physics

80 1200 200

70 1050 175 GPM

60 900 150

50 750 125

40 600 100 MBH

30 450 75

20 300 50

10 150 25
Delta T
0 0 0

Delta T MBH GPM

February 8, 2006

37
Cooling Coil Physics

1200 200

1050 175 GPM

900 150

750 125 ewt

600 100
44 F
450 75

300 50

150 25

0 0

MBH GPM
February 8, 2006

38
Cooling Coil Physics

1200 200

1050 175 GPM

900 150

750 125 ewt

600 100 38 F
44 F
450 75 50 F
300 50

150 25

0 0

MBH GPM
February 8, 2006

39
Cooling Coil Physics

1200 200

1050 175 38 F GPM

900 150

750 125 ewt

600 100 38 F
44 F
450
450 75 50 F
300 50

150 25

0 0

MBH GPM
February 8, 2006

40
Cooling Coil Physics

1200 200

1050 175 38 F GPM

900 150

750 125 ewt

600 100 38 F
44 F
450
450 50 F
300 44

150 25

0 0

MBH GPM
February 8, 2006

41
Cooling Coil Physics

1200 200

1050 175
44 F GPM
900 150

750 125 ewt

600 100 38 F
44 F
450 75 50 F
300 50

150 25

0 0

MBH GPM
February 8, 2006

42
Cooling Coil Physics

1200 200

1050 175
44 F GPM
900 150

750 125 ewt

600 100 38 F
44 F
450
450 75 50 F
300 50

150 25

0 0

MBH GPM
February 8, 2006

43
Cooling Coil Physics

1200 200

1050 175
44 F GPM
900 150

750 ewt
79 38 F
600
44 F
450
450 75 50 F
300 50

150 25

0 0

MBH GPM
February 8, 2006

44
Cooling Coil Physics

1200 200

1050 175
50 F GPM
900 150

750 125 ewt

600 100 38 F
44 F
450 75 50 F
300 50

150 25

0 0

MBH GPM
February 8, 2006

45
Cooling Coil Physics

1200 200

1050 175
50 F GPM
900 150

750 125 ewt

600 100 38 F
44 F
450
450 75 50 F
300 50

150 25

0 0

MBH GPM
February 8, 2006

46
Cooling Coil Performance
Existing

TMBH 476.5 475.6

EWT 44 F 41 F

WTR 10 F 15.1 F

GPM 95.3 63.0

February 8, 2006

47
water-cooled
HeliRotor Chillers

selling chilled condenser chiller

proposition water capacity flow efficiency

1efficiency 43F 420 tons 3 gpm/ton 0.583

February 8, 2006

48
water-cooled
HeliRotor Chillers

selling chilled condenser chiller

proposition water capacity flow efficiency

1efficiency 43F 420 tons 3 gpm/ton 0.583

2colder water 41F 404 tons 3 gpm/ton 0.602

February 8, 2006

49
water-cooled
HeliRotor Chillers

selling chilled condenser chiller

proposition water capacity flow efficiency

1efficiency 43F 420 tons 3 gpm/ton 0.583

2colder water 41F 404 tons 3 gpm/ton 0.602

3lower flow 43F 415 tons 2 gpm/ton 0.621

February 8, 2006

50
water-cooled
HeliRotor Chillers

selling chilled condenser chiller

proposition water capacity flow efficiency

1efficiency 43F 420 tons 3 gpm/ton 0.583

2colder water 41F 404 tons 3 gpm/ton 0.602

3lower flow 43F 415 tons 2 gpm/ton 0.621

Mess
Mess with
with suction:
suction:
Lose
Lose capacity
capacity
Mess
Mess with
with head:
head:
Lose
Lose efficiency
efficiency

February 8, 2006

51
water-cooled
HeliRotor Chillers

selling chilled condenser chiller

proposition water capacity flow efficiency

1efficiency 43F 420 tons 3 gpm/ton 0.583

2colder water 41F 404 tons 3 gpm/ton 0.602

3lower flow 43F 415 tons 2 gpm/ton 0.621

4series evaps 41F 428 tons 2 gpm/ton 0.605

Series
Series evaporators
evaporators with
with low
low condenser
condenser flow:
flow:
Cold
Cold water,
water, better
better capacity,
capacity, competitive
competitive efficiency
efficiency

February 8, 2006

52
water-cooled
HeliRotor Chillers

selling chilled condenser chiller

proposition water capacity flow efficiency

1efficiency 43F 420 tons 3 gpm/ton 0.583

2colder water 41F 404 tons 3 gpm/ton 0.602

3lower flow 43F 415 tons 2 gpm/ton 0.621

4series evaps 41F 428 tons 2 gpm/ton 0.605

5series evaps 41F 434 tons 3 gpm/ton 0.571

Series
Series evaporators
evaporators with
with standard
standard condenser
condenser flow:
flow:
Cold
Cold water,
water, maximum
maximum capacity,
capacity, best
best efficiency
efficiency
February 8, 2006

53
water-cooled
HeliRotor Chillers

selling chilled condenser chiller

proposition water capacity flow efficiency

1efficiency 43F 420 tons 3 gpm/ton 0.583

2colder water 41F 404 tons 3 gpm/ton 0.602

3lower flow 43F 415 tons 2 gpm/ton 0.621

4series evaps 41F 428 tons 2 gpm/ton 0.605

5series evaps 41F 434 tons 3 gpm/ton 0.571

February 8, 2006

54
air-cooled
HeliRotor Chillers

air-cooled chiller
(400 tons) 43F

pump

conventional
conventional system:
system:
efficiency
efficiency = = 9.9
9.9 EER
EER
capacity
capacity = = 406
406 tons
tons coil
pump
pump = = 17.2
17.2 hp
hp

55F

February 8, 2006

55
air-cooled
HeliRotor Chillers

air-cooled chiller
(400 tons) 41F

pump

EarthWise
EarthWise system:
system:
efficiency
efficiency =
= 9.8
9.8 EER
EER
capacity
capacity =
= 392
392 tons
tons coil
pump
pump =
= 7.6
7.6 hp
hp

56F

February 8, 2006

56
air-cooled
HeliRotor Chillers

air-cooled chillers 41F

(400 tons, total)

48F
pump

Series
Series evaporators:
evaporators:
efficiency
efficiency = = 10.2
10.2 EER
EER
capacity
capacity == 423
423 tons
tons 56F coil
pump
pump == 15.8
15.8 hp
hp

February 8, 2006

57
Annual Chiller Plant Energy Consumption

basic balanced

26%
17%
18%
9%
57%
73%

Chiller
Cooling Tower
Water Pumps February 8, 2006

58