airah qld presentation · pdf file · 2013-06-19airah ( qld ) presentation to...
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AIRAH ( QLD ) presentationAIRAH ( QLD ) presentationTo efficiency and beyond
Introductory Concepts:Design load vs Annual loadChiller rating tools ‐ COP & IPLVBin weather data & NPLV
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Chiller58% Chiller
33%Fans43%
Fans Tower
Design Performance
Tower5%
24%Pumps
13%
Annual Energy Usage
Pumps22%
Tower2%
A historical focus on chiller full load efficiency [COP/EER]Increased focus today on‐y1. Chiller part load efficiency [IPLV / NPLV]2. Reduction of air and water ‘transport’ energy
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Tools used to identify appropriate chiller technology
Constant condenser vs AHRI relief (IPLV)Load % time entering condenser water temperature
IPLV without AHRI relief with AHRI relief
100% 1 29 5 29 5100% 1 29.5 29.5
75% 42 29.5 23.9
50% 45 29.5 18.3
25% 12 29.5 18.3
h h b b lConstant high ambient wb climates Seasonal climates
What is the weather data and load profile for the jobsite location ? => NPLV
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YorkCalc BIN WEATHER DATA – Brisbane AUSTRALIA
temperature bin canberra melbourne adelaide perth sydney brisbane cairnsdeg F deg C HRS WB HRS WB HRS WB HRS WB HRS WB HRS WB HRS WB105-109 40.6- 42.8 6 21.7100-104 37.8- 40 1 20 1 21.7 27 21.1 2 22.2 4 22.2 3 23.3 3 2595 99 35 37 2 17 19 4 12 21 1 55 20 17 21 1 6 21 1 15 22 2 14 25 695-99 35- 37.2 17 19.4 12 21.1 55 20 17 21.1 6 21.1 15 22.2 14 25.690-94 32.2- 34.4 50 18.9 22 20.6 116 19.4 42 21.1 18 20.6 131 23.3 94 25.685-89 29.4- 31.7 112 17.8 50 20 215 18.3 14 20.6 40 21.1 643 21.7 781 2580-84 26.7-28.9 193 17.2 96 18.9 313 17.8 37 21.1 158 20.6 1374 20.6 1620 23.375-79 23.9- 26.1 332 16.1 160 18.3 477 16.7 151 20.6 618 20.1 1744 18.9 2513 22.270-74 21.1-23.3 480 15.6 276 17.2 696 15.6 612 20.1 1493 18.3 1814 16.7 1984 20.165-69 18.3- 20.6 725 14.4 485 16.7 1013 14.4 1478 18.3 1975 16.1 1307 14.4 1163 17.860-64 15.6- 17.8 1096 13.3 958 15.1 1495 12.8 1966 16.1 1772 13.9 913 12.2 344 15.655-59 12.8- 15 1316 11.1 1650 13.3 1852 11.1 1764 13.9 1383 11.1 484 9.4 107 12.850 54 10 12 2 1307 8 9 1938 11 1 1522 9 4 1384 11 1 852 8 9 223 7 2 23 10 150-54 10- 12.2 1307 8.9 1938 11.1 1522 9.4 1384 11.1 852 8.9 223 7.2 23 10.145-49 7.2- 9.4 1160 6.7 1776 8.9 702 7.8 853 8.9 397 6.7 65 5.1 2 7.840-44 4.4-6.7 859 4.4 930 7.2 218 5.6 396 6.7 38 5.1 11 2.835-39 1.7- 3.9 547 2.2 277 5.1 38 2.8 38 5.1 1 1.1 0.630-34 (1.1) - 1.1 307 0.1 50 2.8 1 0.6 1( )25-29 (3.9)-(1.7) 137 -2.8 420-24 (6.7)-(4.4) 27 -5.1 0.615-19 (9.4)-(7.2) 1 -7.2 66% annual operating hours full mechanical cooling
56% annual operating hours 19‐24 deg c tower water
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30% potential for integrated economizer assist
56% annual operating hours 19 24 deg c tower water
ReviewReview• Variable speed drives are widely applied today to motors used in HVAC
plant applications as a cost effective means to reduce energy use.
• Chilled water plants typically operate only 1% of the time at full load, design conditions.
• IPLV (integrated part load value) is a useful tool to evaluate chillers, but is based on a single chiller plant using standard AHRI water temperatures and average US weather data.
• NPLV (non‐standard part load value) can be used where the standard AHRI chilled and condenser water temperatures, load profile, and weather data do not apply.
• Brisbane bin weather data indicates there is opportunity for significant chiller operating hours at reduced off‐design entering condenser water.
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Chiller full load efficiency trends
( 0)COP=7
COP=6
COP 5
(6.50)(>7.0)Chiller COP trend
COP=5
COP=4
1970 1980 1990 2000 2010
Recent gains through cycle efficiency
Since 1980, average chiller efficiency has improved over 35%, despite using less efficient refrigerants.
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• Significant gains in full load efficiency through advances in h h d l ffi i iheat exchanger, compressor, motor, and cycle efficiencies.
• The biggest single gain however has been in part load efficiency with the adoption of the variable speed drive.
MR ifi DC
Supply
L1
L2
L3
Motor
M3
U1
V1
W
Rectifier InverterDCL
C UV1 V3 V5
V4 V6 V2
Monitoring ControlControl electronics
Control, monitor, and communication
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Over 30 years of VSD technology development for chillers
Generation 5 (2010s)
Generation 4 (2000s)
Generation 3 (1990s)
Generation 2 (1986)
Generation 1 (1979)Significant innovation in
VSD technology since 1979
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Real World Energy @ Lower LiftCapitalizing on ‘off‐design’ conditions –99% of the timeCapitalizing on off design conditions 99% of the time
LoweringLowering Condenser Water Condenser Water TemperatureTemperaturePressure
L th LiftL th Liftd Lowers the LiftLowers the Lift
Compressor
Condenser
Lift Expansion
Reduces Compressor WorkReduces Compressor WorkEvaporator
Reduces Energy Reduces Energy ConsumptionConsumption
Enthalpy
Direct Indirect
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How does LIFT impact efficiency ?Chiller Energy Usage Analogy ‐ Constant Speed Driven Chillers
100% Condenser Temp.85°F (29.5°C) ECWT
gy g gy p
Lift
RGY
Design
Lift
(height of mountain)
ENER Load
(weight of rock)
0% Evaporator Temp.44°F (6.7°C) LCHWT
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How does LIFT impact efficiency ? Chiller Energy Usage Analogy ‐ Constant Speed Driven Chillers
85°F (29.5°C) ECWTCondenser Temp.
gy g gy p
70%
55°F (12.8°C) ECWT
RGY
n Lift
ENER
Off‐D
esign
Load
(weight of rock)
0%44°F (6.7°C) LCHWTEvaporator Temp.
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How does LIFT impact efficiency ? Chiller Energy Usage Analogy ‐ Variable Speed Driven Chillers
Condenser Temp.85°F (29.5°C) ECWT
gy g gy p
VariableVariableSpeedSpeed
50%
RGY
n Lift
55°F (12.8°C) ECWTDrive Drive
ENER
Off‐D
esign
Load
(weight of rock)
0% Evaporator Temp.44°F (6.7°C) LCHWT
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How Can You Save Energy in an HVAC Central Plant ?
YK Chiller with VSD Performance
Loading has little effect on efficiency4.7
COP
on efficiency
[~ 10%]
6.6
5.5
4.7
11
8.3
33
17
29.5 C24.0 C
18.3 C12.8 C
Entering condenser water
13Johnson Controls ‐ Proprietary & Confidential
YK Chiller with VSD Performance
How Can You Save Energy in an HVAC Central Plant ?
YK Chiller with VSD Performance
Loading has little effect on efficiency4.7
COP
Lift has significant
[~ 10%]
6.6
5.5
Lift has significant effect on efficiency
[~ 50%]11
8.3
33
17
29.5 C24.0 C
18.3 C12.8 C
Entering condenser water
14Johnson Controls ‐ Proprietary & Confidential
Variable Speed Drives save energy and reduce noise
Constant Speed
Variable Speed
15 Johnson Controls ‐ Proprietary & Confidential
Variable Speed DrivesLow Voltage Liquid Cooled Unit Mounted VSDg q
²YMC²Magnetic VSD Centrifugal
YVAAVSD Screw air cooled
YKOpen VSD Centrifugal
YVWAVSD Screw water cooled
415V
16 Johnson Controls ‐ Proprietary & Confidential
Variable Speed DrivesMedium Voltage (MV) VSDg ( )
YK
3.3 kV & 6.6 kV
VSD Open Centrifugal
YK ‐EP11 kVVSD Open Centrifugal with Economizer
17 Johnson Controls ‐ Proprietary & Confidential
The Purpose of Variable Speed Drives
Starts & stops the motor
Significantly reduces inrush current to < than full load amps
Corrects power factor close to unity
Reduces utility demand charge
Regulates compressor speed to provide the most efficient chiller operation, reducing part load energy consumption
18 Johnson Controls ‐ Proprietary & Confidential
Low inrush current with VSD < 100% FLA
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Superior power factor
0.98 power factor VSD with active IEEE electronic filter0.95 power factor (std VSD)
power factor non VSD (fixed speed)
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100 KW
59 KVARPF = 0.86
actual work
Consumed energy to i fi ld59 KVAR
116 KVAgenerate magnetic fieldtotal energy
provided from supply
100 KW
33 KVAR PF = 0.95total energyConsumed energy to
actual work
33 KVAR105 KVA
PF 0.95total energy provided from supply
generate magnetic field
100 KW20 KVAR PF = 0.98total energy
Consumed energy to generate magnetic field
actual work
what power factor means
102 KVAPF 0.98
provided from supply
p
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Comparison at AHRI condenser ‘relief’
Why VSD ? ‐ Comparative Energy Performance
VSDVSD
Comparison at AHRI condenser relief
No VSDNo VSD% Load ECWT %SAVEDCOP COPLWT% Load ECWT100 29.590 27.2
%SAVED‐1.02.2
COP6.176.73
COP6.116.89
LWT6.76.7
80 25.070 22.860 20.6
8.716.225.9
7.147.427.59
7.828.8610.24
6.76.76.7
50 18.340 18.3 30 18 3
33.036.438 5
7.657.116 36
11.4211.1710 34
6.76.76.76 730 18.3
20 18.3 15 18.3
38.544.145.0
6.365.174.41
10.349.268.01
6.76.76.7
Significant savings ….and with more possibleJohnson Controls ‐ Proprietary & Confidential
Opportunities for Lower Lift
Lower Condenser Higher Chilled Water Water Temperature
• Climatic Conditions
gTemperature
• Chilled Water Reset• Climatic Conditions• Control Strategy• Oversize Towers
• Chilled Water Reset• Chilled Beam Systems• UFAD Applications• Oversize Towers
• Series Counter‐flow• UFAD Applications• Series Counterflow
23
Unit Mounted Low Voltage Solid State Starter
Unit Mounted Low Voltage Variable Speed
Drive Johnson Controls ‐ Proprietary & Confidential
Efficiency breakthrough – low lift magnetic VSD chillers
+ 8% COP+ 13% IPLV
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Air-Cooled�Variable Speed Screw�ChillerYVAA Series % load Ambient COP
YVAA 0345EXV50 (1175 kWr)
100908070
35.031.728.325 0
3.23.64.24 870
605040
25.021.718.315.0
4.85.46.37.6
3020
12.812.8
9.37.6
YVAA Key Technology Elements
Hybrid Falling Film Evaporator
Variable SpeedDrive
Variable SpeedScrew Compressor
Micro‐channel Condenser Coils
Variable Speed Fans
VSD technology offers huge efficiency
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gy g ygains with air cooled chillers
Fixed speed (conventional) staging Variable speed staging
100%
90%
100%
90%
80%
70%
60%
80%
70%
60%60%
50%
40%
60%
50%
40%A hill l d
30%
20%
30%
20%
Average chiller load1 chiller = 57%2 chiller = 67%3 chiller = 75%4 chiller = 83%
10%
0%
min% 33% 67% 100%
10%
0%
min% 26% 52% 100%
5 chiller = 88%
min% 33% 67% 100% min% 26% 52% 100%
Building load Building loadJohnson Controls ‐ Proprietary & Confidential
All variable speed plant ‐ key CPO functions
1. Energy based staging algorithms
2 Condenser water set point reset2. Condenser water set‐point reset
3. Chilled water set‐point reset Reduce chiller lift
4. Series / Series counter‐flow chillers
5. Variable chilled water flow (VPF) with large delta T
6 System differential pressure set point reset Reduce pump energy6. System differential pressure set‐point reset
7. Variable condenser water flow
Reduce pump energy
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Chiller COP=16.9 !Metasys screenshot of YK VSD chiller installed on jobsite
29Johnson Controls ‐ Proprietary & Confidential
Cooling load 516 kWrMetasys screenshot of tower at same chiller load
Total fan energy 3.8 kWJohnson Controls ‐ Proprietary & Confidential
8.6 An instantaneous delivered plant COP of 8.6 !!
Chiller Input 30 kWChiller Input 30 kWChw Pumps 8.5 kWCondenser Pump 18 kWTower Fans 3.8 kW
/Plant COP = 516/ 60.3 = 8.6
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High EfficiencyVSD chillers
Minimize LIFT
Design to minimize‘transport’ energy
System level control optimizationoptimization
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