chilled water plant seminar - 04-2014

8/19/2019 Chilled Water Plant Seminar - 04-2014

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Presented by:

Mark HydemanSteve Taylor

Taylor Engineering LLCAlameda, CA

http:// !taylor"engineering!#om

The P$%E Pa#i&i# Energy Center Presents:

'ptimi(ing the )esign and Control o&

Chilled *ater Plants

April +, -.


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Logisti#s

Sa&ety0estrooms0e#y#ling

Cell phone eti12etteL2n#h0evie &orms*ebinar eti12ette

P$%E 0eso2r#es• Rebates• Tool Lending Library• Marlene Vogelsang ([email protected])


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+

Handouts

3o2 #an get a #opy o& the hando2tsin P)4 &ormat as &ollo s:• Type the ollo!ing lin" into yo#r !eb

bro!ser$http:// !taylor"engineering!#om/&tp/PECClassHando2ts!html

• %lic" on the lin" or the %hilled &ater 'lant%lass on * +,- to do!nload the crobat

ile o the presentation.


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About Mark Hydeman4o2nding Prin#ipal, Taylor EngineeringEd2#ation• /tan ord 0niversity1 2/ 3eneral 4ngineering1 -5 +• /tan ord 0niversity1 M/ Mechanical 4ngineering1 -5 *

ASH0AE• 7ello!• 4xceptional /ervice !ard• /tandard 5,.- 4nergy /tandard1 t!o to#rs o d#ty1 Vice8%hair • Technical %ommittee -.91 %omp#ter pplications1 'ast %hair • Technical %ommittee 5.51 Mission %ritical 7acilities• Technical %ommittee 5.-,1 Laboratory /ystems• 4lectronic %omm#nications %ommittee1 Vice8%hair • /'% +,91 Vice %hair

0esear#h• :eveloped a sim#lation and assessment tool"it or data centers !ith L2;L• 'rincipal


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5

About Steve TaylorPrin#ipal, Taylor EngineeringEd2#ation• /tan ord 0niversity1 2/ 'hysics1 -5B6• /tan ord 0niversity1 M/ Mechanical 4ngineering1 -5BB

ASH0AE• 7ello!• /tandard 6+ V % /#bc.1 - years• /tandard 99 Thermal %om ort• 3#ideline -6 4conomiAer :ampers1 chair • 3#ideline -* /peci ying :irect :igital %ontrol /ystems1 chair • T% .* Ventilation1 vice8chair • T% -. %ontrol Theory D pplications1 chair • #thor E7#ndamentals o :esign and %ontrol o %entral %hilled &ater 'lantsF %o#rse• :isting#ished Lect#rer

6S$7C LEE)•


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;

Who are You?

Cons2lting Engineers<)esign/72ild Engineers<Contra#tors<Energy/$reen 72ilding Cons2ltants<72ilding ' ners/Engineers<E12ipment rep/s2pplier/man2&a#t2rer<Commissioning a2thority<'ther


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Articles (1 of !Available at this 60L:http:// !taylor"engineering!#om/p2bli#ations/arti#les!shtml


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Articles ( of !Available at this 60L:http:// !taylor"engineering!#om/p2bli#ations/arti#les!shtml


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..

"esign #uide Sco$e

e Constr2#tion• >ydronic design• %hiller selection• %ooling to!er selection• %ontrol optimiAations• %ommissioning

0etro&it• Replacement

chillers• ddition o V/:s• %ontrol optimiAation• %ommissioning


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.

%$timi&ing 'nergy sage

Chillers• Type1 e iciency1 siAe1 V/:

Cooling To ers• 7an type1 e iciency1 approach1 range1 speed control1 lo!

t#rndo!nChilled *ater P2mps• rrangement1 lo! rate (delta8T)1 press#re drop1 V/:

Condenser *ater P2mps• 7lo! rate (delta8T)1 press#re drop

Air Handling 6nits• %oil siAing1 air8side press#re drop1 !ater8side press#redrop


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)o$ *ui& 1

*hat happens to #omponentenergy 2sage i& e lo er C*Ssetpoint<• %hiller • To!ers• '#mps


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)o$ *ui&

*hat happens to #omponentenergy 2sage i& e lo er C* &lo <• %hiller • To!ers• '#mps


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)o$ *ui& +

*hat happens to #omponentenergy 2sage i& e lo er C* &loA ) the C*S setpoint<• %hiller • To!ers• '#mps


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.;

%$timi&ing ,HW )lant "esign

8deal: )esign a plant ith lo est li&e #y#le#osts 9&irst #ost pl2s li&elong operating#osts a##o2nting &or all the #ompleBitiesand intera#tion among plant #omponents

Pra#ti#al: )esign plant s2bsystems to benear"li&e #y#le #ost optim2m 2singte#hni12es that are simple and pra#ti#aleno2gh to be 2sed itho2t a signi&i#ant

in#rease in design time


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,hilled Water "istributionSystems


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.>

Water "istribution System ,lasses

Constant 4lo• ;o control valves• *8!ay control valves

ariable 4lo• 'rimary8Hnly• 'rimary /econdary

( Tertiary)• 'rimary :istrib#ted

/econdary• 'rimary Variable /peed

%oil /econdary


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.?

%>&'0M'

H'T


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-

,onstant -lo.T.o ,hillers/ Single ,oil/ 0o ,ontrol alve

%>&'0M'

H'T


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.

2,onstant3 -lo.+4Way alves

1556 to ,oil 756 to ,oil 56 to ,oil

Pipe/Valves 2 2 2Coil and/or Bypass 8 2 6Globe Control Valve 10 7.5 12

Total 20 11.5 20

GPM 20! ∆ P" 100 1#2 100

Press$re %rop 100 GPM

"a&t$al ∆ P available 'ay &(an)e

8tem

+"*ay MiBingalve

7ypass 7alan#ealve

DP

'ress#re atconstant lo!

7lo! at constant'ress#re (+, )


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,onstant -lo.Single ,hiller/ Multi$le ,oils

%>&'0M'

%H


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+

%>&'0M'

%H


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5

ariable -lo.

ary 4lo Thro2gh Coil Cir#2it• T!o8!ay valves• Variable speed coil p#mp

Con&ig2rations• 'rimary8secondary• 'rimary8secondary variations

• 'rimary8only


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ariable -lo. ,hilled WaterSystems

'ld Paradigm• %ontrols respond to changes in %>&

temperat#re

• Variable lo! ca#ses lo! temperat#re trips1loc"s o#t chiller1 re?#ires man#al reset(may even reeAe)

• >ence$ Maintain constant lo! thro#ghchillers


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=

)rimary9Secondary


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)rimary9Secondary

H;

H;

-,,gpm

-,,gpm

-,,gpm

H;

H77

-,,gpm

-,,gpm

, gpm


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ariable -lo.)rimary9Secondary/ Multi$le ,hillers and ,oils

%>


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+-

ariable -lo.)rimary9Secondary/ Series -lo./ Multi$le ,hillers


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+.

ariable -lo.)rimary9"istributed Secondary


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ariable -lo.)rimary9Secondary9Tertiary


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ariable -lo. ,hilled Water Systems

e Paradigm• Modern controls are rob#st and very

responsive to both lo! and temperat#re

variations• Variable lo! HI !ithin range and rate8o 8

change spec d by chiller man# act#rer


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+

ariable -lo.)rimary4only/ Multi$le ,hillers

%>


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+5

ariable -lo.)rimary/ :y$ass alve

Lo#ation• ;ear chillers

2est or energy%ontrols less expensive%ontrol more di ic#lt to

t#ne P ast response• Remote/maller press#re

l#ct#ations (easier tocontrol)Ieeps loop cold or astresponse

Less li"ely to #ne?#allyload chillers

Si(ing• /iAing critical !hen at

chillers p#mps• :i erent siAe i p#mp has

V7: or not

4lo meas2rement• 7lo! meter

Most acc#rate;eeded or 2t# calc orstaging

• :' across chiller Less expensive

cc#racy red#ced as t#beso#l

Hne re?#ired or each chiller


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:alancing ariable -lo.Systems

See F Balancing Variable Flow Hydronic Systems G ASH0AE o2rnal '#t --


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ariable -lo. :alancing %$tions

.! o balan#ing• Relying on +8!ay control valves to a#tomatically provide

balancing

! Man2al balan#e• 0sing ball or b#tter ly valves and coil press#re drop• 0sing calibrated balancing valves (%2Vs)

+! A2tomati# &lo limiting valves 9A4L s! 0everse"ret2rn

5! 'versi(ed main piping;! 6ndersi(ed bran#h piping=! 6ndersi(ed #ontrol valves>! Press2re independent #ontrol valves

• ;ot st#died in o#r />R 4 paper


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)i$ing Systems Analysis

Heating system• 9 , gpm• ,, V V reheat coils• %onstant speed p#mps

• 2ased on act#al b#ilding in Ha"landCooling system• -1+,, gpm• +, 7loor8by8 loor >0s• Variable speed p#mps

All valves: " ay mod2latingAnaly(ed 2sing Pipe"4lo


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.

HW )i$ing -loor )lan


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Ty$ical ,oil )i$ing

Hptions -1 1 91 61 D B

Hption +


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+

Ty$ical ,oil )i$ing

Hption *

Hption


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%$tion 1; 0o :alancingAdvantages• ;o balancing labor • %oils may be

added s#btracted!itho#t rebalance

)isadvantages•


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%$tion ; Manual .9,: s

Advantages• Valves can be #sed or

#t#re diagnosis ( lo! canbe meas#red)

• Red#ced over8press#riAation o controlvalves at lo! lo!

)isadvantages• dded cost o calibrated

balancing valve• >igher balancing cost• %omplete rebalance

may be re?#ired i coilsadded s#btracted• /lightly higher p#mp

head d#e to balancingvalve

• %oils may be starved ivariable speed drivesare #sed !itho#t :'reset

• /lightly higher p#mpenergy depending on

lo! variations andp#mp controls


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Starved


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%$tion +; Automatic -lo. igher p#mp head and

energy d#e to strainer andlo! limiting valve

• Valves have c#stom lo!rates and m#st beinstalled in correct location

• Valves can clog or springscan ail over time• %ontrol valves nearp#mps can be over8press#riAed1 red#cingcontrollability


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%$tion ; >everse4return


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5-

>everse >eturn ,onfigurations

% %

% %

% %

% %

0everse ret2rn riser 9elevation

0everse ret2rn on &loor 9plan

> %

> %

> ) %

> ) %

> %

> %


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%$tion 7; %versi&ed Main )i$ing

Standard main design

% %

% %

% %

% %

'versi(ed main riser

6F

6F

6F

6F

% %

% %

% %

% %

+F

6F

+F

6F

*F *F

F F


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%$tion 7; %versi&ed Main )i$ing

Advantages• ;o balancing labor • %oils may be

added s#btracted !itho#trebalance

• Red#ced over8press#riAation o controlvalves close to p#mps

• Lo!est p#mphead energy d#e tooversiAed piping1 nobalance valves

•


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%$tion @; ndersi&ed :ranch )i$ing

Advantages• ;o balancing labor • Red#ced cost o smaller

piping• %oils may be


• Red#ced over8press#riAation o controlvalves close to p#mps!here piping has been#ndersiAed

)isadvantages• Limited e ectiveness and

applicability d#e to limitedavailable pipe siAes

• >igh design and analysiscost to determine correctpipe siAing• Red#ced lexibility to addcoils !here piping hasbeen #ndersiAed

• %oils may be starved ivariable speed drives are#sed !itho#t :' reset

• /lightly higher p#mpenergy depending on lo!variations and p#mpcontrols


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%$tion ; ndersi&ed ,ontrol alves

Advantages• ;o balancing labor • Red#ced cost o smaller

control valves• %oils may be


• Red#ced over8press#riAation o controlvalves close to p#mps!here control valves havebeen #ndersiAed

• igh design and analysiscost to determine correctcontrol valve siAing

• %oils may be starved ivariable speed drives are!itho#t :' reset

• /lightly higher p#mpenergy depending on lo!variations and p#mpcontrols


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5;

%$tion B; )ressure 8nde$endent ,ontrol alves

Advantages• ;o balancing labor • %oils may be

added s#btracted!itho#t rebalance

• ;o over8press#riAationo control valves closeto p#mps

• 4asy valve selection Plo! only not %v

• 'er ect valve a#thority!ill improvecontrollability

• Less act#ator travel andstart stop may improveact#ator longevity

)isadvantages• dded cost o strainer and

press#re independent controlvalve

• %ost o labor to clean strainerat start8#p

• >igher p#mp head and energyd#e to strainer and press#reindependent control valve

• Valves have c#stom lo! ratesand m#st be installed in correctlocation

• Valves can clog or springs canail over time


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5=

)8, s May 8m$rove CT?

;2%


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5?

'nergy D -irst ,osts

8ncremental -irst ,ostsvsF %$tion 1)um$ head/

feet

Annual )um$'nergy/

G9yr GG $er design

g$m:alancing Method

,HW

HW ,HW HW ,HW HW ,HW HW

1 *o balan&in) 58.5 82.7 1 310 # 3#0 9 9 9 9

2 Man$al balan&e $sin) &alibrated balan&in) valves

60.# 8#.6 1 370 # 370 7 360 +7 5#0 6.60 88.00

# $to'ati& lo li'itin) valves 66.6 30.8 2 170 + #10 11 +20 50 750 3.50 3+.00

+ everse ret$rn 55.# 80.0 1 810 # 800 28 +60 17 230 2#.70 #2.00

5 4versi ed 'ain pipin) +5.0 53.# 1 +70 2 820 12 300 7 0+0 10.80 1#.00

6 ndersi ed bran&( pipin) 58.5 * 1 310 * - 250: * - 0.20: *7 ndersi ed &ontrol valves 58.5 * 1 310 * - 2 #+0: * - 2.00: *


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>anks :alancing Method ,ontrollability(all conditions!

)um$ 'nergy,osts -irst ,osts

1 *o balan&in) 7 # #2 Man$al balan&e $sin) &alibrated

balan&in) valves + 6 6

# $to'ati& lo li'itin) valves 7 7 7

+ everse ret$rn 2 2 55 4versi ed 'ain pipin) # 1 +6 ndersi ed bran&( pipin) 6 + 27 ndersi ed &ontrol valves 5 + 18 Press$re independent &ontrol

valve 1 8 87


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,onclusions D >ecommendations forariable -lo. Hydronic Systems

A2tomati# &lo "limiting valves are not re#ommended on any variable&lo system• They only limit lo! or transients !hich has little or no val#e

Calibrated balan#ing valves are also not re#ommended &or balan#ingvariable &lo systems• 2#t #se #l or #t#re diagnostics on small lo! press#re drop coils P =#st leave them

!ide open (no throttling)'versi(ed mains may have reasonable p2mp energy savings payba#k on

/= #hilled ater systems6ndersi(ing piping and valves near p2mps improves balan#e and #ostsare red2#ed, b2t signi&i#ant added engineering time re12iredPress2re independent valves sho2ld be #onsidered on very largesystems 9I.-- &t head &or #oils near p2mps

• %ost is high b#t going do!n no! !ith competition• &hen costs are competitive1 this may be best choice or all =obs

4or other than very large distrib2tion systems, option . 9no balan#ingappears to be the best option• Lo! irst costs !ith minimal or insigni icant operational problems


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:reak


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)roblems caused by "egrading ∆∆∆∆ T

4or a $iven Load J, *hen ∆∆∆∆ T $oes )o n, $PM $oes 2p

C 9,, S 3'M S ∆ T

0es2lt:• R 4 /ymposi#m 'aper1 E:egrading %hilled&ater 'lant :elta8T$ %a#ses and Mitigation


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5 o4

o4

*hen ∆∆∆∆ T )egrades,Se#ondary 4lo

EB#eeds Primary5- o4

; o4

o4>-K

4)

4)

)rimary9secondary 2death s$iral3

%hillers staged by Load


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∆∆∆∆ T "egradation in


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;=

"egrading ∆ TI1F ,auses that can be eliminated by design9o$eration

8mproper Setpoints or Calibration• e.g. dropping coil / Tsp by +U7 !ill do#ble the lo! rate

and halve the GT6se o& Three" ay alves•


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"egrading ∆ TI1F ,auses that can be eliminated by design9o$eration

(contin#ed)6n#ontrolled Pro#ess Loads• need isolation valves

8n#orre#tly Sele#ted Control alves• HversiAed valves h#nt and res#lt in higher average lo!• 0ndersiAed act#ators have ins# icient close8opress#re

8n#orre#tly Sele#ted Coils• %ommon problem !hen ne! b#ildings don t ollo! the

camp#s standard GT8mproper F7ridgeG Conne#tion % Control• 2ridge valve cannot raise the %>&RT !itho#t starvingthe load


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"egrading ∆ TI Measures that im$rove ∆ T but energy trade4off

Chilled *ater 0eset to Lo er Chilled*ater S2pply Temperat2re• Lo!ering %>&/T by -U7 increases ∆ T by -

to +U7 b#t red#ces chiller e iciency• ;et e ect co#ld be better (i high p#mpenergy) or !orse (lo! p#mp energy)


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=-

Coil P2mps to Prevent ∆∆∆∆ T )egradationat Lo 4lo )2e to FLaminar 4loE&&e#tG• May (or may not) improve ∆ T at lo! lo! b#t

coil p#mp energy is very high

"egrading ∆ TI Measures that im$rove ∆ T but energy trade4off


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)rimary9Secondary vsF )rimary9Secondary.ith ,oil )um$s

P/S/T ith#onstant

∆∆∆∆ T

P/S ithdegrading

∆∆∆∆ T

0.00

5.00

10.00

15.00

20.00

25.00

#0.00

#5.00

+0.00

+5.00

50.00

0, 20, +0, 60, 80, 100,

6 )lant


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,auses of "egrading ∆ TI+F ,auses That ,annot :e 'liminated

Air E#onomi(ers and .--K '2tdoor AirSystems

)egrading Coil E&&e#tiveness ith AgeCH*ST Setpoint 0eset'thers as 3et 6ndetermined<

55 o4SAT

;- o4EAT

o4

CH*ST

OO;- o4CH*0T

(:esign %>&RT o6+1 based on design4 T o ,)


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=

,onclusions

)esign, Constr2#tion, and 'perationErrors that Ca2se Lo )T #an andSho2ld be Avoided

72t 'ther Ca2ses &or Lo )T #an everbe EliminatedCon#l2sion: At Least Some )T)egradation is 8nevitable

There&ore: )esign the CH* Plant to Allo&or E&&i#ient Chiller Staging )espite)egrading )T


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=5

Some Solutions

6se ariable Speed )rives on Chillers so thatthey 'perate E&&i#iently at Lo Load)esign CH* )istrib2tion System so Chillers #anhave 8n#reased 4lo So They #an be More 42lly

Loaded at Lo )T• 'rimary8only p#mping• 0ne?#al chiller and primary p#mp siAes1 headered p#mps

so large p#mp can serve small chiller • Lo! design delta8T in primary loop

igher primary loop irst costs D energy costs

• 'rimary secondary p#mping !ith chec" valve in commonleg


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=;

,heck alve in the ,ommon


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>eal "isadvantages,heck alve in ,ommon


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=?

,heck alve in the ,ommon


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>-

,ondenser Water "istributionSystems


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,ondenser Water )um$ %$tions

)edi#ated P2mping Advantages:• Less #ontrol #ompleBity• C2stom p2mp heads / 2nmat#hed #hillers• 6s2ally less eBpensive i& ea#h p2mp isad a#ent to #hiller served and head press2re#ontrol not re12ired and no atersidee#onomi(er

Headered P2mping Advantages:• 7etter red2ndan#y• alves #an do2ble as head press2re #ontrol• Easier to in#orporate stand"by p2mp• Can operate &e er C* p2mps than #hillers&or &iBed speed p2mps•Easier to integrate ater"side e#onomi(er

COOLINGTOWER #1

COOLINGTOWER #2

COOLINGTOWER #3

CHILLER #1

CHILLER #2

CHILLER #3

CHW PUMP #1

CHW PUMP #2

CHW PUMP #3

COOLINGTOWER #1

COOLINGTOWER #2

COOLINGTOWER #3

CHILLER #1

CHILLER #2

CHILLER #3

CHW PUMP #1

CHW PUMP #2

CHW PUMP #3

OPTIONAL


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>+

To.er 8solation %$tions

.! Sele#t to er eir dams% no((les to allo onep2mp to serve allto ers

• l!ays most e icient• lmost al!ays least

expensive• 0s#ally possible !ith + or *

cells

! 8nstall isolation valveson s2pply lines only

• ;eed to oversiAe e?#aliAers+! 8nstall isolation valves

on both s2pply % ret2rn• 0s#ally most expensive• 4asiest to design• Valve se?#encing iss#es and

possible ail#re

COOLINGTOWER #1

COOLINGTOWER #2

COOLINGTOWER #3

COOLINGTOWER #1

COOLINGTOWER #2

COOLINGTOWER #3

COOLINGTOWER #1

COOLINGTOWER #2

COOLINGTOWER #3


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'L T4 D 7R M4>4 T 4S%> ;34R

CHILLER #1

CHILLER #2

COOLING

TOWER #2

COOLING

TOWER#1

0on48ntegrated

'conomi&er65F

Twb 34F

44F

47F

47F

44F

>o#rs in /7 2ay rea!ith T !b W * 7NN

-, hrs yr

HeatEB#hangerin parallel

ith #hillers


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'L T4 D 7R M4

>4 T 4S%> ;34R

CHILLER #1

%>)

COOLINGTOWER #2

COOLINGTOWER#1

MH:0L T


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COOLINGTOWER #2

COOLINGTOWER#1

'L T4 D 7R M4

>4 T 4S%> ;34R

CHILLER #1

CHILLER #2

2J' //&/48H;LJ

MH:0L T


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>=

8ntegrated vsF 0on48ntegrated

Advantages o& 8ntegrated *SE:• M#ch higher energy savings• /o t start stop$ economiAer slo!ly loads #p as chillers

slo!ly #nload and vice versa

• ;o ris" o losing the load on s!itchover < the &/4 is enabled !hen it sho#ld remain disabled then the2M/ simply disables the &/4 !ith no e ect on chillers

• ;o s#dden s!itchovers• Meets Title + and />R 4 5,.-

Advantages o& on"8ntegrated *SE:• ;H;4X

B

' $l WS' i


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>>

'=am$le WS' savingsbuilding descri$tion

--,--- &t o&&i#e b2ilding ith Q ..- tonso& data #enter load!Lo#ation Pleasanton CA 9ASH0AE Climate+79 +.5 ton #hillers 9;+- tons total !72ilding has air"side e#onomi(er!)ata #enter has C0AH 2nits!

*ater"side e#onomi(er on #entral plantith HR 9integrated, see previo2s slide


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'=am$le WS' Savings

~30% ~24%

~48%

~2%


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?-

"ata ,enter in Santa ,lara

Cooling Tower

CWS

What’s Missing from this Picture

! heat e"changer# $i$e antwo $um$s


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?.

>etrofit WS' HJ


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"esign )rocedure


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?

"esign )rocedure

Sele#t Chilled *ater )istrib2tion SystemSele#t Temperat2res, 4lo 0ate andPrimary Pipe Si(esSele#t Cooling To er )esign CriteriaSele#t Chillers4inali(e Piping System )esign, Sele#tP2mps)evelop 'ptim2m Control System and

Control Se12en#es


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Se#ondaryP2mp / 4)

at ChillerPlant

"*ay Controlalves at

AH6s

Se#ondaryP2mp / 4)

at ChillerPlant

"*ay Controlalves at

AH6s

)rimary9Secondary


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?=

)rimary9"istributed Secondary

Central Plant

)istrib2tedSe#ondary

P2mp / 4) "Typi#al at ea#h

72ilding

o Se#ondaryP2mps atPlant

"istributed )9S versus


98/214

?>

istributed )9S versus,onventional )9S or )9S9T

Advantages• Red#ced '#mp >' 8 4ach '#mp /iAed or >ead

7rom 2#ilding to 'lant• /el 8balancing• ;o Hver8press#riAed Valves at 2#ildings ;ear 'lant• Red#ced '#mp 4nergy1 'artic#larly &hen Hne orMore 2#ildings re o Line• ;o 4xpensive1 %omplex 2ridge %onnections 0sed

in ' / T /ystems• /imilar or Lo!er 7irst %osts

)isadvantages 9vs! P/S• '#mp room needed at b#ilding• >igher expansion tan" pre8charge and siAe


99/214

??

)rimary9,oil Secondary

LargeAH6".

)istrib2tedSe#ondary

P2mp / 4) "Typi#al atea#h AH6

o Se#ondaryP2mps at Plant

LargeAH6"

o Controlalves at

AH6s


100/214

.--

Hybrid systems


101/214

"isadvantages of -" oil )um$s


102/214

.-

isadvantages of - ,oil )um$sversus conventional )9S system

Cannot Tap into )istrib2tion Systemitho2t P2mp• May be problem !ith small coils (lo! lo!1 high

head p#mp)

Possible 0ed2#ed 0ed2ndan#y/0eliability2nless )2pleB Coil P2mps are AddedPossible Lo Load Temperat2re4l2#t2ations

• Minim#m speed on p#mp motor • May need to cycle p#mp at very lo! loads


103/214

.-+

)rimary4only System

73PASSAL E

Headered P2mps % A2to 8solation alvesPre&erred to )edi#ated P2mps:• Allo s slo staging• Allo s . p2mp/ #hiller operation• Allo s p2mp/. #hiller operation i& there islo DT

4lo Meteror )P Sensor A#ross Chiller

Advantages of $rimary4only versus


104/214

.-

Advantages of $rimary4only versus$rimary9secondary system

Lo er 4irst CostsLess Plant Spa#e 0e12ired0ed2#ed P2mp HP

•Red#ced press#re drop d#e to e!er p#mpconnections1 less piping

• >igher e iciency p#mps (#nless more expensivered#ced speed p#mps #sed on primary side)

Lo er P2mp Energy

• Red#ced connected >'• E%#be La!F savings d#e to V7: and variable lo!

thro#gh both primary and secondary circ#it

) $ ' g


105/214

.-5

)um$ 'nergy)rimary vsF )rimary9Secondary (+4chiller $lant!

0.00

5.00

10.00

15.00

20.00

25.00

#0.00

#5.00

+0.00

10, 20, #0, +0, 50, 60, 70, 80, 30, 100,

, GPM

P $ ' p

C D

Pri'ary only

Pri'aryse&ondary

"isadvantages of $rimary4only versus


106/214

.-;

isadvantages of $rimary4only versus$rimary9secondary system

4ail2re o& 7ypass Control• ;ot as ail8sa e 8 !hat i valve or controls ailN• M#st avoid abr#pt lo! sh#t8o (e.g. valves interloc"ed !ith

>0s all timed to stop at same time)• M#st be !ell t#ned to avoid chiller short8cycling

4lo 4l2#t2ation hen Staging Chillers 'n• 7lo! drops thro#gh operating chillers• 'ossible chiller trips1 even evaporator reeAe8#p• M#st irst red#ce demand on operating chillers and or slo!ly

increase lo! thro#gh starting chillerY ca#ses temporary high%>&/ temperat#res

9Problems above are seldom an iss2e ith verylarge plants, e!g! more than + #hillers

) i 4 l S S i


107/214

.-=

)rimary4only System Staging

-,,, 3'M

, 3'M

, 3'M

) i 4 l S S i


108/214

.->

)rimary4only System Staging

9,, 3'M

9,, 3'M

, 3'M


109/214

.-?

)rimary9Secondary .ith ,HW Storage

P/S allo s TES tank to be#harged or dis#harged atsame time itho2t anyvalves s2per simpleSpeaking o& TES:• dvantages

'ea" shaving/impli ies chiller staging'rovides bac"8#p or chiller ail#re/econdary !ater so#rce or iredepartment/econdary !ater so#rce or coolingto!ers

• :isadvantages


110/214

..-

)rimary4only vsF )rimary9Secondary

6se Primary"only Systems &or:• 'lants !ith many chillers (more than three) and !ith

airly high base loads !here the need or bypass isminimal or nil and lo! l#ct#ations d#ring staging

are small d#e to the large n#mber o chillersY and• 'lants !here design engineers and #t#re on8siteoperators #nderstand the complexity o the controlsand the need to maintain them.

'ther ise 6se Primary"se#ondary• lso or plants !ith %>& storage


111/214

)i$e Si&ing

)i$ Si&i


112/214

..

)i$e Si&ing

eed to balan#e• %ost o pipe and its installation• %ost o p#mp energy

• Longevity o piping (erosion)• ;oise• /ometimes space limitations

A l i&i $ $ h d


113/214

..+

Accurately si&ing $um$ head

$2essing at p2mp heads• &astes money in oversiAed p#mps1 motors and (sometimes)

V7:s and (sometimes) need or impeller trimming• &astes energy (minor impact ! V7: or i impeller is trimmed)

Cal#2lating p2mp heads• Ta"es abo#t +, min#tes o engineering time

$2essing #annot possibly be #ost e&&e#tive

T' < S$ d h


114/214

..

T'


115/214

..5

Sim$lified )i$e Si&ing ,hartMaBim2m $PM &or

High Per&orman#e Constant 4lo ,Constant Speed System

Pipe Diameter 2000 4400 8760 2000 4400 8760 1/2 5.0 3.9 3.0 1.8 1.8 1.8 3/4 12 9.0 7.0 4.6 4.6 4.6

1 19 14 11 8.9 8.9 8.91 1/4 34 26 20 15 15 151 1/2 57 43 34 24 24 24

2 73 55 44 51 51 44

2 1/2 100 77 60 81 77 603 180 140 110 140 140 1104 320 240 190 280 240 1905 430 330 260 430 330 2606 700 530 420 700 530 4208 1,200 900 720 1,200 900 720

10 1,900 1,500 1,200 1,900 1,500 1,20012 2,900 2,200 1,700 2,900 2,200 1,70014 4,000 3,000 2,400 4,000 3,000 2,40016 4,900 3,800 3,000 4,900 3,800 3,00018 7,000 5,300 4,200 7,000 5,300 4,20020 7,700 5,800 4,600 7,700 5,800 4,600

24 12,000 8,900 7,100 12,000 8,900 7,10026 14,000 11,000 8,500 14,000 11,000 8,500

CRITICAL RUNNon-noise sensitive Noise sensitive

)o nload &rom:http:// !taylor"engineering!#om/p2bli#ations/design@g2ides!shtml

Pipe Diameter 2000 4400 8760 2000 4400 8760 1/2 7.8 5.9 4.6 1.8 1.8 1.8 3 /4 18 14 11 4.6 4.6 4.6

1 29 22 17 8.9 8.9 8.91 1/4 51 39 30 15 15 151 1/2 88 67 52 24 24 24

2 120 84 67 51 51 51

2 1/2 160 120 91 81 81 813 270 210 160 140 140 1404 480 360 290 280 280 2805 670 510 390 490 490 3906 1,100 800 630 770 770 6308 1,800 1,400 1,100 1,500 1,400 1,10010 2,900 2,200 1,800 2,700 2,200 1,80012 4,400 3,300 2,600 4,200 3,300 2,60014 6,000 4,600 3,600 5,400 4,600 3,60016 7,400 5,700 4,500 7,200 5,700 4,50018 10,000 8,000 6,300 9,200 8,000 6,30020 11,000 8,800 7,000 11,000 8,800 7,000

24 17,000 13,000 11,000 17,000 13,000 11,00026 21,000 16,000 13,000 20,000 16,000 13,000

CRITICAL RUNNon-noise sensitive Noise sensitive

MaBim2m $PM &or

High Per&orman#e ariable 4lo , ariableSpeed System

T i i 8 $ ll


116/214

..;

Trimming 8m$ellers

R

GPM HEAD Impleller Eff 1,710 78.0 10.125 86.16%1,900 96.3 10.875 88%


117/214

%$timum CT

l t d CT


118/214

..>

-lo. rate and CT

TGPM500 ∆=QLoad rom Load%alc s (2t# hr)

%onversionEconstantF.** lb gal Z

6, min#tes hr

7lo! rate(3'M)

Temperat#reRise or 7all (U7)

HW ∆∆∆∆ T T d ff


119/214

..?

,HW ∆∆∆∆ T Tradeoffs

Typi&al 1an)e 8° ; to 25 ° ;

;irst CostE'pa&t

s'aller &oil s'aller pipes'aller p$'p

s'aller p$'p 'otor

Fner)y Costi'pa&t

lo0er /an ener)y lo0er p$'p ener)y

oil )erformance ith ∆∆∆∆ T


120/214

. -

,oil )erformance .ith ∆∆∆∆ T

Ch lle! "#$er ∆ % 10 13 16 19 22 25

C& l '#$er pre(()re !r&p, fee$ H 2* 23.5 13.9 9.1 8.3 6.7 4.7C& l # r( !e pre(()re !r&p, + he( H 2* 0.48 0.50 0.52 0.60 0.63 0.78

-&'( 6 6 6 8 8 8+( per + h fp 7.4 8.3 9.4 7.7 8.6 11.6

Cooling coil pressure air- and waterside drops were determined from a manufacturer’s ARI-certified selection program assuming 500 fpm coil face velocity, smooth tubes, ma imum !" fpi fin spacing, #$ ° % chilled water supply

temperature, &' ° %()$ ° % entering air and 5$ ° % leaving air temperature*

System )erformance With ∆∆∆∆ T


121/214

. .

,

+,,

,,

6,,

,,

-,,,

-- -* -9 - +,CH* )elta"T

k * h / t o n / y e a r

%>' 4nergy "&h year %hiller 4nergy "&h year 7an 4nergy "&h year

System )erformance With Tarying Airside )ressure

CH*ST U 4

System )erformance and ∆∆∆∆ T


122/214

.

System )erformance and T,onstant Airside )ressure

,

+,,

,,

6,,

,,

-,,,

-+,,

- ,,

- -6 + - * -+ -,CH*ST/)elta"T

k * h / t o n

/ y e a r

%>' 4nergy "&h year

%hiller 4nergy "&h year

7an 4nergy "&h year

oil costs vsF CT


123/214

. +

,oil costs vsF CT

+H)

%oil%ost

'ipe/iAe

%oil%onnection

Total%ost

-, ,.B, -,.- -- .B 5.- [*195 * [ 199- [ 1- 5-- 6 ,.69 - .+ 66., B.6 [ 1 9 +.9 [*19 - [ 1 +6-, ,. , + .5 B., 9.B [91596 + [+1-,- [ 1,9B

hoosing the 2>ight3 HW ∆∆∆∆ T


124/214

.

,hoosing the 2>ight3 ,HW ∆∆∆∆ T

7oth energy and &irst #osts arealmost al ays minimi(ed by pi#kinga very high DT 9I.> 4 to 5 4

Savings even greater ith systemsthat have• &ater8side economiAers• %>& thermal energy storage

>ecommended )rocedure;


125/214

. 5


)etermine CH* 4lo 0ate at 5 4Pi#k primary pipe si(es 9p2mps, headers, main risers in F#riti#al#ir#2itG 9that hi#h determines p2mp head

• 0se pipe siAing spreadsheet or shortc#t tables4ind maBim2m &lo &or ea#h pipe si(e and re#al#2late DT &or these&lo rates

• 0se pipe siAing spreadsheet or shortc#t tablesThe #al#2lated DT is the minim2m average DT &or that leg o& the#ir#2it6se > ro /.- &pi 9or . &pi &or some &in types #oils &or all #oils

• Largest coil meeting /tandard 6+.- cleanability limits• 0se 6 ro! on small an8coils !here ro! not available

8terate on #oil sele#tions to determine hat CH* s2pplytemperat2re res2lts in sele#ted DT on average &or ea#h leg o& the#riti#al #ir#2it

• &e #se + 7 minim#m. May need to ad=#st pipe siAe and GT i + 7 not coldeno#ghThe lo est re12ired CH* s2pply temperat2re is the designtemperat2re!)etermine a#t2al DT and &lo in other #oils 2sing #oil program s2mto determine plant &lo and gpm" eighted average CH*0T

Short4cut )rocedure;


126/214

. ;

Short4cut )rocedure;

6se 4 CH*ST6se > ro .- &pi #oils• /tandard 6+.- limit

)etermine a#t2al #oil DT and &lo2sing #oil program s2m to determineplant &lo and gpm" eighted averageCH*0T

This may res2lt in a #older CH*ST than o2ld be possible ith there#ommended pro#ed2re b2t i& CH*ST is reset based on load, the energyimpa#t is small! 4irst #osts may be lo er sin#e p2mps #an be slightlysmaller!


127/214


128/214


129/214

,ondenser Water (To.er! >ange


130/214

.+-

( gat ,onstant ,WST

∆∆∆∆ T

ange B °°°° 4 to 5 °°°° 4

-irst ,ost 8m$act smaller condenser smaller $i$esmaller $um$

smaller $um$ motorsmaller cooling to.er

smaller cooling to.er motor

'nergy ,ostim$act

lo.er chillerenergy

lo.er $um$ energylo.er cooling to.er energy

,ondenser Water >ange


131/214

.+.

, gat constant To.er -an 'nergy

0

100

200

#00

+00

500

600

B* -6 B*.9 - B .9 -+ B9.9 -,

C*ST/)elta"T

k * h / t o n

/ y e a r

To!er 7an

%& p#mp%hiller

< Analysis K 1555 ton )lant


132/214

.+

ecommended )rocedure;


133/214

.++


)etermine C* 4lo 0ate at .5 4Pi#k primary pipe si(es 9p2mps, headers,main risers in F#riti#al #ir#2itG• 0se pipe siAing spreadsheet or shortc#t tables

4ind maBim2m &lo &or ea#h pipe si(e andre#al#2late DT &or these &lo rates• 0se pipe siAing spreadsheet or shortc#t tables

The largest DT is then the plant design DTAd 2st C* 4lo 2p per sele#ted DT

This proced#re attempts to minimiAe cost by red#cing pipe siAeas m#ch as possible1 b#t then ta"ing #ll advantage o theres#lting pipe siAe to minimiAe GT to red#ce chiller energy.

'=am$le :uilding


134/214

.+

am$le :uilding

--.+ 7 ∆ T drops the pipe rom - F to -+FX

ooling To er Selection


135/214

.+5

,ooling To.er Selection

9

B

5

--

-*

-9

-B-5

---,

5

B6

9

*+

-,O

-,O+,O*,O

,O9,O6,OB,O

,O5,O

-,,O--,O-+,O-*,O- ,O-9,O-6,O-B,O- ,O

-5,O+,,O+-,O

K ) e s

i g n

C a p a #

i t y

Approa#h 9 4

0ange 9 4

+,,O8+-,O-5,O8+,,O- ,O8-5,O-B,O8- ,O-6,O8-B,O

-9,O8-6,O- ,O8-9,O-*,O8- ,O-+,O8-*,O--,O8-+,O-,,O8--,O5,O8-,,O

,O85,OB,O8 ,O6,O8B,O9,O86,O

,O89,O

*,O8 ,O+,O8*,O-,O8+,O,O8-,O


136/214

)ro$eller fan to ers


137/214

.+=

)ro$eller fan to.ers

To.er -an ,ontrol


138/214

.+>

To.er an ,ontrol

4ree CoolingQ .5K o& Capa#ity

Single Speed4an

T o"Speed or ariable"Speed

4an

K Capa#ity

K Po er

'ne Cell To er

To.er -an ,ontrol


139/214

.+?

To.er an ,ontrol

,O

-,O

+,O

*,O

(,O

9,O

6,O

B,O

,O

5,O

-,,O

, O 9 O -,O - 9O + ,O + 9O * ,O *9O (, O ( 9O 9,O 9 9O 6 ,O 6 9O B ,O B 9O ,O 9 O 5 ,O 59O - ,,

O

K Capa#ity

K P o e r

T o ."Speed 4ans

T o ,"Speed 4ans

'ne ."Speed 4an and'ne ,"Speed 4an

4ree Cooling 7elo .5KCapa#ity

T o ariable Speed

T o Cell To er

To.er -an ,ontrol


140/214

. -

To.er an ,ontrol

'ne"speed #ontrol is almost never the optim2m strategyregardless o& si(e, eather, or appli#ationT o"speed .>--/?-- rpm motors typi#ally best li&e #y#le#osts at mid".??- S) #osts, b2tV

S)s are best #hoi#e any ay

• %osts contin#e to all• /o t start red#ces belt !ear • Lo!er noise• %ontrol savings or ::% systems (net!or" card options)• More precise control

Pony motors are more eBpensive than t o"speed b2t o&&erred2ndan#yM2ltiple #ell to ers m2st have speed mod2lation on atleast /+ o& #ells 9re12ired by Title Standards b2t &orred2ndan#y, 2se S)s on all #ells!

To.er 'fficiency


141/214

. .

To.er fficiency ,,

5, 3'M >' B, 3'M >' 9, 3'M >'

-,,, ton

Ha"landH ice

/>R 4 4 iciency$

The lo! rate the to!er cancool rom 597 to 97 at B97!etb#lb temperat#re divided by

an po!er (3'M >')

To.er A$$roach


142/214

.

To.er A$$roach

Ha"land H ice Ha"land :ata %enter

%$timum A$$roach Tem$erature


143/214

. +

0

5

10

15

20

25

30

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

T o w e r A p p r o a c ! R a n " e

Coo#in" De"ree-Da$s - %ase &0'

*# l#+!

Ch # &Al ) )er )e

M #m

A$l#+$#

#( e #(

50CW A CDDT T 001.027 −∆−=

To.er 'fficiency #uidelines


144/214

.

y

6se Propeller 4ans• void centri #gal except !here high static needed or

!here lo!8pro ile is needed and no prop8 an optionsavailable.

• %onsider lo!8noise propeller blade option and highe iciency to!er !here lo! so#nd po!er is re?#ired.

E&&i#ien#y• Minim#m , gpm hp or commercial occ#pancies• Minim#m -,, gpm hp or + B plants (data centers)

Approa#h• %ommercial occ#pancies$ /ee previo#s slide7 to 5 7 or 2ay rea

• + B plants (data centers)$ * 7


145/214

:reak

,H8


146/214

. ;

, ,

'art8Load Ratio

,hiller )rocurement A$$roaches


147/214

. =

, )

Most Common Approa#h• 'ic" n#mber o chillers1 #s#ally arbitrarily or as

limited by program or space constraints• Ta"e plant load and divide by n#mber o chillers

to get chiller siAe (all e?#al)• 'ic" avorite vendor • >ave vendor s#ggest one or t!o chiller options• 'ic" option based on minimal or no analysis

• 2id the chillers along !ith the rest o the =ob andlet mar"et orces determine !hich chillers yo#act#ally end #p installing

,hiller )rocurement A$$roaches


148/214

. >

, )

7etter Approa#h• 'ic" a short list o vendors based on past

experience1 local representation1 etc.• Re?#est chiller bids based on a per ormance

speci ication. M#ltiple options enco#raged.• d=#st bids or other irst cost impacts• 4stimate energy #sage o options !ith a detailed

comp#ter model o the b#ilding plant

• /elect chillers based on lo!est li e cycle cost• 2id the chillers at end o design developmentphase

,hiller :id S$ecification


149/214

. ?

,

)onNt Spe#i&y:• ;#mber o chillers• %hiller siAe• %hiller e iciency

• %hiller #nloadingmechanism• s m#ch as possible

)o Spe#i&y:• Total design load• nticipated load pro ile• Minim#m n#mber o

chillers and red#ndancy

re?#irements• :esign %>& %& enteringand leaving temperat#resand or lo!s (or tables oconditions)

• vailable energy so#rces• 'hysical1 electrical or

other limitations• co#stical constraints• cceptable re rigerants

Sam$le


150/214

.5-

)

,

-, ,

+, ,

*, ,

, ,

9, ,

6, ,

B, ,

, ,

-,O +,O *,O ,O 9,O 6,O B,O ,O 5,O -,,O

Per#ent Load

H o 2 r s p e r y e a r


151/214

Lero Tolerance "ata


152/214

.5

,O

9O

-,O

-9O

+,O

+9O

*,O

*9O

,O

9O

,O +,O ,O 6,O ,O -,,O -+,O

K o& 42ll Load

K T o l e r a n # e

-,7 :elta8T-97 :elta8T+,7 :elta8T

A08 55-/5?- Toleran#e C2rve

-actory Tests and


153/214

.5+

amage ,lausesCerti&ied 4a#tory Tests• ;eed to veri y per ormance to ens#re acc#rate

claims by chiller vendors in per ormance bids• 7ield tests are di ic#lt or impossible and less

acc#rate• Last chance to re=ect e?#ipmentLi12idated )amage Cla2se• Hne8time penalty or ailing tests as an option to

reb#ilding or repairing chiller

,hiller :id -orm


154/214

.5

3ello : 4ields to be#ompleted by endor

7l2e: Cal#2lated&ields

*hite: 4iBed&ields

,hiller :id -orm


155/214

.55

,hiller :id -orm


156/214

.5;

,hiller :id 'valuation


157/214

.5=

Ad 2st &or 4irst Cost 8mpa#tsEstimate Maintenan#e CostsCal#2late Energy Costs• :H48+.-4 or :H48+.+ model o b#ilding and plant

Cal#2late Li&e Cy#le CostsTemper Analysis ith Consideration &orFSo&tG 4a#tors4inal Sele#tion

'=am$le )ro ects


158/214

.5>

)

Large Central Plant• %entral plant serving ind#strial o ice research

par"1

/an Qose1 % . -B1,,, tons total capacityLarge High"rise '&&i#e 72ilding• H ice pl#s small data center1 retail1

/an 7rancisco1 % . -9 stories1 9 ,1,,, t +


159/214

1 555Ton

,hiller

)lant

hiller %$tions


160/214

.;-

Description1st Cost Rank

Ener !"sa e Rank

#i$e C!c%eCost &ers's

(ase #CC Rank

Carrier K1 T o 1#27 tons 0.57 D/t 1 5 0 1Carrier K2 T o 1+21 tons 0.55 D/t 2 + 87 0+7 +Trane K1 T o 1##0 tons 0.56 D/t # # 3 33+ 2

Lor K1 T o 1230 tons 0.56 D/t 5 6 266 80+ 7Lor K2 T o 128+ tons 0.57 D/t + 7 131 5#3 6Lor K# T o 1250 tons 0.5# D/t 6 2 5# 010 #Lor K+ T o 127# tons 0.5# D/t 7 1 87 83+ 5

Sele#tedChillers

,hiller %$tions

LCC Ass2mptions:"iscount rate N6'lectricity 'scalation 56Analysis years 17

- +2 -

% -% +% *%


161/214

San -ranciscoHigh4rise

%ffice1155 tons

.; TH 4L''0

; TH 4L''0

A6R

4A "C'8LS

% C06s

Hi)( ise4//i&e To er )es#ription

1stCostRank

EnergyCostRank

Life CycleCost

Savings vsBase

LCCRank

vs.


162/214

C(iller4ptions

Trane - ,, ton1 ,.9, "& tYB,, ton1 ,.99 I! ton 6 5 [- +1,-6 -,

Trane + ,, ton ! V7:1 ,.9, "& tYB,, ton1 ,.99 I! ton 5 + [++1,5+

%arrier - *69 ton1 ,.96 "& tYB*9 ton1 ,.9, "& t - -+ [-B*156+ -+

%arrier +*69 ton ! V7:1 ,.96 "& tYB*9 ton1 ,.9, "& t * 9 [+-1+ 6 *

%arrier **69 ton ! V7:1 ,.96 "& tYB*9 ton ! V7:1 ,.9, "& t [B1B,+ +

McC#ay -+,, ton1 ,.9, "& tY5,, ton d#al ,.9 "& t + [B 1-95 9

McC#ay + 99, ton d#al1 ,.96 "& t99, ton d#al1 ,.96 "& t 9 -- [- -1-B5 5

McC#ay * ,, ton d#al1 ,.9* "& tYB,, ton d#al ,.9* "& t B [--+1 -5

McC#ay +,, ton1 ,.9* "& tY*9, ton d#al ,.9B "& tY99, ton d#al ,.95 "& t B -, [- B1 , --

Jor" - 99, ton ! V7: 1 ,. 5 "& tY99, ton1 ,. "& t -- 6 [-, 1,B B

Jor" +*,, ton ! V7: 1 ,.9, "& tY

,, ton1 ,. "& t -, - [, -

Jor" **69 ton ! V7: 1 ,.9+ "& tY*66 ton1 ,.9- "& t*66 ton1 ,.9- "& t -+ * [5+1 +- 6

Sele#tedChillers

-

+

2 -

2 +

2 *

% -

% +

% *

%

: -

: +

: *

L%% ss#mptions$%is&o$nt rate 8,Fle&tri&ity Fs&alation 0,.nalysis years 15

,onsidering 2Soft -actors3


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.;+

*hy 'ption 7+ as Sele#ted over 'ption) :• %lose in L%% (+nd behind Hption :+) P !ithin the

margin o error in the analysis

• Hption 2* #sed R-* a !hich !as pre erred byclient d#e to Aero H:' (:+ #sed R8-+*)• 2oth Hption 2* chillers had V/:s (only one in

Hption :+)• /mall chiller p#mp can operate large chiller ( lo!

minim#m design ranges overlap)• Hption 2* hermetic1 Hption :+ is open8drive• Hption 2* had lo!er irst cost

Advantages D "isadvantages%- >',%MM'0"'" ,H8


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.;

, , , )) ,

)isadvantages• 4xtra !or" or both engineer and vendor • :i ic#lt to incl#de maintenance impact• ss#mes energy rate sched#les !ill remain as they

are no! !ith simplistic ad=#stments or escalation

Advantages• llo!s man# act#rers to each ind their o!n Es!eetF

spots1 both or cost and e iciency• 0s#ally higher energy e iciency

• More rational than typical selection approaches


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.;5

%)T8M8L80# ,%0T>%


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.;;

All plants are di&&erent• To!er e iciency1 approach• %hiller e iciency1 #nloading control• '#mp e iciency1 head1 #nloading control• ;#mber o chillers1 p#mps1 to!ers

Too many independent variables• %T an speed• %hiller staging• %& p#mp speed and staging

*hat is the optim2m #ontrol se12en#e &or a

given plant


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.--- Tons total #apa#ity)2al #hillers/p2mps/to ers

ariable speed drives oneverything 9optional onC*Ps

'Eui$ment Models


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.;>

Chillers• >ydeman et al1 Regression 2ased 4lectric %hiller Model• M#lti8point calibration #sing Aero8tolerance man# act#rer s

data

To ers• :H48+.+ model calibrated #sing man# act#rer s data

P2mps• M#ltiple piping sections G' %Z3'M -.• '#mp e iciency rom regression o man# act#rer s data4) and motor e&&i#ien#y• 'art load c#rves rom man# act#rer s data

#eneric )lant "esign %$tions


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.;?

Plant• H ice b#ilding• 'ea" Load 5,, ton• T!o chillers each 9,, ton• T!o %& p#mps D to!ers• T!o %>& p#mps• ll variable speed

Climate:• *%$ Ha"land• 2$ lb#?#er?#e• 9%$ %hicago

Chillers:

• $ t!o stage R8-+* hermetic• 2$ one stage R8-* a opendrive

To er Approa#h• 8 $ * \ 97• 82$ 9 \ B7• 8%$ B \ -,7• 8:$ 5 \ -+7

To er 0ange:

• 8-$ 57• 8+$ -+7• 8*$ -97

To er E&&i#ien#y• >$ \5, gpm hp• M$ \B, gpm hp• L$ \9, gpm hp

Theoretical Hptim#m'lant 'er ormance(TH'') M d l


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(TH'') Model

R#n Time$ \9ho#rs r#n Z +-6 r#ns -, , ho#rs1 notincl#ding analysisX

"etermining SeEuences


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.=.

Plot T'PP res2lts vs! vario2sindependent variables to see i& thereare trends'n#e independent variables aresele#ted, determine #orrelationsTest the se12en#e 2sing the modelsto see ho #lose they are to the

T'PP


172/214


173/214

,hilled Water )um$s

)rimary $um$s of $rimary9secondary system


174/214

.=

Staging• /tage !ith chillers

Speed #ontrol 9i& variable speed• Maintain secondary %>& s#pply temperat#re e?#al to

primary %>& s#pply temperat#re0se trim D respond logic !ith Ere?#estsF generated !hen secondary%>&/T exceeds primary %>&/T

• < lo! meters on both primary and secondary1 maintainprimary lo! e?#al to secondary lo!

4ns#re lo! meters are chec"ed or consistency

)rimary4only D Secondary ,HW )um$s


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.=5

'ercent o :esign7lo!

'ercent o '#mp/peed

H p

t i m # m

; # m

b e r o

' # m p s

• /taging o lo! better than o speed• Logic$

• Hne '#mp$ %>&7R W BO• T!o '#mps$ %>&7R ] BO• Time delays to prevent short8

cycling

TH'' Model Res#lts

)rimary4only D Secondary ,HW )um$s


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.=;

Control speed by di&&erential press2re meas2redas &ar o2t in system as possible• />R 4 5,.- re?#ires :' sensors at (all) remote

coils heat exchangers

Position matters be#a2se )P setpoint not &2llyreset by valve position 9dis#2ssed beloTo avoid long iring r2ns, #ontrol may be o&&lo#al )P sensor at plant ith setpoint reset byremote )P sensors #onne#ted to plant #ontrollervia net ork

S" )um$ )o.er vsF Set$oint


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.==

0,

10,

20,

#0,

+0,

50,

60,

70,

80,

30,

100,

0 10, 20, #0, +0, 50, 60, 70, 80, 30, 100,

)ercent #)M

) e r c e n t ) u m $ k W

%P setpoint %esi)n Head

%P setpoint Head".75

%P setpoint Head/2

%P setpoint Head/#

%P setpoint 0 -reset:

,hilled Water Set$oint >eset


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.=>

0eset 8mpa#ts• Resetting %>&/T #p!ards red#ces chiller energy b#t !illincrease p#mp energy in V/: variable lo! systems

• :eh#midi icationReset !ith EopenF or indirect control loops (e.g. H T) can starve coilsand red#ce deh#midi ication

Reset by control valve position !ill never h#rt deh#midi ication ^h#midity o s#pply determined almost entirely by s#pply airtemperat#re setpoint1 not %>&/T

0e#ommendations• Reset rom control valve position #sing Trim D Respond logic• 7or variable lo! systems !ith V/:s

Reset o %>&/T and V/: di erential press#re setpoint m#st bese?#enced ^ not independent li"e V V systems since control valvesare press#re8dependent/e?#ence reset o %>&/T and :' ^ next slide_

,HWST9") Set$oint >eset for S",HW System


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.=?

2ac" o on %>&/T irstThen bac" o on :' setpoint irstReverse this or constant speed chillers

T'inN15O;

T'in

%P'aI

5 psi

CHDsetpoint

CHDsetpoint

%Psetpoint

%Psetpoint

CHD Plant eset0 100,50,

,HW vsF ") Set$oint >eset


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.>-

'lant !ith -9, t. %>& p#mp head1 variable speed chillers


181/214

,ooling To.ers

>eset by Wetbulb Tem$erature?


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.>

2T4,HWST! vsF 6


183/214

.>+

Li t Reset 2est 7it or H ices

&etb#lb reset best or data centers sinceload does not vary


184/214


185/214

,ondenser Water )um$

,W $um$ ,ontrol


186/214

.>;

Constant speed C* p2mps• /tage along !ith chillersariable speed C* p2mps<

6,W


187/214

.>=

S" ,W) ,ontrol


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.>>

P2mp speed #ontrol• %&7R %Z'LR ` :• %&7/' %&7RZ%&:7• %ontrol speed to maintain %& lo! at setpoint

Staging• /ame logic as %>& p#mps

)isadvantages• Re?#ires lo! meter • % and : coe icients only optimiAed by sim#lation

,Watio O,P)lantatio Q "


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.>?

C 0.0000811 CDD55 : 0.01293 "; : 3.486


190/214

ariable S$eed ,W )um$s;'nergy Savings (%ffice :uilding!


191/214

.?.

Ha"land H ice 2#ilding

TheoreticalHptim#m 'lant'er ormance

%onstant 7lo!

TheoreticalHptim#m 'lant'er ormanceVariable 7lo!

/im#lated%onstant 7lo!

!ith Real/e?#ence

/im#latedVariable 7lo!

!ith Real/e?#ence

ariable S$eed ,W )um$s;


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.?

L i & e C y #

l e C o s

t s ,

Z

TheoreticalHptim#m 'lant'er ormance

%onstant 7lo!

TheoreticalHptim#m 'lant'er ormanceVariable 7lo!

/im#lated%onstant 7lo!

!ith Real/e?#ence

/im#latedVariable 7lo!

!ith Real/e?#ence

2arely coste ective !ith

ideal controls

;ot coste ective !ithreal controls

'nergy se May 8ncreaseR


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.?+

0

200000

400000

600000

800000

1000000

1200000

1400000

Ch ller %&'er CH"P C"P Pl#+$%&$#l

A n n ( a

# C i # # e ) * a t e r P # a n t + n e r " $ U s e

, - *

.

%*PP

=%D

GE< 1*A>

:enver H ice 2#ilding

'er ormance in :enver #sing % and : optimiAed or Ha"land

'nergy se May 8ncreaseR


194/214

.?

'er ormance in Miami #sing % and : optimiAed or Ha"land

Ha"land

Miami H ice 2#ilding

Miami


195/214

.?5

*# l#+! ?M #m ?

@ 0.9069 : 0.0388

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

C * "

p m

/ Tota# P#ant Desi"n Capacit$

C* "pm vs / Loa)

>ecommendations


196/214

.?;

4or o&&i#es et#!, 2se #onstant speedp2mps4or data #enters and other /=plants• 0se V7:s• :etermine % and : coe icients thro#gh

modelingHther logic may increase energy #sage


197/214

,hiller Staging

Staging -i=ed S$eed ,hillers


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.?>

4iBed Speed Chillers• Hperate no more chillers than re?#ired to meet

the load• /tage on !hen operating chillers maxed o#t as

indicated by meas#red load (3'M1 ∆ T)1%>&/T1 lo!1 or other load indicator.

• 7or primary8secondary systems ! o chec" valvein the common1 start chiller to ens#re 'rimary8

lo! ] /econdary8 lo!

• /tage o !hen meas#red load lo! indicatesload is less than operating capacity less onechiller P be conservative to prevent short cycling

Staging ariable S$eed ,hillers


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.??

)art 8 Tolerance


200/214

--

,O

-,O

+,O

*,O

,O

9,O

6,O

B,O

,O

5,O

-,,O

,O -,O +,O *,O ,O 9,O 6,O B,O ,O 5,O -,,O

K Load 9 ith Condenser 0elie&

K k *

7ixed /peed

Variable /peed

T.o4,hiller )lant )erformanceat


201/214

-.

0,

10,

20,

#0,

+0,

50,

60,

0, 10 , 20 , #0 , +0 , 50,

6 )lant


202/214

-

Staging logi# m2st limit possibility &ors2rge operation &or #entri&2gal #hillersSome variable speed #hillers donNtdynami#ally meas2re s2rge #onditions

• Jo# !ill lose some o the savings !ith primary8only variable lo! systems beca#se minim#mspeed may have to be increased to avoid s#rge

• Jo# may have premat#re tripping d#e to onset os#rge other!ise

• This is only an iss#e !ith variable evaporatorlo! systems (li"e primary8only variable lo!)

Staging D Surge


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-+


204/214

,orrelation .ith


205/214

-5

%hiller Q1 Miami1 :8*

%hiller Q1 %hicago1 :8*

%hiller Q1 tlanta1 :8*

%hiller Q1 Ha"land1 :8*

#eneric ,ontrol SeEuencesAll4variable s$eed $lant


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-;

) T T E *+#R C,W* CWR +−= :-Stage ,hillerson

0ominal,a$acity Stage u$ to ne=t stage if either;

Stage do.n tolo.er stage if;

0 ll o 0 −

ny C(iller Plante $ests and

4 T @4T ands&(ed$le is a&tive

−

2 @ead&(iller 50,or 15 'in$tes

load )reater t(an


207/214

-=

TE Correlations• 4 ,.,9B 8 ,.,,,965Z&2 8 ,.,6 9Z ` ,.,--BZR ;34 8-.**ZI& TH;

eed to test &or reasonableness)e&a2lt val2es• 4 ,.,, and 7 ,.*,

'=am$le


208/214

->

'akland o&&i#e b2ildingAll variable speed plantCoe&&i#ients best &it &rom T'PP

model• B1 2 9.+• % -.*1 : ,.-*• 4 ,.,,51 7 ,.+-

T%)) )lant 'nergy; %akland


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-?

> o # r s

) y e a r

"& ton

T%)) vsF >eal SeEuences


210/214

.-


211/214

..

Waterside 'conomi&ers

8ntegrated WS' ,ontrol SeEuences

02 ll i h dl i #l2di g d2 d t 2 it ith i bl


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.

02n all air handlers, in#l2ding red2ndant 2nits ith variablespeed drives0eset CH*ST setpoint based on valve demandEnable *SE i& CH*0T I predi#ted HRL*T Y • 'redicted >SL&T mbient !etb#lb ` >S pproach ` To!er pproach

>S pproach :esign >S approach Z O>S8LoadTo!er pproach :esign To!er approach or o ice type occ#pancies

d=#st based on &2T rom man# act#rer s data or datacenterP see slide 9

)isable *SE i& HRL*T I CH*0T ")isable #hiller9s hen HRL*T [ CH*ST setpointEnable #hiller9s hen CH*ST I setpoint02n as many to er #ells as minim2m &lo ill alloTo er speed:• &hen &/4 is disabled control speed EnormallyF• &hen &/4 and chiller(s) are enabled r#n 59O speed• &hen chiller is disabled control speed to maintain %>&/T setpoint

Summary


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.+

8n this #o2rse, yo2 have learned te#hni12es todesign and #ontrol #hiller plants &or near"minim2m li&e #y#le #osts, in#l2ding:• /electing optim#m chilled !ater distrib#tion system• /electing optim#m %>& s#pply D ret#rn temperat#res

• /electing optim#m %& and to!er range and approachtemperat#res1 to!er e iciency1 and an speed controls• /electing optim#m chillers #sing a per ormance bid and

L%% analysis• HptimiAing control se?#ences and setpoints

*uestions


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chilled water plant seminar - 04-2014

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