Chiller Plant Control

What We Will Cover

Factory-integrated controls on chillers

Chiller plant control strategies
Tracer control features
Reliability and serviceability
Chiller plant optimization
Additional discussion

Introduction to Trane Control Systems

2010 Trane

Trane AdaptiView Control System

4th Generation Microprocessor Chiller Control
Adaptive control
Reliable operation through difficult
operation conditions

Feed-forward control
Accurate and stable control under
the most dynamic system transients

Sophisticated diagnostics
Fast restarts
Operator tested informative display
Multiple open protocol communication options

Introduction to Trane Control Systems

2010 Trane

Trane AdaptiView Control System

Feed-forward Control
Feed-forward control enables the chiller to respond
faster to load changes
Feed-forward control uses flow change and entering water
temperature as an indication of load change

It proactively compensates for load changes

Introduction to Trane Control Systems

2010 Trane

Trane AdaptiView Control System

Feed-forward Control
Feedback

PID

Typical Controller
42

Feedforward

Trane
UC800/AdaptiView

UC800

Feedback

Return Water Temp

Evaporator Flow

40

56
DP
627 gpm
5

Introduction to Trane Control Systems

2010 Trane

Trane AdaptiView Control System

Variable Flow Compensation

Directly measures chilled water flow

Enhances leaving water temperature control during
rapid flow rate changes of up to 50%/min.
>30 % /min commercial control
10% /min precision process control

Auto-tunes control gains to maintain stability and

accuracy over chillers full range of flow rates.

Introduction to Trane Control Systems

2010 Trane

What Do Customers Really Care About ?

Reliable chilled water flow

Operating cost (energy efficiency)
Operator safety
Environmental awareness
Reduced maintenance cost

Introduction to Trane Control Systems

2010 Trane

Tracer Chiller Plant Control

Repeatability performance from plant to plant
Maximize the use of pre-engineered features
Minimize on-site customization

Flexibility supports a variety of:

Plant layouts
Chiller types
Control strategies

Maximized energy savings

Load matching
Chiller tower optimization
Distributed pump pressure optimization
Thermal ice storage
Minimize manual intervention

Minimized operational costs

Minimize manual intervention, but anticipate it
Maintain chilled water flow and temperature
Minimize service surprises

Introduction to Trane Control Systems

2010 Trane

Chiller Plant Control

Chiller Plant Control

Load
Determination

Chiller
Sequencing

Introduction to Trane Control Systems

User
Interface

System
Optimization

2010 Trane

Plant Layout Flexibility

Constant Flow

CW Return
Temp

UC
P2
UCP2

Chiller #2

CW Supply
Temp

UC
P2
UCP2

Chiller #1

10

Introduction to Trane Control Systems

2010 Trane

Plant Layout Flexibility

Variable Flow - Decoupled
UC
P2
UCP2

Chiller #2

UC
P2
UCP2

SUPPLY

DE MAND

Chiller #1
Bypass Line

Variable-Speed
Drive

11

Introduction to Trane Control Systems

Production

Air Handling Units

Distribution

Pressure
Differential
Controller or
Transmitter

Control
Valves

2010 Trane

Plant Layout Flexibility

Variable Primary Flow
UC
P2
UCP2

Variable-Speed
Drive

Differential Pressure
Sensor or
Transmitter

UC
P2
UCP2

S UPPLY

Flow
Meter

DE MAND

Bypass Line

Production

Air Handling Units

Distribution

Control Valves

12

Introduction to Trane Control Systems

2010 Trane

Pre-engineered Features

Load determination
Capacity matching
Rotation
Chiller setpoint control
Failure recovery
User interface

Installation and operating reliability and efficiency

13

Introduction to Trane Control Systems

2010 Trane

Load Determination
(when to add or subtract a chiller)

What is the optimal sequencing for chillers?

Should I run one chiller at 100% or two chillers at 50%?

The givens
whether you run one chiller or two

The building load does not change

The outside wet bulb temperature does not change
When you run two chillers

You may double the number of pumps

You may double the number of tower cells

14

Introduction to Trane Control Systems

2010 Trane

One Chiller at 100%? or

Two Chillers at 50%?
Constant Speed Centrifugal Chiller
Unloading at constant condenser water temperature
1.4
1.3
1.2

kW/ton

1.1
1
0.9
0.8
0.7
0.6
0.5
0.4
0

15

20

Introduction to Trane Control Systems

40
60
Percent Load

80

100

2010 Trane

Capacity Matching
(turn the right chiller on)
Dependent on chiller plant design

Normal
Base
Pea
Swing
Custom

- identical chillers
- heat recovery/super efficient
- back up/alternate energy source/inefficient
- match the load!
- mix and match/nested CPC objects

Reduce operating costs

16

Introduction to Trane Control Systems

2010 Trane

UCP2
UCP2
450 Ton Chiller
(Swing)

900 Ton Chiller

(Normal-1)

450

900
1350
Building Load (Tons)

900 Ton Chiller

(Normal-2)

1800

2250

Reduce operating costs

17

Introduction to Trane Control Systems

2010 Trane

Flexible Rotation
Which chiller is next?

Schedule based
Run-time
Manual operator decision
Customized
Number of starts
Other?

Reliable chilled water

18

Introduction to Trane Control Systems

2010 Trane

Unload Before Start

Keep chillers online

Ride out flow transients on startups

Deals with less sophisticated chiller controllers

Variable flow / multiple pump systems

Low supply water temperatures

Reliable chilled water

19

Introduction to Trane Control Systems

2010 Trane

Failure Recovery
Keep chilled water flowing

No manual intervention required

Follow the standard sequence
Multiple failure inputs

Chiller level
System level

Reliable chilled water

20

Introduction to Trane Control Systems

2010 Trane

Intuitive User Interface

Minimize training time
Minimize undesirable manual control
Maximize operator efficiency

Reduced Operational Costs

21

Introduction to Trane Control Systems

2010 Trane

Chiller - Tower Optimization

Tower Setpoint Optimization

Load

Load

Condenser water

Condenser water

temperature
Wet bulb

temperature
Chiller design

Tower design

22

Introduction to Trane Control Systems

2010 Trane

Chiller - Tower Optimization

ChillerTower Interaction
400

Energy Consumption, kW

Total
300

Chiller

Optimal
control point

200

100

Tower

0
72

74

76

78

80

82

84

Condenser Water Temperature, F

23

Introduction to Trane Control Systems

2010 Trane

Chiller - Tower Optimization

North America
350K
Annual Operating Cost, $ USD

Control Strategy

300K

Optimal Control

250K

Design ECWT

200K
150K
100K
50K
0

24

55F Lvg Tower

Mexico City

Introduction to Trane Control Systems

Orlando

San Diego

Toronto
2010 Trane

Distribution Pumping
Critical Valve Pressure Control

Critical valve reset

Benefits
Reduced pump energy
Better coil control
Extend pump life

Pressure
Differential Air Handling Units
Controller or
Transmitter

Control
Valves

Reduce operating costs

25

Introduction to Trane Control Systems

2010 Trane

Chiller Plant Dashboard Details

System and
Chiller Status

Chilled Water Temps

Tower Water Temps

Pump Status
System
Efficiency
System
Load

Pump
Flow
Daily Average Metrics
26

Introduction to Trane Control Systems

Pump Pressure
2010 Trane

Summary
Key points to remember
Integrated chiller controls
Factory quality; better performance, efficiency
and serviceability; lower risk

Performance
Temperature control; reliability; extended equipment life;
automatic failure response

Efficiency
Lower energy and maintenance costs

Sustainability
Maintain performance over time
Document performance

27

Introduction to Trane Control Systems

2010 Trane

Thank you!

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