Professional Documents
Culture Documents
FOR
COOL THERMAL STORAGE
Principal lnvestigators
Charles E. Dorgan, Ph.D, P.E.
James S. Elleson, P.E.
ISBN 1-883413-07-9
No part of this book may be reproduced without permission in writing from ASHRAE,
except by a reviewer who may quote brief passages or reproduce illustrations in a
review with appropriate credit; nor may any part of this book be reproduced, stored in
a retrieval system, or transmitted in any form or by any means--electronic, photocopy-
ing, recording, or other-without permission in writing from ASHRAE.
ASHRAE has compiled this publication with care, but ASHRAE has not investigated,
and ASHRAE expressly disclaims any duty to investigate, any product, service,
process, procedure, design, or the like which may be described herein. The appearance
of any technical data, editorial material, or advertisement in this publication does not
constitute endorsement, warranty, or guaranty by ASHRAE of any product, service,
process, procedure, design, or the like. ASHRAE does not warrant that the information
in this publication is free of errors, and ASHRAE does not necessarily agree with any
statement or opinion in this publication. The entire risk of the use of any information
in this publication is assumed by the user.
Thirty-one individuals reviewed the final two drafts. The following deserve special
thanks for theirdetailedcomments, suggestions, and supplementalinformation: David
Arnold, John Andrepont, William Bahnfleth, Jim Denkmann, Bill Dietrich, Wallace
Donley, Don Eppelheimer, Don Fiorino, Don Gatley, Ken Gillespie, Jim Holtzapple,
Steve Houston, David Knebel, Ian Mackie, Mark MacCracken, Skip McCullough,
Frederick McDonough, Victor Ott, Bill Stewart, Martin Tirnrn, Sherrod Waites, and
Bud Wildin.
Dorgan Associates staff members who deserve recognition for their contributions
include technical writers Marion McGavock and Steve Parsons, whose input and
assistance in setting the concepts of the Guide down on paper were invaluable. Steve
Leight, Mike Armstrong, Steve Dingle, Naorni Sirndon, and Dane Taival assisted with
research, the development of illustrations, and example calculations. As always,
Marisue Quigley did an excellent job of word processing, proofreading, and final
editing and formatting.
ASHRAE staff who edited and prepared the pages for this guide were Robert Parsons
and Claudia Forman.
Chapter 1 INTRODUCTION
1.1 BACKGROUND
ASHRAE commissioned this design guide in response to the need for a comprehen-
sive, current cool storage reference manual. This document will assist engineers and
owners to evaluate cool storage for specific applications, to select the appropriate
cool storagetechnology for a given application,and to design successful cool storage
systems. The guide is a valuable first-level reference, which discusses cool storage
fundamentals, compares cool storage technologies, and describes a rational proce-
dure for designing cool storage systems.
Cooling contributes 35%of the summer electric demand in many areas of theunited
States. Unlike other building electric uses, cooling incurs a peak demand for only a
few days or weeks each year. Electric utilities have recognized the ability of cool
storage to favorably alter electric usagepatterns.Many now offer incentiveprograms
and special rate structures that encourage cool storage usage. In addition, cool
storage technology has improved significantly since 1980. Designers and their
clients continue to express strong interest in the use of cool storage to reduce energy
costs.
The guide is organized into ten chapters. Chapter 1, Introduction, provides basic
background on cool storage concepts and terminology. Chapter 2, Fundamental
Design Considerations, presents information that is common to all cool storage
systems,regardless of the specific storage technology used. Chapter 3, Comparison
of Storage Technologies, provides an overview and comparative discussion of six
cool storage technologies. Chapters 4 through 9 provide detailed, specific discus-
sions of the six technologies. Chapter 10, Design Procedure, gives a step-by-step
1-2 Design Guide for Cool Thermal Storage
description of the cool storage design process, with representative examples for
specific steps of the process. Appropriate references and a bibliography are provided
at the end of each section, and a complete reference list is included at the end of the
book.
All costs given in this guide are in terms of 1992 U.S.dollars, unless specifically
noted otherwise. Costs reflect United States averages and may be higher or lower in
some geographical areas.
Early refrigeration systems used blocks of icecut from frozenlakes as stored cooling.
With the advent of mechanical refrigeration, most stored cooling systems were
replaced by instantaneouscooling systems sized to meet the maximum expectedload
at any time.
Interest in cool storage for commercial applications grew in the 1970s and 1980s,
when electric utility companies recognized the need to reduce the peak demand on
their generation and distribution systems. For many utilities, the peak system
demand is driven by the air-conditioning load on the hottest days of the year.
Utilities realized that if cooling could be generated and stored during off-peak
periods for later use, more peak capacity would be available for other uses, and off-
peak capacity would be more fully used. Many utility companies began to offer
financial incentives in the form of specialized rates, peak demand charges, rebates,
and subsidies to encourage customers to shift their on-peak energy consumption to
off-peak periods.
Cool storage systems permit such a shift by decoupling chiller operation from
instantaneous loads. A cool storage system meets the same total cooling load in a
given period as a non-storage system but with a smaller instantaneous cooling
capacity. The total cooling capacity distributed over the period is matched more
closely to the total cooling load encountered in the same period. Often, the money
saved by downsizing chillers can offset the cost of adding a cool storage medium.
Some cool storage technologies facilitate further cost reductions by making the use
of lower supply air and supply water temperatures practical and cost effective. Air
Introduction 1-3
and water distribution equipment can be downsized when supply temperatures are
reduced and operating differentials are increased.
By decoupling chiller operation from instantaneous load, cool storage systems also
facilitate more constant loading on the refrigeration equipment and increase chiller
efficiency due to lower condensing temperatures during nighttime operation. Cool
storagesystems can provide substantial operating cost savings by generating cooling
using cheaper off-peak energyand reducing or eliminating on-peak demand charges.
Owners and designers should consider selecting a cool storage system when any of
the following criteria apply:
The maximum cooling load of the facility is significantly higher than the
average load. This is true for most nonindustrial facilities.
The electric utility rate structure includes high demand charges, a significant
differential between on- and off-peak rates, or special rebates or incentives for
cool storage installations.
An existing cooling system is undergoing expansion.
An existing tank suitable for cool storage use is available.
Cooling is needed for an application in a remote region or country where
refrigeration equipment is extremely expensive.
Electric power available at the site is limited.
Backup or redundant cooling capacity is desirable.
Cold air distribution can be used, is necessary, or would be beneficial.
Office building cooling loads often peak at a level two or more times higher than the
daily 24-h average load. Some industrial processes also have load peaks or spikes
that rise much higher than the average load. A d a q , for example, might operate its
refrigeration system at full capacity to cool a batch of milk, then throttle back to
maintenance mode or even shut down completely. A cool storage system generates
cooling during low-load periods and meets the peak loads using stored cooling. The
higher the ratio of peak load to average load, the greater the potential reduction in
required chilling capacity using cool storage.
In some cases, electric power available to a site may be limited, or the availability
of additional power may depend on the addition of expensive transformers or
switchgear. Here the use of cool storage can significantly reduce electric demand for
cooling.
Cool storage can provide short-termbackup or reserve cooling capacity for computer
rooms and other critical applications. Cooling loads can be met from storage simply
by operating pumps, thus reducing the required size of emergency generating
equipment. For f i i backup capacity, storage must be oversized to provide the
desiredresemeeven if a chiller goes down at the end of the normal discharge period.
Cool storage technologiesusing ice as the storagemedium permit the economical use
of reduced supply water and air temperatures. In such systems, engineers can
downsize pumps, piping, air handlers, and ductwork and realize substantial reduc-
tions in first cost.
Introduction 1-5
Cold air distribution systems using supply air between 42 and 49'F (6 and 9°C)
provide several benefits to building owners (see Section 2.5). They include reduced
distribution system costs, improved comfort and indoor air quality, and reduced
construction costs in some high-rise buildings. In buildings where cooling loads
have increased beyond the capacity of the existing distribution systems, the in-
creased loads can be met with colder supply air. Increasing the capacity of the
distribution system in this way requires minimal changes to existing ductwork. In
applications where the benefits of cold air distribution are of primary importance,
cool storage systemsusing ice as the storage medium are generally preferable to low-
temperature nonstorage chillers.
An evaluation of cool storage economics for a given application compares the first
costs and the operating costs of a cool storage system with those of a nonstorage
system. In applications particularly favorable for cool storage, the total first cost of
a storage system can be lower than that of a nonstorage system. However, the fist
cost of a storage system is usually greater than that of a nonstorage system. The
operating costs for a storage system are lower than those for a nonstorage system.
System first cost includes refrigeration equipment, storage tank, controls and
instrumentation, and air and water distribution equipment. Refrigeration equipment
for a storage system is generallysmaller and less expensive than that for a nonstorage
system. Therelative costs of refrigeration equipment and storage capacity depend on
the storage technology and operating strategy selected for the application.
Distribution system costs can often be reduced by using cool storage systems. Many
storage technologies take advantage of wider water temperature differentials than
typical nonstorage systems; this reduces the size and cost of pumps and piping
systems. Cool storage systems using ice as the storage medium can supply air at
reduced temperatures, thus decreasing the cost of air distribution systems.
First costs for cool storage systems can also be reduced by direct utility subsidies.
Many utilities offer incentive payments or rebates to building owners who install
cool storage systems, generally in the range of $100 to $500 per kilowatt of on-peak
demand reduction.
Operating costs for electrical energy and demand are reduced for cool storage
systems. The amount of reduction depends on the utility rate schedule, including
demand charges, differentialbetween on-peak and off-peak energy charges, and the
length and schedulingof on-peak periods. Reductions in operating costs also depend
on the load profile for a given application.
1-6 Design Guide for Cool Thermal Storage
The Electric Power Research Institute (EPRI) provides funding for research of
interest to the electric utility industry. EPRI has funded most recent research related
to cool storage, and has published a number of research reports. These reports are
available at no charge from EPRI member utilities, or researchers, by contacting the
EPRI Distribution Center, 207 Coggins Drive, PO Box 23205, Pleasant Hill, CA
94523;Phone (510) 934-4212.EPRI also supports the Thermal Storage Applications
Research Center (see Section 1.5.4).
Introduction 1-7
BIBLIOGRAPHY
Ahlgren, R.M. 1987. Water treatment technologies for thermal storage systems.
EPRI EM-5545.December.
ASHRAE. 1985. Technical Data Bulletin: Thermal Storage.
ASHRAE. 1989.ASHRAE Guideline 1-1989,Guidelinefor Commissioning HVAC
Systems.
ASHRAE. 1989. Technical Data Bulletin: Cool Storage Applications 33).
ASHRAE. 1989. Technical Data Bulletin: Cool Storage Modeling and Design 5(4).
ASHRAE. 1993.1993 ASHRAE Handbook-Fundamentals.
Dorgan, C.E. and J.S. Elleson. 1988. Cold air distribution design guide. EPRI EM-
5730, March.
Gatley, D.P. 1992. Cool storage ethylene glycol design guide. EPRI TR-100945,
September.
Gatley, D.P.and J.J. Riticher. 1985. Successful thermal storage. ASHRAE Transac-
tions 91(1B):843-55. Reprinted in ASHRAETechnical Data Bulletin: Thermal
Storage (January):37-49.
Mackie, E.I. and G. Reeves. 1988. Stratified chilled-water storage design guide.
EPRI EM-4852s, May.
Mackie, E.I. and W.V.Richards. 1992. Design of off-peak cooling systems. ASHRAE
Professional Development Seminar.
Chapter 2 FUNDAMENTAL DESIGN
CONSIDERATIONS
This section introduces the concepts essential to the design of cool thermal storage
systems. These concepts apply to cool storage systems in general, regardless of the
specific storage medium or storage technology selected. The design considerations
relevant to specific storage technologiesarediscussedin Chapters4 through 9, while
application of the fundamentals to the design procedure is discussed in Chapter 10.
The cooling load profile over a period of 24 h or more is as important as the peak
hourly load for design of a cool storage system. In a nonstorage system, the total 24-
h system capacity is 24 times the peak hourly load, allowing sufficient "catch-up"
capability if the &sign load is exceeded for a short period. However, a cool storage
system must be designed to be able to meet the extended load over time as well as
the peak hourly load. Therefore, it is important to accurately calculate the total
integrated load over the complete storage cycle.
2-2 Design Guide for Cool Thermal Storage
Designers may elect to use less extreme design weather conditions for full storage
systems, since a full storage system can fall back to partial chiller operation if design
loads are exceeded. Owners shouldbe informed that at very high loads some on-peak
operation of cooling equipment may be required.
The ambient temperature profile on a design day can be estimated using the method
given in Example 1, Chapter 26, of the 1993ASHRAE Handbook-Fundamentals.
The temperature for any hour can be calculated by subtracting the tabulated
percentage of daily range from the peak dry-bulbtemperature. Thesepercen tages are
reprinted in Table 2-1. Local weather data can also be used to develop a more
accurate profile.
71 17 10
56 18 21
39 19 34
23 20 47
11 21 58
3 22 68
0 23 76
3 24 82
Historical weather data are generally preferable to constructed data, particularly for
locations where occasional extreme temperature episodes may not be accurately
Fundamental Design Considerations 2-3
The selection of design days for weekly cycles requires the evaluation of local
weather patterns. The most conservative approach is to design for five consecutive
weekdays with peak temperature profiles. If such an extreme episode is unlikely to
occur in a given area, it may be reasonable to use a design week consisting of two or
three peak days with the remaining days at lower temperatures.
Today, most load calculations are performed using a computer program. Many
programs will calculate hourly temperature profiles and hourly loads for a design
day. In other cases, temperature profiles may have to be calculated manually, as
discussed earlier.
Load profiles must be calculated for the entire design charge-discharge cycle of the
cool storage system. The most common cycle is 24 h long, but weekly cycles are also
applied when appropriate. Longer or shorter cycles are also possible for certain
applications. Charging cycles are discussed in greater detail in Section 2.4.
The calculation procedure for the hourly load is similar to that for a nonstorage
system. Chapter 26 of the 1993 ASHRAE Handbook-Fundamentals provides a
detailed discussion of cooling load calculation procedures. Mackie and Reeves
(1988) and Fields and Knebel(1991) discuss load calculation specifically for cool
storage systems.
Pull-down loads are important to consider in cool storage design. In systems that
provide cooling only during occupied periods, unoccupied heat gains are generally
2-4 Design Guide for Cool Thermal Storage
met during the first hour or two of operation. These pull-down loads normally do not
affect sizing of nonstoragesystems,but they must be taken into account in the design
load profile for cool storage systems.
Pull-down loads vary with the weekly day type: Monday, Tuesday through Friday,
Saturday and Sunday. These day types depend on building occupancy and use. For
example, for office buildings, Mondays have the highest pull-down loads if the
building HVAC systems are off during the previous day(s). All thermal energy
entering the building through solar gains, envelope transmission, or internal heat-
producing devices since the building HVAC system was last operated becomes a
pull-down load on Monday morning.
The designer of a cool storage system should bear in mind that many buildings,
particularly office facilities, have their HVAC systems shut down before solar
irradiation ceases on building surfaces. This solar heat gain becomes a pull-down
load on the following day. Care should be exercised when running computer
software to be sure that pull-down loads are properly accounted for.
For daily cycle systems,not all weekend hours are needed to charge storage. Monday
morning pull-down loads can be met by starting chillers one or two hours early, or
by providing additional storage capacity, which can be charged during the available
weekend hours.
If supply air temperatures are to be reduced, latent heat gains due to infiltration
should be calculated based on the expected space relative humidity.
The design load profile must also take pump heat and heat gains to the storage tank
into account. While pump heat represents a small instantaneous cooling load, the
contribution to the total load over the entirecycle can be significant. All chilled water
pumping energy appears as a load on the cooling system. Pump heat during charging
can be considered as a reduction in the chiller capacity available to be stored; pump
heat during discharging represents an increase in the cooling load.
Fundamental Design Considerations 2-5
Heat gains to the storage tank are generally referred to as thermal losses, consistent
with the loss of cooling capacity due to the heat gains. Thermal losses are another
relatively small instantaneous load that becomes significant over the design cooling
cycle. Thermal losses can be treated as adirect reduction in stored cooling capacity.
Some computer programs used for sizing cool storage systems offer the option of
using generic load profiles for various building types. Typically, a generic profile is
expressed in terms of the percentage of full load for each hour. An estimated profile
for a specific building can then be generated by multiplying the percentage for each
hour by the peak load for the building.
This approach should be used only for initial economic screening purposes, to
evaluate whether more detailed load and sizing calculations are warranted. The use
of such generic profiles for final sizing and design cannot be justified unless it is
known that the generic profile represents the actual building load profile.
The most common cool storage media are water, ice, and other phase-change
materials, commonly known as eutectic salts. These media differ in the amount of
energy stored per unit volume, the temperaturesat which they store cooling, and the
physical requirements of storing energy.
Chilled Water
Chilled water storage uses the sensible heat capacity of water-1 Btu per pound per
degree Fahrenheit (4.184 kJ/kg=K)-to store cooling. The storage volume depends
on the temperature differencebetween the water supplied from storageand the return
water. A temperature difference of 20°F (11°C) is the practical maximum for many
building cooling applications, although systems with differentials above 30°F
(17°C) have been installed.
The storage volume of chilled water storage is also affected by the degree of
separation maintained between the stored cold water and the warm return water. The
practical minimum storage volume for chilled water is approximately 10.7 ft3 per
ton-hour (0.086 m3/kWh) at a 20°F (11°C) temperature difference. With a 30°F
(17OC) differential, the storage volume is about 7 ft3per ton-hour (0.056 m3/kWh).
and distribution systems. Return water temperatures must be kept high to maximize
usable storage volume. This requirement may involve some departure from conven-
tional design practice.
Ice
Ice thermal storage uses the latent heat of fusion of water-144 Btujlb (335 kJ/kg).
The storage volume depends on the final proportion of ice to water in a fully charged
tank and is generally in the range of 2.4 to 3.3 ft3per ton-hour (0.02 to 0.03 m3/kWh),
depending on the specific ice storage technology.
Thermal energy is stored in ice at the freezing point of water- 32°F (0°C). To store
this energy, refrigeration equipment must provide charging fluid at temperatures of
15 to 26OF (-9 to -3OC). This is below the normal operating range of conventional
cooling equipment for air-conditioning applications. Depending on the ice storage
technology, special ice making equipment is used, or standardproduction chillers are
selected for low-temperature service.
The heat transfer fluid for ice making may be a refrigerant or a secondary coolant,
such as glycol or some other antifreeze solution.
The low storage temperature of ice also provides the ability to produce lower
temperature air for cooling. The lower chilled water supply temperature available
from ice storage allows a higher temperaturerise at the load, up to 25OF (14OC). The
benefits of cold air distribution are discussed in Section 2.5.2.
Eutectic Salts
Eutectic salt phase-change materials are available in various formulations to melt
and freeze at selected temperatures. The most common formulation for cool storage
applications is a mixture of inorganic salts, water, and nucleating and stabilizing
agents, which melts and freezes at 47OF (8.3OC). This material is encapsulated in
rectangular plastic containers stacked within a storage tank through which water is
circulated. The net storage volume of such a system is approximately 6 ft3 per ton-
hour (0.048 m3/kWh),including piping headers, containers, and water in the tank.
The 47OF (8.3"C) phase-change point of this material allows the use of standard
chilling equipment to charge storage. Discharge temperatures are higher than the
supply temperatures of most conventional cooling systems, so operating strategies
may be limited.
A eutectic salt formulation that freezes and melts at 41°F (5OC) is currently being
developed. Its 41 to 43OF (5 to 6OC) discharge temperature will be compatible with
conventional distribution and air handling systems.
2-8 Design Guide for Cool Thermal Storage
Eutectic salt mixtures are also available for lowering the storage temperatures of ice
systems. Additives that produce freezing temperatures of 28OF (-2OC) and
12OF (-1 1°C) in ice storage tanks are available. These additives reduce the latent
heat capacity of water, as well as lowering the freezing point.
Since most cool storage systems use electrically driven compression chillers to
generate cooling, so this type of refrigeration plant receives the greatest emphasis
here. Compressors may also be driven by steam turbines or natural gas engines.
Absorption chillers may be used for certain storage applications.
The choice of operating strategy for engine- or turbine-driven cool storage systems
should be based on different considerations than those for systems with electrically
driven chillers. Electric demand and energy charges for the chiller are eliminated by
using the alternative prime mover. The operating strategy will probably be selected
primarily to minimize the required size of cooling equipment and storage. A load-
leveling strategy will achieve this goal. Selection of a chiller priority or storage
priority operation depends on the other cooling equipment available and on operat-
ing costs for the various types of system operation.
Operation and maintenance of engines and turbines is more complex than that for
electric motors and is beyond the scope of this guide. Engine and turbine drives are
discussed in Chapter4 1of the 1992ASHRAE HandbookSystems and Equipment.
Absorption chillers may be used to generate cooling for some cool storage systems.
Since absorption chillers are limited to minimum chilled water temperatures of 40
to 41°F (4 to 5*C), they will generally be applicable only to chilled water storage or
eutectic salt systems or to precooling applications.
Absorption chillersmay be direct fued by natural gas (or other fossil fuels)or indirect
fired by steam or by heat recovered from another process.
Operating strategies for cool storagepowered by aprimary energy source other than
electricity are selected based on the following considerations:
Fundamental Design Considerations 2-9
A steam turbine or steam absorption system could store cooling during periods
when ademand for steam for other uses is low. The stored cooling couldbe used
to meet the entire cooling load of the facility, to supplement nonstorage cooling
equipment when the load exceeds the nonstorage system capacity, or to replace
electric chiller operation during on-peak hours.
An engine- or turbine-driven chiller could operate in the load-leveling strategy,
minimizing the required sizeof the chiller and prime mover. When loadsare less
than the chiller capacity, the prime mover could operate at its peak efficiency
point.
An absorption system using recovered heat could store cooling whenever an
incinerator or other heat-producing process is in operation.
Facilities served by a central district cooling plant can reduce the size of service
mains by generating and storing cooling during low-load periods. Cordaillat and
Tamblyn (1988) describe a new cooling system that reduced its initial, one-time cost
for connection to a central district cooling loop by using storage to reduce its peak
demand on the central system. Cost savings may also result if chilled water charges
vary with time of day.
Chilled water storage. Chilled water is storedin tanks, using natural stratifica-
tion or other techniques to separate cold water from warm return water.
Ice harvesting.Ice is formedon an evaporator surfaceand periodically released
into a water filled storage tank.
External melt ice-on-coil. Ice is formed on submerged pipes or tubes through
which a refrigerant or secondary coolant is circulated. Cooling is discharged by
circulating the water that surrounds the ice pipes, melting the ice from the
outside.
2-10 Design Guide for Cool Thermal Storage
Ice sluny storage has also been used in some systems, but this approach has not seen
wide commercialapplication. With this approach,suspendedice crystalsare formed,
typically in an antifreeze solution, in a scraped surface evaporator or by other means.
The ice crystals are concentrated and stored in a tank. Cwling is discharged by
circulating a warm antifreeze solution through the tank.
Ice slurry storage has the advantages of separating the storage of ice from its
generation, providing flexibility in the location of refrigeration equipment, and
eliminating the defrost losses of ice harvesters. However, specialized equipment is
required, and costs are high.
A variation of ice slurry storage is being developed for application with ice
harvesting equipment. In this "slippery ice" approach, additives are added to the
system water to allow ice to be released from evaporator surfaces without using a
defrost cycle. Current research is focusing on identifying the combination of
additives that will provide the desired release characteristics while minimizing the
freezing point depression.
Ice slurries are also being investigated for application in district cooling systems,
where their high latent cooling capacity can offer significant reductions in pumping
energy. Winters and Kooy (1991), Graham et al. (no date), Sukhwal et al. (1987),
Sukhwal el al., and Heavener (1986) discuss applications of ice slurry storage.
2.3 EQUIPMENT
Equipment for cool storage systems consists primarily of refrigeration equipment
and storage tanks. In addition, controls and instrumentation are also important.
Fundamental Design Considerations 2-1 1
Chillers
Most cool storage applications use packaged chillers to generate cooling. Some
systems use built-up refrigeration plants. Ice harvesting systems typically use
specially designed packaged ice making plants (Chapter 5). Some externalmelt ice-
on-coil systems are installed with built-up refrigeration systems (Chapter 6). Many
of the considerations for packaged chillers can also be applied to the selection of
compressors for built-up systems.
Chiller types include reciprocating, rotary screw, centrifugal, scroll, and absorption
chillers. The primary consideration in selecting the chiller type is capacity. Typical
capacity ranges for each type of chiller are given in Table 2-2.
Ca~acitvRanee
The leaving fluid temperature achievable by the chiller is another major consider-
ation, especially for ice systems, which typically operate at charging temperatures
of 15 to 26OF (-9 to -3OC). Reciprocating and rotary screw chillers are adaptable to
a wide range of leaving temperatures and can generally be applied to ice storage
systemswith little difficulty. Centrifugalchillerscan also be applied for ice making,
but the selections must be made for the specific anticipated operating conditions.
Harmon and Yu (1991) discuss the proper selection of centrifugal chillers for stable
operation at ice making conditions.
Lithium bromide absorption chillers can produce leaving fluid temperatures as low
as 40°F (4.4OC), but are not applicable for ice making. Ammonia absorption chillers,
which are able to produce leaving temperatures below -40°F (-40°C), have been
used for ice making. However, ammonia absorption chillers are not readily available
as packaged equipment.
Efficiency is highest for centrifugal chillers, with typical ratings of 0.6 to 0.7 kW/
ton (5 to 5.9 COP) for 40 to 44OF (4 to 7OC) discharge temperatures, and 0.85 to 1.0
kW/ton (3.5 to 4.1 COP) for ice making. Packaged chillers using reciprocating and
rotary screw compressors are less efficient, with ratings around 0.65 to 0.85 kW/ton
(4.1 to 5.4 COP) at conventionaltemperatures, and 0.9 to 1.2 kW/ton (2.9 to 3.9 COP)
for ice making. Rotary screw compressors are typically more efficient than recipro-
cating compressors at a given rating point. Rotary screws have lower part-load
efficiency but better capacity modulation than reciprocating chillers.
Scroll compressors operate at 0.85 to 1.15 kW/ton (3.1 to 4.1 COP) at standard
temperatures and approximately 1.2 to 1.3 kW/ton (2.7 to 2.9 COP) at ice making
temperatures. Absorption chillers operate with typical COPS of 0.65 to 1.0.
Chiller capacity for ice making is generally 60 to 70% of nominal capacity. Packaged
ice harvesters are rated by ice making capacity, and chilling capacity is 30 to 60%
higher than the ice making rating, depending on return water temperature.
Some designers may elect to apply a safety factor of 5 to 10% to the rated chiller
capacities. This can be accomplished, for example, by specifying a chiller capable
of cooling 105% of the design flow rate to the design temperature.
Condensers
Condenserscan be water-cooled, air-cooled, or evaporatively cooled. Water-cooled
condensers are generally supplied with cooling water from a cooling tower. Air-
cooled condensers reject heat by blowing ambient air over a coil through which hot
refrigerant gas is circulated. Evaporative condensers also blow air over a refrigerant
coil,but water sprayed over the coil evaporates and increases the rate of heat transfer
from the refrigerant.
Maintenance is simpler for air-cooled condensers than for the other two types, since
no water circuits are involved, Maintenancecosts for water-cooled condensers with
cooling towers are highest. The cost of cleaning condenser tubes is added to the
cooling tower maintenance requirements, which are comparable to those for evapo-
rative condensers. Also, in evaporativecondensers,the refrigerant coils are prone to
scaling, and proper water treatment is essential.
Refrigerants
Refrigerant considerationsfor cool storage systems are essentially the same as those
for nonstorage systems. Positive displacement chillers for ice making applications
usually require high-pressure refrigerants, such as R-22 or R-717 (ammonia).
Centrifugal chillers generally useR-134aorR-123, although R-22 is now offered by
some manufacturers in larger chiller sizes.
2-14 Design Guide for Cool Thermal Storage
A partial storage system usually has a smaller chiller, running on less refrigerant,
than a nonstorage system. In many cases, a required capacity increase in an existing
system can be achievedby adding cool storage, with no addition of refrigerant-using
equipment and no increase in the volume of refrigerant in the system.
Chiller Control
Chiller control for cool storage systems differs from control for nonstorage systems
because there is likely to be more than one normal operating strategy. Particularly
with ice and eutectic salt storage systems, the chiller leaving temperature during
charging will be lower than during direct cooling or chiller-assisted discharging. A
chiller selected for such a system must be capable of operating at different leaving
temperature setpoints in response to an external control signal.
Under some cool storage operating strategies, chiller output is varied while supple-
menting storage discharge to minimize total facility demand or to optimize the use
of storage. In other cases, chiller capacity during charging is varied to minimize off-
peak demand or to maximize part-load efficiency. For such applications,continuous
capacity control is generally preferable to staged or stepped capacity control.
Buried tanks must withstand the weight of asoil covering as well as the load imposed
by parking lots, tennis courts, helipads, or other additional uses planned for above
the tank. Partially or totally buried tanks should also be designed to withstand soil
loadings on the tank walls, as well as hydrostatic pressure from groundwater, that
may occur if water in the tank is removed.
Storage tanks for cool storage are generally rectangular or cylindrical. For chilled
water storage and ice harvesting systems, tank geometry influences the amount of
Fundamental Design Considerations 2-15
usable cooling that can be recovered from the tank. The effects of tank geometry in
these systems are discussed in Chapters 4 and 5.
where
For underground tanks, the heat transfer properties of the soil must be estimated.
Table 7, Chapter 22, of the 1993 ASHRAE Handbook-Fundamentals lists soil
(0.58 to 1.9 W/m-K) for various
conductivities ranging from 4 to 13 Btu-in/h*ftZ-OF
soil types.
Tanks located outdoors should have a vapor barrier and a weatherproof covering
over external insulation. For tanks exposed to sunlight, radiation heat gains may be
significant. A light-colored or reflective covering is recommended to minimize heat
gain from solar radiation.
Tanks for cool thermal storage are generally constructed of steel, concrete, fiber-
glass, or plastic. Regardlessof the material, the tank should be designed and installed
to have zero leakage. If a leak is detected during acceptance testing, the tank
contractor should be required to repair the leak at no additional cost to the owner.
Steel Tanks
Steel tanks for cool storage are available in a number of configurations. Large tanks
of several hundred thousand to several million gallons' capacity are field-erectedof
welded plate steel. Smaller tanks of 300 to 3,000 ft3 (9 to 90 m3) are constructed of
galvanized sheet steel with reinforcing framework. Cylindrical pressurized tanks are
generally applied in sizes between 400 and 7,500 ft3 (11 and 210 m3).
Large field-erected steel tanks are typically supplied with internal and external
corrosion protection, external insulation, and weather-protective roof or cover. The
tanks are cylindrical in shape and are installed aboveground on a concrete founda-
2-16 Design Guide for Cool Thermal Storage
tion. The American Water Works Association Standards D100-84 (AWWA 1984)
and D102-78 (AWWA 1978) address tanks and their corrosion protection.
Uninsulated steel tanks subject to weather require external painting at 15- to 20-year
intervals to prevent corrosion. Insulated tanks do not require repainting but do
require that the integrity of the vapor barrier covering be maintained to prevent
condensation on the exterior surface. Some form of corrosion control, either an
epoxy coating or tank water treatment, must be used to protect the tank interior.
Smaller manufactured galvanized steel tanks are typically constructed with insula-
tion and exterior panels surrounding the tank itself. The tanks are generally rectan-
gular in shape and are installed indoors or outdoors at grade. Tanks should be
constructed of galvanized steel or provided with some other corrosion-protective
coating.
Concrete Tanks
Concrete tanks can be precast or cast-in-place. Precast tanks must also be pre-
stressed. Cast-in-place tanks may be prestressed or reinforced concrete should be
used. Precast tanks are generally most economical in sizes of one-million gallons
(3,800 m3) or more. Cast-in-place tanks can often be integrated with building
foundations, thus reducing their cost. Chow (1987) discusses the design and
selection criteria pertinent to concrete tanks.
Large precast concrete tanks are cylindrical in shape and may have either clear-span
spherical dome roofs or column-supported flat slab roofs. Smaller tanks can be
rectangular or cylindrical. A cylindrical tank is structurally more efficient because
the wall acts as a membrane structure, which is subjected to less bending moment
than a straight-sidedwall. A cylindrical tankalso has a lower surface-to-volume ratio
than a rectangular tank (Chow 1987).
Large precast concrete tanks are generally built in accordance with AWWA Stan-
dards D100-84 and D l 10-86,Type I11 (AWWA 1986) which prescribes design and
construction procedures. These standards allow minimal leakage for some storage
applications; however, zero leakage must be specified for cool storage applications.
Fiorino (1991) describes a 2.7-million gal (10,000 m3) precast, prestressed concrete
tank with an enclaved steel liner which has experiencedzero leakage. A large number
of concrete tanks for cool storage, including water, ice, and eutectic storage
applications, have zero leakage. These include water, ice, and eutectic storage
applications.
Fundamental Design Considerations 2-17
Precast, prestressed concrete tanks can typically withstand thermal shocks of 30°F
(17°C) or more. Cast-in-placeconcrete is more susceptibleto cracking and leakage
caused by thermal shock, and caution should be exercised when initially starting a
system using such a storage tank. When starting a system for the first time, the tank
temperature should be slowly pulled down to design conditions over a period of
several days to minimize or prevent tensile cracking due to contraction of the
concrete.
Sealant coatings provide extra security against leaks but add expense. For chilled
water and ice harvester tanks, which can be emptied relatively easily, it is practical
to rely on care in tank design and installation to prevent leaks and to install a liner
or other repair if leaks develop. For tanks containing encapsulated eutectic salts or
ice, which cannot be easily emptied, a liner may be more advisable with the initial
installation.
Plastic Tanks
Plastic tanks for cool thermal storage are typically delivered as prefabricated,
modular units. These polyethylene tanks provide the structural strength and water-
tightness required for cool storage.
Tanks may also be constructed of fiberglass. Plastic tanks for outdoor installation
require UV-stabilized plastic or opaque covering to protect against degradation by
the ultraviolet radiation in sunlight. Proposed applications for plastic tanks should
be evaluated in terms of past experience and factory warranty, as well as for the
2-18 Design Guide for Cool Thermal Storage
Methods to directly measure the inventory of stored cooling differ according to the
storage technology and are discussed in Chapters 4 through 9 for each storage
approach. The storage inventory can also be calculated by continuously monitoring
the amount of cooling delivered to or discharged from storage.
Some type of alarm function that signals any abnormal termination of storage
charging should be provided. Ideally, such an alarm will include dial-up capability
to notify appropriate personnel when cooling is not being stored as required.
A complex control system is not necessarily required for a successful cool storage
operation. At a minimum, the control system must be able to select charging,
discharging, and direct cooling modes according to time of day and load conditions.
Charging cycles
Daily
Weekly
Other
Optimized operation
Chiller priority
Storagepriority
Charging rate control
Load pmbction
I m i k OE -
Full Storage
I
Time OEDay
e Time Of Day
Cooling Load
(met by chillu)
Time Of Day
A full storage, or load shifting, strategy transfers the entire on-peak cooling load to
off-peak periods. A system designed for full storage typically operates at full
capacity during all non-peak hours on the design day. The refrigeration equipment
does not run during on-peak hours, and all cooling loads are met from storage. Such
a system requires relatively large refrigeration and storage capacities. Full storage
operation is most attractivewhere on-peak demand charges are high or where the on-
peak period is relatively short. Control of this type of system is relatively simple.
A partial storage system meets a portion of the on-peak cooling load from storage,
with the remainder of the load met by operation of the chilling equipment. Partial
storage operating strategies can be further subdivided into load-leveling and de-
mand-limiting operation.
The demand limiting approach represents a middle ground between load shiftingand
load leveling. Demand savings as well as equipment costs are higher than those for
a load-leveling system, and lower than those for a load-shifting system. Additional
variations on full and partial storage strategies are possible by scheduling the
operation of multiple chillers in a cool storage system.
Baseloading of one or more chillerscan often improve the economicsof cool storage,
particularly in applications with relatively flat load profiles and those using ice
technologies for storage. Typically, an efficient chiller is used to meet the constant
component of a facility's load. A downsized storage chiller is then used to level or
shift the remaining load. Figure 2-2 illustrates the use of baseload chillers.
2-22 Design Guide for Cool Thermal Storage
I
Cwling load -
k' Storaae chiller
PARTIAL STORAGE
Storage chiller
meets load
7
load
7 Storage chiller
capacity
FULL STORAGE
Much of the work on cool storage, including this guide, refers to the period during
which a thermal storage system must reduce electric demand as the on-peak period.
However, this period is not always synonymous with the on-peak hours as defined
by the electric utility. In many cases, the appropriate demand-shift window may
actually be shorter than the utility on-peak period. In addition, the peak electric
demand from cooling may not occur simultaneously with the peak facility demand.
The billing demand profile at the facility meter should be evaluated to determine the
appropriate time period during which cooling system demand should be reduced.
Sohn and Tomlinson (1989) describe the sizing of a cool storage system with
selection of the demand-shiftwindow based on the facility demand profile. Tamblyn
(1990) describes the savings available by controlling cool storage system operation
based on facility demand.
Figure 2-3 shows an instance where stored cooling is used to reduce cooling system
demand over a period shorter than the utility on-peak period. In this example, the
storage system is controlled to limit the facility demand below a predetermined level.
2-24 Design Guide for Cool Thennal Storage
Facilitv electric
demand (kw)
-\
Facility electric
demand limit -
1
Reduction in cooling
- demand through use
of storage
I \
Time of day Facility
peak demand
+period----D
b-Utility on-peak period--q
Cool thermal storage systems are most often sized for a daily charging cycle,
generating enough cooling in a 24-h period to meet all the loads in that period.
However, longer charging cycles are used in many applications. A weekly charging
cycle would be advantageous where the peak cooling load does not repeat each day
Fundamental Design Considerations 2-25
of the week and there are many hours at low loads. A church is an excellent example
of an application with a high one-day peak load and low loads for the remainder of
the week. A convention center or sports arena also has high peak loads that do not
repeat every day. Even in offices, the number of off-peak, low-load weekend hours
available to charge storage can make a weekly storage cycle attractive.
Weekly storage systems serving these facilities can be sized with much smaller
refrigeration equipment than nonstorage or daily storage systems, resulting in
greatly reduced first costs. In facilities with infrequent peak cooling loads, storage
cycles longer than weekly may be appropriate. Figure 2-4 illustratesa typical cooling
load, chiller capacity, and stored cooling inventory for a weekly storage cycle.
\
I
I "
f \
.'
I
\ I \
\
\
acity I I
I
*
A weekly storage system sized exactly to the load of the design week has minimal
excess capacity over the entire week. To allow for unusually high loads or for
equipment malfunctions, some designers size weekly systems with an allowance of
12 to 24 h when the system is not committed to charging storage. This period is
intended to allow the system to catch up in the event of unusual conditions.
2-26 Design Guide for Cool Thermal Storage
Long-term storage cycles are best applied with technologies for which storage
capacity is relatively inexpensive relative to chilling capacity. Weekly and other
long-term storage cycles have primarily been used with ice harvesting systems.
Seasonal cool storage,by which cooling generated during winter periods is stored for
use during the cooling season, has not proven to be commercially viable on a wide
basis. Proposed seasonal storage approaches include storing chilled water in lakes,
ponds, or aquifers and freezing alarge mass of saturated soil by means of a secondary
coolant circulated through buried pipes. Francis (1985) and Midkiff et al. (1991)
discuss seasonal storage considerations.
The optimizing control strategies of chiller priority, storage priority, and variations
thereof apply to partial storage systems. Some full storage systems can be optimized
by regulating the level of charge based on a prediction of the load for the following
day. Some partial storage systems can be operated in the full storage strategy during
the cooler months of the year.
A chiller priority operating strategy uses the chiller to directly meet as much of the
load as possible. Storage is used to supplement chiller operation only when the load
exceeds the chiller capacity. This approach is most often used in applications where
the cost of stored cooling energy is higher than the cost of direct cooling, and where
utility cost savings are gained largely through reductions in on-peak demand.
Chillerpriority may bejustified in cases where chiller cooling is more expensive than
stored cooling, if the simplicity of the control strategy is considered more valuable
than the additional energy cost.
Fundamental Design Considerations 2-27
A storage priority strategy uses stored cooling to meet as much of the load as
possible, with direct cooling supplied by chillers only when the daily load exceeds
the total stored cooling capacity. This approach is typically used where the cost of
stored cooling energy is lower than the cost of direct cooling.
Storage priority operation generally requires more complex control sequences than
chiller priority. While the objective is to maximize the use of stored cooling, it is
important to have enough stored cooling capacity remaining to supplement the
chiller in meeting high late-afternoon loads.
Grumman and Butkus (1989) describe a storage priority control sequence that
compares the average remaining discharge rate (ton-hoursin storage divided by the
remaining on-peak hours) with a predetermined trigger value. The system is operated
in a chiller priority strategy until the averagedischarge rate reaches a value based on
the specificload characteristics of the application. When the trigger value is reached,
operation of the chillers is locked out, and the entire load is met from storage for the
remainder of the on-peak period.
Full storage systems are optimized differently. By design, a full storage system has
excess storage capacity on every day but the design day. With some storage
technologies, it is advantageousto charge a full storage system only with the amount
of cooling required to meet the on-peak load of the next day. In other cases, it is
beneficial to fully charge the tank each day, providing reserve cooling capacity on
all but the design day. The selection of an optimum full storage operating strategy
depends on tank thermal losses, off-peak demand and energy charges, and the
charging characteristics of the specific storage technology.
Control algorithms that can predict cooling load and electric demand are powerful
tools in optimizing cool storage system operation. Load can be predicted at various
levels. A simple predictive control could use the daily forecasted high outside
ambient temperature, or the temperature at a given hour, to determine the control
strategy for the day.
For example, a given storage priority system may operate without any on-peak
chiller operation if the outside temperature is below 65°F (18°C) at 8:00 A.M., but it
may operate the chiller at up to 50%capacity if the 8:00 A.M. temperature is between
70 and 75°F (21 and 24°C). Other predictive control methods may use the load of the
current hour to estimate the load profile for the rest of the day. These control
strategies require fairly detailed knowledge of the characteristics of the load.
Specific control parameters must be determined for each individual application.
Mathur (1987) and Spethmann (1989, 1993) describe sophisticated control algo-
rithms that predict the load profile of the next day based on outside temperatures and
historical profile shape factors. The algorithmscontrol chiller operation to minimize
overall electric costs.
Electric utilities are currently developing direct load control and real-time electric
pricing as options for load management. In future, these utility strategies will have
an important effect on cool storage system design and control and may increase the
advantages of cool storage systems over nonstorage systems.
Direct load control has been used in the past with residential water heaters and with
residential and small commercial air-conditioning units. In return for a favorable
electric rate, customers allow utilities to install remote switches that will shut off
selected electric appliances during periods of high system demand. Cool storage can
be used under such an arrangement to provide uninterrupted cooling even when
chilling equipment is taken off-line.
Real-time electric pricing involves setting electric rates according to the cost of
providing service at any given time, depending on the total demand on the system.
Most proposed real-time pricing schemes involve communicating upcoming price
changes to customers by telephone lines or other data links. An optimally controlled
cool storage system would select a charging or discharging mode and manage the
proportion of cooling provided from storage and from direct cooling based on current
and upcoming electric rates.
Fundamental Design Considerations 2-29
Ice
Chilled Water
Eutectic Saltb
Notes:
a The range given is the typical minimum temperature available, with appropriate sizing
of storage capacity. Higher temperatures than those listed can also be obtained from
each medium.
The range given is for the most commonly available eutectic salt formulation. Other
formulations are available with typical discharge ranges of 41 to 44OF (5 to 7OC), 28 to
31°F (-2 to -l°C), and 12 to 15OF (-1 1 to -9OC).
In new construction, the low storage discharge temperatures available from ice
storage systems can provide several advantages to the building owner. Low dis-
charge temperatures may also be advantageous in some retrofit situations. In other
cases, limitations of existing systems may favor higher discharge temperatures.
The temperature of return water from the load is also an important building interface
parameter. Generally, it is recommended to maintain return temperatures as high as
possible, to maximize storagedischargecapacity and system efficiency.The specific
effects of return water temperature on system performance for the various storage
technologies are discussed in Chapters 4 through 9.
Ice storage systems typically operate with distribution water temperature differen-
tials of 20 to 24OF (11 to 13OC),compared to typical nonstorage system differentials
of 10to 16OF(6 to9OC). Chilled water storagesystemsalso operate with differentials
of 20°F (11°C) or higher. This increased range allows a reduction in water flow of
40 to 60%,with corresponding reductions in pipe size, pump size, pump power, and
pumping energy. A large temperature differenceis accomplished by variable volume
pumping with properly selected two-way control valves on the coils, and by
appropriate coil selection.
Existing systems with three-way valve control at the cooling coils would require
conversion to two-way valve control. For some three-way valves smaller than 1-1/
4 in. (32 mm) nominal diameter, the actuator and the valve design may permit
conversion to two-way control simply by capping the bypass port. To determine
suitability of particular valves for conversion, valve manufacturers should be
consulted.
The low flow rates resulting from increased temperature differentials make coil
selection particularly important. Recent research indicates that the cooling coil
model used by manufacturers to rate cooling coils may overestimate coil perfor-
mance at low tube velocities (Mirth et al. 1993). This model is used to develop ARI-
certified coil ratings with tube velocities above 1 ft/s (0.3 m/s). However, lower
velocities are not uncommon with the high-temperatureranges often used with cool
Fundamental Design Considerations 2-31
storage systems. When cooling coils must be selected for these conditions, consider
alternativecircuitingto increasethe water flow rate, to specify turbulatorsto increase
water-side heat transfer coefficients, or to allow a safety factor in the specification
of coil performance. One method for providing reserve coil capacity is to specify
cooling coils capable of providing the required cooling capacity with entering water
temperatures 2OF (l°C) higher than the design supply temperature.
Mackie and Reeves (1988) state the following about coil selection and control for
chilled water storage, much of which also applies toother storagetechnologies using
high chilled water temperature ranges:
"The reduction in water flow through the coil, combined with the increase
in coil surface, tends to emphasize the problem of maintaining proper air-
side performance. The flow through the control valve is reduced, and the
increased coil surface increases the capacity response of the coil to a change
in control valve position.
Coil manufacturers offer coils with extended water circuiting that are
capable of the higher water-side temperature differentials. In addition,
selection procedures enable review of selected coil water-side temperature
performance at a variety of flow conditions.
In storagedesign, the control valves for the coils shouldbe selected fortight
shut-off in addition to the usual performance requirements. The contractor
must be advised as to the much more critical water balance requirements,
since both supply air temperature and retum water temperature must be
maintained."
Cold air distribution can also be beneficial in some retrofit applications. Where
cooling loads have exceeded the capacity of the existing distribution systems,
conversion to cold air distribution allows existing piping and ductwork to supply the
increased loads. Where high indoor humidity levels contribute to perceptions of
thermal discomfort or poor indoor air quality, a reduction in supply air temperature
and the resulting reduction in humidity can improve satisfaction with indoor
conditions.
Fundamental Design Considerations 2-33
A detailed discussion of the advantages of and design for cold air distribution is not
included in this guide. A bibliography on the subject is given in Chapter 2.
With an open tank, static pressure control of some kind is required to maintain the
desired static pressure in the building system and, at the same time, to prevent
overflowing of the open tank.
In most cases, the storage tank(s) will be located at ground level or below, at the base
of the chilled water distribution system. In some cases, storage tanks may be located
on the roof or upper stories of a building. In a central district cooling system, a storage
tank may be located at a point higher than some or all of the distribution system.
When the level of water in the tank is at or above the high point of the distribution
system, no further pressure control may be required. Control of static pressure can
be accomplished with a heat exchanger, or with pressure sustaining valves and
pumps.
The use of a heat exchanger provides fail-safe isolation of static pressure, without
reliance on the proper operation of a pressure-sustaining valve. In addition, the
distribution system remains closed, reducing water treatment costs. Especially with
storage technologies where tank water is highly aerated, heat exchangers are often
recommended to protect distribution systems from corrosion.
operated regulating valve that modulates to maintain the desired upstream static
pressure by its throttling action. The control setpoint is typically selected to provide
a minimum static pressure of 5 psig (35 Wa) or more at the highest point in the
distribution system under all load conditions.
An automatic, positive shutoff valve should be installed in series with the pressure-
sustaining valve to provide isolation when the system is not operating. Two valves
of differing capacity, controlled in sequence, provide the extended flow range
needed in some applications. Two valves may need to be installed in series if the
static pressure is very high. This arrangement also provides more effective pressure
control over a wider range of flow rates.
Mackie and Richards (1992) and Chapter 39 of the 1991 ASHRAE Handbook-
Applications discuss the selection and application of pressure-sustaining valves in
direct pumping from open storage. Mackie and Reeves (1988) present an extensive
discussion of pumping considerationsfor open storage tanks and provide an example
calculation comparing direct pumping with the use of a heat exchanger. Tackett
(1988) discusses tradeoffs between direct pumping and heat exchangers, as well as
the evaluation, selection, and control of energy recovery hydraulic turbines.
Positive suction head required at the pump should also be considered for open tanks
installed at or below grade. Suction header design and pump selection and placement
should ensure that the required net positive suction head is available. A common
approach is to provide a pump pit at or below the tank bottom, making the static head
of the tank available at the pump suction. Mackie and Reeves (1988) discuss
provision of adequate suction head when pumping from open tanks.
Pressure drop through the storage tank can be significant for some types of storage,
and must be considered in system design. Pressure drop data are typically available
from storage equipment manufacturers.
trations. The discussion in this section is based on the use of ethylene glycol, but the
same considerations would apply to other secondary coolants.
Ethylene glycol solutions have a higher density, higher viscosity, lower specific
heat, and lower thermal conductivity than pure water. These differences in physical
properties result in increased flow requirements, reduced fluid side heat transfer
coefficients, and increased pressure drops, compared to pure water. Where glycol is
to be used in an existing system designed for water, these disadvantages can
generally be overcome by reducing the supply temperature by about 2OF (l°C).
When ethylene glycol is used in a cooling plant, the advisability of separating the
glycol primary loop from the building distribution system with a heat exchanger
should be evaluated. The heat transfer and pumping performance penalties and the
cost of the glycol solution should be weighed against the heat exchanger cost,
additional pumping energy, and increase in the minimum supply temperature
available to the distribution system.
While each application is unique, heat exchangers are typically used in systems with
peak cooling loads above 500 tons (1800 kW). Where peak cooling loads are less
than 200 tons (700 kW), it is generally economical to use glycol in the building
distribution system. For peakcooling loads between 200 and 500 tons (700 and 1800
kW), the decision whether or not to use a heat exchanger will be determined by the
specific conditions at the site.
The volumetric expansion of glycol over the expected range of temperatures should
be evaluated and expansion tanks sized accordingly. In northern climates, where
storage tanks are located outdoors, sections of the system may be exposed to
temperatures below 20°F (-7OC). In such cases, the natural burst protection of the
heat transfer solution should beevaluated. Expansion tank sizing should be based on
the greater of expansion due to temperature changes and either expansion due to
phase change. Denkmann (1985) discusses calculation of the expansion volume
required to accommodate the increased fluid volume as the fluid crystallizes.
Glycol heat transfer fluid should be analyzed by alaboratory several times during the
first year of operation and annually thereafter. According to the laboratory's and the
manufacturer's recommendations, the fluid should be treated for glycol concentra-
tion and proper levels of corrosion inhibitors and reserve alkalinity.
A cool storage system with heat recovery can supply recovered heat when it is
needed, while generating cooling for later use. Normal cooling system operation
transfers heat from daytime interior gains to the cool storage tank, rather than
rejecting it to the outdoors by an air-side economizer cycle. This heat is then
recovered by operation of the storage chillers and used to meet the nighttime heating
loads of the building.
Heat can be recovered from chillers using a double-bundlecondenser, which has one
circuit connected to the open cooling tower system and one circuit part of the closed
hot water piping system. Alternatively, hot condenser water can heat building
heating water in a plate frame heat exchanger,or it can be supplied directly to the hot
water distribution system.
Operating costs for heat recovery systems include pump energy and the efficiency
penalty incurred by operating chillers at an elevated condenser water temperature.
Fundamental Design Considerations 2-37
Particularly where heat recovery is replacing electric resistance heat, large cost
savings are possible.
Hopkins and Schettler (1990) and Tackett (1989) describe thermal storage systems
that integrate heat recovery. Tackett (1987) describes a chilledwater storage system
in which two of four tanks are used for heat storage during the heating season. Leight
and Elleson (1993) describe the performance of a cool stofage and heat recovery
system that circulates warm condenser water through an auxiliary preheat coil in the
air handling unit of each floor. The same coils use cooling tower water for free
cooling in a water side economizer cycle when outdoor conditions are favorable.
Where a cool storage system recovers condenser heat to meet building heating loads,
the same piping system can be used to circulate cooling tower water to provide free
cooling. Leight and Elleson (1993) describe the performance of such a system. This
combination heat recovery and free cooling system was made possible because of the
use of cool storage. Nighttime operation of the storage chiller allows recovery of
heat. Daytime periods when all cooling is provided from storageallow lower cooling
tower water temperatures and increased savings from free cooling.
Cooling towers can also be used to generate water cold enough to charge storage.
Particularly in areas such as the southwestern United States, there are many hours
during the year when nighttime wet-bulb temperatures are low, while daytime dry-
bulb temperatures rise high enough to cause significant cooling loads. With storage
technologies that store cooling at relatively high temperatures, such as chilled water
storage and 47°F (8.3OC) eutectic salts, the free cooling available at night can be
stored for later use when cooling loads rise.
Elleson et al. (1993) describe the performance of a eutectic salt system in Arizona
designed to store free cooling. In this particular system, nighttime coaling loads were
high enough to demand nearly all of the free cooling, and very little was stored.
However, with a better match between the cooling tower capacity and the load
profile, this approach can provide large energy and cost savings over a nonstorage
system.
2-38 Design Guide for Cool Thermal Storage
A thermal storage cooling plant can provide significant benefits even when it is
simply added to an existing building or design in place of a nonstorage chiller.
However, the many potential benefits of cool storage are best realized when the total
building design is planned with storagein mind. Mechanical systems can be planned
with variable volume, high-temperature-differentialsecondary distribution, cold air
distribution, heat recovery, and water-side economizer. Dual-use water tanks can
meet both cooling and fire protection needs. The building structure can be designed
with an integrated storage tank and with allowances for reduced duct space require-
ments. Even in retrofit projects, redesign of existing distribution systems can
improve cool storage system performance and reduce demand and energy consump-
tion.
Depending on specific conditions present in each application, these steps may occur
in a slightly different order, and some steps may be repeated in an iterative process.
Each of the steps is discussed below. Additional discussion of sizing is provided in
Chapter 10.
2.6.3 Calculate the Initial Chiller Size and Initial Storage Capacity
To start the sizing procedure, quick estimates of chiller size and storage capacity can
be approximated using relatively simple equations. These estimates are calculated
based on total system load ton-hours, number of hours in the charging and discharg-
ing modes, and chiller performance ratios for charging and discharging conditions.
In combination with the storage volume for aparticulartechnology, the quick storage
size calculation provides an estimate of the space required for storage.
The quick chiller size and storage size estimates are useful for comparing operating
strategies or storage technologies in initial feasibility analyses. However, the initial
sizing estimates should never be used as the basis of final design, unless they have
been confirmed by the detailed analysis and system simulation described later. Quick
chiller size and quick storage size estimates are discussed in more detail in Section
10.3.
2-40 Design Guide for Cool Thermal Storage
Each of the cool storage technologies has unique performance and operational
characteristicsthat affect its suitabilityfor aparticular application. While the general
procedure for sizing is similar for all the technologies, each is treated differently in
the sizing phase because of differences in these performance characteristics. A
comparative overview of the approaches to cool storage is given in Chapter 3.
2.6.5 Refine and Finalize the Chiller and Storage Equipment Selection
When the designer has determined that a certain storage technology is most
appropriate, the unique sizing considerations of that technology are factored into
system performance calculations.
The input and output characteristics of the chiller affect the input and output
characteristicsof storage, and vice versa. Chiller performanceis affectedby load and
ambient conditions and entering and leaving temperatures. Storage performance,
particularly with latent storage media, also depends on inlet and outlet temperatures,
as well as dischargerate, and the stateof charge of the storage tank. Storage geometry
may also play an important role. Therefore, accurate system sizing can only be
achieved by comprehensively examining the combined performance of chiller and
storage in response to ambient conditions and load.
Even if total nominal capacity appears to be adequate, acool storage system will not
operate properly if the charging and discharging performance of the chiller and
storage are not matched to each other and to the design load. Chapter 10 describes
the refining and final sizing procedure in greater detail. Information on the specific
charge and discharge characteristicsof each cool storage technology is provided in
Chapters 4 through 9.
A full economic evaluation of a cool thermal storage system requires analysis and
comparison of equipment costs and operating costs. The analysis often involves
comparison of several options, usually including a nonstorage system and, possibly,
various storage strategies or technologies. In most cases, the applicable utility rate
structure has a major effect on the selection of operating strategy and system size as
well as on operating costs. Utility rate structures, equipment costs, and system
efficiency and operating costs are discussed next. The analysis of annual demand,
energy consumption, and operating costs is discussed in Chapter 10.
Electric utility rate structures generally determine thermal storage operating cost
savings as well as the optimum system size and operating strategy. Elements of
utility rate structures include demand charge, on- and off-peak schedule, on- and off-
peak energy charge differential, and direct incentives. In addition, some utilities
offer special thermal storage rate schedules. Information on utility rates for a
particular application should be obtained from a local utility representative.
2-42 Design Guide for Cool Thermal Storage
Demand Charge
The electric demand charge is assessed by the utility based on the highest rate of
power (kilowatts)drawn by a facility in a given month. High utility demand charges
increase the operating cost savings of a cool storage system. Demand charges above
$10/kW per month make storage particularly attractive. Where demand charges are
below $5/kW per month, cool storage should be justified by other benefits.
Utility ratchets may justify the purchase of standby equipment, especially for
components having the shortest mean time before failure. If a pump or other
component fails and forces chillers to run during the on-peak period, the system may
set a demand level for that month that will raise the utility bill for the following 12
months.
For a cool storage system designed primarily to reduce on-peak demand, such as a
full storage system, the length and timing of the on-peak period directly affect the
required chiller and storage capacities. When the on-peak period is 10 h or longer,
the total on-peak load is high, and there are relatively few off-peak hours available
to recharge storage. This situation requires a large storage capacity and a large
storage chiller. With a short on-peak period of 6 h or less, the total on-peak load is
relatively small, while many off-peak hours are available to recharge storage. Here,
a relatively small chiller and storage capacity can shift the entire on-peak load to off
peak.
For a partial storage load-leveling system, the length of on- and off-peakperiods is
not as critical to system sizing, since the objective is to minimize the sizes of the
Fundamental Design Considerations 2-43
chiller and storage and to match the total capacity to the total load. A partial storage
demand-limiting system can be sized to provide the optimum combination of on-
peak demand reduction and equipment size for a given utility rate and load profile.
Direct Incentives
Some utilities offer direct incentive payments to customers who install cool storage
systems. The payments are typically in the range of $100 to $300 per kilowatt of peak
demand reduction compared to a nonstorage system.For some utilities,payments are
basedon tons of on-peak load shifted to off-peak periods. These payments reduce the
cool storage system first cost, improving the economic comparison with nonstorage
systems.
operating cost savings. However, in many cases, the first cost and operating cost of
a thermal storage system can be less than that for a nonstorage system.
Some applications where cool thermal storage can result in decreased equipment
costs include:
Mackie and Reeves (1988) discuss further opportunities for low capital cost with
cool storage.
Coolingplant costs given on the basis of nominal capacity are similar for storageand
nonstorage systems. Ice making capacity for ice storage chillers is generally 60 to
70%of the nominal capacity. Costs for ice harvesting equipmentare not comparable
with packaged water chillers and are discussed separately in Chapter 5.
Equipment costs are highly dependent on local conditions and the current economic
climate, and it is difficult to provide accurate general guidelines. Bare equipment
costs for chillers are typically $200 to $300 per ton ($57 to $85 per kW) for
centrifugal chillers, and $400 to $500 per ton ($114 to $142 per kW)for screw and
reciprocating chillers. Estimates of installed cooling plant costs vary from $500 to
over $1000 per nominal ton ($142 to $284 per kW), depending on which equipment
costs are included. Such estimates are most useful for comparing several options in
initial feasibilitystudies.For more accuratecost estimates,consult local vendorsand
contractors.
Costs for the interfacebetween chiller and storage also vary considerably, depending
on the length of piping runs, the type of pumping arrangement, the use of heat
exchangers, and other factors. Costs for storage vary depending on the specific
technology considered (see Chapters 3 through 9).
Cool storage system operating costs are generally lower than those of nonstorage
systems. On-peak demand charges are reduced, and energy consumption is shifted
from expensive on-peak periods to less expensive off-peak times.
Cool storage systems are commonly thought to use more energy than nonstorage
systems, even though operating costs are lower. Field monitoring of several systems
has shown relatively poor energy performance (Merten et al. 1989, Sohn 1991).The
conclusionsof poor performance in these studies are based on comparisons of chiller
energy consumption.
However, other studies illustrate cool storage systems that use equivalent or less
energy than nonstorage alternatives.Fiorino (1993)describesa chilled water storage
retrofit that reduced energy consumption by 12% compared to its nonstorage
predecessor. Energy savings resulted from improved chiller operating efficiency,
reduced distribution energy, and improved control of cooling and dehumidifying
processes.
Leight and Elleson (1993) describe an ice storage system that used less overall
energy than a modeled nonstorage alternative,even though chiller energy consump-
tion increased. Energy savings resulted from downsized pumps and cooling tower,
and the use of a waterside economizer cycle. In addition, heating energy consump-
tion was reduced by the use of heat recovery, and supply fan energy use was lowered
by reducing the design supply air temperature.
Many cool storage systems have been designed with demand reduction as the
primary objective and most have successfully met this goal. As commercial cool
storage technology matures, designersare faced with the additional goal of reducing
energy consumption. The examples cited earlier show that this goal can be achieved
by taking advantageof the full potential offered by thermal storage technology and
by treating thermal storage as one element of a comprehensive approach to energy
conservation in building mechanical systems.
In many cases, the energy consumption of chiller auxiliaries can be lower in storage
systems than in nonstorage systems. Primary chilled water pumps, condenser water
pumps, and to some extent, cooling towers, typically operate at a fixed capacity,
independent of chiller load. Auxiliary energy consumption per ton-hour of cooling
load can often be minimized by operating chillers at maximum capacity whenever
they run.
Operators can increase the benefits of thermal storage by continuing to improve and
optimize system operation. Cool storage systems offer increased flexibility in
meeting cooling loads by decoupling generation of cooling from the instantaneous
loads. During the majority of the year when cooling loads are below design levels,
operators have the option of meeting loads from chiller operation or from storage. As
operators gain experience with system response to actual loads, they can refine
design operating strategies and control setpoints to minimize operating cost.
In some cases, cool storage allows cooling loads to be met while some equipment is
taken out of service for maintenance, particularly where the required maintenance
can be performed in a relatively short time, or where storage can supplement the
capacity of the equipment remaining on line.
1994 Refrigeration
Liquid Chillers, Chapter 42
1991 Applications
Operation and Maintenance Management, Chapter 35
Automatic Control, Chapter 41
Maintenance requirements for storage tanks vary with the type of storage
technology. Specific requirements for each technology are discussed in
Chapters 4 through 9.
System Cleaning
Starting with a clean system cannot be stated strongly enough-a clean system at
startup minimizes problems throughout the life of the system.
Remove all extraneous loose debris, construction material, trash, and dirt from
tanks,piping, filters, etc. Removal of as much dry material as possible prevents
transfer to hard-to-reach portions of the system.
Flush water fill line separately to drain. If a new water line has been installed,
be sure that rust and debris from it is not washed into the thermal storage system.
Fill system with soft, clean, fresh water. Open all system valves and lines to get
thorough, high-velocity recirculation.
Add prescribed cleaning chemicals to circulating water. Most cleaners are a
blend of alkaline detergents, wetting agents, and dispersants. Be sure cleaning
chemical is dissolved and distributed thoroughly so that cleaner does not settle
out in one part of the system.
Circulate cleaning solution for manufacturer's recommended time, frequently
8 to 24 h. Check during recirculation for any plugging of filters, strainers, etc.
While water is being recirculatedat high rate, open drain valve at lowest points
in system and drain cleaning solution as rapidly as possible. Draining while
under recirculation will prevent settling of solids in remote portions of system.
Open and inspect system for thoroughness of cleaning. Refill with water and
start rinse recirculation. If significant amounts of contaminating materials are
still present, repeat cleaning and draining procedure.
When cleaning has been thoroughly accomplished, refill system with fresh
water for recirculation rinse. Drain rinse water and add fresh makeup until all
signs of cleaning chemicals have been removed.
System is now in clean, unprotected state. Fill with makeup water and proceed
with passivating steps to develop protective films on all metallic surfaces.
Fundamental Design Considerations 2-49
Water should be treated as soon as possible after cleaning the system. The cleaning
procedure removes any protective films from equipment surfaces, leaving them
susceptible to corrosion. Especially when there is an extended time period between
cleaning and actual system startup, corrosion and biofouling can become significant
problems if water treatment is not treated promptly.
Chemical Treatment
Corrosion, biofouling, scaling, and deposits can be controlled by beginning with a
clean system and adding appropriate chemicals to the water in the system. The
system may need little or no chemical additions if properly cleaned at the outset and
if other conditions, such as water quality, are good.
Scaling and deposits are a problem best avoided, as they can greatly reduce system
efficiency. To avoid scaling, flush the system with soft water before startup. At this
point, soft water will remove most or all of the materials that could promote scaling.
To avoid deposits, filter the water before it enters the system and/or add chemicals
that inhibit the ability of suspended matter to attach to any part of the system.
Glycol Solutions
Water treatment considerations for cool storage systems using glycol or other
secondary coolants are different than for systems using water. This discussion is
2-50 Design Gulde for Cool Thermal Storage
based on ethylene glycol coolant, but the same considerations would apply to other
secondary coolants.
Only inhibited glycol from a major manufacturer should be used in cool storage
applications requiring glycol. Use of another glycol formulation not intended for
HVAC applications is not recommended. Inhibited glycol is provided with corrosion
inhibitorsand antifoamadditives; glycol without these additivesbecomes extremely
corrosive on mixing with air.
Test the glycol solution for glycol concentrationand levels of corrosion inhibitorand
other additives four times the first year and once a year thereafter. Add glycol,
inhibitor, and additives as required, according to the glycol manufacturer's recom-
mendations.
2.9 COMMISSIONING
Commissioningis a process whereby the subsystems and components of an HVAC
system are integrated into a whole system that functions according to the design
intent. Commissioning is sometimes thought to involve only startup and perfor-
mance testing; however, the complete commissioning process, as outlined in
ASHRAE Guideline 1-1989 (ASHRAE 1989) is part of the entire project. Commis-
sioning begins in the predesign phase and lasts through training of the building
operators and the first year of operation of the building.
Cool thermal storage systems have a particular need for commissioning. Storage
systems, particularly partial storage systems, have much less reserve-integrated
cooling capacity than do nonstorage systems. A nonstorage system has excess
capacity in every hour that is not a design hour. Storage systems derive their benefits
from the use of an additional system element, stored cooling, to achieve a closer
match of total integrated capacity to total integrated load. These benefits are
achieved at the price of (1) some additional complexity to control the inventory of
stored cooling and (2) a reduced safety factor. Therefore,there is a need for increased
care in design, installation, and operation, ensured by the commissioning process.
Fundamental Design Considerations 2-51
Thermalstorageisa new technology for most of the HVAC industry. Most designers,
contractors, and operatorsdo not have the extensive knowledge and experience with
cool storage that they have with nonstorage cooling technology. Without this
experience, more potential problems will remain undetected throughout the design
and installation process, to the detriment of the efficiency and effectiveness of
system operation. The commissioning process is intended to minimize these prob-
lems. Commissioning also provides documentation of actual system capacities,
which allows control strategies to be optimized to take full advantage of system
capabilities.
Redesign
Design
Construction
Startup
Operator training
Performance testing
System operation and optimization
In this phase, the person, company, or agency that will plan and carry out the
commissioning process is selected. This commissioning authority may be the
designer, contractor, owner, or a consultant specifically retained for this purpose.
The commissioning authority must have the knowledge, experience, and tempera-
ment to work with the other members of the commissioning team and to effectively
oversee the entue process.
The commissioning team includes all or some of the following members: owner,
designer, contractors (general, mechanical, controls, test and balance), system
operators, equipment manufacturers, commissioning consultant, and thermal stor-
age consultant.
In the design phase, detailed requirements for HVAC commissioning are developed
for inclusion in design documents. These include documentation of design criteria
2-52 Design Guide for Cool Themal Storage
and assumptions, a description of the system and its intended operation and
performance, and a commissioning plan.
Startup phase activities are typically those usually specified for HVAC projects,
including startup of pumps, fans, chillers, and other equipment, cleaning and
pressure testing of piping systems, leak testing of ductwork, etc.
Training of operators is essential for cool storage systems, Most operators are not
familiar with the general concepts or the details of storage system operation. If not
properly trained, they may operate the systems based on misconceptions of the
design intent, which generally results in poor performance. Training should include
fundamentals of cool storage, details of the particular storage technology for the
specific application, and a complete review of the design intent for the particular
installation.
Performance testing is that phase of the process most often associated with commis-
sioning. It involves testing each system or subsystem under actual or simulated
operating conditions, to verify that it performs according to the design intent.
Performance testing for cool thermal storage systems is described in greater detail
in the following section.
During the system operation and optimization phase, operators gain experience with
the system and adapt its operation to achieve optimum performance. In addition, any
Fundamental Design Considerations 2-53
changes in the system must be recorded in as-built documents. Changes in the use
and function of facilities must be monitored and documented, and appropriate
adjustments made in system operation. For example, changes in utility rate sched-
ules, occupancy schedules, or loads may require modifications in cool storage
system operating strategies.
The followingperformance tests should be carried out on every cool thermal storage
installation:
In some cases, depending on the storage technology and details of the specific
application, two or more of these parameters may be evaluated as part of the same
test. In other cases, each of these tests must be performed separately. Other tests may
alsobe warranted for some applications.Details on performancetesting for each cool
thermal storage technology are provided in Sections 4 through 9.
Cool storage performance testing generally must be carried out with the system
subjected to a design load profile. The performance of a cool storage system at a
given time depends on the load, the temperature and flow rate entering the storage
tank, and the state of charge of the tank. For the purposes of performance testing, a
design operatingprofile shouldbe compiled, to include the following informationfor
each hour of the design cooling cycle:
The design operatingprofile is normally compiled at the time detailed system sizing
is performed. In some cases, it may become evident prior to or during the course of
commissioning that the original design profile must be revised. A new profile
including the information just listed should then be developed based on the best load
information available.
If it is not feasible to test the system at design or near-design loads, a false load may
be used to simulate the design load profile. For partial storage systems, the chiller
capacity and storage capacity can be tested separately, with partial system loads
providing a design load to either the chiller or the storage.When a secondary coolant
other than water is used as a heat transfer fluid, performance testing should include
measurement of the density and specific heat of the coolant.
Total storage capacity is evaluated by fully charging the storage tank, then monitor-
ing the discharge output until no usable cooling remains in the tank. For storage
technologies that are sensitive to discharge rate, the storage tank must be subjected
to its design discharge profile to accurately evaluate the usable design day capacity.
Discharge rate and discharge temperature tests verify that the load can be met at the
required discharge temperature for each hour of the design profile. For most load
profiles, this check is especially important for the last few hours of the discharge
cycle. The discharge rate and discharge temperature are normally evaluated during
the course of the storage capacity test.
The charging capacity test evaluates the ability of the system to fully charge storage
within the allotted time period. This test is begun in the fully discharged condition,
with no usable cooling remaining in storage. If such a test results in some cooling
remaining in storage, it may also be run following the completion of adischargetest
against the design load profile. This option may be a more realistic test of system
performance under actual operating conditions.
If the design load profile includes loads occurring during the charge cycle, these
loads should be provided during the test of charging capacity. The charging test
should be run with the chiller operating at the design charging temperature. Repeat
tests can be used to establish the appropriate charging setpoint to most efficiently
charge storage within the allotted time.
Performance testing of scheduling and control sequences verifies that the system
switches to the correct operating mode at the appropriate time. These tests typically
involveclose observation of system operation over several charge-dischargecycles.
Fundamental Design Considerations 2-55
Automatic operation of all valves, resetting of setpoints, and starting and stopping
of equipment should be verified for each time that the system cooling mode changes.
Correct proportioning of chiller and storage output at part load conditions should be
verified. Storage inventory measurement devices should be calibrated, particularly
at the fully charged and fully discharged conditions.
Predictive control and load estimation algorithms should also be tested during
commissioning and parameter values set or refined as needed.
Peak demand and energy efficiency demands are important for evaluating the
performance of a cool storage system. These tests can be used to assess the validity
of operating cost projections made during the economic evaluation phase of design.
In some cases, utility incentive payments depend on the results of these tests.
In most cases, maximum demand during the utility or facility on-peak period is of
greatest interest, although the maximum 24-h demand may also be important. The
total system demand is established primarily by the chiller, with significant contri-
butions from pumps and cooling towers.
For chillers using natural gas as the primary energy source, instantaneous demand
may be relatively unimportant. For chillers powered by steam or waste heat, the
demand for primary energy will affect scheduling of generation equipment as well
as other loads in the facility.
Eleciric demand is often available as a readout from packaged chiller control panels.
Portable power-monitoring instrumentation may also be used to measure demand.
Instruments that measure power factor and true power provide the most accurate
measurements. While less accurate, calculations of demand based on measured
current and voltage and estimated power factor may be suitable in some cases.
Demand measurements for electric utility purposes are generally based on the
averagepowerover a 15-minperiod. Constant volume pumps and cooling tower fans
need not be monitored continuously, since the demand for these devices will be the
same whenever they are operating.
The monitoring and trend-logging functions of the installation's control system can
often be used to collect data for performance testing. Commissioning test and
monitoring requirements should be considered in the development of control system
specifications. Control systems should be capable of recording averages of moni-
tored quantities over specified intervals.
Trend logs taken over periods of one week or longer can provide valuable informa-
tion on system operation. Reviewing such logs prior to performance testing can help
identify specific areas for attention during testing.
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2-62 Design Guide for Cool Thermal Storage
Chapter 3 COMPARISON OF STORAGE
TECHNOLOGIES
This chapter gives an overview of six cool storage technologies and compares the
primary attributes to be considered when selecting a cool storage system for a
specific application. Table 3-1 summarizes the primary features of the six cool
storage technologies.
Chilled water and eutectic salt storage systemsuse standard water chillers operating
at conventional HVAC system temperatures. These storage technologies are gener-
ally applied in systemswith relatively large cooling loads, where centrifugal chillers
are most often used.
Internal melt ice-on-pipe, encapsulated ice, and some external melt ice-on-coil
systems use standard packaged chillers selected to chill secondary coolants to ice
making temperatures. Chillers using reciprocating, screw, or scroll compressors are
typically used for these technologies. Centrifugal compressors may also be used,
provided they are properly selected for the intended range of evaporator tempera-
tures. Harmon and Yu (1991) discuss the selection of centrifugal chillers for ice
making at 24 to 26OF (4to-3OC). External melt systems may also be installed with
built-up refrigeration plants, with refrigerant as thecharging fluid, and the ice builder
pipes serving as the evaporator for the system. Ice harvesting systems use packaged
or built-up refrigeration systems, with especially designed evaporator sections for
building and harvesting ice.
3-2 Design Guide for Cool Thermal Storage
Tank volume
Storage installed costb $30 to $100 per ton-hr $20 to $30 per ton-hr
($8.50 to $28/kWh) ($5.70 to $8.50Wh)
Notes:
a Costs are for chiller or refrigeration plant only, and do not include installation. All
costs, except ice harvesters, are per nominal ton. Derating for actual operating
conditions may be required.
Costs are for storage only, and include tank, internal diffusers, headers, and heat
transfer surface.
Comparison of Storage Technologies 3-3
External Melt Ice Internal Melt Ice Encapsulated Ice Eutectic Salt
$50 to $70 per ton-hr $50 to $70 per ton-hr $50 to $70 per ton-hr $100 to $150
($14 to $20/kWh) ($14 to $2O/kWh) ($14 to $20/kWh) per ton-hr
($28 to $43/kWh)
0.85 to 1.4 kW/ton 0.85 to 1.2 kW/ton 0.85 to 1.2 kW/ton 0.60 to 0.70 kW/ton
(3.0 to 4.9 COP) (3.0 to 4.9 COP) (3.0 to 4.9 COP) (2.1 to 2.5 COP)
Separate charge
and discharge circuits.
Charge with coolant
or liquid refrigerant
Costs for chilled water tanks are based on tank volume; thus, the cost per unit of
energy depends on the chilled water temperature range. The storage cost figures
given in Table 3-1 are general guidelines for use in initial economic evaluations of
storage systems. These guidelines include the cost of storage tanks and any required
internal diffusers, headers, or heat transfer surface. Costs vary depending on the size
of the project and site-specific considerations,as well as on the geographic area and
local economic conditions. Accurate cost estimates for a specific application can be
obtained from contractors or vendors.
The cost of chillers or refrigeration equipment must be considered along with thecost
of storage capacity. Chilled water and eutectic salt storage are compatible with
typical conventionalHVAC temperatures and can often be added to existing systems
without adding new chillers. For ice harvesting systems,the low storage cost is offset
by a relatively high cost for the ice making equipment.
Ice systems provide discharge temperatures between 34 and 38°F (1and 3OC). These
temperaturesallow the use of extended chilled water temperature ranges and reduced
supply air temperatures, resulting in decreased equipment cost and operating costs
for water and air distribution systems.
The available discharge temperatures for all storage technologies rise as storage is
discharged. Storage tanks must be sized to provide the required storage cooling
capacity at or below the maximum usable chilled fluid supply temperature.
With some storage technologies, the increase in discharge temperature through the
discharge cycle is more pronounced than for others, and the available discharge
temperature tends to increase with the rate of cooling discharge.
Chilled water storage systems can deliver cooling at up to the maximum design
discharge rate with no effect on the discharge temperature.
Ice harvester and external melt ice storage systems can also be discharged at very
high rates with very little effect on discharge temperature. However, the available
temperatureincreases during the last 10to 20% of the discharge cycle, especially at
high discharge rates.
The available dischargetemperatures for internal melt and encapsulated ice systems
depend mainly on discharge rate. Storage capacity must be correctly sized to ensure
that the required dischargerate will be availableat the required temperature for every
hour of the design load profile.
3-6 Design Guide for Cool Thermal Storage
Internal melt ice storage is installed in closed, pressurized systems. Encapsulated ice
systems can be closed or use open, unpressurized tanks. The other technologies use
open tanks.
Chilled water and eutectic salt storage operate at typical conventional HVAC
temperatures and can use exist in retrofit applications. Chilled water storage tanks
can also serve as frre protection tanks in some cases.
Modular internal melt ice storage tanks are well suited for applications with
relatively low loads and are also applicable with higher loads.
Ice harvester and external melt ice systems are capable of high instantaneous
discharge rate, and maintain constant low discharge temperatures through most of
the discharge cycle.
REFERENCES
Harmon, JJ. and H.C. Yu. 1991. Centrifugal chillers and glycol ice thermal storage
units. ASHRAE Journal (December):25-3 1.
Chapter 4 CHILLED WATER STORAGE
Uses standard chillers operating at high rates of efficiency. No need for special
equipment.
Is ideal for increasing capacity of existing conventional systems and for aiding
the transition to reduced capacity non-CFC refrigeration.
Becomes increasingly economical with larger tank sizes. Competitive first cost
at approximately 2,000 ton-hours or 200,000 gal (7000 kwh, 760 m3). Systems
with multimillion gallon tanks commonly have lower capital costs than equiva-
lent nonstorage chiller plants.
Can serve double duty by providing a water reservoir for fire protection.
Is proven and reliable, with a good track record.
Can be configured to store both warm and chilled water.
Chilled water storage using stratified tanks with properly designed diffusers is a
simple, low-maintenance cooling option. Tanks for chilled water storage are often
very large and may be difficult to site due to space limitations and aesthetic
considerations. Tanks may be installed partially or completely below grade, but this
increases the fist cost.
Chilled water storage systems are typically charged with water at temperatures
between 39 and 44OF (4 and 7OC). This temperature range is compatible with most
nonstorage cooling systems and allows the use of conventional chillers, including
absorption chillers operating at conventional temperatures.
Storage volume for chilled water storage systems with temperature differentials of
10 to 20°F (6 to 11°C) is generally between 11and 21 ft3per ton-hour (5.9 and 11.3
kwh/m3). If a temperature differential of 30°F (17°C) can be maintained, the
required storage volume is reduced to about 7 ft3per ton-tour (17.7 kwh/m3). This
space requirement is three to seven times that of ice storage systems and two to three
times that of eutectic salt phase-change systems. However, because chilled water
storage tanks are relatively tall, plan area requirements are often comparable with
other storage technologies. When space is available, chilled water storage can be an
economical way of storing large amounts of cooling capacity.
Chilled water storage is most economical for applications with cooling loads
requiring storage of more than 2,000 ton-hours (7000 kwh) or about 200,000 gal
(760 m3). The larger the tank, the lower the surface-to-volumeratio, and the lower
the cost per ton-hour of stored cooling. Many large chilled water storage systems
store over 1-million gal of water; some store over 5-million gal (40,000 m3).
Stratification
Multiple tank
Membrane or diaphragm
Labyrinth and baffle
4.2.1 Stratification
Stratifiedchilled water storage tanks rely on the tendency of water to form horizontal
layers or temperature zones based on its density. The density of water is directly
related to its temperature. As water gets colder, it becomes more dense, until it
reaches 39.2"F(4"C).As water is cooledbelow this point, itbecomesless dense, until
it freezes. Cold water near to 39.2OF (4OC) and up to 42OF (6OC) will collect and
stabilize in the lowest regions of the tank, while warmer water, 50 to 65OF (10 to
lg°C), will collect in the upper regions of the tank. Well-designed stratified chilled
water storagetanks can deliver 85 to 95%of the stored energy as useful cooling. This
performance is equal to or better than the other approaches to chilled water storage
(Tran et al. 1989).
The term "stratification" has been used in some contexts to denote all techniques for
maintaining separation between warmer and cooler water in storage. In this guide,
stratification is used to refer to what is sometimescalled "natural stratification," i.e.,
the separation of warm and cool water based on density only.
Properly designed stratified storage tanks achieve the necessary separation between
cold and warm water by creating and maintaining a thermocline or transition layer
between the warm upper zone and the cool lower zone. A stable, sharply defined
thermocline prevents cold water below from mixing with the warm water above.
During the charging cycle, cold water from the chilling equipment enters the tank
through diffusers at the bottom, and warm water exits the tank at the top. As the
volume of chilled water increasesand warm water is displaced, the thermocline rises.
The total volume of water in the tank remains the same. The flow of water is reversed
during discharging. The system draws chilled supply water from the low portion of
the tank and sends warm return water into the top of the tank.
A diffuser distributew the flow into and out of the tank. With a properly designed
diffuser, water gently flows into and out of the tank, minimizing turbulence and
leaving the thermocline undisturbed. Figure 4-1 is a schematic diagram of a basic
stratified chilled water storage system.
4-4 Design Guide for Cool Thermal Storage
Variable
Air temp. regulating
volume
valve (modulating)
distribution
'
IVent
Warm v v v v v v v v v
STORAGE
/\ A /\ A f\ fiA A nC001
Pressure sustaining
and check valve Chiller primary
Pump
CHILLER
The storage capacity of a stratified chilled water tank, like that of other chilled water
storage methods, increases with the temperature difference between the stored
chilled water and the warm water returning from the load. In addition, a larger
temperature differential increasesthe density differencebetween the warm and cold
water, which facilitates stratification. A large temperature differential also reduces
the flow rate through a chilled water tank,further enhancing stratification.
as long as a week or more, depending on the size of the tank, the insulation value, and
other factors.
In a good design, thermocline thickness ranges from about 1 to 3 ft (0.3 to 1.0 m),
depending on diffuserdesign and the age of the thermocline. Figure 4-2 illustrates
a typical temperature profile versus height for a stratified tank. The figure shows that
a distance of approximately 3 ft (1 m) separates cold water at 40°F (4OC) and warm
water at 58OF (14°C).
0 (0)
-5 (-1.5) -
-10 (-3)-
-1 5 (-4.5)
-
- 2 0 (-6) - - - - - ' - - - - ' - - " ' " - - ' ~ ~ . - ' . ~ - ~ ' m - - - ' - - m L
35 (2) 45 ( 7 ) 55 ( 1 3) 65 (1 8)
Temperature, OF (OC)
A well-designed stratified storage tank that is charged daily will provide chilled
water to the load at a gradually rising temperatureduring discharge and warm water
to the chiller at a gradually falling temperature during charging. This critical design
characteristic is discussed further in Section 4.9.
In a stratified chilled water storage system, separation of warm and cold water is
accomplished by careful diffuser design (Section 4.4). Since they do not require the
physical barrier of a membrane system or the relatively complex piping and valving
Chllled Water Storage 4-7
of a multiple tank system, stratified systems are lower in capital cost and simpler to
operate and maintain than other types of chilled water storage. Thermal losses are
reduced due to the relatively low surface-to-volume ratio of a single tank. Finally,
operating costs are equal to or lower than those of other chilled water storage
systems, since optimum separation of warm and cold water is maintained.
An empty tank system consists of two or more tanks, one of which is always empty
at the start of a charging cycle. During charging, warm water from one tank is cooled
and pumped into the empty tank. During discharging, stored chilled water is
withdrawn to meet thecooling load, and warm return water is pumped into the empty
tank.Because of the necessary empty tank, the total tank volume exceeds the usable
chilled water storage volume.
Empty tank systemsrequire relatively complexpiping and controls to direct the flow
to the appropriate tanks. Selection of pumps is made more complex with this
approach, because the pumps must workagainst a continually varying dynamic head.
This scheme uses a flexible membrane or rigid, movable diaphragm mounted inside
the storage tank to maintain the separationbetween cold water and warm water. The
membrane system is designed to eliminate mixing of cool and warm water without
the need for diffusers. Thermal conduction across the membrane results in some
degradation in stored cooling capacity.
Tran et al. (1989) found that stratified and membrane systems provided essentially
equivalent thermal separation performance. The first cost of the membrane and of
possiblerepairs to tears in the membrane eliminate any cost advantageof membranes
over well-designed diffusers used in stratified chilled water storage.
4-8 Design Guide for Cool Thermal Storage
t PLAN
SECTION
In practice, however, labyrinth and baffle designs suffer from significant mixing of
warm and cold water due to turbulence, density currents, velocity currents, thermal
conduction, and water-wall interaction. When the flow rate is low enough to avoid
turbulence in each cell, pockets of dead water form along the flow path, reducing
effective storage capacity.
One implementation of the labyrinth approach is the series tank design, which
consists of a number of tanks connected in series. Chilled water is pumped into the
first tank through an inlet port at the base of the tank. Overflow from the first tank
is piped to the base of the second tank and so on. Eventually, all the tanks become
charged with cold water. During extraction, the flow is reversed. Chilled water is
drawn from the base of the first tank and warm return water enters the top of the tank
at the end of the series.
The fundamental weakness of the labyrinth design is that in both charge and
discharge mode, the water alternates between a top and bottom entry. Mixing occurs
due to buoyancy effects, because at every other cell, the water enters at the wrong
end.
Absorption chillers are most compatible with chilled water storage systemsin which
water is supplied to the tanks at or above 42OF (6"C), or where the absorption units
are used for precooling. The efficiency of absorption chillers drops significantly at
discharge temperatures below about 42OF (6OC).
4-10 Design Guide for Cool Thermal Storage
Chilled water storage can often be added to an existing cooling plant simply by
adding a storage tank and associated piping, In most cases, existing chillers are
compatible with chilled water storage with no modification.
Adding chilled water storage to a conventional system can also ease the transition to
non-CFC refrigerants. Chilled water storage enables a building owner to add
capacity now, at relatively low expense, in anticipation of a future loss of capacity
associated with the performance of the new refrigerants.
The favored tank shape for stratified chilled water storage is a flat-bottomedvertical
cylinder. A cylindrical tank has a lower surface-to-volumeratio than a rectangular
tank of the same volume. A tank with a low surface-to-volume ratio has a lower
degree of thermal loss and a lower construction cost per ton-hour of stored cooling.
Local soil conditionsaffect excavation and foundation costs and must be considered
in selecting the most economical tank shape.
Other tank shapes can be used with stratified thermal storage. Spherical tanks
provide the lowest surface-to-volume ratio but do not stratify well. The diffuser
design criteriadiscussedhere are for tankswith flat floors and straight vertical walls.
Other tank shapesmay be used, but special treatment is required to avoid mixing due
to vertical motion that can be induced if inlet fluid strikes sloping or curved tank wall
or floor surfaces. Scale model testing can be helpful in cases where a proposed Eank
shape has not been previously used or studied. Mackie and Reeves (1988) discuss the
use of scale modeling.
Wildin and Truman (1985) describe scale modeling performed in their work that
determined the role of the gravity current in thermocline formation. Hussain and
Peters (1992) describe a rectangular fire pond with slanted sidewalls that was
successfully retrofitted for use as a stratified chilled water storage tank.Extensive
scale model testing was done during the design phase to confm that the tank shape
would provide acceptable stratification performance.
Horizontal cylindrical tanks are not recommended for stratified chilled water
storage. Though no published data are available, the variation in plan area of the
thermoclineas itrisesand falls is thought to cause mixing (Mackie and Reeves 1988).
Steel tanks do not retain significantamounts of heat in the walls, which are relatively
thin. However, steel walls conduct heat across the thermocline, resulting in some
degradation of storage efficiency. Such degradation can be relatively high in small
tanks of less than 50,000 gal (190 m3).
The walls of concrete tanks have a higher insulation value than steel tanks and can
be located partially or fully underground. Burial of concrete tanks in well-drained
soil reduces their external heat gain. However, the relatively massive walls of
concrete tanks retain heat, which can contribute to degradation of the thermocline.
The relative thermal characteristics of steel and concrete tanks affecting stratifica-
tion have not been quantified for chilled water storage. It is likely that a large, well-
insulated steel tank and a concrete tank of the same size will each maintain
stratification in roughly the same manner. Cost, leakage, possible underground
service, and site-specific factors should all be evaluated when selecting the tank
material.
lower diffuser is above the tank floor and is identical to the lower diffuser in shape.
The diffusers in a stratified chilled water storage system must form, or reform, a
thermoclinewith minimal mixing between warm andcold water, and then ensure that
the thermocline is not impaired by subsequent mixing. The thermocline is formed by
designing diffusers with the appropriate Froude number and by properly sizing
diffuser openings. Degradation of the thermocline is minimized by designing for an
appropriate inlet Reynolds number and by proper operation of the system.
The Froude number is the dimensionlessratio of the inertia force to the buoyancy
force acting on a fluid. In their work that established the importance of the inlet
Froude number in thermocline formation, Yoo et al. (1986) verified that with a
Froude number of 1or less, the buoyancy force in the inlet flow is greater than the
inertial force, and a gravity current is formed. A gravity current will form at Froude
numbers above 1, but above a Froude number of about 2, the effects of mixing
become apparent, and small increases in the Froude number result in significant
increases in mixing.
Fr,. = A
[&( P i ' P O ) /Po]
where
and
where
For a given flow rate and diffuser length, the Froude number criterion is used to
determinethe required inlet height. The inlet height is definedas the vertical distance
occupied by the incoming flow or density current as it leaves the diffuser. For a
diffuser close to the bottom of a tank,this height is the distance from the tank floor
to the top of the diffuser inlet opening. The inlet height should be selected to yield
a Froude number of 1. The Froude number must be less than 2.
Mixing above and below the thermocline, and the resulting degradation of the
thermocline, are affected by the inlet flow rate per unit length of diffuser, expressed
in terms of an inlet Reynolds number (Wildin and Truman 1989). The Reynolds
number in a flowing fluid is the dimensionless ratio of inertial to viscous forces. The
inlet Reynolds number is calculated by:
Re, = q-h,
where
For a given flow rate, the desired Reynolds number can be achieved by adjusting the
total effective length of the diffuser.
Mixing can be minimized and storage capacity maximized by designing diffusers for
lower Reynolds numbers. The lower limit below which decreasing the Reynolds
number yields little further reduction in mixing depends on the shape of the tank.For
very short tanks or tanks with sloping sidewalls, the lower limit of about 200 is
recommended. For tanks greater than about 15 ft (5 m) deep, data are insufficient to
provide rigid guidelines,but limits of 400 to 850 have been suggested. For tall tanks,
40 ft (12 m) deep or more, there is evidence that diffusers with inlet Reynolds
numbers of 2,000 or more may provide acceptable stratification. For design pw-
poses, a maximum of 2,000 for the Reynolds number should be used. In general, an
upper limit of 850 is recommended, unless data are available for a specific tank to
support proper stratification at higher Reynolds numbers.
The openings in diffuser branches should be sized and spaced to provide a nearly
uniform flow rate per unit length,and to promote merging of the flow from individual
openings within a very short distance of the openings.
Chilled Water Storage 4-15
A uniform discharge velocity along the length of the diffuser is essential to creating
the gravity current. Nonuniform flow through the diffuser openings can cause
horizontal swirling in the storage tank. A high-velocity stream from one diffuser
opening can interrupt and degrade the thermocline. Uniform discharge velocity is
achieved when the static pressure throughout the interior of the diffuser piping is
uniform. While absoluteuniformity is difficultto achieve, it can be approximatedby
making the total opening area in any diffuser branch no greater than half the cross-
sectional area of the branch pipe (Hudson et al., 1979, McNown 1980).
Distribution piping should also be designed to reduce flow velocity to less than 1ft/
s (0.3 m/s) before the water reaches the diffuser openings. This reduces dynamic
pressure and momentum at the diffuser openings and helps to maintain the necessary
uniformity of static pressure inside the diffuser piping.
Diffuser openings should be oriented to direct the entering fluid toward the adjacent
floor or upper surface so that it encounters this boundary at a low speed and spreads
horizontally to merge with the fluid leaving adjacent openings. It is important that
no upward momentum be imparted to fluid entering at the lower diffusers or
downward momentum at the upper diffusers.
Detailed discussions of diffuser design for stratified chilled water storage are
provided in Mackie and Reeves (1988) and Wildin (1990,1991). Wildin (1990) and
Fiorino (1991) provide examples of the diffuser design procedure.
4-16 Design Guide for Cool Thermal Storage
Octagonal and radial disk diffusers are geometrically best suited for cylindrical
tanks, whereas horizontal slot and H-style diffusers are geometrically best suited for
square or rectangular tanks. Octagonal headers, in either single, double, or multiple
configurationsconstitute one approach. Octagonal diffusers have been successful in
both controlled studies (Wildin and Truman 1989) and several field applications in
multimillion-gallontanks. Fiorino (1991) provides an example of a double-octagon
diffuser system in a 2.7-million gal (10,200 m3) tank.
Octagonal diffusersare formed by eight straight sections of pipe connected with 45'
elbows. A seriesof equally sized, shaped,and spaced lateral slot openingsare cut into
the top of the straight sections of pipe comprising the upper (warmwater) diffuser
or the bottom of the pipe comprising the lower (cold water) diffuser. Figure 4-5
illustrates an octagon diffuser.
C
Density current
-
P
Tank floor
The use of arc-shaped slots centered on the diffuser vertical center plane of the pipe
assures equal subdivision of flow in both the radial inward and outward directions
as it exits the diffuser pipe, doubling the effective length of the diffuser and reducing
its Reynolds and Froude numbers by 50%.
Circular holes drilled in the bottom of the lower diffuserpipe or the top of the upper
diffuser pipe can also introduce the fluid with minimal mixing. In this case, for the
lower diffuser, hiis the distance between the bottom of the pipe and the tank floor.
Joyce and Bahnfleth (1992) discuss a 4-million gal (15 000 m3) tank with an
octagonal diffuser. In this case, the diffuser is a dual-pipe design, with an inner
carrier pipe and a longitudinally slotted outer pipe. The dual-pipe approach allows
independent controlof flow uniformity along the length of the diffuser and inlet fluid
velocity. However, single-pipe diffusers designed according to the guidelines
outlined in Section 4.4.3 can provide good stratification performance with lower
material and labor costs.
Continuous horizontal slot diffusers are typically mounted along the center plane of
square or rectangular tanks. In large tanks, a single linear diffuser may not have
sufficient length to satisfy the Reynolds number criterion. In such cases, an
arrangement of H-shaped diffusers may be required to provide the necessary length
of the diffuser. Figure 4-6 illustrates an H-style diffuser arrangement.
A radial disk diffuser consists of two closely spaced disks, mounted parallel to the
tank floor. The incoming water flows between the disks and enters the tank
horizontally. Radial diffusers have been used successfully in many recent stratified
chilled water installations. Wildin (1990) presents an example design for a radial
disk diffuser.
Because the water leaves the radial disk in an outward direction only, the Reynolds
number of a radial disk diffuser is higher than that of an octagonal diffuser of the
same circumference. The Reynolds number can be reduced by increasing the
circumference of the diffuser. However, the areaof aradial disk diffuser should not
exceed 50%of the plan area of the tank. The opening height should not exceed 5 to
10%of the overall depth of water in the tank, with a maximum of 5% preferred.
If the visual impact of a large aboveground tank is a problem, the tank may be located
next to a building, parking deck, or other structure. It can also be camouflagedby the
creative use of landscaping, lighting, surface texture, andforcolor. Even large-scale
graphics have been applied to tanks.
For new construction, costs can be reduced by integratingthe tank into the structure
of the building. Tanks integrated with the structure are usually less expensive than
tanks constructed separately.
Locating the storage tank close to chillers and pumps minimizes the thermal losses
and costs of transfer piping, However, if necessary, tanks can be located several
hundred feet or more from associated mechanical equipment. For large chilled water
distribution systems, storage can often be located at a convenient location along the
main supply and return headers, which may also increase the peak distribution
system capacity.
From a hydraulic standpoint, the water level in the tank should exceed by at least 25
ft (8 m) the elevation of the highest piping inside the building it serves in order to
avoid transfer pumps and to simplify pressure sustainment. If this condition cannot
be met, transfer pumps are best located adjacent to the tank and below its water level
to assure a flooded suction and positive suction head. Transfer pumps should not be
Chilled Water Storage 4-19
located on the tank roof due to loss of prime, negative suction head and potential
vibration transmission to the tank.
Sensors spaced more closely together provide more accurate monitoring of storage
status. With a spacing of 6 to 8 in. (150 to 200 mm), several sensors will be located
in the thermocline itself. A 20-sensor array may be sufficient, since it provides
storage inventory monitoring to an accuracy of within 5%, regardless of the total
depth of the water.
A water level sensor is required to monitor system volume and to signal when
makeup water is needed.
Nonpressurized tanks that are not isolated by heat exchangers require pressure-
sustaining valves on the tank inlet and outlet to separate the static head of the tank
from the remainder of the chilled water distribution system. The use of these valves
is discussed in Sections 2.5 and 4.7.
Multiple tank systems require relatively complex valving and controls to manage
water flow to and from the appropriatetanks and to maintain separationof warm and
cold water.
With chilled water storage, the cost of stored cooling is often lower than the cost of
direct cooling because of utility rates and differences in chiller operation. In such
cases, a storage priority control scheme is used to optimize part-load operation.
4-20 Design Guide for Cool Thermal Storage
The storage priority approach requires some type of load estimation or prediction.
The object is to meet as much of the building load as possible using stored cooling,
supplementing with chiller cooling only when necessary. The task of the control
system is to predict in advance the total amount of stored cooling needed to meet the
load so that chillers can be started early enough in the day to prevent storage from
being exhausted too soon. Even during part-load conditions, the building load late
in the day can exceed the capacity of chillers sized for partial storage operation.
Another optimizing strategy for part-load operation is to reduce the rate of charging
and to use the maximum available charge time. This can save money in situations
where an off-peak demand charge applies.
In areas with no off-peak demand charges, chillers may operate best at maximum
capacity as much as possible to reduce the relative amount of energy consumed by
auxiliary equipment. Condenser water pumps, primary pumps, and to some extent,
cooling towers, operate at constant capacity independent of load. Running chillers
at maximum capacity minimizes the operating hours required to meet a given total
integrated cooling load. This, in turn,minimizes the energy consumption of auxiliary
equipment.
Standby losses in chilled water storage tanks can be significant in small tanks. Over
time, the necessary separation between warm and cold water is reduced by conduc-
tion across the thermocline, conduction through the tank walls, and mixing. These
effects undermine the usable cooling capacity of the tank. Therefore, the residence
time of chilled water in the tank should not be unnecessarily extended, particularly
in small tanks.
Make-upwater should be introduced through the upper diffuser or in some other way
as not to interfere with the thermocline.
It is also important that the system be operated so that the inlet fluid temperature does
not fluctuate. In particular, the inlet temperature should not increase at the lower
diffuser during charging, or decrease at the upper diffusers during discharging.
Since chilled water storage tanks are almost always unpressurized and vented to the
atmosphere, the building interface must also account for any pressure differential
Chilled Water Storage 4-21
resulting from differences in height between the tank and the building system. A
minimum sustaining pressure setpoint of 5 psig (35 P a ) is recommended for the
water in the uppermost piping in the building under all load conditions.
In some cases, the water in the storage tank may also be used for fire protection.
The low flow rates resulting from increased temperature differentialsmake coil and
control valve selection particularly important. A discussion of coil selection and
control for high water temperature differentials is given in Section 2.5.1.
Tackett (1987) describes one chilled water storage system that experienced a
reduction in the design temperature differentialbecause of improperly selected coils
and an excessive pressure differential across the control valves.
Figures 4- 1,4-7, and 4-8 illustrate three approaches to configuring the chilled water
storage system and its interface with the building system.
Air temlmrature
Direction control
w . .
Distributionpump(8)
' 1 EXCHANGER
HEAT )
Primary Temperature regulating
valve (modulating)
(variable volume)
~ r e s & r esustaining
and check valves
4 CHILLER /+A+-$
Chiller primary pump
The use of heat exchangers with chilled water storage has the disadvantage that they
reduce the temperature differential available for storage, increasing the size and cost
of the tank. With a heat exchanger differential of 2°F (l°C), the temperature of the
chilled water is increased by 2 O F (l°C) each time that cooling is transferred across
the heat exchanger. With the arrangementof Figure4-8,the heat exchanger increases
the supply temperature to the load and reduces the return temperature to the storage
tank during discharging. If a heat exchanger is used to isolate the storage tank from
the cooling plant, the temperature of the chilled water will increase both when it is
put into the tank and when it is discharged. Also, the pump energy expended to pump
water through both sides of the heat exchangersrepresents an increased parasitic load
on the system.
Because most tanks used for chilled water storage are so large, the height of water
in the tank may exceed the height of the building piping enough to provide the static
pressure required in the building system.
4.8 SIZING
The tank volume required to store a given cooling capacity in a chilled water storage
system depends on the temperature difference between the supply and return water
and on the storage effectiveness of the tank in discharging stored cooling at a usable
temperature. That effectivenessis expressed as the figure of merit (FOM) of the tank.
The required tank volume can be minimized by maximizing the water temperature
differential and by maximizing storage effectiveness with careful diffuser design.
424 Design Guide for Cool Thermal Storage
Storage eflciency is the ratio of the amount of energy removed from storage to the
amount of energy put into storage during one chargeldischarge cycle. Storage
efficiency is a measure of the loss of energy to the surroundings, such as conduction
through tank walls. However, the storage efficiency for chilled water tanks does not
take into account any reduction in usable energy caused by mixing or thermal
conduction across the thennocline.
The storage tank FOM is a better measure of cooling available from a tank than the
storage efficiency. The FOM is the ratio of the amount of cooling removed from
storage to the amount of cooling theoretically available from fully charged storage.
The FOM takes into account the actual loss of usable stored cooling capacity due to
thermal conduction and mixing in the tank.Figure 4-9 illustrates the FOM concept.
Area A represents the total cooling removed from the tank during the discharge
cycle. Area A plus Area B represent the total cooling theoretically available, based
on the inlet temperature during charging and thereturn temperature during discharg-
ing. The FOM is the ratio of these areas.
I \ Charge inlet I
50
Percent of total volume
FOM = AreaA
&eaA + Area B )
Tran et al. (1989) provide a detailed explanationof the derivation and calculation of
FOM.
Stratified chilled water storage tanks with well-designed diffusers perform at FOM
levels of 90% or better, so that if a chiller introduced 100 ton-hours of cooling into
a tank, the system could withdraw up to 90 ton-hours of cooling before the tank
discharge temperature would rise above the maximum usable temperature.
The most reliable estimate of FOM for a tank under design may be obtained from
field data on tanks with similar geometry or from scale model testing. In the absence
of such data, a factor of 85 to 90% is recommended for sizing calculations, for a
diffuser designed according to the guidelines presented in Section 4.4.3. A lower
factor should be used with small tanks or when the designer believes that the diffuser
design may not be optimal.
Volume Cgallond =
ton-hr x Btu/ton-hr
AOF x 8.36 Btu/gab°F x Tank Figure of Merit
Volume [m3] =
(5)
k w h x 3600 kJ/kWh
AK x 998 kg/ms x 4.2 lrJ/Ckg.Kl x Tank Figure of Merit
The tank volume will be somewhat greater since some clearance between the water
level and top of the tank will be required. In seismically active areas, an additional
allowance may be required to accommodate the "sloshing wave" which can occur
during seismic events.
Stored water typically gains 1to 2OF (0.5 to 1°C) in storage due to conduction heat
gains and unavoidable mixing. Ideally, water will be discharged from the tank at a
constant temperature. In practice, the discharge temperature gradually rises through
the discharge period, increasing more rapidly at the end of the discharge period as
the thermocline begins to be drawn into the lower diffuser. The degreeof temperature
rise during discharge depends on the quality of stratification within the tank, which
is a direct result of diffuser design and heat transfer within the tank and through the
tank walls.
I I
.
I 1 I
For a given installation, the actual temperature rise above the average inlet tempera-
ture and the percentage of storage volume available as usable cooling depends on
diffuser design and system operation. Many systems can withdraw up to 90% of the
storage volume at a maximum of 2OF (l°C) above the average inlet temperature. To
achieve this performance, diffusers must be designed to minimize the thickness of
the thermocline, and the system must be operated to remove all or most of the
thermocline from the tank during each charging cycle. A well-designed diffuser
maintains a stable thermocline and minimizes the loss of usable cooling by mixing
warm and cool water.
During the charging phase, the temperature curve for the warm water exiting the
upper diffuser follows a reversed curve as shown in Figure 4-11. The temperature
gradually descends until the thermocline approaches the diffuser. As the water from
the thermocline is drawn out, the temperature falls more rapidly. The reduced chiller
inlet temperature at the end of the charging cycle results in partial loading of chillers
and should be accounted for in developing the design operating profile.
0 10 20 30 40 50 60 70 00 00 100 11
Percent of tank volume
Thermal convection and mixing are the primary causes of losses in a stratifiedchilled
water storage tank. Thermal conduction occurs across the thermocline, along the
walls of the tank, and through the walls of the tank. Heat transfer by thermal
conduction across the thermocline and along the walls of the tank reduces the usable
cooling energy in the tank.Heat transferred through the tank walls is energy lost from
the entire system and can be minimized by insulating steel tanks or by burying
concrete tanks to the top of their walls.
Conduction along tank walls depends on the tank material. Steel tank walls conduct
heat from the warm to the cool side of the tank more quickly than does concrete.
4-28 Design Guide for Cool Thermal Storage
However, concrete walls store heat and exchange it with the tank water as the
thermocline moves up and down.
Some heat gain may occur through exposure of tank roofs to intense sunlight. This
can be reduced by insulating the top of the tank and applying a reflective white outer
coating to the insulation.
The first cost in a chilled water cool thermal storage system includes the cost of the
tank, excavation if the tank is placed underground outside of the building; a chiller
if a new one is needed; and pumps, diffusers, initial water treatment, and control and
instrumentation to run and monitor the system. On large systems, the cost of
connecting piping may also be significant. Depending on the design, there may also
be costs associated with heat exchangers or energy recovery turbines. Retrofit
applicationsmay also have costs associated with measures necessary to assure a high
return temperature, e.g., two-way control valves, variable volume pumping, etc.
4.10.1 Tanks
The cost of the storage tank is the most variable of any of the costs in a stratified cool
storage system. The cost of the tank depends on:
Material
Shape
Size
Local conditions affecting ease of construction
Insulation
Foundation
Figure 4-12 indicates ranges of costs for surface-mounted steel and concrete tanks
as a function of tank size. For subsurface concrete tanks, excavation and backfill
costs must be added. Costs vary by region and local vendors should be consulted for
quotes on specific projects.
Chilled Water Storage 4-29
4.10.2 Chillers
Refrigeration plants for chilled water storage systems are essentially the same type
as those for nonstorage applications, and costs per ton are comparable. Standard
sources of cost data, such as vendors,contractors, or past experience, should be used.
If the storage chiller is to supply water at 39 to 40°F (4 to 5OC), the cost per actual
ton may be slightly higher than for a non-storage chiller designed for 42 to 45OF (6
to 7 O C ) supply temperatures.
In new construction, a chiller for chilled water storagewill generally be smaller and
less expensive than one for a nonstorage system. When converting or expanding an
existing system for storage, existing chillers can often be used, and additional
cooling capacity can be obtained simply by installing a storage tank and interface.
In such cases, the first cost of the chilled water storage system may be less than that
of a nonstorage system.
4-30 Design Guide for Cool Thermal Storage
The tank interface includes pumps, wiring, insulated piping, valves, strainers,
automatic control, and instrumentation. Costs are variable, depending on site-
specific factors. Mackie and Reeves (1988) give interface costs ranging from $70 to
$470 per ton ($20 to $134 per kwh) depending on chiller size (using 1985 dollars).
Some chilled water storage systems have been documented to show an actual
reduction in seasonal energy consumption compared to nonstorage operation at the
same facility due to more efficient nighttime chiller operation and the improved use
of auxiliary equipment.
Chilled water storage systems can incur higher costs of operation and energy usage
due to the presence of transfer pumps, blend pumps, pressure sustaining valves,
external storage heat gains, and internal storage heat transfer. Except for external
storage heat gains, all these factors can be minimized by maintaining a high
temperaturedifferential. Transfer pump energy can be minimized by setting the tank
water level at the appropriate height above the system level. External storage heat
gains can be minimized by tank burial and/or insulation. When these energy
Chilled Water Storage 4-31
increases are minimized by careful design, they can often be offsetby the efficiency
improvements available with chilled water storage.
The operation of a chilled water storage system can be improved and refined as
operators gain experience with the system. Section 2.8.1 discusses optimization of
storage systems in general. Specific considerations for optimizing a chilled water
storage system include maximizing the system temperature differential and making
the best use of storage in nonpeak seasons. Increasing the differential through
improved control of cooling coil valves and distribution pumping increases the
available storage capacity. In nonpeak seasons, charging temperatures can be
increased to maximize chiller efficiency, and the length of charging and discharging
periods can be adjusted, For storage priority systems in particular, optimization of
storage capacity depends on fully discharging storage during each cycle.
Water treatment considerations for chilled water storage include the following
(Mackie and Reeves 1988):
Low circulation rates through stratified tanks make after-the-fact cleaning and
flushing difficult.
The materials used in tank construction or tank surface finishing need to be
included in the corrosion review.
The volume of water in the system is many times greater than that of a
nonstorage system.
4-32 Design Guide for Cool Thermal Storage
Although chilled water tanks have a large volume of water open to atmospheric
pressure, the water contains little oxygen. The volume of air in contact with the water
surface is small, there is little if any air exchange to the tank, and the water surface
is deliberately kept very still. These factors minimize the uptake of oxygen by the
water, causing littleincrease in corrosion potential compared to anonstorage system.
Therefore,water treatment requirementsare similar to those for a nonstorage system
in the same application, except for the volume of water to be treated.
4.13 COMMISSIONING
Commissioningis an ongoing process starting in the predesign phase and continuing
through the first year of system operation. The overall commissioning process is
discussed in Section 2.9. Here, the performance evaluation phase of the commission-
ing process for chilled water storage systems is covered.
To test the total storage capacity of achilled water storage system, begin with a fully
charged tank. With the tank subjected to a design load profile, monitor the cooling
discharged until the storage outlet temperature rises above the maximum usable
temperature. If it is not feasible to provide the design load profile, the total storage
capacity can be tested over more than one day. Because of differences in storage
losses admixing, such a test will not precisely reflect the amount of storagecapacity
available to meet the design load profile, especially for small tanks; for tanks where
the ground temperature around the tank has not reached a state of quasiequilibrium,
conduction losses over an extended discharge period may be significant. However,
this test may provide a reasonable estimate.
During the course of storage capacity testing, verify the ability of the system to
dischargecooling at the design rate with the required dischargetemperature for each
Chilled Water Storage 4-33
hour of the design profile. Monitor the discharge temperature profile to confirm that
the tank and diffusers perform as designed.
Charging capacity is tested by monitoring the cooling delivered to the storage tank
during a complete charge cycle, starting from the fully discharged condition. The
chiller should be able to fully chargethe tank in the time available,while meeting any
loads that occur during the charging period.
Data collected during the charge and discharge capacity tests can be used to
determine the figure of merit (FOM)of the tank.
Scheduling and control sequence testing verifies that all pumps, valves, and other
components operate as specified, in the correct sequences and at the correct times.
Measurement of peak demand and energy efficiency is discussed in Section 2.9.3.
REFERENCES
AWWA. 1984. Standard for welded steel tanks for water storage, ANSVAWWA
D100-84. Denver, CO: American Water Works Association.
AWWA. 1986. Standard for wire-wound circular prestressed-concrete water tanks,
ANSIJAWWA D l 10-86. Denver, CO: American Water Works Association.
Andrepont,J.S. 1992.Central chilled water plant expansionsand the CFC refrigerant
issue--Case studiesof chilled water storage. Proceedings of the Association of
Higher Education Facilities Officers, 79th Annual Meeting, Indianapolis, IN,
July.
Fiorino, D.P. 1991. Case study of a large, naturally slratified,chilled-water thermal
energy storage system. ASHRAE Transactions 97(2):1161-69.
Holness, G.V.R.1992.Case study of combined chilled-waterthermal energy storage
and fire protection storage. ASHRAE Transacfions !%(I):1119-22.
Hudson, H.E.,R.B.Uhleer, and R.W. Bailey. 1979. Dividing flow manifolds with
square-edgedlaterals. Journal of Environmental Engineering Division, ASCE,
Vol. EE4 (August):745-55.
4-34 Design Guide for Cool Thermal Storage
Hussain, M.A. and D.C.J. Peters. 1992.Retrofit integration of fire protection storage
as chilled-water storageiA case study. ASHRAE Transactions 98(1): 1123-
32.
Joyce, W.S. and W.P. Bahnfleth. 1992.Cornell thermal storage project saves money
and electricity. District Heating and Cooling (2):22-29.
Mackie, E.I. and G. Reeves. 1988. Stratified chilled-water storage design guide,
EPRI EM-4852s, May.
McNown, J.S. 1980. Discussion of paper by Hudson, Uhleer, and Bailey. Journal of
the Environmental Engineering Division, ASCE, Vol. EE4 (August):864-66.
Meckler, M. 1992. Design of integrated fire sprinkler piping and thermal storage
systems: Benefits and challenges. ASHRAE Transactions 98(1):1140-48.
NFPA. 1987. Water tanks for private fire protection, ANSI/NF'PA Vol. 22, June.
Quincy, MD: National Fire Protection Association.
Tackett, R.K. 1987. Results from operation of a large membrane stratified cool
storage system with heat recovery. ASHRAE Transactions 93(1):728-39.
Tackett, R.K. 1988. The use of direct pumping and hydraulic turbines in thermal
storage systems. ASHRAE Transactions 94(1):1989-2007. Reprinted in
ASHRAE Technical Data Bulletin 5(4): 103-1 11.
Tran, N., J.F. Kreider, and P. Brothers. 1989. Field measurement of chilled water
storage thermal performance. ASHRAE Transactions 95(1):1106-12.
Wildin, M.W. and CR. Truman. 1985.Evaluation of stratified chilled-waterstorage
techniques, EPRI EM-4352, December.
Wildin, M.W. and C.R.Truman. 1989. Performanceof stratified vertical cylindrical
thermal storage tanks, Part I: scale model tank. ASHRAE Transactions
95(1):1086-95. Reprinted in ASHRAE Technical Data Bulletin 5(3):63-72.
Wildin,M.W. 1990.Diffuserdesign for naturally stratified thermal storage. ASHRAE
Transactions96(1):1094-1102.
Wildin, M.W. 1991. Flow near the inlet and design parameters for stratified chilled
water storage, ASME 91-HT-27, July.
Yoo, J., M.W. Wildin, and CR. Truman. 1986. Initial formation of a thermocline in
stratified thermal storage tanks. ASHRAE Transactions 92(2): 28&92.
BIBLIOGRAPHY
Andrepont, J.S. 1992. Chilled water storage case studies: Central plant capacity
expansions with O&M and capital cost savings. The International District
Heating and Cooling Association (IDHCA) Fifth Annual CollegeAJniversity
Conference, February.
Bjorklund. A.E. 1987. Heat recovery and thermal storage at a state office building.
ASHRAE Transactions 93(2):832-49.
CBI. 1989. Transient temperature profiles of North Mesquite High School. Oak
Brook, IL: Chicago Bridge and Iron Co.
Cordaillat, B. and R.T. Tamblyn. 1988. French office tower pioneers with thermal
storage. ASHRAE Transactions 94(l): 1861-65. Reprinted in ASHRAE Tech-
nical Data Bulletin, Cool Storage Applications 5(3):61-62.
Cottone, A.M. 1990. Featured performer: Thermal storage. HeatinglPipinglAir
Conditioning (August):5 1-55.
Fiorino, D.P. 1990. Thermal energy storage retrofit project at a large manufacturing
facility. In Energy & Environmental Strategiesfor the 1990's, Ch. 82,485-509.
Fiorino, D.P. 1992. Thermal energy storage program for the 1990's. Energy
Engineering 89(4):23-33.
Fiorino, D.P. 1993. Energy conservation with thermally stratified chilled water
storage. ASHRAE Journal 35(5):22.
Gray, B. F., C.A. Johnson, G.J. Schoenau, et al. 1988. Energy consumption and
economic evaluation of thermal storage and recovery systems for a large
commercial building. ASHRAE Transactions 94(1):412-24.
Hensel, E.C., N.L. Robinson, J. Buntain, et al. 1991. Chilled-waterthermal storage
system performance monitoring. ASHRAE Transactions97(2): 1151-60.
Hiller, C.C. andD. Limaye. 1986.Chilled water storage system design and operating
recommendations.EPRI Proceedings: International Load Management Confer-
ence, Section 44, June.
Hiller, C.C. 1987. Stratified chilled water storage techniques. EPRI Seminar Pro-
ceedings: Commercial Cool Storage, State of the Art, EM-5454-SR, October.
Hopkins, KJ. and J.W. Schettler. 1990. Thermal storage enhances heat recovery.
HeatinglPipinglAir Conditioning (March):45-50.
Schepers, 0. 1992. University hits a home run with underground thermal storage.
Consulting-SpecifyingEngineer (November):34-37.
Tamblyn, R.T. 1985. College Park thermal storage experience. ASHRAE Transac-
tions 9l(lB):947-55. Reprinted in ASHRAE Technical Data Bulletin: Thermal
Storage (January):95-103.
Tamblyn, R.T. 1987. Chilled water storage goes to college. EPRI Seminar Proceed-
ings: Commercial Cool Storage, State of the Art, EM-5454-SR, October.
4-36 Design Guide for Cool Thermal Storage
Wildin, M.W. and C.R. Truman. 1985. A summary of experience with stratified
chilled water tanks. ASHRAE Transactions 91(1B):956-76. Reprinted in
ASHRAE Technical Data Bulletin: Thermal Storage (January):104-123.
Wildin, M.W., E.I. Mackie, and W.E. Harrison. 1990. Thermal storage forum:
Stratifiedthermal storage:Anewlold technology. ASHRAEJournal (April):29-
39.
Chapter 5 ICE HARVESTING SYSTEMS
5.1 PRIMARY FEATURES
Ice harvester thermal storage systems:
GENERAL DESCRlPllON
The ice harvesting refrigeration plant generates and releases sheets or tubes of ice
with a speciallydesigned evaporatorsection.Water is pumped out of the storage tank
at low pressure and is distributed over the evaporator surfaces, where it is chilled or
frozen (see Figure 5- 1).The ice harvestingplant is technically called an ice harvester
chiller, or ice harvester, since it operatesas both an ice maker and as a water chiller.
In the ice making mode, a portion of the water flowing over the evaporator plates or
tubes solidifies, forming a layer of ice that is periodically harvested or dropped into
the storage tank below. In the water-chilling mode, warm return water flows over the
same evaporator surfaces, is cooled, and falls into the tank as chilled water.
The selection of ice making or chiller mode is made automatically, depending on the
temperature of the water as it enters the evaporator. If the water is at or near the
freezing point, ice making mode is selected, and a defrost cycle is activated at
intervals to release the ice from the evaporator.
In chiller mode, the defrost cycle is deactivated.The cooling capacity and efficiency
increase with the temperature of the water entering the evaporator.
5-2 Design Guide for Cool Thermal Storage
Building load
Fig. 5-1
During the discharge cycle, ice water is taken from the bottom of the tank and
circulated to the building load. The discharge temperature remains relatively
constant throughout the discharge cycle, rising only as the last ice has melted.
Direct expansion systems allow limited capacity modulation because of the diffi-
culty in providing adequate oil retum at part load. Some systems include two
compressors with independent refrigerant circuits, which allows operation at 50%
capacity. Because a constant pressure drop is needed across thermal expansion
valves, some direct expansion systems do not allow operation at reduced head
pressures, limiting their ability to take advantage of low nighttime condensing
temperatures.
Liquid overfeed systems offer good part-load performance and can take advantage
of low head pressures. However, the liquid overfeed design is more expensive,
particularly for ice making capacities below approximately 100 tons (350 kW).
Flooded systems also offer good part-load performanceand can operate at low head
pressures. Flooded systems require proper design and maintenance to avoid oil-
logging. First cost is between that of direct expansion and liquid overfeed systems.
Ice building and defrosting in the ice making mode is controlled by timers supplied
with the ice harvester package. The machine builds ice for a predetermined amount
of time, typically 10 to 30 min. During the defrost cycle, hot refrigerant gas is
released into the evaporator for 20 to 60 s to release the ice. Refrigeration systems
must be designed to accommodate the pressure fluctuations due to variations in
condensing conditions during defrosting.
Timing of the ice build and defrost cycles is important to ice harvester performance.
An overly long build cycle may produce layers of ice too thick to be released during
the defrost cycle. An overly long defrostcyclereduces efficiencybecause the defrost
heat represents an increased load on the equipment. Knebel(1990) discusses the
determination of optimum ice build and defrost times for ice harvesters.
General storage tank considerations are discussed in Section 2.3.2. This section
addresses specific concerns for ice storage tanks. Tanks may be placed indoors or
out, above or below grade. Enough headroom is needed so that the evaporator
package or the complete ice harvester chiller package can be mounted on top of the
tank. Ice can also be augered or conveyed from an ice harvester to a remote tank for
5-4 Design Guide for Cool Thermal Storage
storage. However, this approach adds expense and operating complexity to the
systems, as well as possible safety concerns.
Tanks are most often site-built of concrete in arectangular shape. However, modular
concrete, steel, or fiberglass tanks can be used if they are built to support the weight
of the evaporator package or the refrigeration plant. Michols (1985) provides
guidance on the design of concrete storage tanks for ice harvesters.
Tank geometry can affect the storage capacity of ice harvesting systems. Depending
on tank shape, the natural angle of repose of the ice as it fills the tank will leave some
void spaces that contain no ice. The presence of these voids reduces the tank storage
capacity by reducing the amount of ice that can be stored in the tank. The smaller the
area of the ice harvester evaporator opening relative to the plan area of the tank, the
greater the tendency for the ice to produce larger void volumes in the tank.
Ice harvesting systems with a large storage capacity in relation to their ice making
capacity, such as weekly load-leveling systems, have the smallest ratio of ice
opening area to tank plan area. These systems also have the greatest void volumes.
To minimize unused tank volume, the tank should be as tall as practical, minimizing
the plan area for a given volume. If possible, dividing evaporator modules among two
or more ice openings will distribute the ice more evenly through the entire tank. A
single ice opening should be located as near to the center of the tank as possible.
The initial fill level of water in the tank also affects the formation of void volumes.
With the correct water level, the weight of the ice pile above the water level will push
ice into the lower corners of the tank. With excess water in the tank, the ice pile will
form voids in the lower tank comers.
The shape of the ice fragments determines the angle of repose that the ice pile will
assume, which affects the amount of void volume in the tank. Flatter ice shapes tend
to form shallowerangles of repose, leaving less void volume. Angles of repose range
from less than 20 to 40° or more for the various ice harvesting systems. The angle
of repose must be considered when designing a storage tank. A tank sized for a
particular ice harvesting system must be resized if different equipment with a
different angle of repose is later substituted. Mechanical means, such as rotating
water nozzles shooting high velocity jets of water, or augers, have been used to level
ice piles and fill void volumes. Figure 5-2 illustrates factors influencing the
formation of void volumes in ice harvester tanks.
Ice Harvesting Systems 5-5
C. ImrePting helgM reducesvoids given D. lntial water level too high. Ice floats leaving voids at bonorn.
same lee opening and volume as B.
D. SMlow angle of rep- reducesvoid volume. E. Sleep angle of r e p a increases void volume.
Note: Tlus (Igure for illustrativepupsss Onb. Voids will always be present.
Ice harvester manufacturers can provide guidance on tank design. At least one
manufacturer offers a computer program to estimate the usable storage capacity of
a tank of given dimensions.
5.4.3 Piping
Design of discharge headers and, in some cases, inlet headers, affects the perfor-
mance of an ice harvester tank. Properly designed headers prevent short-circuiting
of return water through the ice, which can result in increased discharge temperatures
and unusable storage capacity.
Discharge headers must draw water evenly from all points in the tank bottom. Header
piping should be installed on the tank bottom, against the outer wall. This location
provides the most protection from the forces exerted by the weight of the ice in the
tank, and by falling and shifting ice.
If the discharge header riser is located within the tank,it should be shielded to prevent
ice from freezing around it. A mass of ice fused around the riser pipe can exert a
destructive bending moment as ice in the center of the tank melts out. A riser located
in the comer of the tank can be protected by a steel plate mounted at 45O across the
comer and f h l y anchored in both walls.
In some applications,a spray header is used to distribute incoming warm return water
over a wide area of the tank to prevent short-circuiting. Inlet headers should be
considered in systems where the ice opening area is small relative to the tank plan
area, especially if warm building return water enters the tank directly without
precooling. Return water is diverted to a spray header rather than running it over the
idle evaporator surfaces and through the ice opening.
Systems designed for partial storage may also use a spray header to distribute a
portion of return water directly into the tank rather than directing all the water over
the evaporator plates and through a small ice opening.
Internal timers and solenoid valves direct liquid refrigerant and hot gas in turn to the
appropriate evaporator sections to build and harvest ice. Ice building is generally
terminated by an external signal from the control system at the end of the charging
period or when an ice level sensor indicates that the tank is full.
Ice level sensorsdetect when the pile of ice approachesthe bottom of the evaporator.
One sensor type is asmall spinningpaddlewheel, which signals the endof ice making
when the ice level is high enough to stop its motion.
Ice harvesters generally switch from ice making mode to chiller mode, locking out
the defrost cycle, when the temperature of the water onto the evaporator is high
enough to ensure that no ice will form. This temperature depends on the specific ice
harvester design and is typically about 36°F (2°C).
Ice harvesting systems are favored for storageoptions with small chiller capacity and
large storage capacity, because the cost per ton-hour of storage tanks is low and the
cost of refrigeration equipment is high. Weekly storage cycles, illustrated in Figure
2-4, are especially well-suited to ice harvesters.
Ice harvesters function well with a chiller priority control scheme, where stored
cooling is used only when the load exceeds chiller capacity. The refrigerationplant
operates at full capacity. When the load falls below the chiller capacity, the surplus
output is stored in the tank.When the load rises above the chiller capacity, the excess
load is met from stored cooling.
18 Design Guide for Cool Thermal Storage
The storage priority approach attempts to meet as much of the building load as
possible using stored cooling, supplementing with chiller cooling only when neces-
sary. This approach requires that the control system estimate or predict the cooling
load for each day, so that enough chiller mode cooling can be provided to prevent
storage from being exhausted too soon.
Charging operation during nonpealc periods can ,be optimized by running the
refrigeration plant at the minimum capacity that will store the required amount of
cooling in the available time. For example, providing a partial charge by running at
50% capacity for 10 hours will generally use less energy than charging at full
capacity for 5 h. Consult ice harvester manufacturers and be careful in specifying
equipment for such operation to ensure that the necessary part-load capabilities are
provided. Knebel(1991) discusses charging rate control for ice harvesters.
A heat exchanger is recommended to isolate the storage tank from the building
distribution system. This arrangement simplifies water treatment considerations, as
the building distribution system becomes a conventional closed system.
Ice harvester systems can use separate pumps (to recirculate water to the evaporator
and to pump chilled water to the load), or a single pump. Figure 5-3 illustrates three
possible pumping configurations.
Ice Harvesting Systems 5-9
Ice Constant
Hanrester flow
Chlller
Storege Tank
To load
b
Storage Tank
To bad
Ice water recirculation pumps must be sized to account for the variation in static
suction pressure as ice builds and the tank water level drops.
5.8 SIZING
Sizing of an ice harvester system requires selection of the appropriate ice making
capacity and tankdimensions fora given application. Initial ice making capacity and
storage capacity can be estimated using the quick sizing procedure presented in
Section 10.3.Final size requirements should be determined by a detailed simulation
of hourly performance during the design storage cycle, as discussed in Sections 2.6
and 10.6.
For buildings in which HVAC systems are shut down during unoccupied periods,
cooling loads on Mondays are often greater than for other days due to heat that
accumulates over the weekends. The additional cooling needed for Monday morning
pulldown can be provided by sizing the storage tank according to the load profile for
Monday. Ice harvester capacity can be sized according to the slightly lower Tuesday
through Friday load profiles. Over the weekend, the ice harvester chiller has
additionaltime to fill the oversized tank with enough ice to meet the load on Monday
while remaining appropriately sized for the days that follow.
The capacity of ice harvesting equipment depends largely on the return water
temperature entering the evaporator. Figure 5-4 shows a typical relationship of
capacity and entering water temperature. The detailed sizing simulation should take
into account the variation in entering water temperature with building load and the
resulting capacity variation. Calculation of the entering water temperature requires
information on the pumping arrangement and flow rates for recirculated water to the
evaporator and chilled water to the load.
Ice Harvesting Systems 5-11
/ lcemaking
Ice harvester capacity also varies with condensing temperature, which is related to
ambient temperatures. This variation should also be taken into account in the sizing
simulation. Several ice harvester manufacturers, as well as at least one software
vendor, offer computer programs that perform the detailed sizing simulation for ice
harvesting systems. Computer analysis results should be carefully reviewed to
ensure that they accurately represent the intended system operation.
When selecting condenser or cooling tower capacity, consider the heat rejection at
the maximum expected equipment cooling capacity. Since ice harvester capacity
increases dramatically with evaporator entering temperature, condensing capacity
may fall short if higher than expected return water temperatures are experienced.
For example, a full storage system, in which the ice harvester chiller operates only
to charge storage, may be expected to experience a maximum entering temperature
of 32°F (0°C). However, any loads occurring during charging periods increase the
return temperature, the equipment capacity, and the heat rejection. Unanticipated
future load increases or changes in utility rate schedules may require operating the
system in a partial storage strategy, again resulting in increased capacity and heat
rejection.
5-12 Design Guide for Cool Thermal Storage
When the required storage capacity has been determined, tank dimensions must be
selected. Experiencehas shown thata storage volumeof 3.3 ft3per ton-hour (0.03m3/
kwh) is a good rule for sizing ice harvester tanks. When the ice opening area is large
relative to the plan area of the tanks, storage densities as low as 3.0 ft3per ton-hour
(0.025 m3/kWh)may be achieved. Tank design criteria are discussed in Section5.4.
Unlike the other ice storage technologies,the charging performance of ice harvester
systems remains the same throughout the charge cycle, independent of the amount
of ice in the storage tank. High rates of discharge from an ice harvester storage tank
are possible because of the large surface area of fragmented ice. Discharge tempera-
ture from a properly designed storage tank can remain at about 34 to 36OF (1 to 2OC)
until 80 to 90% of the ice is depleted. At that point, the contact area between ice and
water in the tank is reducedenough that the temperaturerises.At very high flow rates,
or when tank design is not optimal, the discharge temperature begins to rise earlier
in the discharge cycle. Figure 5-5 shows a typical range of discharge temperatures
over the discharge cycle.
0 20 40 60 80 1 00
Percent of ice melted
Under someconditions,the ice in the tank fuses together into aporous block, holding
its shapeand leaving a hole below the ice opening. When this occurs, the surfacearea
of icelwater contact is reduced, and return water tends to short-circuit to the
discharge header. This is more likely to occur when ice remains in the tank for a long
time, such as in weekly or other extendedcycle systems. These systemsare also more
likely to have a small ice opening area in relation to the tank plan area. Full storage
systems, in which warm return water is introduced directly to the tank without
precooling by the chiller, may also be more susceptible to short-circuiting. Inlet
spray headers can be used to prevent short circuiting, as discussed in Section 5.4.3.
Ice harvesting systems require particular attention to tank design to ensure that the
desired discharge characteristics are achieved. Tank design considerations are
discussed in Section 5.4.
Approximate ice harvester costs overa range of equipment sizes are shown in Figure
5-6. These costs include evaporator package; refrigeration plant; and air-cooled,
water-cooled, or evaporative condenser. Note that these costs are given in terms of
ice making capacity, while chiller costs for other technologies are often given in
terms of nominal chilling capacity.
5-14 Design Guide for Cool Thermal Storage
500 (140)i
200 400 600 800 1000
I
124
(700) (1400) (2100) (2800) (3500) (4200)
lcemaking capacity, tons (kW)
Costs for concrete storage tanks for ice harvesting systems are depend on site-
specific factors such as soil conditions and local labor rates. A rule of thumb for tank
costs is $20 to $25 per ton-hour ($6to $7 per kwh). A slightly more accurate estimate
may be developed based on a guideline of $7 to $8 per ft2($75 to $86 per rn2)of tank
surface. For detailed estimates, consult local contractors with experience in building
concrete tanks.
Rated compressor efficiency for ice making is typically in the range of 0.95 to 1.3
kW/ton (3.7 to 2.7 COP), with evaporatively cooled models most efficient and air-
cooled models least efficient. Efficiency increases with return water temperature,
with power consumption of 0.7 kW/ton (5 COP) or lower at 48OF (9°C) entering
water. Figure 5-7 illustratesthe variation in efficiency with entering water tempera-
ture.
Ice Hawesting Systems
1.2 (2.9)
-
2
!z
1 .I (3.2) -
1 .O(3.5)-
\ Icemaking
-$
.-
e
0.9 (3.9) -
5r
U)
U
0
L
m
0.8 (4.4) -
g
a
0.7 (5.0)
32 34 36 38 40 42 44 46 48 50
(0) (1) (2) (3) (4) (5) (7) (8) (9) (10)
Entering water temperature, "f (%) -
Ice making efficiencies are directly related to the ice-build and defrost times built
into the equipment. Knebel(l990) discusses maximizing efficiency by controlling
ice-build and defrost times based on ambient conditions.
Ice making efficiency can be increased during nonpeak load periods by controlling
the charging capacity to the minimum level needed to provide the desired amount of
stored cooling.
Water treatment considerations are discussed in Section 2.8.3. Because of the highly
aerated water in an ice harvesting system, water treatment for corrosion protection
should receive special attention.
The refrigeration technology used with ice harvesting systems has been commonly
used in industrial applications. However, many HVAC operating personnel and
servicecontractorswho are used to packaged water chiller systems may be unwilling
or unable to adjust to the maintenance requirements of ice harvesters. Maintenance
personnel responsible for ice harvesting systems should have a good understanding
of the refrigeration equipment employed or should receive appropriate training.
5.13 COMMISSIONING
Total storage tank capacity is measured by fully charging the tank and discharging
it against aload with no other cooling supplied.Measure the usable cooling delivered
up to the point that the discharge temperaturefrom the tank rises above the maximum
usable chilled water supply temperature. Discharging the tank at the rate specified
in the design operating profile provides the most accurate evaluation of actual tank
capacity under design conditions. However, if this is not practical, other discharge
rates will provide acceptable estimates. For most tank configurations, the total
storage capacity is relatively insensitive to discharge rate.
The discharge rate and discharge temperature tests verify that the load can be met at
the required discharge temperaturefor each hour of the design profile. The discharge
rate and discharge temperature profile are generally verified during the test of
storage tank capacity.
Ice Harvesting Systems 5-17
The test of charging capacity verifiesthat the storage tank can be charged in the time
allotted. Long cycle storage systems require two or more days to evaluate the
charging capacity.
Tests of scheduling and control sequences verify that the system operates according
to the design intent. Over the course of several charge-discharge cycles, verify the
proper starting and stopping of pumps and the operation of controlled devices. In
addition, verify that the ice harvester switches from ice making to chiller mode at the
correct return water temperature. Confm that timers are set correctly to provide the
appropriate ice build and defrost times and verify that ice level sensors are set at the
correct levels and that they operate correctly.
REFERENCES
Knebel, DE. 1990. Optimal control of ice harvesting thermal energy storage
systems. AICE Proceedings, 209-214.
Knebel, D.E. 1991. Optimal design and control of ice harvesting thermal energy
storage systems, ASME 91-HT-28, July.
Michols, K.A. 1985. Design guide for reinforced concrete chilled water and ice
storage tanks. Turbo Refrigerating Co., May.
5-18 Deslgn Guide for Cool Thermal Storage
BIBLIOGRAPHY
Dorgan, C.E. 1985. Ice-maker heat pumps operation and design. ASHRAE Trans-
actions 91(1B):856-64. Reprinted in ASHRAE Technical Data Bulletin: Ther-
mal Storage (January):5&56.
Fields, W.G.and D.E. Knebel. 1991. Cost effective thermal energy storage. Heat-
inglPipinglAir Conditioning (July):59-72.
Henry Vogt Machine Co. Vogt product information manual.
Knebel, D.E. 1986. A showcase on cost savings. ASHRAE Journal (May):28-3 1.
Knebel, D.E. 1988. Economics of harvesting thermal storage system: A case study
of a merchandise distribution center. ASHRAE Transactions 94(1):1894-
1904. Reprinted in ASHRAE Technical Data Bulletin 5(3):35-39.
Knebel, D.E. and S. Houston. 1989. Thermal storage retrofit. ASHRAE Journal
(May):3442.
Landry, C.M. and C.D. Noble. 1991. Making ice thermal storage first-cost competi-
tive. ASHRAE Journal (May):19-22.
Morris and Associates, Inc. Moms product information manual.
Paul Mueller Co. Mueller product information manual.
Sohn, C.W. 1991b. Field performance of an ice harvester storage cooling system.
ASHRAE Transactions 97(2): 1187-93.
Stovall, T.K. 1991b. Turbo Refrigerating Company ice storage test report, ORNLI
'I'M-1 1657, June. Oak Ridge, TN:Oak Ridge National Laboratory.
Stovall, T.K. and JJ. Tomlinson. 1991. Laboratory performance of a dynamic ice
storage system. ASHRAE Transactions 97(2): 1179-86.
Turbo Refrigeration Co. Turbo product information manual.
Vogt. 1988.Award winning thermal storagesystem fact sheet KirkProduceCompany,
Orange County, Placentia, California. Vogt Fact Sheet, June. Louisville, KY.
Chapter 6 EXTERNAL MELT ICE-ON-COIL
STORAGE SYSTEMS
Require approximately 2.8 ft3 of storage tank volume per ton-hour of stored
cooling (23 LIkWh).
Supply chilled water from an open ice-builder tank to the load.
Use liquid refrigerant or a secondary coolant as the charging fluid.
Provide discharge temperatures of 34 to 36OF (1 to 2°C) through most of the
discharge cycle.
Are subject to an efficiency penalty if all ice is not melted during each discharge
cycle.
CHARGING DISCHARGING
Cold refrigerant or glycol Warm return water
flows in pipe, builds layer flows through tank,
of ice melting ice
I Water
Ice is normally built to a thickness of 1.5 to 2.5 in. (40 to 65 mm) on the pipes,
depending on the application. The greater thickness requires lower charging tem-
peratures and is generally applied where an existing refrigeration is operating at 10
to 15OF (-12 to -9OC). Thinner ice is built in applications where higher charging
temperatures and greater efficiency are desired.
If an external melt ice tank is overcharged, ice may freeze solid between adjacent
tubes. While some bridging may not have serious consequences, extensive bridging
can impede water flow and ice melting, resulting in increased discharge tempera-
tures.
External melt systems can be divided into those that use refrigerant directly to build
ice, with the ice-builder pipes acting as the evaporator, and those that build ice
indirectlyusing a secondary coolant cooled by achiller. The direct refrigerant system
was used in early external melt systems, and is still widely applied in industrial
applications such as dairies and food processing plants. Secondary coolant systems
are most commonly used for HVAC applications, because the refrigeration plant is
simpler to design, install, and maintain, and because the volume of refrigerant used
is much less.
The direct refrigerant system uses a large amount of refrigerant, which adds cost and
raises environmental concerns. However, where an ice builder is being added to an
existing plant, this is typically not a major issue. The use of ammonia refrigerant is
well-suited to direct refrigerant external melt systems; it reduces or eliminates cost
and environmental concerns.
6-4 Design Guide for Cool Thermal Storage
Details of refrigeration system design are not covered in this guide. Mackie and
Richards (1992) give some recommendations for design of direct refrigerant ice
builders.
Oil separator /\ /\ /\ /\
Evaporative condenser
Reciprocating
compressors
Refrigerant
PlPW
Chi!led water
I
I I
1 132t Design
PlPW
temperatures, O F
Low pressure receiver (0) ("C)
,r Refrigerant pumps
I - Ice tank
Water chiller
LN
1
Ice
water
< 3 Pump
Secondary coolant-based systems use standard water chillers selected for charging
temperatures of 18 to 26OF (-8 to-3OC). Systemswith charging temperatures below
18°F (-8OC) generally require specially engineered chillers. Chillers that must also
provide direct cooling typically operate at 36 to 42OF (2 to 6*C), depending on the
specific application. Positive displacement compressors, such as reciprocating or
rotary screw types, are typically used because of the low charging temperatures and
the relatively wide range of operating temperatures.
Centrifugal compressors may be used provided they are properly selected for the
intended range of evaporator temperatures. Harmon and Yu (1991) discuss the
selection of centrifugal chillers for ice making at 24 to 26OF (-4 to -3OC).
Figure 6-4 illustrates one configuration for secondary coolant-based external melt
ice storage. In this system, the storage tank is directly connected to the building
distribution system, with pressure control provided by a pressure-sustaining valve.
A heat exchanger allows the storage chiller to provide direct cooling to supplement
storage during discharge. Supplemental cooling could also be provided by a second
chiller in the chilled water loop.
Load
Pressure
sustaining
valve
\r
iL 2-position
- Ice Tank
Direct cooling
heat exchanger
General storage tank considerations are discussed in Section 2.3.2. This section
addresses specific considerations for external melt ice-on-coil storage systems.
Tanks for external melt thermal energy storage systems are generally constructed of
steel or concrete. Steel tanks are typically supplied by the manufacturer of the heat
exchange coils and are made of galvanized steel and insulated. Manufacturers build
their tanks in rectangular shape of various dimensions according to the storage
capacity desired.
Pay special attention to corrosion protection of steel tanks, since the water in the
tanks is highly aerated. A thorough galvanizing or other coating process and
attention to quality control in the tank construction process are important.
Site-built concrete tanks, in which the prefabricated heat exchange coils are in-
stalled, can also be used. Concrete tanks can be buried or at grade.
Tanks should have easy access. To provide access, allow a lane of 3 ft (1 m) around
the tank. Multiple tanks require additional space for external piping. Buried tanks
should include hatchways for visual and physical access.
Multiple tanks in an external melt system are typically connected in parallel. A series
arrangement is sometimes used in systems requiring high discharge rates, where a
longer residence time of water in the storage tank is desired. However, flow between
tanks is driven only by a difference in water levels. A connection with a large cross-
sectional area is necessary to minimize the pressure drop and the water level
difference between tanks. Series connection of more than two tanks is generally not
recommended.
In large tanks with multiple ice-builder coil modules, baffles may be installed to
induce a serpentine flow of chilled water over the coils. This arrangement produces
a discharge characteristic similar to a series connection of several smaller tanks.
External melt ice storage systems require instrumentation to monitor the ice
inventory and to signal the end of ice making. Ice thickness sensors are used to
determine when the desired amount of ice has been built. These instruments typically
sense the difference in conductivity between liquid water and ice.
External Melt Ice-on-Coil Systems 6-7
Storage inventory can be monitored by the increase in tank water level as the water
freezes and expands. The water level is typically measured in an external water
column using a differential pressure sensor; it can also easily be monitored visually
with a sight glass.
The tank water level is affected by operation of chilled water distribution pumps.
There is also a water level differencebetween the tankinlet and outlet,corresponding
to the tank pressure drop when there is flow through the tank. This change in water
level depends on the flow rate and the specific tank configuration.
Tank water level is also affected by operation of air agitation pumps. The increase
in water level with air pumpopetation generally results in an inventory measurement
error of about 2 to 3%. Inventory readings should be calibrated with air pumps
operating to avoid overestimating stored cooling inventory.
Control strategies for external melt systems should be able to melt as much ice as
possible each day and prevent the formation of ice bridges between tubes.
Ice built on bare pipes at the beginning of the charge cycle is built at the highest
suction temperaturesat the best efficiency and at the lowest cost. In contrast, the last
ice built on the pipes is formed at the lowest suction temperatures, at the lowest
efficiency, and at the highest cost. To maximize efficiency and minimize energy
consumption and cost, all ice should be melted each day so that the charge cycle for
the next day begins with bare pipes. If only part of the storage capacity is used, the
charge cycle should be limited so that only the required amount of cooling is stored.
Ice bridging across pipes is also prevented by discharging all ice each day. While
bridging is typically caused by overcharging the tank,it may occur if the ice melts
unevenly, so that some tubes are bare while ice remains on others. Over the course
6-8 Design Guide for Cool Thermal Storage
of several chargeldischarge cycles, the ice thickness may build up in some areas to
the point that ice on adjacent tubes meets and fuses, Some facilities incorporate a
control sequence to provide a complete discharge of all ice at least one day a week,
such as on a Saturday.
Storage priority control is generally recommended for external melt systems. Such
strategies typically require some method of estimating or predicting the load for the
upcoming day to provide the appropriateamount of cooling from the supplementary
chiller. Grumman and Butkus (1989) describe one such control strategy.
In some cases, chiller priority control may be appropriate. With some utility rates,
the cost of off-peak electricity may be low enough that the efficiency penalty for not
melting all ice each day is outweighedby the simpler control. If off-peak energy costs
are relatively high, a chiller priority sequence with load prediction can minimize
costs by limiting the daily charge to that part of the load for the next day that cannot
be met by the chiller.
Full storage systems should be controlled to build only as much ice as is needed
during the next day. When a full charge is not needed, charging efficiency can be
increased by running compressors at partial capacity at a higher charging tempera-
ture over the entire charging period.
External melt ice-on-coil systems use open, nonpressurized tanks and are subject to
the interface considerations discussed for open tanks in Section 2.5.3. Water
treatment and corrosion protection may be of increased concern, since water in the
tank is highly aerated.
A heat exchanger should be used to isolate the storage tank from the building
distribution system. This arrangement simplifies water treatment, as the building
distribution system becomes a conventional closed system.
External Melt Ice-on-Coil Systems 6-9
Charging temperatures for an external melt system depend on the charging rate and
the amount of ice on the pipes at a given time. A shorter charging cycle, which
requires higher charging rates, dictateslower charging temperatures to freeze a given
quantity of ice. Thechargingtemperature decreases through thecharging cycleas the
thickness of ice through which heat must be transferred increases.
For the secondary coolant system, the results were similar. Charging temperatures
varied from 29 to 25°F (-1.5 to -4°C) for a 14-hcharging period, and from 25 to 16OF
(4to -g°C) for an 8-h charge time. While these temperatures are nearly the same
as those for the direct refrigerant system, note that the chiller should run at a suction
temperature 3 to 5OF (1.5 to 3OC) lower than the coolant temperature. Figure 6-5
shows a typical range of charging temperatures, based on the results of these tests.
6-10 Design Guide for Cool Thermal Storage
0 20 40 60 80 100
Percent of ice charged
Stovall (1991) also tested external melt discharge characteristics at various dis-
charge rates and inlet temperatures. The results,summarizedin Figure 6-6, show that
discharge temperatures remained below 35OF (l.S°C) until 80%or more of the ice
in the tank melted.
30 (-I)++
0 25 50 75 100
percent of ice melted
In discharge tests beginning with overcharged tanks with some bridging between
tubes, discharge temperatures were found to be 2 to 3OF (1 to lS°C) higher than
normal during the last half of the discharge period. In ksts of discharging with no
tank aeration, discharge temperatures increased by 4 to 5OF (2 to 3OC).
Initial estimates of required chiller and storee capacitiescan be developed using the
quick sizing procedurepresented in Section 10.3. Final size requirements should be
determined by a detailed simulation of hourly performance during the design storage
cycle, as discussed in Sections 2.6 and 10.6.
The instantaneous heat gain of aeration pumps is relatively small, but the total heat
gain over the entirecharge/dischargecyclecan be significant. For system sizing, this
heat should be treated as a tank loss, and the total storage capacity should be
increased accordingly.
Selection of a chiller for a secondary coolant system requires the average entering
and leaving temperatures for a given storage unit to be determined based on the
required charging rate.
Installed costs of external melt storage capacity, including storage tanks and ice-
builder coils, are typically in the range of $50 to $70 per ton-hour ($14 to $20 per
kwh). For more accurateestimates fora specific application,obtain cost quotes from
suppliers.
Chiller cost estimates are discussed in Section 2.7.2. Since ice making capacity for
a given chiller is typically 60 to 70%of nominal capacity, rules of thumb for chiller
costs should be adjusted accordingly.
External melt ice storage systems are capable of delivering low chilled water supply
temperatures, allowing significant savings in water and air distribution equipment
costs.
Average efficiency during ice making can be expected to be between 0.9 and 1.4 kW
per ton (3.9 and 2.5 COP). The charging efficiency will be higher with a refrigerant
system than with a secondary coolant system because of the more direct heat transfer.
Operation of an external melt ice storage system can be refined and optimized over
time. Section2.8.1 provides a general discussion of optimizing storage system
operation.For an external melt system,controlstrategiescan be devised to maximize
efficiencyby melting all ice beforebeginning charging whenever possible. Charging
at the maximum temperature practical also improves efficiency.
Water treatment considerations are discussed in Section 2.8.3. Because of the highly
aerated water in an extemal melt system, water should be treated for corrosion
protection.
6.13 COMMISSIONING
Commissioningis an ongoing process starting in the predesign phase and continuing
through the first year of system operation. The overall commissioning process is
discussed in Section 2.9. The performance evaluation phase of the commissioning
process for external melt ice storage systems is described here.
For secondary coolant external melt systems, performance testing should include
measurement of the density and specific heat of the coolant so that heat transfer rates
from coolant temperatures and flows may be accurately calculated.
Total storage tank capacity is measured by fully charging the tank and discharging
it against aload with no other cooling supplied. Measure the usable cooling delivered
up to the point that the discharge temperature from the tank rises above the maximum
usable chilled water supply temperature.
The total usable storage capacity of an external melt system is relatively independent
of the rate at which cooling is discharged. Discharging the tank at the rate specified
6-14 Design Guide for Cool Thermal Storage
in the &sign operating profile provides the most accurate evaluation of actual tank
capacity under design conditions. However, if this is not practical, other discharge
rates will provide acceptable estimates.
The discharge rate and discharge temperature tests verify that the load can be met at
the required dischargetemperature for each hour of the design profile. The discharge
rate and the discharge temperature profile are generally verified during the test of
storage tank capacity.
Testing the charging capacity of the system verifies that the storage tanks can be
charged in the required time period. Operate the chiller at the design charging
setpoint and monitor the cooling stored in the tanks. If the design operating profile
calls for the chiller to meet a load while charging storage, this load must be included
in the test.
The charging time in an external melt system depends on the charging temperature.
By repeating thecharging test several times, the highest temperature setting that will
fully charge storage in the time available can be identified.
Scheduling and control sequence tests confirm that the system is operating as
intended. During testing, verify that the system switches modes at the appropriate
times, with pumps starting or stopping and valves operating in the correct sequences.
Also, confm that the air agitation pump turns on and off at the appropriate times.
Verify and calibratechiller setpointsfor charging and direct cooling modes. Confirm
that the mixedchilled water supply temperature to the load is controlledat the correct
setpoint. Calibrate the inventory sensor by noting the output signal at the fully
charged and fully discharged conditions.
REFERENCES
Grumman,D.L. and A.S. Butkus. 1989.Ice storage application toan Illinois hospital.
ASHRAE Technical Data Bulletin 5(3):27-33.
Harmon, J J. and H.C. Yu. 1991. Centrifugal chillers and glycol ice thermal storage
units. ASHRAE Journal (December):25-3 1.
Mackie,E.I. and W.V. Richards, 1992.Designof off-peakcoolingsystems. ASHRAE
Professional Development Seminar.
Silver, S.C., J.W. Jones, J.L. Peterson, andB.D. Hunn. 1989. CBS/ICE: A computer
program for simulation of ice storage systems. ASHRAE Transactions
95(1): 1206-13. Reprinted in ASHRAE Technical Data Bulletin, 5(4):35-42.
Stovall, T.K. 1991. Baltimore Aircoil Company (BAC) ice storage test report,
ORNL/IM-11342, March. Oak Ridge, TN: Oak Ridge National Laboratory.
BIBLIOGRAPHY
Reardon, J.G. and K.M. Penuel. 1985. An ice-making showcase. ASHRAE Journal
(May):24-29.
Sohn,C.W. 1991. Thermalperformanceofan ice storagecooling system. ASME91-
HT-26,July.
Yu, H., S. Wu, and C, Fan. 1989. Computer simulation for ice making process of
direct expansion ice storage system for air-conditioning. 9th Annual Interna-
tional Congress on Energy and Environment, 119.
Chapter 7 INTERNAL MELT ICE-ON-COIL
STORAGE SYSTEMS
Use a secondary coolant, typically ethylene glycol, as both the charging and
discharging fluid in a closed loop system.
Provide sustained discharge temperatures of 36 to 38OF (2 to 3OC), which are
dependent on discharge rate and the amount of ice remaining.
Require chillers capable of producing charging temperatures of 22 to 26°F (4
to -3OC).
Are available with modular tanks.
Figure 7-1illustrates acomplete internal melt storage tank, and Figure 7-2 illustrates
the charging and discharging process in an internal melt system. Internal melt ice
systems are typically configured with the storage tanks in series with the chiller, in
either chiller upstream or chiller downstream arrangements.
Charging Discharging
the higher operating temperatures. However, the usable portion of the total nominal
storage capacity is reduced because of the lower storage discharge temperature.
Discharge temperature characteristics are discussed in Section7.9.
In a chiller downstream configuration, warm return water first flows through the
storagetanks, where it is cooled before entering the chiller.This arrangementresults
in a higher usable storage capacity, as well as an assured constant discharge
temperature. However, chillers operate at lower discharge temperatures and less
efficiently than in the chiller upstream arrangement. Figure 7-3 presents schematic
diagrams of typical chiller upstream and chiller downstream configurations.
Chiller
-lt
@ Load
A CHILLER UPSTREAM
Load
B. CHILLER DOWNSTREAM
Modular internal melt tanks are generally connected in parallel in a reverse return
arrangement to ensure equal flow through all tanks.
Centrifugal compressors may be used provided they are properly selected for the
intended range of evaporator temperatures. Harmon and Yu (1991) discuss the
selection of centrifugal chillers for ice making at 24 to 26OF (-4 to - 3 O C ) .
General storage tank considerations are discussed in Section 2.3.2. This section
addresses specific concerns for internal melt ice-on-coil storage systems.
Storage tanks for internal melt systems are available in several configurations.
Modular tanks with 100 to 200 ton-hours (350 to 700 kwh) nominal capacity are
manufactured in cylindrical plastic or rectangular steel configurations, with plastic
heat exchange tubing. Rectangular steel tanks are available with galvanized steel
heat exchange coils. Prefabricated steel pipe heat exchangers are also available for
installation in site-built tanks, which are generally concrete.
Tanks can be located indoors or outdoors. Concrete tanks may be buried or located
on-grade. Cylindrical tank modules can be stacked on a supporting framework.
Modular tank manufacturers recommend an overhead clearance of 3 ft (1 m) to
facilitate inspection and repair.
Modular internal melt tanks are designed to freeze all the water between the heat
exchange tubes. If the tanks are overcharged, the water forced up into the expansion
volume of the tanks during freezing will also be frozen. Since there is little or no heat
transfersurface in this area, it is difficult to melt ice once it forms here. The formation
of such an ice cap reduces the storage capacity of the tank by reducing the volume
of water available to cover the heat exchange tubes.
Internal Melt Ice-on-Coil Systems 7-5
Internal melt systems normally use a bypass around the storage tanks to control the
leaving water temperature. A three-way mixing valve, or two linked two-way valves,
modulates to control the proportion of chilled fluid flow bypassing storage, based on
the desired leaving temperature. As the temperature available from storage in-
creases, an increasing proportion of the flow is diverted through the storage tanks,
maintaining the desired mixed leaving temperature.
Charging of internal melt storage tanks is generally terminated when the coolant
temperature leaving storage drops to about 2OF (1°C) below the design leaving
temperature. This method provides a more reliable means of determining a full
charge than do inventory sensors. A timeclock control is often used to lock out ice
making at the end of the scheduled charging period. However, this is primarily a
safety feature. In a properly sized system under normal operation, charging will be
completed before being terminated by a timeclock.
Internal melt systems are compatible with each of the three basic operating strategies
discussed in Section 2.4--full storage,partial storageload leveling, or partial storage
demand limiting.
Internal melt systems with chiller upstream arrangements are well-suited to chiller
priority control. When the load is less than the chiller capacity, the storage tanks are
bypassed completely. As the load rises above the chiller capacity and the chiller
leaving temperature increases above the supply temperature setpoint, the control
system diverts part of the chilled fluid flow through storage to achieve the desiced
supply temperature. This control strategy is simple to implement and minimizes the
risk of storage being depleted prematurely.
7-6 Design Guide for Cool Thermal Storage
Chiller priority control can also be applied when the chiller is installed downstream
of storage. The storage bypass is controlled to maintain the temperature leaving
storage at the maximum chiller return temperature. All the flow bypasses the storage
tanks until the load exceeds the chiller capacity. At this point, the appropriate
proportion of flow is diverted through the storage tanks.
Direct-connected systems operate with the storage loop secondary coolant in the
entire building system. For some buildings, the winter freeze protection provided by
the coolant may be advantageous. The expense of providing a large volume of
coolant is also a consideration. In addition, cooling coil capacity will be reduced
compared to performance with water. Design considerations for glycol secondary
coolants are discussed in Section 2.8.3 and in Gatley (1992) and Nussbaurn (1990).
If a heat exchanger is used to separate the storage loop from the chilled water
distribution loop, the distribution side must be protected from freezing during
charging, when the coolant temperature may be as low as 22°F (-6'C). Typically, a
charging bypass is provided around the heat exchanger. Flow should be diverted
through the bypass using two linked two-way valves rather than a three-way valve,
since the three-way valve is more likely to allow some leakage to the heat exchanger.
It is also advisable to provide heat exchanger freeze protection, such as starting
secondary pumps if the primary side temperature falls below 36°F (2OC).
Internal Melt Ice-on-Coil Systems 7-7
The low discharge temperatures available from intemal melt systems allow the use
of chilled water temperatureranges of U°F (13OC) or higher, resulting in significant
reductions in the cost of pumps, piping, and pump energy compared to typical
nonstorage systems. These discharge temperatures are also well-suited to the use of
cold air distribution.
7.8 SIZING
Sizing an internal melt ice storage system requires selecting the appropriate ice
making capacity and storage capacity for a given application. Initial chiller and
storage capacities can be estimated using the quick sizing procedure presented in
Section 10.3.1. Final size requirements should be determined by a detailed simula-
tion of hourly performance during the design storage cycle, as discussed in Sections
2.6 and 10.6.
Storage capacity must be selected to ensure that the required discharge capacity is
availableat the required temperaturefor each hour of the design load profile. Storage
manufacturers help in the selection process and may provide computer simulations
of storage performance for given load profiles and chiller temperatures.
Charging temperatures for an internal melt system depend on the charging rate and
the state of charge of the storage tanks at a given time. A shorter charging cycle
requires lower charging temperatures to freeze a given quantity of ice. The charging
temperature decreases through the charging cycle as the thickness of ice through
which heat must be transferred increases. Manufacturers provide data on the
minimum charging temperature required for various charging rates.
I I I I I
20 40 60 80 100
Percent of ice charged
This supercooling occurs only when there is no ice in the tank at the beginning of
charging. If any ice remains unmelted from the previous cycle, as is usually the case,
freezing of additional water proceeds without supercooling.
Internal melt ice storage tanks have a steadily falling discharge rate if a constant
discharge temperature is maintained, or a steadily rising temperature if a constant
dischargerate is maintained. This characteristic results from the insulating effect of
water around the tubes as the ice is melted.
30 (-111 I I I I
25 50 75 100
Percent of ice melted
In practice, cool storage tanks will rarely be discharged at aconstantrate. The actual
dischargetemperature profile experienced in a given application dependson the load
profile. The load during the last several hours of the dischargecycle is generally most
7-10 Design Guide for Cool Thermal Storage
In general, the usable portion of the nominal storage capacity is greater with lower
dischargerates and higher dischargetemperatures. High dischargerates and constant
low discharge temperatures can be achieved by providing additional storage capac-
ity.
Steel heat exchange coils for internal melt applications are available with a finned
tube section near the outlet of the coil. This option provides a lower, more constant
discharge temperature characteristic because of the improved heat transfer between
the secondary coolant and the 32°F (0°C) water in the tank.
Jekel et al. (1993) discuss the development of a computer model of charging and
discharging performance of intemal melt ice storage tanks.
Chiller cost estimates are discussed in Section 2.7.2. Ice making capacity for a given
chiller is typically 60 to 70%of nominal capacity, so rules of thumb for chiller costs
should be adjusted accordingly.
Internal melt ice storage systems are capable of delivering low chilled water supply
temperatures, allowing significant savings in water and air distribution equipment
costs.
Chiller efficiencyfor charging internal melt ice systems typically in the range of 0.85
to 1.2 kW/ton (4.1 to 2.9 COP).The efficiency varies depending on the charging
temperaturerequired for aspecific application as well as the type of chiller installed.
Internal Melt Ice-on-Coil Systems 7-11
Efficiency during the direct cooling mode dependson the chillerentering and leaving
temperatures, which vary widely for various design alternatives. A chiller upstream
arrangement will have higher chiller efficiency but a lower usable percentage of the
nominal storage capacity. Chiller downstream arrangements maximize the usable
portion of storage capacity, but chiller efficiency is reduced because of the lower
operating temperature.
Leight and Elleson (1993) describe an internal melt ice storage system with a
reciprocating and a centrifugal chiller installed downstream of storage. The average
overall efficiencyforthis system, forcharging and direct cooling, was 0.9 1kWh/ton-
hour (3.9 COP). The centrifugal chiller operated at an average charging efficiency
of 0.92 kWh/ton-hour (3.8 COP), and the reciprocating chiller charged at an average
efficiency of 1.0 kWh/ton-hour (3.5 COP). The centrifugal chiller provided direct
cooling at 32 to 3S°F (0to 2*C), with an average efficiency of 0.78 kWh/ton-hour
(4.5 COP).
Sohn et al. (1990) describe an internal melt ice system with a reciprocating chiller,
which operated at average efficiencies of 1.19 kW/ton (2.96 COP) for charging and
0.96 kW/ton (3.7 COP)for direct cooling.
Operation of an internal melt ice storage system can be refined and optimized over
time. Section 2.8.1 provides a general discussion of optimizing storage system
operation. For an internal melt system, efficiencycan be improved by determining
the maximum practical charging temperature.
Maintenance requirements of the storage tanks themselves are minimal. The water
level in the tanks should be checked at least annually, and makeup water should be
added if necessary. Tank inventory sensors should be calibrated at regular intervals,
particularly at the fully charged and fully discharged conditions.
7.13 COMMISSIONING
Commissioning is an ongoing process starting in the predesign phase and continuing
through the first year of system operation. The overall commissioning process is
discussed in Section2.9. The performance evaluation phase of the commissioning
process for internal melt ice storage systems is described here.
Test for the following during the performance evaluation phase of commissioning:
To allow accurate calculation of heat transfer rates from coolant temperatures and
flows, performance testing should include measurement of the density and specific
heat of secondary coolants.
The total usable storage capacity of an internal melt system depends on the rate at
which cooling is discharged. Therefore,to evaluate the design storage capacity, it is
essential to test the system against the design load profile. For partial storage
systems, if it is not feasibleto provide the design loadon the entire system,the storage
can be tested separately from the chiller. The design inlet temperatures and flow
rates, as specified in the design operating profile, must be supplied to the storage
tanks.
The test of total storage capacity begins with the tanks fully charged. As the tanks
are discharged against the design load profile, monitor and record the amount of
cooling supplied before the discharge temperature rises above the maximum usable
temperature.
The discharge rate and discharge temperature tests verify that cooling is supplied
each hour at the specified discharge temperatures and flow rates. These checks are
particularly important during the last few hours of the discharge cycle. The discharge
rate and the discharge temperature profile are generally verified during the test of
storage tank capacity.
Internal Melt Ice-on-Coil Systems 7-13
Testing the charging capacity of the system verifies that the storage tanks can be
charged in the required time period. Operate the chiller at the design charging
setpoint and monitor the cooling stored in the tanks. If the design operating profile
calls for the chiller to meet a load while charging storage, this load must be included
in the test.
The charging time in an internal melt system depends on the charging temperature.
Over the course of several charging cycles, the optimum charging temperature
setpoint can be identified. The optimum charging setpoint is the temperature setting
that will fully charge storage in the time available, while minimizing chiller and
auxiliary energy consumption.
Scheduling and control sequence tests confm that the system operates as intended.
Verify that the system switches modes at the appropriate times, with pumps starting
or stopping and valves operating in the correct sequences. Verify and calibratechiller
setpoints for charging and direct cooling modes. Confirm that the temperatureof the
fluid leaving storage is controlled at the correct setpoint.
REFERENCES
Denkmann, J.L. 1990. Cool storage retrofit of rooftop units and direct expansion
systems. ASHRAE Transactions 96(1):1067-79.
Gatley, DP. 1992. Cool storage ethylene glycol design guide. EPRI TR-100945,
September.
Harmon, JJ. and H.C. Yu. 1991. Centrifugal chillers and glycol ice thermal storage
units. ASHRAE Journal (December):25-31.
Jekel, T.B., J.W. Mitchell, and S.A. Klein. 1993. Modeling of ice-storage tanks.
ASHRAE Transactions 99(1),
Keeler, R.M. 1990. Scrap DX for CW with ice storage. HeatinglPipinglAir Condi-
tioning (August):5942.
Leight, S.P.and J.S. Elleson. 1993. Case study of an ice storage system with cold air
distribution and heat recovery, Draft report. Palo Alto, CA: Electric Power
Research Institute.
MacCracken, C.D. 1987.Rooftops: The big challenge for COPAC (commercial off-
peak air conditioning).EPRI Seminar Proceedings: Commercial Cool Storage,
State of the Art, EM-5454-SR, October.
Nussbaum, O.J. 1990. Using glycol in a closed circuit system. HeatinglPipinglAir
Conditioning (January):75-85.
7-14 Design Guide for Cool Thermal Storage
Pandya, D.A. 1990. Retrofit unitary cool storage system. HeafinglPipinglAir Con-
ditioning (July):35-37.
Sohn, C.W., G.L. Cler, and R.J. Kedl. 1990. Performance of an ice-in-tank diurnal
ice storage cooling system at Fort Stewart, GA. USA CERL Technical Report
E-90110, June.
Stovall, T.K. 1991. CALMAC ice storage test report, ORNL/I'M-11582, August.
Oak Ridge, TN:Oak Ridge National Laboratory.
BIBLIOGRAPHY
Use a secondary coolant, typically ethylene glycol, as a bath for plastic water
containers.
Require approximately2.4 to 2.8 ft3of tank volume per ton-hour (0.019 to 0.023
m3/kWh)of available stored cooling.
Can be applied with both large and small loads.
Require chillers capable of producing charging temperatures of 22 to 26OF (-6
to -3°C).
CHARGING DISCHARGING
Encapsulated ice containers are currently available in two designs in the United
States: rectangular containers in 4.5-gal and 1-1-gal (17.0 L and 4.2 L) sizes, and
dimpled spheres about 4 in. (100 mm) in diameter. In Europe, 3.75-in. (95 mm) and
3-in. (75 mm) diameterrigidspheres are also used. The containers are made of high-
density polyethylene and are designed to accommodate the expansion and resulting
pressure of the freezing ice. Spherical containers are factory-filled with deionized
water and nucleating agent. Rectangular containers are generally filled on site with
deionized water.
Encapsulated ice storage can use open, nonpressurized tanks, or pressurized tanks.
Open tank systems generally require a restraining grate or barrier to keep the frozen
containers submerged.
fluid does not open unwanted passages for fluid flow, which can lead to short-
circuiting and degradation in performance.
Encapsulated ice systems are typically configured with the storage tanks in series
with the chiller, in either chiller upstream or chiller downstream arrangements.
Arrangements with the tanks in parallel with the chiller during discharge are also
possible.
In a chiller downstream configuration, warm return water first flows through the
storage tanks,where it is cooled before entering the chiller. This arrangementresults
in a higher usable storage capacity, as well as an assured constant discharge
temperature. However, chillers operate at lower discharge temperatures and less
efficiently than in the chiller upstream arrangement. Figures 8-3 and 8-4 are
schematic diagrams of typical chiller upstream and chiller downstream configura-
tions.
c CHILLER
1
A
\1
STORAQE TANK
Centrifugal compressors may be used provided they are properly selected for the
intended range of evaporator temperatures. Harmon and Yu (1991) discuss the
selection of centrifugal chillers for ice making at 24 to 26°F (-4 to -3°C).
Encapsulated k e 85
General storage tank considerations are discussed in Section 2.3.2. This section
covers specific concerns for encapsulated ice systems.
Tanks are generally constructed of steel or concrete and may be located indoors or
outdoors. Steel tanks may be either open to the atmosphere or closed and pressurized.
Concrete tanks may be located underground. The inside surface of the tank must be
smooth to prevent abrasion of the containers as they move about during the charge
and discharge cycles.
Tank insulation should be installed on the exterior of the tank only. Internal
insulation is susceptible to damage from the movement of containers and the
resulting exposure to tank fluid.
With the rectangular containers,a horizontal baffle is sometimes installed in the tank
at mid-level to direct the heat transfer solution in a two-pass flow pattern. This
approach is intended to provide a longer flow path for the coolant for a longer
residence time in the tank and for improved heat transfer. The design flow through
a baffled tank should not be exceeded. An excessive pressure drop between the tank
inlet and outlet may rupture the baffle, degrading the heat transfer characteristics of
the installation.
Systems with spherical containers use inlet and outlet manifolds to distribute the
fluid flow evenly throughout the tank.The design of these manifolds vary according
to the style container selected and the shape and size of the tank. Container
manufacturers provide assistance with manifold design.
Condensation on support saddles for cylindrical steel tanks has been significant in
some installations. Saddles should be thermally isolated from tanks by nonconduct-
ing inserts, or they should be provided with insulation and vapor barriers.
8-6 Design Guide for Cool Thermal Storage
In open tanks, the change in water level is measured with a static pressure transducer
that senses the height of a column of water, or with another type of level sensor. In
pressurized tanks, the expansion of the freezing containers forces fluid from the tank
into a separate inventory tank, which may also functionas the system expansion tank.
A level sensor in the inventory tank provides a signal that is calibrated to indicate the
stored cooling inventory. As cooling is discharged and the volume of storage
containers decreases, a pump acting in response to the reduced tank pressure pumps
fluid from the inventory tank back into the storage tank.
Inventory measurement is more difficult and less reliable with rigid, non-dimpled
spherical containers, which expand very little as the encapsulated ice freezes.
Storage inventory can be monitored based on integrated flow and temperature
measurements.
Encapsulated ice systems typically use a bypass around the storage tank to conbrol
the leaving water temperature. A three-way mixing valve, or two linked two-way
valves, modulate to control the proportion of chilled fluid flow bypassing storage,
based on the desired leaving temperature. As the temperatureavailable from storage
increases, an increasing proportion of the flow is diverted through the storage tank,
maintaining the desired mixed leaving temperature.
Charging of encapsulated ice storage tanks is generally terminated when the coolant
temperature leaving storage drops to about 2OF (1 K) below the design leaving
temperature. This method provides a more reliable means of determining a full
charge than inventory sensors. A timeclock control is often used to lock out ice
making at the end of the scheduled charging period. However, this is primarily a
safety feature. In a properly sized system under normal operation, charging will be
completed before being terminated by a timeclock.
Encapsulated ice systems are suitable for any of the three operating strategies
discussed in Section 2.4--full storage,partial storage load leveling, or partial storage
demand limiting.
Encapsulated Ice 8-7
Chiller priority control can also be applied when the chiller is installed downstream
of storage. The storage bypass is controlled to maintain the temperature leaving
storage at the maximum chillerreturn temperature. All the flow bypasses the storage
tanks until the load exceeds the chiller capacity. At this point, the appropriate
proportion of flow is diverted through the storage tanks.
Encapsulated ice systems using open tanksare subject to the interface considerations
discussed in Section 2.5 for open tanks. Closed tanks do not require special pressure
control or water treatment considerations.
Direct-connected systems operate with the storage loop secondary coolant in the
entire building system. For some buildings, the winter freeze protection provided by
the coolant may be advantageous. The expense of providing a large volume of
coolant is also a consideration. In addition, cooling coil capacity will be reduced
8-8 Design Guide for Cool Thermal Storage
If the inventory tank is used as a system expansion tank, ensure that control valves
do not isolate the expansion tank during any mode of operation.
If a heat exchanger is used to separate the storage loop from the chilled water
distribution loop, the distribution side must be protected from freezing during
charging, when the coolant temperature may be as low as 22°F (4°C). Typically, a
charging bypass is provided around the heat exchanger. Flow should be diverted
through the bypass using two linked two-way valves rather than a three-way valve,
since the three-way valve is more likely to allow some leakage to the heat exchanger.
It is also advisable to provide heat exchanger freeze protection, such as starting
secondary pumps if the primary side temperature falls below 36OF (2OC).
The low discharge temperatures available from encapsulated ice systems allow the
use of chilled water temperature ranges of 24°F (13 K) or higher, resulting in
significant reductions in the cost of pumps, piping, and pump energy compared to
typical nonstorage systems. These discharge temperaturesare also well-suited to the
use of cold air distribution.
Sizing an encapsulated ice storage system requires selecting the appropriate ice
making capacity and storage capacity for a given application.
Initial chiller and storage capacities can be estimated using the quick sizing
procedure presented in Section 10.3. Final size requirements should be determined
by a detailed simulation of hourly performance during the design storage cycle, as
discussed in Sections 2.6 and 10.6.
An initial estimate of the required tank size for pressurized tanks can be made based
on an approximate storage volume of 2.4 ft3per ton-hour (0.019 m3/kWh).For open
Encapsulated Ice 8-9
tanks, initial sizing should be based on approximately 2.7 ft3 per ton-hour
(0.022 m3/kWh). This estimate includes an allowance for storage containers,
required expansion volume, and tank headers.
Storage capacity must be selected to ensure that the required discharge capacity will
be available at the required temperature for each hour of the design load profile.
Storage manufacturers assist in the selection process by providing computer simu-
lations of storage performance for given load profiles and chiller temperatures.
Figure 8-5 shows a typical range of charging temperatures for encapsulated ice
storage. The figure is based on charging periods of 8 to 16 h, with flow rates
corresponding to chiller temperature ranges of about 4 to 7OF (2 to 4 K).
8-10 Design Guide for Cool Thermal Storage
Encapsulated ice storage tanks have a steadily falling discharge rate if a constant
discharge temperature is mJntained or a steadily rising temperature if a constant
discharge rate is maintained. This characteristic results from the decreasing area of
ice in contact with the container walls as the ice melts. Figure 8-6 shows a typical
range of discharge temperatures for constant discharge rates over periods of 6 to 8
h with an inlet temperature of 50°F (10°C).
In practice, cool storage tanks are rarely discharged at a constant nte. The actual
discharge temperature profile in a given application depends on the load profile.
During the last several hours of the discharge cycle, the load is generally most
important in determining the maximum discharge temperature. Storage capacity
must be selected so that the required discharge temperature and discharge rate can
Encapsulated Ice 8-11
0 10 20 30 40 50 60 70 80 90 100
-
Percent of ice melted
In general, the usable portion of the nominal storage capacity is greater with lower
dischargerates and higher dischargetemperatures. High dischargerates and constant
low discharge temperatures can be achieved by adding storage capacity.
Installed costs for encapsulated ice storage capacity, including the tank, ice contain-
ers, and inventory measurement, are typically in the range of $50 to $70 per ton-hour
($14 to $20 per kwh). This guideline is useful for initial economic evaluations.
Obtain cost quotes from vendors for an accurate estimate for a specific application.
Chiller cost estimates are discussed in Section 2.7.2. Ice making capacity for a given
chiller is typically 60 to 70% of nominal capacity, so rules of thumb for chiller costs
should be adjusted accordingly.
Chiller efficiency for charging encapsulated ice systems is typically in the range of
0.85 to 1.2 kW/ton (4.1 to 2.9 COP). The efficiency varies depending on the charging
temperature required for a specific application as well as on the type of chiller
installed.
Efficiency during direct cooling mode depends on the chiller entering and leaving
temperatures which vary widely for various design alternatives. A chiller upstream
arrangement has higher chiller efficiency but a lower usable percentage of the
nominal storage capacity. Chiller downstream arrangements maximize the usable
portion of storage capacity, but chiller efficiency is reduced because of the lower
operating temperature.
8.13 COMMISSIONING
Commissioningis an ongoing process starting in the predesign phase and continuing
through the first year of system operation. The overall commissioning process is
discussed in Section 2.9. This section describes the performance evaluation phase of
the commissioning process for encapsulated ice thermal storage systems.
Test for the following during the performance evaluation phase of commissioning:
To allow accurate calculation of heat transfer rates from coolant temperatures and
flows, performance testing should include measuring the density and specific heat
of secondary coolants.
8-14 Design Guide for Cool Thermal Storage
The usable storage capacity of an encapsulated ice system depends on the rate at
which cooling is discharged. Therefore, to evaluate the design storage capacity, it is
essential to test the system against the design load profile. For partial storage
systems,if it is not feasible to provide the design loadon the entire system,the storage
can be tested separately from the chiller. The design inlet temperatures and flow
rates, as specified in the design operating profile, must be supplied to the storage
tanks.
To test the total storage capacity, start with the storage tank fully charged. Then,
while discharging the tank against the design load profile, monitor the cooling
supplied. Verify that coaling is supplied each hour at the specified discharge
temperatures and flow rates. The peak hour discharge rate is especially important,
particularly if it must be supplied late in the discharge cycle.
The test of total storage capacity begins with the tanks fully charged. As the tanks are
discharged against the design load prof~le,monitor and record the amount of cooling
suppliedbefore the dischargetemperaturerises above the maximum usable temperature.
The discharge rate and discharge temperature tests verify that cooling is supplied
each hour at the specified discharge temperatures and flow rates. These checks are
particularly important during the last few hours of the dischargecycle. The discharge
rate and the discharge temperature profile are generally verified during the test of
storage tank capacity.
The test of charging capacity verifies that the storage tank can be charged in the time
available. Operate the chiller at the design charging setpoint and monitor the cooling
delivered to the tanks. If the design load profile calls for the chiller to meet a load
while charging storage, this load must be included in the test.
The charging time in an encapsulated ice system depends on the charging tempera-
ture. Over the course of several charging cycles, the optimum charging temperature
setpoint can be identified. The optimum charging setpoint is the highest temperature
setting that will fully charge storage in the time available.
Scheduling and control sequence testing confirms that the system switches modes at
the correct times and that pumps, valves, and other controlled devices operate in the
correct sequences. Verify and calibrate chiller setpoints for charging and direct
cooling modes. During testing, confm that the mixed fluid supply temperature to
the load is controlled at the correct setpoint. Also, calibrate the inventory sensor by
noting the output signal at the fully charged and fully discharged conditions.
REFERENCES
BIBLIOGRAPHY
A eutectic salt is a chemical mixture which changes phase from liquid to solid at a
specific temperature. Just as water stores a large amount of cooling at 32'F (0°C) as
it changes from a liquid to solid ice, eutectic salts store cooling at their phase-change
temperatures.
Eutectic salt phase-change materials have been used for various heat storage
applications since the 1800s,but only recently have they been used as a cool storage
medium. The most common formulation for cool storage applications is a mixture
of inorganic salts, water, and nucleating and stabilizing agents, which melts and
freezes at 47'T (8.3"C). This material is encapsulated in rectangular plastic contain-
ers, which are stacked within a storage tank.Figure 9-1 shows a stack of containers.
Water serves as the heat transfer fluid; it circulates through the storage tank among
the eutectic salt containers, carrying heat to or from the storage medium.
9-2 Design Guide for Cool Thermal Storage
The 47°F (8.3"C)eutectic salt can be charged with typical conventionalchilled water
temperatures of40 to 42OF (4 to 6OC). This allows the addition of storage to existing
systems with no modifications to existing chillers and few or no changes to existing
distribution systems.
Typical discharge temperatures of 48 to W°F (9to 10°C) are relatively high for most
HVAC systems. This limitsthe use of full storage operating strategies to applications
with low dehumidification requirements.
I Load
1L
Storage Tank
Pressure
sustaining
Storage tank
valve
booster pump
Temperature
A eutectic salt formulation that freezes and melts at 41°F (5°C) is currently being
developed. Its 42 to44OF (6 to 7OC) dischargetemperature wouldbe compatiblewith
conventional distribution and air-handling systems. While some conventional cool-
ing equipment can produce the 36OF (2OC) temperatures that would be required to
freeze this eutectic salt, a low-temperature chiller using glycol or ether secondary
coolant may be needed.
Eutectic salt mixtures are also available for lowering the storage temperatures of ice
systems. Additives are available that produce freezing temperatures of 28 and 12°F
(-2 and -1 1°C) in ice storage tanks.
Absorption chillers could be used to charge eutectic salt systems. However, the
efficiencyof absorption chillers falls off significantly at leaving water temperatures
below approximately 42OF (6°C).
9.4.1 Tanks
General storage tank considerations are discussed in Section 2.3.2. This section
addresses specific concerns for eutectic salt phase-change systems. Typically, the
tank is constructed of concrete and is rectangular in shape, 8 to 10 ft (2.4 to 3.0 m)
Eutectic Salt Phase-Change Materials 9-5
deep, with apolyurethane liner. The specifications for eutectic salt thermal storage
tanks are often provided by the manufacturer of the storage medium.
Tanks may be constructed either above or below ground and should include access
to test water quality. They are often located under parking lots, patios, or access
roads. Tanks are sized on the basis of a storage volume of 6.0 ft3per ton-hour (20.7
kWh/m3), which includes internal volume for entrance and exit headers. Each tank
is different in terms of exact dimensions, loading requirements, water table and soil
conditions and, therefore, should be designed by a structural engineer familiar with
water tank design.
Gunite, i.e., pneumatically applied concrete, has been used for many eutectic salt
storage tanks. Other methods and materials, such as cast-in-place concrete, have also
been used satisfactorily.
Eutectic salt storage systems are often installed with uninsulated tanks. Most
installations have been in dry soils, which tend to insulate the tank. Installations in
wetter soils may require insulation, or losses may be higher.
Entrance and exit headers are located at oppositeends of the tank so that water makes
one horizontal pass through the tank at a rate of 1 to 2 ft/min (5 to 10 mm/s). The
headers are typically fabricatedof perforated PVC pipe and are designed to distribute
the flow of water across the entire cross section of the tank. The diameter of the pipe
and the perforation pattern depend on the water flow rate and the width of the tank.
Consult the storage medium manufacturer for specific recommendations on header
design.
9.4.2 Containers
The 47°F (8.3"C) phase-change material is hermetically sealed in interlocking
rectangular polyethylene containers, which are positively located with respect to
each other, inhibiting any tendency to shift and maintaining the desired fluid flow
paths around the containers. The material does not float because it is 1.5 times the
density of water; neither does it expand on freezing, so that there is no stress on the
containers. Because of the high density, the interlocking containers, and the lack of
9-6 Design Guide for Cool Thermal Storage
expansion and contraction, the eutectic salt units do not move or shift in the tank
during freezing and thawing.
Pressure-sustaining valves are used for static pressure control (see Section 9.7).
These discharge temperatures may also limit some partial storage applications. The
proportion of the load that can be met from storage depends on the relative
temperature differences across the load and across the storage tank. For example, in
an existing chiller plant operating with 42OF (6°C) supply water and 52°F (11°C)
return water, the storage will never be able ta meet more than (52 - 47)/(52 - 42) =
50%of the load. At low loads, when it may be desirable to meet more of the load from
storage, the return temperature and the proportion from storage will decrease. It may
be necessary to operate mechanical refrigeration during all months of the year, even
when the storage capacity would otherwise be sufficient to meet the entire on-peak
load with no chiller operation.
In many buildings, nonpeak loads can be met with higher temperature supply water
even though the distribution system may have been designed for 42°F (6°C) water
at design conditions. However, if chilled water below 48 to 50°F (9 to 10°C) is
Eutectic Salt Phasechange Materials 9-7
Those applicationsthat use the higher temperature during design conditions have the
full range of operating strategies, optimizing control strategies, and piping configu-
rations available to them.
For applications requiring lower supply temperatures, chillers are placed down-
stream of storage so that they can cool the storage discharge to the required
temperature. Full storage operation is not possible with this arrangementbecause the
chiller must always supplement storage during discharge.
Chiller priority or storage priority control schemes can be used to control storage
system operation at less than peak loads. A chiller priority strategy would typically
be implemented by controlling the mixed temperature leaving storage at the
maximum chiller entering temperature. When the load exceeds the chiller capacity,
and the return temperature rises above this mixed temperature setpoint, some of the
return flow is diverted through the storage tank and is precooled.
Storage priority requires a method of predicting the total load for the day, so chillers
can be operated at a sufficient capacity to prevent storage from being exhausted too
soon. Particularly at the end of the charging cycle, the temperature rise through
storage may be 5°F (3 K) or less. Chillers should be controlled to remain as fully
loaded as possible during the entire charge cycle. Partial loading can reduce system
efficiency and may result in storage not being completely charged at the end of the
availablecharging time. As return temperatures to the chiller drop during charging,
chiller loading will also drop if the chiller outlet temperature is held constant.
With some configurations, it is possible to use the water leaving storage to meet
nighttime loads, increasing the load on the chiller. Multiple chiller installations
should allow chillers to be taken off line as the charging load drops, with the entire
charging flow directed through the remaining chillers. With such an approach, flow
through each chiller should not be allowed to exceed the manufacturer's recom-
mended maximum.
valve on the downstream side of the tank. These valves prevent water from flowing
uncontrollably into the tank.
The storage loop pump should be accurately sized for the pressure drop of the tank
and piping circuit. Since storage flow control is often accomplished by a throttling
valve, oversized pumping capacity results in excess wasted energy. Elleson et al.
(1993) describe a eutectic salt system modified to allow previously wasted storage
pump energy to be used to distribute chilled water to the load, resulting in a
significant reduction in pump energy consumption.
A major advantageof the47OF (8.3OC) eutectic system is its ability to take advantage
of "free cooling" from cooling towers. When wet-bulb temperatures drop below 40
to 44OF (4 to 7OC), the water temperature available from cooling towers is low
enough to provide cooling with no chiller operation. With appropriate straining and
treatment, this cool water can be supplied directly to a chilled water loop. It can also
be supplied to a heat exchanger, which is then used to cool the chilled water loop.
Free cooling provided by cooling towers can be stored at night when wet-bulb
temperatures are low, to meet cooling loads later in the day.
Elleson et al. (1993) describe the performance of a eutectic salt system in Arizona
designed to store free cooling. In this particular system, nighttime cooling loads were
high enough to demand nearly all the free cooling, and very little was stored.
However, with an appropriate match between the cooling tower capacity and the load
profile, this approach can provide large energy and cost savings over a nonstorage
system.
9.8 SIZING
Sizinga eutectic salt storage system requires the appropriate ice making capacity and
storage capacity for a given application to be selected.
Sizing of eutectic salt storage tanks is based on a volume of 6 ft3 per ton-hour
(0.048m3/kWh)of stored cooling. The cross-sectional dimensions of the tank are
selected for a water velocity of 1 to 2 ft/min (5 to 10 mrn/s). The eutectic salt
manufacturer provides assistance with determining the required storage volume and
tank dimensions for a given application.
Percent charged
Discharge temperatures typically rise steadily through the discharge period, from
about 45°F (7OC) at the beginning of discharging to about 50°F (10°C) when the
latent capacity of the tank is exhausted. Figure 9-5 shows a typical discharge
temperature profile.
0 25 50 75 1 00
Percent discharged
Refrigeration plants for eutectic salt storage systems are the same as those for
nonstorage applications,and costs per ton are comparable. Standard sources of cost
data, such as vendors, contractors, or past experience, should be used.
In new construction,a chiller for eutectic salt storage is generally be smaller and less
expensive than one for a nonstorage system. When converting or expanding an
existing system for storage, existing chillers can often be used, and additional
cooling capacity can be obtained simply by installing a storage tank and interface.
In such cases, the first cost of the storage system can be less than that of a nonstorage
system.
Eutectic Salt Phase-Change Materials 9-11
Elleson et al. (1993)provide data for a eutectic salt storage system that operated at
an overall chiller efficiencyof 0.66kwh per ton-hour (5.3 COP). Efficiency was 0.69
kWh/ton-hour (5.1 COP) while charging storage, 0.67 kWhjton-hour (5.2 COP)
while supplementing storage cooling, and 0.62 kWh/ton-hour (5.7 COP) when
cooling with no storage operation. Total energy consumption for the storage system
is calculated to be slightly less than for a nonstorage system.
Merten et al. (1989)report on two eutectic salt systems for which measured chiller
efficiency was essentially equivalent to that calculated for nonstorage systems.
9.13 COMMISSIONING
Commissioning is an ongoing process starting in the predesign phase and continuing
through the first year of system operation. The overall commissioning process is
discussed in Section 2.9. This section describesthe performanceevaluation phase of
the commissioning process for eutectic salt thermal storage systems.
9-12 Design Guide for Cool Thermal Storage
Totalstoragecapacity
Discharge rate and discharge temperatures
Charging capacity
Scheduling and control sequences
Peak demand and energy efficiency
Total storage tank capacity is measured by fully charging the tank and discharging
it against a load with no other cooling supplied. Measure the usable cooling
delivered, up to the point that the discharge temperature from the tank rises above the
maximum usable chilled water supply temperature.
Discharging the tank at the rate specified in the design load profile provides the most
accurate evaluationof actual tank capacity under design conditions. However, if this
is not practical, other discharge rates will provide acceptable estimates. For most
tank configurations, the total storage capacity is relatively insensitive to discharge
rate.
The discharge rate and discharge temperature tests verify that the load can be met at
the required dischargetemperaturefor each hour of the design profile. The discharge
rate and discharge temperature profile are generally verified during the test of
storage tank capacity.
Charging capacity is tested by monitoring the cooling delivered to the storage tank
during a complete charge cycle, starting from the fully discharged condition. The
chiller should be able to fully charge the tank in the time available, as well as meet
any loads that occur during the charging period.
Scheduling and control sequence testing verify that the storage system switches the
operating modes correctly. All pumps and valves should operate according to the
design intent. Mixing valves and the pressure-sustainingvalve should be calibrated
and their performance verified.
REFERENCES
Elleson, J.S., S.S. Dingle, and S.P. Leight. 1993. Field evaluation of a eutectic salt
thermal storage system. Palo Alto, CA: Electric Power Research Institute.
Eutectic Salt Phase-Change Materials 9-13
Merten, G.P.,SL. Shum, R.H. Sterrett, and W.C.Racine. 1989. Operation and
performance of commercialcool storage systems, Vol. 1: 1987 Cooling season,
and Vol. 2: 1988 Cooling season and project summary. EPRI CU-6561,
September.
BIBLIOGRAPHY
Ames, D.A. 1986. Design and control of eutectic salt thermal storage systems.
Transphase System Inc. Brochure, August.
Ames, D.A. 1989. Thermal storage forum: The past, present and future of eutectic
salt storage systems. ASHRAE Journal (May):26-28.
Ames, D.A. 1990. Thermal storage forum: Eutectic cool storage: Current develop-
ments. ASHRAE Journal (April):46-53.
Transphase Systems Inc. 1986. Transphase thermal energy storage design guide.
Transphase Systems Inc. Transphase coolness storage systems.
9-14 Design Guide for Cool Thermal Storage
Chapter 10 DESIGN PROCEDURE
10.1 INTRODUCTION
This chapter gives guidance in applying the design fundamentals discussed in
Chapter 2 to the storage technologies described in Chapters 4 through 9. The cool
storage design procedure includes the following general steps:
Because each application is unique, the design process will not necessarily conform
to an absolute sequenceof steps or standardprocedure. However, the stepsjust listed
generally appear in some form in every cool storage design.
The sections that follow are presented in an ideal sequence. In actual practice, the
design procedure may pass through each step in a different order. In many cases, the
intermediate design steps will be repeated for the sake of comparison or refinement.
The selection of design weather conditionsis typically the first step in the calculation
of load profiles. The design weather profile is also important to the calculation of
load profiles, as well as equipment performance. The selection of peak design
conditions and weather profiles is discussed in Section 2.1.1, and an example is
provided here.
For new construction, load profiles must be calculated based on the best available
estimates of heat gains within the space and of schedules of occupancy, ventilation,
lighting,and equipment use. Wherecool storage is to beadded to an existing system,
measurement of existing load profiles is recommended. Examples of load profile
calculation for new and existing projects are given next.
Month O F O C OF O C
Daily weather profiles are constructed for each design day according to the method
presented in Chapter26 of the 1993ASHRAE Handbook-Fundamentals.Dry-bulb
temperatures are calculated for each hour, based on the peak temperature and the
daily range to give an approximately sinusoidal variation with a maximum at 3 P.M.
and a minimum at 5 A.M. The daily range of 18°F (7.8 K) is given in Table 1,Chapter
24, of the 1993 ASHRAE Handbook-Fundamentals for the project location. Wet-
bulb temperatures are calculated based on the assumption of a constant dew-point
temperature throughout the day. Table 10-2 illustrates the calculation of the design
day temperature profile.
10-4 Design Guide for Cool Thermal Storage
Hour % of Range OF OC OF OC
Notes:
Daily range = 18OF (7.8OC); Peak dry-bulb = 92OF (33.3OC); Mean coincident wet-bulb =
74OF (23.3OC); dew point = 67OF (19.4OC) (assumed constant). Percent of range is
from Table 2, Chapter 26, of the 1993 ASNRAE Handbook-Fundamentals.
The dry-bulb temperature for a given hour is calculated by subtracting the listed percent-
age of the daily range from the peak dry-bulb temperature. The wet-bulb temperature
for each hour is determined from the dew point and the dry-bulb temperature for that
hour.
This example is based on the design of a cool storage system for a large convention
center. The initial design for the center was completedbasedon anonstorage cooling
Design Procedure 10-5
plant, and cool storage was being considered as an alternatebecause of the potential
savings in both first cost and operating cost.
A critical factor in the load profile calculation for this project was determining a
schedule of occupancy, lighting, and equipment gains for the design day. With this
information, calculation of cooling loads is a straightforward procedure.
Om7 7
V
8 9 10 11 12 13 14 15 16 17 18 19
Hour
Expected heat gains from lighting and equipment were analyzed for each zone and
expressed in terms of maximum watts per square foot. These figures were conserva-
tively assumed to apply for each occupied hour of the design day. Unoccupied heat
gains were analyzed and expressed as a percentage of the occupied gains for each
zone. Data for all zones were combined into an overall block load figure for occupied
and unoccupied periods.
1&6 Design Guide for Cool Thermal Storage
People Schedule
(Fraction of total for each hour)
Hour Mon Tue Wed Thu Fri Sat Sun
Design Procedure 10-7
People
Activity level = 5
Number = 25.000
Lighting and Equipment = 4.5 W/ft2 (47.0 W/m2)
Internal Loads
System gains = 11.0%
Miscellaneous sensible = 280,000 Btu/h (82.0 kW)
Lighting/Equipment Schedule
(Fraction of peak for each hour)
Mon Tue Wed Thu Fri Sat Sun
10-8 Design Guide for Cool Thermal Storage
Areas and heat transmission factors of walls, roof, and glass were taken from the
architectural plans. This information was entered into a commercial cooling load
calculation program, along with the occupancy schedule and internal heat gains, to
provide a calculated cooling load for each hour of the design day. Table 10-3
summarizes the load calculation data for this example.
Heat gains occurring during unoccupied periods, when cooling distribution equip-
ment does not run, were accumulated and added to the instantaneous loads early in
the occupied period. This pulldown load was assumed to be met over several hours,
with the majority of the load met in the first hour.
Table 10-4 summarizes the design day cooling load profile calculated for a trade
show with an attendance of 25,000.
This project consisted of the design of a central plant expansion for a university
chilled water system. The design load profile was developed from current load data
and estimates of future loads supplied by the owner.
To determine the current load profile, the latest available year of load data were
sorted by day according to the maximum dry-bulb temperature. Hourly loads from
three of the hottest days were averaged to provide a typical peak load profile.
Estimates of future peak load additions were provided by plant operations personnel.
Future load projections were divided into three categories-office/classroom, re-
search, and clinical.
Hourly load profiles expressed as the percentage of the peak load for each hour were
developed for each building type. In this case, the generalized profiles represented
Design Procedure 10-9
the best possible estimate of the load shapes, since no detailed information was
available on the individual building loads. At any rate, the effect of small errors in
the future load profiles on the total campus load shape would be minimal.
The existing plant capacity includes both electric centrifugal and steam absorption
chillers. The absorption chillers are baseloaded to provide a steam load for the
campus cogeneration plant. Therefore, the cool storage analysis considered only
those loads that would be met by the centrifugal chillers. The load profile for the
storage analysis was determined by subtracting the absorption chiller capacity for
each hour from the total load.
Table 10-5 summarizes the current loads, future loads, absorption capacity, and
centrifugal chiller load for a design day, andFigure 10-2 illustrates the load profiles.
This initial screening begins with the design load profile to be met by the cooling
system and the applicable utility rate schedule. The required chiller capacity and
storage capacity for various operating strategies are estimated using quick rule-of-
thumb formulas. These estimates are used to project approximate operating cost
savingscomparedto anonstoragesystem.Finally,installation costs areestimated for
alternative storage technologies, and the economics of each option are compared.
In some cases, an estimateof the load profile can be developed based on the projected
peak load and a typical profile shape for the type of building under consideration.
However, a more accurate load profile is mandatory for final system sizing.
The quick chiller size and quick storage size are calculated based on the requirement
that the total integrated capacity of the refrigeration plant must equal the total
integrated cooling load plus any losses. If storage losses and pump heat gains are not
considered for the purpose of initial sizing estimates, they must be included in the
final sizing analysis. That is:
The total integrated chiller capacity can be approximatedby the nominal capacity by
the number of hours available. In many systems, the chiller capacity varies depend-
ing on whether it is charging storage or meeting the load directly. In systems with
demand-limiting operation, the direct cooling capacity will be limited during on-
peak periods.
The total integrated capacity is the summation of the chiller capacity in each mode,
times the number of hours in that mode.
where
H ~ ~ o ,
-
-- hours direct cooling during on-peak period
capacity when direct cooling during on-peak period
C ~ ~ o n p -
HDCoffp = hours direct cooling during off-peak period
CDCoffp = capacity when direct cooling during off-peak period
The calculations for quick chiller size and quick storage size, with examples
following the general discussion, follow.
where
For a full storage system, the on-peak chiller capacity is zero. For a load-leveling
system, the direct cooling capacity is the same during on and off peak.
For quick chiller sizing of chilled water storage systems, the chiller capacity is
generally assumed to be constant.
Design Procedure 10-13
For ice harvesters, the ice making capacity is typically considered the nominal
capacity, and the direct cooling capacity ratio is approximately 1.2 to 1.3.
For other ice storage systems, chiller ice making capacity is typically 60 to 70% of
the nominal capacity. The direct cooling capacity ratio depends on the chilled water
temperature required for direct cooling. For example, the capacity of a chiller
providing direct cooling at %OF (3OC) will be 80to 90%of the nominal ARI capacity,
where
The total direct cooling capacity is generally equal to the hours available for direct
cooling times the chillercapacity for direct cooling. However, in somecases, the load
for a given hour will be less than the direct cooling capacity. The actual load met from
direct cooling must then be used in calculating the required storage capacity.
The storage capacity calculated by Equation (4) is the nominal storagerequired. The
actual storage capacity must be determined by a detailed analysis of the charge and
discharge characteristicsof the selected storage type and their interactions with the
load and chiller performance for each hour.
The initial sizing of chiller and storage is illustrated here for the convention center
example introduced earlier. Quick size estimates are developed for the following
operating strategies:
Table 10-6 summarizes the information required for the quick size estimates. This
table shows that even though the utility on-peak period lasts through 10 P.M., there
are no loads after 6 P.M. Since the facility demand for lighting and other electrical
loads also drops off at this time, chilling equipment can be operated between 6 P.M.
and 10 P.M. without increasing the peak billing demand. The effective on-peak
window for this system is, therefore, 10 A.M. to 6 P.M.
Utility Load
Hour Period Tons kW Cooling Mode
1 Charging
2
3
'L
4
4'
5
"
6
7
8 Met while charging
9 Discharging and direct cooling
10
11
12
13
14
15
16
17
18
19 Charging
20
21
22
23
24
Notes:
On-peak ton-hr = 28,766 (101 256 kwh)
Off-peak ton-hr = 6,440 (22 669 kwh)
Total ton-hr = 35.206 (123 925 kwh)
l6 hchrg
Nominal chiller e k = 123 925 kwh = 7745 kW (3a)
l6 hchrg
This chiller capacity is less than the loads for hours 9 and 10. Loads during these
hours will be met by direct cooling from the chiller supplemented by discharge of
storage.
For a storage system with different capacities for charging and direct cooling, such
as a glycol-based ice storage system, the initial sizing calculation must take these
capacity differences into account. For example, if the charging capacity ratio is 0.7
and the direct cooling capacity ratio is 1.0, the nominal chiller size is calculated as
follows:
35,206 ton-h
Nominal chiller size =
(14 hChrgx0.7) + (2 hDc x 1.0)
= 2,983 tons
123 925 kwh
Nominal chiller size = (3b)
(14 hch, x 0.7) + (2 hDc x 1.0)
This nominal chiller size is greater than the load for hours 9 and 10, when the
chiller is in direct cooling mode. The chiller size calculation will need to be
adjusted. The loads in hours 9 and 10 are 2,623 and 2,973 tons (9233 and
10465 kW), or 88 and 99% of the initial chiller size estimate. These factors
are substituted in Equation (3b) as follows:
10-16 Design Guide for Cool Thermal Storage
The nominal chiller sizehas increased by about 30 tons (106 kW).The direct cooling
capacity ratios for hours 9 and 10are now 87 and 99% of this new capacity, a small
change from the previous values. Recalculating with these new values would result
in a negligible change in the chiller size calculation.
The direct cooling capacity is equal to the actual loads for hours 9 and 10, since these
loads are less than the actual chiller capacity.
This chiller capacity is less than the load for hour 8. The load during hour 8 will be
met by direct cooling from the chiller supplemented by discharge of storage.
If the direct cooling capacity is equal to the nominal capacity and the charging
capacity is 70% of the nominal capacity, such as for a glycol-based ice storage
system, Equation (3) becomes:
6,600 ton-h
%
% 58 400 kwh
1618 Design Guide for Cool Thermal Storage
The direct cooling capacity in the previous load-leveling examples equals the
number of hours of direct cooling times the chiller capacity in direct cooling mode.
This weekly cycle example is sized with an ice harvesting system. For an ice
harvester, the nominal capacity is typically given as the ice making capacity. For an
ice harvester with a chilling capacity 25% higher than its ice making capacity, the
nominal chiller size is:
Nominal chiller e k =
35,206 ton-h/day x 4 days
(116 hd,,x 1.0) + (40 hDCx 1.25)
= 848 tons
Nominal chiller aize =
123 925 kWh/day x 4 days (30
(116 hCh,,x 1.0) + (40 hDCx 1-25)
= 2985 kW
The chiller sizes and storage sizes determined in the abovementioned examples are
summarized in TablelO-7.
Daily, Full storage Chilled water 2,200 7 745 30,000 105 600
Daily, Full storage Glycol ice 3,017 10 619 28,800 101 300
Daily, Load leveling Chilled water 1,467 5 164 19,700 69 300
Daily, Load leveling Glycol ice 1,778 6259 16,600 58 400
Daily, Demand limiting Glycol ice 2,228 7 843 21,000 73 900
Weekly, Load leveling Ice harvester 848 2985 95,100 334 600
10-20 Design Guide for Cool Thermal Storage
The costs developed at this phase are often rough estimates, used to provide a quick
comparison among various technologies and sizing options. This example uses
Peak
Quick Quick Month
Chiller Storage Demand
Operating Storage Size, Size, On-Peak, Savings
Mode TYpe Tons Ton-hr kW kW
Nonstorage ... 3,900 0 2,730 ...
Daily full Chilled
storage water 2.200 30,000 0 2,730
Daily full Glycol
storage ice 3,017 28,800 0 2,730
Daily load Chilled
leveling water 1,467 19,700 1,027 1,703
Daily load Glycol
leveling ice 1,778 16,600 1,245 1,485
Daily demand Glycol
limiting ice 2,228 21,000 780 1,950
Weekly load Ice
leveling harvester 848 95,100 742 1,988
Notes:
On-peak chiller efficiency = 0.7 kW/ton
generic cost estimating figures to develop such a rough comparison. In some cases,
more detailed cost data may be available or more accurate estimates may be
desirable.
Annual demand savings for full storage systems assume 3 months with peak demand savings
and 5 months with 70%of peak savings.
Annual demand savings for partial storage systems assume 8 months with 100%of peak
demand savings
10-22 Design Guide for Cool Thermal Storage
cost savings constitute a significant portion of the total operating cost savings. In
these cases, an annual energy analysis, including comparisons of on- and off-peak
energy consumption and charges, may be necessary.
For partial storage systems, this example assumes that the demand savings for the
peak month are available for 8 months of the year. For the full storage systems, peak
Peak
Quick Quick Month
Chiller Storage Demand
Operating Storage Size, Size, On-Peak, Savings,
Mode Type kW kwh kW kW
Nonstorage ... 13 728
Daily full Chilled
storage water 7 744
Daily full Glywl
storage ice 10 619
Daily load Chilled
leveling water 5 164
Daily load Glycol
leveling ice 6 259
Daily demand Glywl
limiting ice 7 843
weekly load Ice
leveling harvester 2 985
Notes:
On-peak chiller efficiency = 0.2 kWkW
Harvester cost
Storage cost
Chilled water = $11.36kWh
Glycol ice = $17.05/kWh
Harvester = $4.26/kWh
Utility subsidy = $150/0n-peak kW reduced
Design Procedure 10-23
demand savingsare assumed to be equal to the peak month savingsfor 3 months, and
to 70% of the peak month savings for Smonths. These estimates vary for each
application, depending on climate and load characteristics.
Installed costs for chiller capacity are estimated at $600/ton ($170/kW). This does
not reflect the cost of the entire chiller plant but is useful in evduating the cost
impacts of downsizing chillers, cooling towers, etc.
Costs for ice harvesters vary considerably with ice making capacity. For the
relatively large system considered in this example, ice harvester costs are estimated
at $1,10O/ton ($3121kW).
Annual demand savings for full storage systems assume 3 months with peak demand savings
and 5 months with 70%of peak savings.
Annual demand savings for partial storage systems assume 8 months with 100%of peak
demand savings
1@24 Design Guide for Cool Thermal Storage
Chilled water storage costs are based on a 16OF (9 K) temperature range, resulting
in a storage volume of 100 gal per ton-hour (108 L/kWh). With tank costs at
approximately $0.40/gal ($O.ll/L), storage costs are estimated at $40/ton-hour
($11.37/kWh).
Many electric utilities offer direct incentive payments to encourage the installation
of cool storage systems. These incentives are typically linked to the reduction in on-
peak demand provided by the storage system. In this example, the utility subsidy is
$150 per kilowatt shifted from on-peak periods.
Table 10-8summarizes the preliminary economic comparison for this example. The
table shows many of the cool storage options with lower estimated first costs than a
nonstorage system. This approximate initial analysis indicates that cool storage
definitely warrants more detailed analysis for this application and provides a basis
for ranking the alternatives.
This summary does not show possible savings in fan energy and air distribution
equipment if cold air distribution is used. It also neglects to indicate possible savings
in pump energy and in first costs of pumps and piping, if the chilled water
temperature range can be increased.
In the next step of the design procedure, the quick sizing estimates and the initial
economic analysis are combined with other site-specific considerations to select
appropriate storage types and operating strategies for further analysis.
In some cases, the preferred option is readily apparent based on the preliminary
analysis. In many cases, however, more than one storage type or operating strategy
Design Procedure 10-25
is selected for further analysis. As the subsequent steps of the design procedure are
carried out, the options can be compared in detail and the best system selected.
For the convention center example summarized in Table 10-8, many of the cool
storage options offer first cost savings, as well as operating cost savings, compared
to a nonstorage system. For many applications, cool storage incurs additional frrst
costs, which must be evaluated in terms of operating cost savings.
In general, daily load-leveling systems have the lowest first costs and the lowest
operating cost savings. Capital costs for demand-limiting and full storage systems
are higher, since these systems are sized with larger equipment to increase operating
cost savings.In many applications,weekly storage systemshave the lowest f i t cost,
sincechiller size is minimized.For the convention center example, however, the cost
for increased storage capacity offsets the reduction in chiller size. If the weekly
system is attractive based on noneconomic considerations, better storage cost
estimates than the unit costs used for this analysis should be obtained.
The cost of reserve storage capacity may be a factor in selecting the preferred storage
technology. For technologies such as chilled water storage and ice harvesters, the
marginal cost of additional storage is relatively low. For technologies using modular
tanks, additional capacity can often be easily added in the future, when and if it is
needed.
Both the chilled water temperature range available and the possibility of reducing
water or air distribution temperatures affect the type of storage selected. The use of
pressurized or nonpressurized tanks and the heat transfer fluid used are additional
considerations. At this point in the analysis, some preliminary selections must be
made.
10-26 Design Guide for Cool Thermal Storage
Pressurized storage tanks can be readily integrated into a cooling system design.
Nonpressurized tanks may require heat exchanger isolation or pressure-sustaining
valves. Nonpressurized tanks that are not isolated by heat exchangers also require
additional water treatment. Storage systems that use glycol or other secondary
coolants circulate the storage loop coolant in the secondary distribution system, or
the storage plant needs to be isolated by heat exchangers.
Operation and maintenancealso play a part in selecting a storage. Consider the level
of expertise of the personnel responsible for the storage system. Chilled water and
eutectic salt storage systems use conventional chillers operating at conventional
temperatures and are very similar to nonstorage plants. Glycol-based ice storage
chillers are similar in many respects to nonstorage chillers but involve a different
operating fluid and lower temperaturesthan most nonstoragesystems. Ice harvesting
systems and refrigerant-based ice-on-pipe systems require refrigeration expertise
familiar to many plant operators and service contractors.
The capacity ratings of both chiller and storage must be corrected to reflect their
cooling performance in the actual temperatureconditions at which they will operate.
Determination of the supply air temperature, supply and return fluid temperatures,
and fluid flow rate is an iterative process involving the evaluation of constraints on
any one quantity and their effects on the others. Some applications have preexisting
interface requirements. If no such requirements exist, the engineer can select
optimum or preferred values for these parameters.
The desired supply air temperature is selected based on potential savings in air
distribution system costs and fan energy consumption and on space air distribution
considerations. The lower limit of this parameter depends on the available chilled
fluid temperature, with a typical approach of 6°F (3 K) or more between the chilled
fluid supply and discharge air temperatures. Dorgan and Elleson (1988) discuss the
selection of supply air temperature, and other considerations in cold air distribution
Design Procedure 10-27
The chilled fluid return temperature depends on the heat transfer characteristics of
the cooling coils. Cooling coil selection is discussed in Section 2.5.1. When cooling
coils must be selected for high fluid temperature differentials and tube velocities
below 1 ft/s (0.3 mls), it may be advisable to consider alternative circuiting to
increase the water flow rate, to specify turbulators to increase water-side heat
transfer coefficients, or to allow a safety factor in the specification of coil perfor-
mance. One method for providing reserve coil capacity is to specify cooling coils
capable of providing the required cooling capacity with entering water temperatures
2OF (1 K)higher than the design supply temperature.
The chilled fluid flow rate is determined by the peak load and the temperature rise
from supply to return water. Verify that the available cooling coils will provide the
desired performance at the given temperatures and flow rate. Temperatures, flow
rate, or coil selection may need adjusting until an acceptable combination is found.
Determine whether or not the storage cooling fluid will be used as the distribution
cooling fluid. Heat exchangers may be used to isolate storage and distribution loops
due to the use of glycol or other secondary coolants on the storage side, or because
of water treatment concerns arising from the use of open storage tanks.
While each application is unique, experience with ice storage systems using glycol
as secondary coolant has shown that heat exchangers are typically used in systems
with peak cooling loads above 500 tons (1800 kW). Where peak cooling loads are
less than 200 tons (700 kW), it is generally economical to use glycol in the building
distribution system. For peak cooling loads between 200 and 500 tons (1800 and 7OO
kW), the decision whether or not to use a heat exchanger will be determined by the
specific conditions at the site.
Heat exchangers may also be used in systems with open storage tanks to maintain
desired distribution system static pressures. Direct pumping with pressure-sustain-
ing valves and the use of energy recovery turbines should also be considered for
systems with open tanks. Comparisons of these options are given by Mackie and
Reeves (1988)-Mackie and Richards (1992), and Tackett (1988).
The decision whether to use a heat exchanger must be based on an evaluation of all
pertinent factors, including:
1&28 Design Guide for Cool Thermal Storage
The designer must select the configuration of chilling equipment, storage tanks,
pumps, and other components. Several of the storage technologies may be arranged
with the chiller in parallel with storageor with the chiller in series and located either
upstream or downstream of storage. Common configurations for each of the storage
technologies are illustrated in Chapters 4 through 9.
As discussed in Section 2.6, the detailed sizing process requires an hour by hour
simulation of the performance of chiller and storage in response to the load profile
and ambient conditions over the entire design load cycle. By an iterativeprocedure,
a system operating profile is developed that considers load, ambient temperatures,
storage inventory, and temperatures entering and leaving storage for each hour.
Pump heat gains and storage losses must be included in this analysis. The character-
istics of the secondary distribution system,particularly the return water temperature,
are important, as are the control sequences governing chiller operation and storage.
The purpose of the design is to meet the load during each hour. The supply
temperature is selectedas a design parameter, and the return temperatureor flowrate
will vary in response to the load, as determined by the distribution system control
sequences and cooling coil performance. If the load has been overestimated or if
safety factors have been applied, the design return temperature may not be achieved
in practice. This possibility should be considered during design of a system whose
performancedepends on return temperature. If a heat exchanger is used, its response
to the hourly temperature and flow conditions should be determined. Pump heat
gains must also be added to the load.
Design Procedure 10-29
Some designers elect to apply a safety factor of 5 to 10%to rated chiller capacities
to account for the 5%tolerance allowed in manufacturer's capacity ratings. This can
be accomplishedby specifying a chiller capable of cooling 105%of the design flow
m e to the design temperature.
Storageparameters includechargingcharacteristics,dischargecharacteristics,stored
cooling inventory, and thermal losses (heat gains). The charging temperature
required to completely charge storage within the available time period is specific to
the storage technology and is typically determined based on the storage tank design
or the storage manufacturer's ratings. With some ice storage technologies, the
charging temperature will vary with the storage inventory. A safety factor can be
provided by designing for a shorter charging time than is actually expected.
Thermal losses are generally accounted for by increasing the calculated storage
capacity. Calculation of losses is discussed in Section 2.3.2. A margin of safety can
be provided by increasing the specified storage capacity by more than the amount of
calculated losses.
The result of the detailed sizing procedure is a design operating profile that includes
the following information for each hour of the storage cycle:
Three examples are presented here to illustrate the detailed sizing procedure with
various storage technologies and calculation methods.
10.6.1 Design Example: Detailed System Sizing, Internal Melt Ice Storage
Detailed system sizing is illustrated here for a middle school application with an
internal melt ice storage system. Tables 10-9 and 10-10 summarize the data for this
example.
Table 10-9 shows the cooling capacity as a function of leaving fluid temperatwe for
the air-cooled chiller selected for this design. Although the chiller leaving tempera-
ture varies somewhat during charging, the analysis was simplified by assuming a
constant charging capacity of 92 tons (324 kW).The charging capacity is given for
an ambient air temperature of 85°F (29.4"C), and the direct cooling capacities are
given for an ambient air temperature of 95°F (35°C). A more precise analysis would
consider variations in ambient temperature for each hour and their effects on
capacity.
Notes: Capacity at 24'F (-44°C) is based on 85OF (29'C) air temperature. Other
capacities are based on 95OF (3S°C)air temperature.
Design Procedure 10-31
Table 10-10 shows the completed design operating profile, developed using the
storage tank manufacturer's computer program to calculate charge and discharge
characteristics. The data in Table 10-10 were developed in an iterative process,
beginning with nominal chiller capacities for each hour of direct cooling. The
calculated chiller leaving temperatures were used to determine a new capacity for
each hour, based on Table 10-9. This process was reheated until no further adjust-
ments were required.
The StorageInventory column shows that there may be excess storage capacity in the
system as sized. The total nominal capacity of the six nominal 162 ton-how (570
kwh) tanks is 972 ton-hours (3421 kwh). Only 828 ton-hours (2915 kwh) are put
into the tanks during the charge cycle, and 125 ton-hours (440 kwh) remain at hour
19 at the end of discharging.
To determine whether the design storage capacity could be reduced, the sizing
simulation was repeated fora system with five modular storage tanks, using the same
procedure as for Tablelo-10. The results are shown in Table 10-11. In this case, the
storage leaving temperature rises to 40.Z°F (4.6"C) in hour 14, the peak load how,
and the load is met only by increasing the storage flow above the design flow of 80
gpm (5 L/s) per tank. Similarly, the required discharge temperature cannot be
supplied in hour 15.
Table 10-10 Design Operating Profile for Internal Mett Ice System, School Example (IP Units)
1 Charging
2
3 U
4
5 '4
6 '4
n
7
8 Direct Cooling
n
9
n
10
11 '4
u
12
13
14
15
-
n
16 6'
u
17
18 U
19 "
u
20
u
21
n
22
23 Charging
n
24
Notes:
Chiller Upstream Series Flow Number of tanks = 6
System supply temperature = 38.S°F Flow, gpm
System return temperature = 55.6"F Charge = 400, gpm
Design load = 268 tons Discharge = 400, gpm
Working fluid = 25%ethylene glycol
Nominal chiller size = 130 tons **Condition outside calculation limits of program.
Table 10-10 Design Operating Profile for Internal Mett Ice System, School Example (S1 Units)
Hour
Cooling
Mode
Lcmd,
Tons
Capacity,
Tons
Storage,
Tons
Inventory,
Ton-hr
Capacity,
96
Temp,
OF
Temp.,
O F
Temp.,
O F
per Tank,
Q D ~
Drop,
nsi
I
n"
Charging 0
0
0
0
0
u
0
u
0
u
0
u
0
Direct cooling 26
" 10
'.
0
161
180
4
'
225
" 25 1
u
268
u
262
'a
203
a'
172
'.
a'
'
.
136
128
32
'
.
29
0
27
Charging 0
'
.
0
Notes:
Chiller Upstream Series Flow Flow, gpm
System supply temperature = 38S°F Discharge = 400
System return temperature = 55.6OF Charge = 400
Nominal chiller size = 130 tons
Number of tanks = 5 **Condition outside calculation limits of program.
Working fluid = 25% ethylene glycol
Table 10-11 Design Operating Profile, School Example, Reduced Storage Capacity (SI Units)
Charging
U
'4
'd
Direct cooling
Y
-
Y
s'
.'
4'
Charging
4'
Notes:
Chiller Upstream Series Flow Flow, L/s
System supply temperature = 3.PC Discharge = 25
System return temperature = 13.1°C Charge = 25
Nominal chiller size = 457 k W
Number of tanks = 5 **Condition outside calculation limits of program.
Working fluid = 25%ethylene glycol
10-36 Design Guide for Cool Thermal Storage
Entering
Step Water Temp., Nominal kW/ton kW/kW
Capacity
OF OC Ratio
The sizing program calculates the required chiller size and storage size for the
specified operating strategy and provides an hour-by-hour simulation of the system
based on the specified equipment performance characteristics. Return water tem-
perature to the ice harvester is calculated based on the required recirculation water
flow, the load, and the system pumping arrangement. Such an analysis could also be
performed using a spreadsheet program, or manually, by successively refining the
initial estimates of chiller and storage size.
istics were used in the analysis. For this example, four evaporator assemblies, each
with a nominal capacity rating of 340 tons (1200 kW), were selected for installation
with a separate built-up refrigeration plant.
This example illustrates the detailed sizing procedure for a chilled water storage
system, using the campus example introduced earlier. Table 10-14 contains the
chiller performance data used for the sizing analysis, and Table 10-15 summarizes
the final analysis.
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
On
off
Off
Off
Table 10-$5 Design Operating Profile for Chilled Water Storage, Campus Example (SI Units)
Table 10-15 was generated using the results of a commercially available sizing
program combined with additional analysis using a spreadsheet program to provide
an hour-by-hoursimulation of system performancebased on the specified equipment
performance characteristics.
The intent of the sizing analysis is to determine the minimum storage size required
to meet the future loads on the chilled water plant, using the existing chillers. The
operating strategy is based on a load-leveling operation, but the storage size is
smaller than that for a true load-leveling system to make use of the entire available
chiller capacity. Some of the chillers are operated at 3g°F (3.g°C) to charge storage
during the charging period, while 42°F (5.6OC) operation is simulated for direct
cooling operation.
The result of this analysis is a storage requirement of 6,854 ton-hours (1,947 kwh).
The approximate size of a chilled water tank to store this amount of cooling is
calculated as follows:
Volume (gallons) =
ton-h x 12,000 Btulton-h
A'F x 8.364 Btu/gale°F x Tank Figure of Merit
Volume (m3) =
(5)
kwh x 3600 kJ/kWh
AK x 998 kg/m3 x 4.2 kJ/CkrW x Tank Figure of Merit
For a 14°F (7.8"C) available temperature difference, and an assumed FOM of 0.90,
the required storage volume is about 783,000 gal (2960 m3). A tank 60 ft (18 m) in
diameter and 40 ft (12 m) high would provide a volume of 845,000 gal (3200 m3),
about 8% more than the minimum requirement. These dimensions are tentatively
used to enter the diffuser design procedure.
Diffuser design is not included in this example. A discussion of diffuser design and
references for diffuser design examples are given in Section 4.4.3.
storage tanks are best obtained from manufacturers. For site-built tanks, obtain
estimates from contractors experienced in the construction of tanks for cool storage
or similar duty. Similarly,cost estimatesor bids for installation of equipment should
be solicited from contractors familiar with cool storage.
Operating cost estimates can be developed to varying levels of detail and accuracy.
In some cases, simple estimates based on peak demand savings, as discussed in
Section 10.3, may be adequate. At the other extreme, an hour-by-hour analysis
including energy consumption of chillers, pumps, and air-handler fans may be
desirable.
For most applications, most operating cost savingscome from reductions in demand
charges. Demand savings for each month of the year are calculated based on
estimates or calculationsof load variationsthroughout the year and on knowledge of
system control strategies during nonpeak months. It is generally sbaightforward to
calculateannual demand savingsby repeating the design day analysis with appropri-
ate load profiles for 12 months.
For some applications, particularly where there is a large differential between on-
and off-peak energy charges, chiller energy savings are significant. For many cool
storage designs, pumping energy savings are important. Savings in fan energy
should also be included if cold air distribution is used.
Estimates of energy savings can be developed based on the design operating profile
developed for detailed sizing. Energy savings for a single storage cycle are calcu-
lated from the applicable utility rates and from the differences in on- and off-peak
energy consumption between the storage system and the nonstorage base case. One
method of projecting these data into an annual analysis is to multiply energy savings
for the design day (or week) by the number of effective full-load days (or weeks) in
each month. Effective full-load days must be estimated based on an assessment of
the magnitude and distribution of loads throughout the year, making this method
more accurate than if a peak operating profile were developed for each month.
Energy savings can often be related to the number of ton-hours per day shifted from
on- to off-peak periods. It may be assumed that the energy savings for the peak day
1&44 Design Guide for Cool Thermal Storage
is achieved on any day that the number of on-peak cooling load ton-hours is greater
than or equal to the storage capacity. For lower load days, the entire on-peak load
shifted, and savingsare proportional to the load. Estimates generatedby this method
will not fully account for variations in part-load efficiency of nonstorage chillers.
Annual energy savings can also be estimated by running detailed daily comparisons
of storage and nonstorage performance over a representative range of load and
ambient temperature conditions. The daily energy consumption for each condition
is multiplied by the number of days in each month at the respective temperature level,
as determined from weather data.
The cost breakdown given here is for an internal melt ice storage system, with a
nominal chiller capacity of 2,000 tons (7000 kW). Glycol secondary coolant is used
in the distribution system, with a 20°F (ll.l°C) temperature rise. A supply air
temperatureof 45'F (7.2OC) is used in the exhibit halls, using jet diffusers. In offices
and meeting rooms, 48°F (8.g°C) air is supplied using slot diffusers selected for that
temperature.
Table 10-16 summarizes the cost comparison between the two systems. The
comparison considers only those items that differ for the two alternatives.
Chiller costs are based on estimates provided by vendors for the respective capaci-
ties.
The allowance for glycol for the storage system includes material and labor for
mixing and filling. An allowance is also provided for additional piping details
necessitated by the use of glycol in the distribution system.
Design Procedure 10-45
The cost for storage tanks is based on 19,200 ton-hours (67 584 kwh) of nominal
storage capacity and includes an allowance for extra labor costs to install tanks in a
somewhat restricted location in a parking deck.
Distribution pump sizes are reduced because of the increased chilled water tempera-
ture rise, and condenser water pumps are downsized due to the reduced chiller
capacity. Table 10-17 summarizes the changes in pump capacities. Cooling tower
capacity was cut in half for the storage system.
10-46 Design Guide for Cool Thermal Storage
IP Units
Nonstorage
Chilled water 3 2,320 105 125 16,000 48.000
2 1,160 105 60 12,500 25,000
Condenser water 4 4,050 103 200 24,300 97,200
Total 170,200
Ice storage
Chilled water 3 1,667 135 100 15,000 45,000
2 833 135 50 12,000 24,000
Condenser water 3 2.400 105 100 15,000 45.000
Total 114,500
SI Units
Nonstorage
Chilled water 3 146 314 93 16000 48000
2 73 314 45 12 500 25 000
Condenser water 4 25 6 308 149 24 300 97 200
Ice storage
Chilled water 3 105 404 75 15000 45000
2 53 404 37 12 000 24 000
Condenser water 3 151 314 75 15000 45000
Piping was resized for a 20°F (ll.l°C) temperature rise, resulting in a typical
reduction of one pipe size throughout the system. Table 10-18provides a breakdown
of piping system costs, as well as ductwork costs, which are reduced for the storage
system due to the lower supply air temperatures. An allowance is provided for
additional costs for more expensive diffusers to deliver 48OF (8.9OC) supply air.
Design Procedure 10-47
Pipe and 24
fittings 20
18
16
14
12
10
8
6
5
4
3
s1.5
Pipe and 24
valve 20
covering 18
16
14
12
10
8
6
5
4
3
S1.5
Main valves
Condenser 18
water 16
piping 12
Total for
piping
Main valves
Condenser 450
water 400
piping 300
Total for
piping
Air-handling units for the nonstorage system are priced based on 55°F (12.8"C)
supply air. Air-handling units for the storage system are priced for reduced air
volumes, with cooling coilsselected to provide the reduced supply temperatureswith
glycol secondary coolant.
The utility incentive is based on a payment of $150 per kilowatt of on-peak demand
reduction. The estimated demand reduction is 1280 kW for chillers, 498kW for air
distribution fans, and 339 kW for pumps, for a total reduction of 2117 kW.
The total first cost savings for thecool storage system is over $400,000. This example
illustrates the potential for significant first cost advantages for cool storage in some
applications.
7 Off
8 0if
9 Off
10 Off
11 Off
12 Off
13 Off
14 On
15 On
16 On
17 On
18 On
19 On
20 On
21 On
22 Off
23 Off
24 Off
Table 10-19 Design Day Energy Consumption for Chilled Water Storage Campus Example (St Units)
1 Off
2 Off
3 Off
4 Off
5 off
6 off
7 off
8 Off
9 Off
10 Off
11 Off
12 Off
13 Off
14 On
15 On
16 On
17 On
18 On
19 On
20 On
21 On
22 Off
23 Off
24 Off
10-52 Design Guide for Cool Thermal Storage
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
On
Off
Off
Off
Annual analysis is based on storage system savings for seven months of the year,
since in this system, absorption chillers handle much of the load during winter
months, and savings from storage system operation are expected to be small.
Since the storage capacity is small compared to the total load, assumethat the storage
system will be fully used every day of the analysis period. Therefore, the amount of
energy shifted to off peak will be the same for every day, and the annual energy
consumption is calculatedby multiplying the design day performance by the number
of days. Table 10-21summarizes the annual utility costs for this example.
Design Procedure 10-53
Nonstoraee Storage
Demand
On-peak kW
Off-peak kW
On-peak kW savings
Energy
Monthly on-peak kW
Monthly off-peak kwh
Monthly $ savings
Summer
Winter
Annual $ savings
Power Rates. $
Summer Winter
Demand
On-peak 10.79 5.43 per kW
Economy 1 .03 1.03 per kW
Energy
On-peak 0.04337 0.04337 per kwh
Off-peak 0.02202 0.02202 per kwh
Notes:
Monthly $ savings is computed as the demand savings plus 30 times the daily energy
savings.
Annual $ savings is 4 months times the summer monthly savings plus 3 months times the
winter monthly savings.
10-54 Design Guide for Cool Thermal Storage
Although cool storage projects may be alternatively financed as leases, they are
primarily financed as cost reduction capital projects. As such, they must compete for
funding with other business projects requiring capital, such as equipment replace-
ments, capacity expansions, and environmental compliance measures.
Notes:
a 150%declining balance
2005 declining balance
36% corporate tax rate
* 12%discount rate
Design Procedure 10-55
A life-cycle cost analysis is far more sophisticated than payback analysis, which
measures the liquidity of a project rather than its profitability. A life-cycle cost
analysisuses the results of the first cost and operatingcost analysesdiscussedearlier.
The lifecycle cost analysis of the example chilled water storage project is summa-
rized in Table 10-22. The IRR of this project is 27.4%. The IRR is determined as
follows.
Total
The capital expenditure in retrofit applications is the gross project cost. 'In new
construction, the capital expenditure is the cost differentialbetween the cool storage
system and a comparable nonstorage cooling system.
The book life or useful life of a cool storage system ordinarily exceeds 10 years. To
optimize cash flow, a shorter tax or economic life is used and accelerated tax
depreciation is applied. This has the effect of deferring income taxes to the latter
years of the project, when the time value of money is much lower.
The annual savings and operating expenses for cool storage are determined relative
to those of the existing conventional cooling system in retrofit applications, or
relative to a comparable non-storage cooling system in new construction applica-
tions.
The after-tax cashflow is the sum of after-tax profit and tax depreciation. Here, the
shorter economiclife andacceleratedtax depreciationincreasecash flow in the early
years of the project, when the time value of money is much greater.
If more than one alternative has been analyzed through the detailed sizing and
economic evaluation phases, a final selection of the preferred option is made. Any
appropriate revisions in operating parameters are made, and equipment selections
are verified by a final sizing simulation.
The design operating profile should be included in the design documents. This
information helps clarify the design intent and is necessary for the performance
evaluation phase of commissioning.
The operating profile must be part of the design documents in projects where it is
necessary or desirable to allow for bids on several alternative storage technologies,
or where it is not certain that the specific storage type used as the basis of design will
be part of the successful bid package. Specifications should clearly state that the
storage system supplied must meet the design load profile; they should also indicate
how the storage system must interface with the building distribution system.
Design Procedure 10-57
Design documents must also include complete specifications for system control
sequences during both full-load and partial load conditions. For example, specify
which pumps must start or stop, which valves must open or close, and how chiller
setpointsare to be reset when the cooling strategy changes. Specify how the control
logic will initiate changes in cooling strategy. State how the final chilled water
supply temperature setpoint is to be controlled.
Under partial load conditions, will the system run with storage priority or chiller
priority control? For storage priority sequences, how will storage discharge be
controlled to maximize use of storage while ensuring that the load of each hour will
be met? How will operating schedulesbe modified with seasonal changes in utility
rate schedules?A completecool storage design considers all these questions, and the
answers should be specified in the design documents.
10.9 COMMISSIONING
Commissioning is often thought of as primarily involving system startup and
performancetesting. However, the complete commissioning process, as outlined in
ASHRAE's Guidelinefor Commissioning HVAC Systems (ASHRAE 1989)encom-
passes the entire project from the predesign phase through the system's first year of
operation. This commissioning process is described in detail in Section 2.9.
Redesign pbase
Participate in developing commissioningplan framework and forming commis-
sioning team.
Design phase
Participate in developing commissioning plan details. Review design concepts
and details with commissioning authority. Incorporate commissioning plan in
specifications.
Construction phase
Participate in coordinating trades and reviewing work in progress, or provide
assistance to commissioning authority.
10-58 Design Guide for Cool Thermal Storage
Startup phase
Observe startup activities, review startup reports, or assist commissioning
authority.
Operator training
Develop training program, train personnel, or provide assistance to commis-
sioning authority.
Performance testing
Coordinate or observe performance testing, provide assistance to commission-
ing authority.
REFERENCES
These conversions are for those units most commonly encountered in cool storage
design. Additional information and conversions for other units are given in the
ASHRAE publication. SI for HVAC&R (1992).
Volume
Storage volume
Velocity
A-2 Design Gulde for Cool Thermal Storage
50,000 --
-
-
- 100,000
10,000 -1
- 50,000
5,000 --
-
-
10,000
1,000 -I
- 5,000
500 --
-
-
- 1,000
100 - 748.2
kW1ton COP
-
Generics
A.OOOO Jun 1986 The Case for Thermal Storage
A.1000 Jun 1986 The Generics of Cool Storage
A.3005 Mar 1992* Manufacturers of Cool Storage Products
A.4000 Mar 1989 Cool Storage Engineers and Consultants
A.4001 Jun 1989 Cool Storage Engineers and Consultants (continued)
A.4002 Dec 1989 Cool Storage Engineers and Consultants (continued)
A.4004 Nov 1991 Conservation and Environmental Benefits of CS
A.4005 Ju1 1992* Consolidated Listing of Engineers and Consultants
Index Nov 1992* Index-Technical Bulletins through November 1992
Utility Perspectives
B .2000 Jun 1986 Electric Load Curve Impacts
B .3000 Jul 1986 Potential Impact of Cool Storage Technology
B A006 Feb 1992* Utility Inducement Programs for Cool Storage
B.5003 Sep 1992* Utility Cool Storage Contacts
Ice Storage
C.2000 Nov 1986 Ice Storage Systems
C.2010 Jun 1987 System Sizing and Control Strategies
C.2301 May 1987 Ammonia for Air Conditioning-A Case Study
C.2500 Feb 1987 Calculation of Electric Loads with Ice
C.2501 Sep 1987 Calculation of Elecbric Loads with Ice
C.2502 Jan 1987 Equipment Operating Efficiencies and Demand
C.2600 Mar 1987 Cool Storage Replacing Rooftop Packages
C.2610 Jul1989 Cool Storage Retrofit of Rooftop Units
C.2620 May 1990 Retrofitting Split-DX Systems to Cool Storage
C.2621 Apr 1992 Retrofitting Split-DX Systems to Cool Storage -
A Case Study/Part Two
C.2630 Jun 1990 Test Demonstration of Retrofit Rooftop Storage
C.2631 Apr 1991 Test Results of Retrofit Rooftop Cool Storage
C.2632 Oct 1992 Lennox's Cool Thermal Energy Storage System
for Unitary Air-conditioning
C.2700 Mar 1991 Ice Storage Design for Los Angeles County Jail
C.2701 May 1991 Taipei World Trade Center Office Building
C.2702 Jul 1991 Best Products Corporate Headquarters Building
Advanced Research
J.0001 Sep 1986 Summary of Papers-2lst IECE Conference
J.0002 Dec 1990 Biological Ice Nucleators and Enhanced
Cold Thermal Storage
Industrial Applications
K.lOOO Mar 1987 Low Temperature Storage for Industry
K.lOO1 Aug 1987 Thermal Energy Storage for Vacuum Precoolers
Appendlx 6: Technical Bulletins by Subject Matter 8-3
K.1002 Sep 1989 Wet Air Cooling of Vegetables and Fruit with TES
K.1002 Oct 1989 Industrial Thermal Storage
K.1003 Feb 1990 Cool Storage for Industrial Applications
K.1004 Mar 1990 Cool Storage for Industrial Applications
K.1005 Aug 1991 TU Electric-Industrial Storage Case Histories
Residential Applications
L.0000 Aug 1986 Market Constraints for Residential Storage
L.1000 Dec 1987 Solving the Residential Storage Puzzle
L.1210 Dec 1988 Three-Function Thermal Storage Heat Pumps
L.1100 Nov 1989 Residential Cool Storage Equipment Status
L. 1220 Jan 1990 Electric Load Impacts of SMUD Tests on
Phenix System
Water Treatment
N.lOOO Mar 1988 Water Technology in Thermal Storage System
Environmental Considerations/Refrigerants
0.1000 Oct 1988 The Impact of CFC Refrigerant Production
0.1001 Jun 1992 1992 EPA CFCmCFC Emissions Control Mandates
0.1002 Aug 1992 Characteristics of Ammonia as Cool
Storage Refrigerant
Specific heat
Water at 68°F (20°C)
Water at 50°F (lO°C)
Water at 32°F (0°C)
Ice at 32'F (0°C)
Ice at -4OF (-20°C)
Thermal conductivity
Water at 6S°F (20°C)
Ice at 32OF (0°C)
Mass density
Water See Table C-3
Ice 57.5 lblft3 (920 kg/m3)
This appendix &fines terms commonly encountered in cool storage design. Addi-
tional definitions may be found in the ASHRAE Terminology of Heating, Refriger-
ating, and Refrigeration.
charging storing cooling capacity by removing heat from a cool storage device.
charging cycle the period of time during which a cool storage system goes through
a complete sequence of charging and discharging storage.
chiller priority control strategy for partial storage systems that uses the chiller to
directly meet as much of the load as possible, Storage is used to supplement
chiller operation only when the load exceeds the chiller capacity.
demand limiting a partial storage operating strategy that limits the capacity of the
refrigeration equipmentduring the on-peak period, The refrigerationequipment
capacity may be limited based on its cooling capacity,its electric demand, or the
facility demand.
design load profile the hour-by-hour sequence of cooling loads over a complete
charging cycle, that must be met by a cool storage system.
discharge capacity total amount of usable cooling discharged from storage during
a single cycle.
electric power demand charge part of an electric bill based on maximum kilowatt
demand during specified demand periods.
external melt ice-on-coil ice storage technology that forms ice by refrigerant or
secondary coolant circulating within tubes or pipes, and melts ice by immersion
in circulating water.
facility demand the total electric demand for an entire building or multi-building
facility.
full storage (load shifting) a cool storage operating strategy that meets the entire
on-peak cooling load from storage.
ice harvester machine that manufactures ice on a cooling surface, then delivers it
to storage.
ice-on-coil (ice-on-pipe) ice storage technology that forms and stores ice on the
outside of tubes or pipes.
internal melt ice-on-coil ice storage technology that forms and melts ice by a
secondary coolant circulating within tubes or pipes.
latent storage capacity energy stored by the change of phase of a storage medium
load leveling apartial storage operating strategy that operates with the refrigeration
equipment running at full capacity for 24 hourson thedesign day. When theload
is less than the chiller output, the excess cooling is stored. When the load
Terminology 0-3
mid-peak period for some utilities, the time of day when utility billing rates for
electric demand, energy, or both are between those for on-peak and off-peak
periods.
nominal storage capacity storage capacity of a cool storage device, as rated by the
storage device manufacturer. Compare discharge capacity.
off-peak period time of day during which utility billing rates for electric demand,
energy, or both are reduced.
on-peak period time of day during which acool storage system must reduce electric
power demand. This period may or may not be coincident with the utility on-
peak period, which is the time of day during which billing rates for electric
demand, energy, or both are increased.
partial storage a cool storage operating strategy that meets a portion of the on-peak
cooling load from storage, with the remainder of the load met by operation of the
chilling equipment. Partial storage operating strategies can be further subdi-
vided into load leveling and demand limiting operation.
peak cooling load the highest instantaneous load that must be met by the cooling
plant.
ratchet a utility billing mechanism by which the demand charge for the current
month is based on the higher of two possibilities: either the peak demand for the
present month or a percentage of the highest demand incurred during any of the
previous 12 months.
storage priority control strategy for partial storage systems that uses stored cooling
to meet as much of the load as possible. Direct cooling is supplied by chillers
only if the daily load exceeds the total stored cooling capacity.
storage thermal efficiency ratio of the integrated discharge capacity to the total
cooling added to storage for a single cycle.
stratified chilled water storage a cool storage technology that achieves and
maintains separation between warm and cool water by density differencesalone,
and not by mechanical separators.
thermal storage device container plus all the contents of the container used for
storing thermal energy. The transfer fluid and accessories, such as heat
exchangers, agitators, circulating pumps, flow-switching devices, valves and
baffles that are integral with the thermal storage container are considered part
of the storage device.
total cooling load the integrated load that must be met by the cooling plant over a
given period of time.
usable cooling cooling capacity supplied at or below the maximum usable cooling
supply temperature.