t4s2 Chilled Water System Optimization PDF

POWERFUL BUSINESS
“Facing a Dynamic Energy Future ”
CHILLED WATER SYSTEM

OPTIMIZATON
Presented by
David A. Rogers, P.E

Harold A. Hougham, P.E.
CHILLED WATER SYSTEM OPTIMIZATON
ENGINEERING APPLIED TO
OPERATIONS
(Retro Commissioning)
THE CONCEPT
SYSTEM FUNDAMENTALS
THE PROCESS
THE RESULTS
THE CONCEPT
SYSTEM FUNDAMENTALS
THE THREE RULES FOR HYDRONIC

SYSTEMS OPTIMIZATION
PUMP LESS WATER
PUMP LESS WATER
PUMP LESS WATER

“Distribution System DELTA T
Drives the Plant (s)”

Syllabus
Systems Concepts
Simple Formulas
Rules of Thumb
System Configurations
Hydraulic Profile
System Components
Delta T
Flow Limited Plant
How your System works – Now/Optimized
Systems Concepts
A system is a group of components

that when connected and operating
provide a desired result.
Systems Concepts
Production Distribution Load

Systems Concepts
Pumps
Chillers
Pumps
Load
Cooling Tower
Systems Concepts
Chilled Water System
Secondary Pumps
Chillers
Data & Controls
Decoupler
Production Distribution
System System
Load
Primary Pumps
Simple Formulas
Chilled Water Delta T = T return water - T supply water
GPM/TON = 24/Delta T
Pump Affinity Laws = Q1/Q2=N1/N2

H1/H2=(Q1/Q2)2
BHP1/BHP2=(Q1/Q2)3
Q = Flow, N = rpm, H = Head
BHP = Brake Horsepower

Simple Formulas
Chilled Water Delta T
Control Valve
CHWR T = 60oF Cooling Coil
CHWS T = 42oF
Chilled Water Delta T = T return water – T supply water
Chilled Water Delta T = 60 – 42 = 18 degrees.
Simple Formulas
GPM/Ton = 24/Delta T
How many tons of cooling are served by a 6,000 gpm/12
degree delta T distribution system?
GPM = 6,000
Delta T = 12 degrees
24/Delta T = 24/12 = 2 GPM/Ton
Tons Cooling = GPM/(24/Delta T) = 6,000/2 = 3,000 tons
HOW MANY CHILLERS DO I HAVE ON LINE TO SERVE THIS

3000 TON LOAD?
Simple Formulas
Pump Affinity Laws
Pump Affinity Laws can be used to estimate system performance
but should be modified to reflect system performance.
What is the approximate required pumping horsepower if I
cut system flow in half while still serving the same cooling
load?
10,000 GPM requires 240 BHP
5,000 GPM requires ? BHP.
Q1 = 10,000 GPM, Q2 = 5,000 GPM, BHP1 = 240
BHP2 = BHP1(Q2/Q1)3 or BHP2 = 240(5,000/10,000)3 = 240/8 ≈ 30 BHP

Rules of Thumb
•Water Always Flows from a Higher Pressure to a Lower Pressure.
•Minimum Delta P for a control valve = 5 psig
•Minimum Delta P for a Bldg Interface = 20 psig
•Distribution System Delta T should always be ≥ Production System

Delta T
•Production System Delta T should always be < Chiller Delta T

Rules of Thumb
Minimum Delta P Across a Control Valve is 5 psig
Control Valve
P3= 11 psig P1= 18 psig

Cooling Coil
Delta P = 18 – 11 = 7 psig
WHAT HAPPENS IF DELTA P IS ZERO?

Rules of Thumb
Minimum Delta P Across a Building Interface is 20 psig
Pressure Compensating Control Valve
Pout= 18 psig
Building
Pin= 40 psig
Delta P = 40 – 18 = 22 psig
WHAT HAPPENS IF DELTA P IS 10 PSIG?

Rules of Thumb
Distribution System Delta T should always be ≥ Production System Delta T
TPS=42oF TDS=42oF
Chillers
Secondary Pumps
System System
Load
TPR=56oF
TDR=58oF
Primary Pumps
Distribution Delta T = 58 – 42 = 16 degrees

Production Delta T = 56 – 42 = 14 degrees
Rules of Thumb
Production System Delta T < Distribution System Delta T
Load
Chiller % Production Production Distribution Delta
in
Load CHWR Delta T CHWR T
Tons
2000 100 58 16 58 16
1800 90 56.4 14.4 58 16
1600 80 54.8 12.8 58 16
800 40 48.4 6.4 58 16
Rules of Thumb
Production System Delta T should always be < Chiller Delta T
0.75
0.7
0.65
CHILLER 3
KW/Ton
CHILLER 4&5
CHILLER 6&7
0.6
0.55
0.5
20 30 40 50 60 70 80 90 100
% Full Load
System Configurations
• Primary/Secondary – Constant Flow/Variable Flow
• Primary Only – Constant Flow
• Variable Primary Flow (VPF) – Variable Flow
• Multiple Plants/Common Distribution Loop
–Plant 1 – Primary/Secondary
–Plant 2 – Primary Only
–Plant 3 –Primary/Secondary
Primary/Secondary
Constant Flow/Variable Flow
Chillers
Secondary Pumps
System System
Load
Primary Pumps
Primary Only
Constant Flow
Chillers
Secondary Pumps
Distribution
Production
System
System
Load
Primary Pumps
Variable Primary Flow
Variable Flow
Chillers
Production/
Distribution System
Production/ Load
Distribution Pumps
Multiple Plants on a Common
Distribution Loop
Hydraulic Profile
A graphical representation of the
dissipation of system head.
Ft of Head
Distance
Hydraulic Profile
Primary/Secondary System
Ft of Head
Hydraulic Profile
Two Plants Common Distribution Loop
Ft of Head
Hydraulic Profile
The Hydraulically Most Remote Point
Hydraulically most remote

point & location of VFD DP
sensor
Ft of Head
Physically most remote point
Distance
Hydraulic Profile
Building System/Hydraulically Most Remote Point
Ft of Head
System Components
• Chillers
• Cooling Towers
• Pumps
•Control Valves/Cooling Coils
Chillers/Cooling Towers
Chiller Performance
COP = Output/Input
COP = Q4-1/W1-2
Q2-3 = m(h2 – h3)
Point 3 Pressure = C Point 2
Pressure
h3 = h4
LIFT
Q4-1 = m(h4 – h1)

Pressure = C W1-2 = m(h2 – h1)
Point 4 Temperature = C
Point 1
Compressor
P-1 Work
Enthalpy
Cooling Tower Performance
Entering Condenser Water 95
degrees
Range 95 – 85 = 10 degrees
Leaving Condenser Water 85

degrees
Outside Air Wet Bulb Temperature Approach 85 – 76 = 9 degrees

76 degrees
Cooling Tower Performance
2.5
Constants
Heat Load
2.0
Range
Tower Size Factor
Wet Bulb
1.5
1.0
0.5
5 10 15 20 25 30
Approach
Pumps
How They Work

Arrangements
Pumps – How They Work


B Outlet Tip of Impeller
C Vane
A
Pressure B C
Inlet Tip of
Impeller Vane
A
Centrifugal Pump
Velocity
Suction Discharge
Flow Path
NPSH = Net Positive Suction Head
B Outlet Tip of Impeller

C Vane
A
Pressure B C
A
Centrifugal Pump
Collapsing x
Bubbles x Velocity
x
x
Vapor
Bubbles
Suction Discharge
Pump Impeller Blade Flow Path
Typical Pump Curve
Variable Frequency Drives
Variable Speed Pump Curves
Head Ft.
Pumping Arrangements
Head Ft.
Cooling Coil/Control Valve
Configurations
How They Work

Configurations
CONTROL VALVE
CHWR 56+ degrees
Leaving Air 55 degrees Entering Air 70 degrees
Delta T: 56 – 42 = 14
COOLING COIL
degrees
CHWS 42 degrees
How They Work
“Control Valves Waste Energy”
Ft of Head
How They Work
Actuator Arm Connected
to the Valve Shaft
Valve Shaft
Valve Disc Not Fixed
FLOW
Valve Seat Fixed

How They Work
Delta T
• Difference between CHW Return & CHW Supply
and Chilled Water Supply Temperatures
Delta T = TCHWR - TCHWS
Q = C x GPM x Delta T
• For the same Q if delta T is low then GPM
is high & if delta T is high then GPM is low!
5,000,000 Btuh = C x 1000 gpm x 10 F
= C x 500 gpm x 20 F
Low Delta T / Flow Limited Plant
2,000 Ton Chillers, 14 degree
delta T, 3,429 gpm each Secondary Pump P-2,
Variable Flow 42 degree CHWS
Chiller
Load
Chiller Typical
Distribution
Chiller Loop Pressure
Production Decoupler Compensating
Loop Valve Typical
Load in Production On Line Percent Distribution Distribution Dist.

Tons Gpm Tonnage Loaded Gpm CHWR Delta T
2000 3429 (1)2000 100 3429 56 14

2000 6858 (2)4000 50 4000 54 12
2000 6858 (2)4000 50 6000 50 8
2300 10287 (3)6000 38.3 6900 50 8
Delta T Flow Limited Plant
CENTRIFUGAL CHILLER EFFICIENCIES
0.75
0.7
0.65
CHILLER 3
KW/Ton
CHILLER 4&5
CHILLER 6&7
0.6
0.55
0.5
20 30 40 50 60 70 80 90 100
% Full Load
Delta T Flow Limited Plant
Estimated Annual Part Load Chiller Savings
due to Increased Efficiency for non Flow
Limited Operations
• Flow limited average kw/ton = 0.55
• Non flow limited average kw/ton = 0.523
• Annual average part load = 2000 tons
• Annual part load hours of operation = 8,000
• Cost of electricity including demand = $0.14
• Estimated annual part load chiller
savings due to increased efficiency
of operation =
(0.55-0.523)(2000)(8000)(0.14) = $60,480
High Delta T / Full Load Plant
2,000 Ton Chiller, 14 degree
delta T, 3,429 gpm Secondary Pump P-2,
Variable Flow 42 degree CHWS
Chiller
Load
Typical
Loop Loop Pressure
Compensating
Decoupler
Valve Typical
Load in Production Production Percent Distribution Distrib. Dist.

Tons Gpm CHWR Loaded Gpm CHWR Delta T
2000 3429 56 100 3429 56 14
2000 3429 56 100 3000 58 16
2000 3429 56 100 2667 60 18

High Delta T / Part Load Plant
Load in Production Production Percent Distribution Distrib. Dist.

Tons Gpm CHWR Loaded Gpm Gpm Delta T
2000 3429 56 100 3429 56 14
1800 3429 54.6 90 2700 58 16
1800 3429 54.6 90 2400 60 18
1600 3429 53.2 80 1920 62 20

Chilled Water Cost Variables
Variables Constants
Average Annual Cooling Load 4,500 Tons Flow 500

Electric Chiller/Tower/Condenser & Production Pumps 0.9 Kw/Ton Ton 12000 Btuh
Absorption Chiller/Tower/Condenser & Production Pumps 0.3 Kw/Ton Power 0.746 Kw/Hp
Distribution System Delta T 11 Degrees F Max Speed 60 Hz
Cost of CHP Electrical Power $0.065 $/Kwh GPM/Ton 24
Power Factor 0.9 System Curve Constant 0.8
Pump Efficiency 0.87 MM 1,000,000
Pump Design Flow 15000 GPM
Pump Design Head 155 Ft
Pump Hp 750 Hp Assumptions
Electric Chiller Capacity 2000 Tons
Absorption Chiller Capacity 1385 Tons Absorption Chillers are always lead chillers
Number of Electric Chillers 1 Electrical Cost includes all byproduct burdens
Number of Absorption Chillers 2 Building Pumping is not considered a CHP operatio
Electric Chillers 12 Delta T
Absorption Chillers 16 Delta T
Costs not Included

Calculations
Capital Funding
Distribution Flow 9818 GPM Sinking Funds
Distribution Pump Hp each 210 Hp Load Flow Administrative
Distribution Pumping Kw each 200 Kw
Absorption Chillers Operating 2 2
Electric Chillers Operating 1 2
Number of Distribution Pumps Running 1
Percent rpm each pump 65%
Annual Average Cost of Cooling $5.57 $/MMBtu
Electric Chillers Flow 4000 GPM
Absorption Chillers Flow 2078 GPM
How does your System work Now ?
Existing Distribution System Maximum Delta T = ??

degrees
Existing Distribution System Average Delta T = ?
degrees
Chillers – Staging?
System Pumping Energy – Optimized or not
Optimized? (Control Delta P)
How should your System work

when Optimized?
Optimized Maximum Delta T = ?? degrees
Optimized Average Delta T = ?? degrees
Chillers – Staging ??
System Pumping Energy – Optimized or not
Optimized ??
THE PROCESS
Step #1
Chilled Water Systems Questionnaire
for Initial System Evaluation
SYSTEM DATA
ROI
Step #2
Pre Project Staff Training
Step #3
Pre Project Measurement & Verification (M&V)
Data Historian/Sensors Project ?
BEFORE AFTER
Step #4
Chilled Water System Engineering
Evaluation & Analysis
750 HP; 14,000 GPM; 8o∆ T;
800
Pumping HP
700
600
500
400
300
200
100
0
10
12
14
16
18
20
22
24
8
System Delta T
Step #5
Report of Findings and Recommendations
ROI
Step #6
Implement Chilled Water System
Optimization Construction Project
Step #7
Commission Chilled Water System
Optimization Project
Step #8
Post Project M&V for Rebate Verification
BEFORE AFTER
Step #9
Post Project Staff Training
THE RESULTS
The University of California

Davis Medical Center,
Sacramento
UCDMC
1. 3,000,000 square feet Trauma
Center/Hospital/Clinic & Educational Buildings.
2. 26 MW CHP w/ Primary/Secondary 16 degree
plant serving a 12 degree campus.
3. Each building was decoupled and pumped.
4. Average distribution system delta T was 8
degrees. Maximum delta T was 11 degrees.
Results
Operations
1. 18 degree distribution system delta T w/ 114
degrees outside air temperature.
2. Central plant spare distribution pump and chiller
capacity.
3. Some buildings performing in excess of 20 degree
delta T.
4. Average system delta T is 12 degrees.
Results
Financial
1. Financial data not available due to lack of system
instrumentation.
Energy
2. Energy data not available due to lack of system
instrumentation.
Lessons Learned
1. Create a system optimization sensor project to
facilitate data acquisition for pre & post project
M&V.
2. Provide pre project staff/management training
to facilitate a coordinated effort for all parties.
3. Develop a detailed Site Acceptance Test for
control valve commissioning.
BIOTECHNICAL CORPORATION
Biotechnical Corp
1. 3,000,000 square feet of R&D, Office & Production
across 25 buildings.
2. Three Central Plants on common distribution loop,
14,100 ton installed capacity.
3. Delta T performance was 6 degrees part load and a
maximum of 11 degrees at full load.
4. A 14 degree campus.
Results
Operations
1. Achieving distribution loop 20 degree Delta T @
full and part load.
2. Maximum flow distribution pumping requires 3 and
not 4 operational pumps
3. Delayed major capital infrastructure expansion
project for 3 years due to optimizing use of
existing infrastructure.
Results
Financial
1. Financial data not available due to lack of
system instrumentation.
Energy
1. Energy data not available due to lack of
system instrumentation.
Lessons Learned
1. Discovered other system issues that were masked
by poor system performance; Damper Failures,
Sensor Calibration, etc.
2. Train installing controls contractor on Systems
Optimization Concept and Process.
3. Verify AHU isolation valve arrangement and function
prior to issuing contract requiring continued system
operation during construction.
The University of Iowa
Hospital and Clinics

UIHC
1. 4,000,000 square feet of contiguous hospital/clinic
space between five buildings.
2. Central Plant metered and billed for each building.
3. Each building is decoupled and pumped.
Results
Operations
1. Resolved low chilled water pressure & flow to
Operating Room Air handlers.
2. Resolved condensation issue on cooling panel
ceilings in patient rooms.
3. Removed tertiary building pumps and reduced
operation of building pumps
Results
Financial
1. Savings $2,800,000 for the last 2 cooling seasons
primarily from penalty reduction.
2. Chilled Water billing based on building flow and an
assumed Delta T of 16 Degrees.
Results
Energy
1. Original simple payback estimate 5 years.
2. System instrumentation was not adequate to
measure actual energy reduction.
Lessons Learned
1. Building system instrumentation not adequate
to provide M&V for energy consumption.
2. Building system energy savings and
production/distribution billed savings are not
the same number.
3. Production/distribution system billed savings
represented a simple payback of less than 9
months.
dave@ra-solutions.com
harold@ra-solutions.com
www.ra-solutions.com

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POWERFUL BUSINESS

“Facing a Dynamic Energy Future ”

CHILLED WATER SYSTEM

David A. Rogers, P.E

THE THREE RULES FOR HYDRONIC

PUMP LESS WATER

PUMP LESS WATER

PUMP LESS WATER

“Distribution System DELTA T

Drives the Plant (s)”

A system is a group of components

Production Distribution Load

Data & Controls

Pump Affinity Laws = Q1/Q2=N1/N2

Q = Flow, N = rpm, H = Head

BHP = Brake Horsepower

CHWR T = 60oF Cooling Coil

24/Delta T = 24/12 = 2 GPM/Ton

Tons Cooling = GPM/(24/Delta T) = 6,000/2 = 3,000 tons

HOW MANY CHILLERS DO I HAVE ON LINE TO SERVE THIS

5,000 GPM requires ? BHP.

Q1 = 10,000 GPM, Q2 = 5,000 GPM, BHP1 = 240

BHP2 = BHP1(Q2/Q1)3 or BHP2 = 240(5,000/10,000)3 = 240/8 ≈ 30 BHP

•Minimum Delta P for a control valve = 5 psig

•Minimum Delta P for a Bldg Interface = 20 psig

•Distribution System Delta T should always be ≥ Production System

•Production System Delta T should always be < Chiller Delta T

P3= 11 psig P1= 18 psig

WHAT HAPPENS IF DELTA P IS ZERO?

WHAT HAPPENS IF DELTA P IS 10 PSIG?

Distribution Delta T = 58 – 42 = 16 degrees

Hydraulically most remote

Physically most remote point

Q2-3 = m(h2 – h3)

Point 3 Pressure = C Point 2

Q4-1 = m(h4 – h1)

Leaving Condenser Water 85

Outside Air Wet Bulb Temperature Approach 85 – 76 = 9 degrees

How They Work

Pumps – How They Work

Pumps – How They Work

B Outlet Tip of Impeller

Cooling Coil/Control Valve

Cooling Coil/Control Valve

CHWR 56+ degrees

Leaving Air 55 degrees Entering Air 70 degrees

Valve Seat Fixed

Load in Production On Line Percent Distribution Distribution Dist.

2000 3429 (1)2000 100 3429 56 14

Load in Production Production Percent Distribution Distrib. Dist.

2000 3429 56 100 3000 58 16

2000 3429 56 100 2667 60 18

Load in Production Production Percent Distribution Distrib. Dist.

1800 3429 54.6 90 2700 58 16

1800 3429 54.6 90 2400 60 18

1600 3429 53.2 80 1920 62 20

Average Annual Cooling Load 4,500 Tons Flow 500

Costs not Included

How does your System work Now ?

Existing Distribution System Maximum Delta T = ??

How should your System work

The University of California

The University of Iowa