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Optimizing Central Chilled Water Systems: Kent W. Peterson, PE, FASHRAE P2S Engineering, Inc
Optimizing Central Chilled Water Systems: Kent W. Peterson, PE, FASHRAE P2S Engineering, Inc
Chilled Water
Systems
Kent W. Peterson, PE, FASHRAE
P2S Engineering, Inc.
kent.peterson@p2seng.com
Presentation Outline
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Foundation of Design
GOAL
Deliver CHW to all loads under various load
conditions as efficiently as possible
• Why look “outside the plant”?
• Understand how distribution system will
operate
• Understand how CHW ∆T will be effected by
dynamics of the systems connected
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Understanding Loads & Their
Impact on Design
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Chilled Water Plant Efficiency
• Operating kW/ton achievable in today’s
plants (includes chillers, cooling towers
and pumps)
• 0.5 - 0.7 Excellent
• 0.7 - 0.85 Good
• >1.0 Needs Improvement
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Understanding Hydronics
• The pumping system will be required to
operate under various load conditions
• Variable flow system differential
pressures throughout the system will
be dynamic
• Hydronic systems should be
hydraulically modeled to design or
troubleshoot complex systems
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Caution
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Total Pressure
System & Pump Curves
Total Flow
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Hydronic Fundamentals
Variable Flow System Dynamics
70
60
50
PRESSURE PSIG
30
20
10
0
PUMP CLOSE LOAD REMOTE LOAD
VFD
Load
Load
100 GPM 100 GPM
5 PSID 5 PSID
DP
5 PSID 5 PSID
28 PSID 2 PSID
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Hydronic Fundamentals
Variable Flow System Dynamics
70
60
50
PRESSURE PSIG
40
19 PSID 12 PSID 12 PSID
30
20
10
0
PUMP CLOSE LOAD REMOTE LOAD
Load
5 PSID 0 PSID
DP
5 PSID 12 PSID
2 PSID 0 PSID
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Hydronic Fundamentals
Variable Flow System Dynamics
70
60
50
PRESSURE PSIG
30
20
10
0
PUMP CLOSE LOAD REMOTE LOAD
Load
5 PSID 0 PSID
DP
5 PSID 38 PSID
28 PSID 0 PSID
BAD SENSOR
LOCATION
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Hydronic Fundamentals
Variable Flow System Dynamics
CONTROL VALVE ∆P
AT VARIOUS LOAD CONDITIONS
Branch ∆P 38 38 38 38 38
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Balancing Considerations
Variable Flow Systems
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Hydronic Pumping Conclusions
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What You Must Know
About CHW ∆T
CHW Temperature Differential
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Chilled Water Coil
Characteristics
Assumes Constant Load
CHW ∆T
CHW °F
∆T °F
CHWS
CHWS Temperature
Temperature °F
°F
Factors that Degrade ∆T
Assuming Coils are Selected for Desired ∆T
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∆T Conclusions
• Design, construction and operation
errors that cause low ∆T can be
avoided
• Other causes for low ∆T can never be
eliminated
• ∆T degradation below design
conditions is inevitable, therefore,
system design must accommodate the
level of degradation anticipated
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Chiller Fundamentals
Understanding Refrigerant Lift
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Centrifugal Chiller without VFD
1200T Low Pressure
KW/ton
Percent Loaded
Centrifugal Chiller with VFD
1200T Low Pressure
KW/ton
Percent Loaded
Centrifugal Chiller without VFD
1200T High Pressure
KW/ton
Percent Loaded
Centrifugal Chiller with VFD
1200T High Pressure
KW/ton
Percent Loaded
Centrifugal Chiller Comparison
High Pressure
KW/ton
Low Pressure
Percent Loaded
Constant Speed Variable Speed
Optimizing Plant
Performance
Primary-Secondary vs
Variable Primary Flow
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Primary-Secondary Variable
Flow
Part Load Operation - 6000 Ton Plant
∆P
1500 tons
Load
Load
OFF
54°F 42°F Load
VFD
42°F Load
1500 GPM
3000
3000Ton
TonLoad
Load
6000 GPM 58°F 4500 GPM
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Primary-Secondary Variable
Flow
Effect of Low CHWR Temperature
Low ∆T Syndrome
∆P
1500 tons
Additional chiller will need to be
started to maintain the secondary Load
CHWS temperature setpoint if
1500 tons load increases
Load
Loss of CHWS
temp control Load
OFF
54°F 42°F Load
VFD
44°F Load
1200 GPM
3000
3000Ton
TonLoad
Load
6000 GPM 52°F 7200 GPM
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Variable Primary Flow
Part Load Operation - 6000 Ton Plant
∆P
1500 tons
Load
Load
OFF
58°F 42°F Load
Load
VFD
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Variable Primary Flow
Effect of Low CHWR Temperature
∆P
1500 tons
Load
Load
OFF
54°F 42°F Load
Load
VFD
CLOSED 3000
3000Ton
TonLoad
Load
6000 GPM
FM
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Series Arrangement
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Series versus Parallel
With High Lift Requirement
0.60 KW/ton
56°F 40°F
CH-1
56°F 40°F
56°F 40°F
CH-2
95°F 85°F
Parallel-Parallel
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Series versus Parallel
With High Lift Requirement
30 feet head increase on
condenser water would
result in 230 KW increase
0.555 KW/ton in pump power
0.52 KW/ton 0.59 KW/ton
Series-Counterflow
7% KW Reduction on Chillers
220 or
450 KW Reduction on 10,000 ton Plant
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Series versus Parallel
With High Lift Requirement
0.555 KW/ton
0.50 KW/ton 0.61 KW/ton
Series-Parallel
7% KW Reduction
or
450 KW Reduction on 10,000 ton Plant
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Optimize Heat Rejection
• Oversized cooling towers can decrease
approach to lower chiller lift
requirements and improve plant
KW/ton
• Approximately 1.5% chiller KW
reduction per °F lift reduction
Lowering CWS by from 95°F to 93°F
3% Chiller KW Reduction
or
180 KW Reduction on 10,000 ton Plant
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CHW ∆T
Option 1 Option 2
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Building Interface
Considerations
without Heat Exchangers
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Building Interface
Considerations
without Heat Exchangers
Building
Load Tertiary Loop
VFD
Building
Load
Boosted Secondary
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Control Design Issues
• Control strategies should consider
impact on complete system
• Aim to continually optimize COP for
entire system
• Reliable industrial-grade controls are
essential
• Keep it simple
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A Case for Metering
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Summary
• Understand parameters that affect
chiller plant and overall system
performance
• Optimize operation through equipment
selection and control sequences to
deliver CHW to all loads as efficiently
as possible throughout the year
• Commission plant
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Albert Einstein
“Everything
“Everything should
should be
be as
as simple
simple as
as possible,
possible,
but
but no
no simpler”
simpler”
“Insanity:
“Insanity: doing
doing the
the same
same thing
thing over
over and
and over
over
and
and expecting
expecting different
different results”
results”
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For More Information
• Join ASHRAE
• ASHRAE Self Directed Learning Course
“Fundamentals of Water System Design”
• ASHRAE 2004 HVAC Systems and Equipment
Handbook
• ASHRAE Transactions and Journal articles
• Hydronic System Design & Operation by E.G.
Hansen
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