Central Plant Water Chiller Optimization 259

Chapter 16

Central Plant
Water Chiller Optimization

o determine if the central plant can be optimized, the first step is

T to conduct an energy survey and testing of the system’s operat-

ing performance. The second step is to consider the options. For
example, is it more cost effective to decrease chilled water supply tem-
perature creating a higher delta T, reducing pumping horsepower but
increasing compressor horsepower, or is it better to increase chiller water
supply temperature creating a lower delta T, increasing pumping horse-
power but decreasing compressor horsepower? The third step to any
proposed retrofit is to consider the consequences of the retrofit before
starting the project.

OPTIMIZATION

The following are some ways to optimize the chiller plant:

Select Proper Air Quantities and

Heat Transfer Surfaces for the Cooling Coils
Selecting proper air quantities and heat transfer surfaces for
the cooling coils can substantially reduce circulating water quan-
tities. Consider installing coils suited for a higher water tempera-
ture rise. For example, a 12°F (2 gpm per ton) rise rather than a
10°F rise (2.4 gpm/ton) reduces circulated water quantity by 17
percent and can reduce pump horsepower by 42 percent. How-
ever, a cooling coil with a higher ∆T needs to be larger. There may
also be an increase in air pressure drop through the coil that

259
260 HVAC Fundamentals

would slightly increase the fan horsepower. Cost of operation of

a motor per year is equal to the horsepower times 0.746 kilowatts
per horsepower times the hours of operation per year times the
cost per kilowatt-hour divided by the efficiency of the motor. The
equation is

($/yr = hp × 0.746 kW/hp × hrs/yr × $/kWh ÷ Effm)

Raise the Evaporator Temperature

As evaporator temperature and chilled water temperature
increase, the COP of the system also increases and the power used
by the compressor decreases. The equation for this is: HP/Ton =
4.71 ÷ COP [the horsepower per ton required to run the compres-
sor motor is equal to the constant 4.71 (200 Btu/min/ton ÷ 42.42
Btu/min/hp) divided by the system’s COP (Coefficient of Perfor-
mance)]. One way to increase evaporator temperature is to raise
supply air temperature to follow the building’s cooling load. Ex-
ecuting this task requires retrofitting the control system to raise
supply air temperature when the building cooling load permits
and then raise chilled water temperature to meet the lighter cool-
ing load. Raising the chilled water temperature increases the
evaporator temperature. To accomplish this control strategy,
chilled water control valves are monitored. When chilled water
control valves are closed or partially open (indicating that the
water flow is reduced to match the light load condition), the
chilled water supply temperature setpoint is raised. When one or
more of the coil control valves return to the full open position to
try to match a heavier load, the flow to the coils is increased and
the supply water temperature is lowered.

Lower Condenser Water Temperature

As the condenser temperature decreases, the COP of the
compressor increases and the power used decreases (HP/ton =
4.71 ÷ COP). One way to decrease condenser temperature is to
decrease the temperature of the water entering the condenser.
However, because there practical limits to the lowest acceptable