1/6

If you can read this If you can read this

Click on the icon Click on the icon
to choose a to choose a
1/4
picture or picture or
Reset the slide. Reset the slide.
To Reset: Right click on the To Reset: Right click on the
slide thumbnail and select slide thumbnail and select
‘reset slide’ or choose the ‘reset slide’ or choose the
2/6 ‘Reset’ button on the ‘Home’ ‘Reset’ button on the ‘Home’
ribbon (next to the font ribbon (next to the font
choice box) choice box)

1/2

DC Plant Room Optimization

Can 0.77 ikW/TR be a Reality?
4/6

Nermeen Hammouda
3/4 General Manager - Applied Business, GCC

5/6 Deepak Bhat

Regional Manager - Large Tonnage Chillers, GCC

Johnson Controls — Johnson Controls at DC Dialogue 3rd Edition, 2019

 If you can read this Click on the icon
to choose a picture or
Reset the slide.

1/6
Agenda To Reset: Right click on the slide thumbnail and select
‘reset slide’ or choose the ‘Reset’ button on the ‘Home’
ribbon (next to the font choice box)

1/4
•  Green Box
2/6
•  Variable Speed Technology
Real Numbers ~ Real Value

•  Central Plant Optimization

1/2

4/6

3/4

5/6

If you can read this Click on the icon

to choose a picture or
Reset the slide.
To Reset: Right click on the slide thumbnail and select
‘reset slide’ or choose the ‘Reset’ button on the ‘Home’
ribbon (next to the font choice box)
Evaluate Report Propose Measure Sustain &
Execute
Feasibility Baseline Solution & Verify Maintain

Variable
•  Retrofit Existing chillers with Variable
Speed
Speed Drives
Drives
Central Plant •  Provide complete services of a CPO on
Optimization the existing control system

Johnson Controls at DC Dialogue 3rd Edition, 2019

Socio-environmental Impacts

Johnson Controls at DC Dialogue 3rd Edition, 2019 4

1/6
If you can read this If you can read this
Click on the icon Click on the icon
to choose a to choose a
1/4
picture or picture or
Reset the slide. Reset the slide.
To Reset: Right click on the To Reset: Right click on the
slide thumbnail and select slide thumbnail and select
‘reset slide’ or choose the ‘reset slide’ or choose the
2/6 ‘Reset’ button on the ‘Home’ ‘Reset’ button on the ‘Home’
ribbon (next to the font ribbon (next to the font
choice box) choice box)

1/2

DC Plant Room Optimization

Can 0.77 ikW/TR be a Reality?
4/6

Nermeen Hammouda
3/4 General Manager - Applied Business, GCC

5/6 Deepak Bhat

Regional Manager - Large Tonnage Chillers, GCC

Johnson Controls — Johnson Controls at DC Dialogue 3rd Edition, 2019

 Green Box technology adoption

[VALUE] 4242 1242

90% of Low Voltage Water # of Medium Voltage Variable # of Central Plant
Cooled Centrifugal Chillers in Speed Drives Sold to Date! Optimizers
GCC incorporate VSD ~ 65,000 TR ~12,000 TR

Johnson Controls at DC Dialogue 3rd Edition, 2019

Apprehension towards
Medium Voltage Variable Speed Drives

!  MV Variable Speed Drives are

expensive, with un-attractive payback

!  District Cooling Plants always operate at

Full Load Conditions

!  Use for Thermal Storage means the

chillers will always be operating at full
design load.

!  Chillers which are efficient at Full Load

(Design Conditions) are also the most
efficient throughout the year.

Johnson Controls at DC Dialogue 3rd Edition, 2019

Case Study – Real Data, Real Project!
! The Plant designed for 10 pairs x 5000 TR chillers, had 7 pairs of constant speed
chiller already installed.
! The 8th pair, was equipped with medium voltage variable speed drive centrifugal
chiller.

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR
CONDENSER

CONDENSER

CONDENSER

CONDENSER

CONDENSER

CONDENSER

CONDENSER

CONDENSER
03A 04A 05A 06A 07A 08A 09A 10A
VSD CSD CSD CSD CSD CSD CSD CSD
FUTURE FUTURE
EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR

EVAPORATOR
CONDENSER

CONDENSER

CONDENSER

CONDENSER

CONDENSER

CONDENSER

CONDENSER

CONDENSER
03B 04B 05B 06B 07B 08B 09B 10B
VSD CSD CSD CSD CSD CSD CSD CSD
FUTURE FUTURE

Johnson Controls at DC Dialogue 3rd Edition, 2019

Measurement & Verification

Post the retrofit activities, Client team collected the recorded data critical for
analysis. Amongst the critical parameters recorded, following are the most
important to calculate the performance of the chillers-

•  Entering Chilled Water Temperature (ECHWT), °F

•  Leaving Chilled Water Temperature (LCHWT), °F
•  Chilled Water Flow (CHWF), GPM
•  Entering Condenser Water Temperature (ECWT), °F
•  Leaving Condenser Water Temperature (LCWT), °F
•  Condenser Water Flow (CWF), GPM
•  Chiller Input Power Measure at Protection Relay (ikW), kW

The data collected has been processed and analyzed by JCI team to
compare the performance of constant speed chillers to that of variable
speed chillers. Basic engineering calculations and assumptions are
mentioned below

Johnson Controls at DC Dialogue 3rd Edition, 2019

Chiller Loading Pattern recorded at the DCP

Both VSD and

CSD pairs
were equally
loaded !
Performance Comparison
6000
VSD TR CSD TR

5500

5000
Load, TR

4500

4000

3500

3000
3/1/2019 0:00 3/11/2019 0:00 3/21/2019 0:00 3/31/2019 0:00 4/10/2019 0:00 4/20/2019 0:00 4/30/2019 0:00

Data Collected for 8 months. Data collection on going…

Johnson Controls at DC Dialogue 3rd Edition, 2019
 Power Consumption Pattern recorded at the DCP

Performance Comparison
VSD kW/TR CSD kW/TR

1.000

0.900

0.800

0.700

0.600
SEC, kW/TR

0.500

0.400

0.300

0.200

0.100
Consistently
3/1/2019 0:00
VSD Chillers
3/11/2019 0:00 3/21/2019 0:00 3/31/2019 0:00 4/10/2019 0:00 4/20/2019 0:00 4/30/2019 0:00

are better in
performance!
Data Collected for 8 months. Data collection on going…
Johnson Controls at DC Dialogue 3rd Edition, 2019
Tabulated Data
Sep-18 Oct-18 Nov-18 Dec-18
Description Units
CSD VSD CSD VSD CSD VSD CSD VSD
TR 4,493 3,585 4,728 4,038 4,900 4,583 4,858 4,347
Chiller Pair Delivered Capacity
% 90% 72% 95% 81% 98% 92% 97% 87%
Specific Power Consumption for the
ikW/TR 0.633 0.530 0.614 0.529 0.602 0.522 0.597 0.503
Chiller Pair (SEC)
Energy Consumption for Baseline
kWh 1,399,024 1,170,679 1,197,575 1,033,119 763,181 661,268 1,070,760 901,859
Capacity = Baseline Capacity x SEC
Estimated Energy Savings kWh 228,345 164,457 101,913 168,901
Estimated Monetary Savings AED 68,503 49,337 30,574 50,670

Jan-19 Feb-19 Mar-19 Apr-19

Description Units
CSD VSD CSD VSD CSD VSD CSD VSD
TR 4,174 4,039 4,047 3,645 4,195 3,809 4,380 3,912
Chiller Pair Delivered Capacity
% 83% 81% 81% 73% 84% 76% 88% 78%
Specific Power Consumption for the
ikW/TR 0.533 0.414 0.511 0.365 0.525 0.398 0.545 0.427
Chiller Pair (SEC)
Energy Consumption for Baseline
kWh 1,030,288 799,246 1,118,212 799,424 1,325,764 1,006,222 1,241,547 973,068
Capacity = Baseline Capacity x SEC
Estimated Energy Savings kWh 231,042 318,788 319,542 268,478
Estimated Monetary Savings AED 69,313 95,637 95,863 80,544

•  Chiller load on the plant varies between maximum of 90% and

Chillers
minimumwithofVariable
60% Speed Drive have now realistically recorded Annual
Average efficiency of 0.45 ikW/TR.
•  Condenser Water
First StepTemperature Variation’s
towards achieving 0.77are significant
ikW/TR thru the day
is REAL!
and thru seasons even in UAE.
Johnson Controls at DC Dialogue 3rd Edition, 2019
 Off Design Performance of Chillers

Estimated - Before Retrofit Actual Measure - Post Retrofit

% Chiller Load 65 F ± 1
80 F 75 F 70 F 65 F 80 F ± 1 F 75 F ± 1 F 70 F ± 1 F
F
Constant Speed 0.517 * 0.566 * *
100% Variable Speed 0.464 * 0.475 * *
% Difference -10.20% -16.10%
Constant Speed 0.555 0.518 0.485 0.589 0.553 0.503 *
90% Variable Speed 0.51 0.453 0.401 0.489 0.446 0.426 *
% Difference -8.10% -12.60% -0.173 -17.10% -19.30% -15.40%
Constant Speed 0.561 0.523 0.49 0.683 0.571 0.519 *
80% Variable Speed 0.504 0.445 0.391 0.503 0.445 0.398 *
% Difference -10.10% -15.00% -0.203 -26.30% -22.00% -23.30%
Constant Speed 0.499 * * 0.548 *
70% Variable Speed 0.51 0.444 0.384 0.332 0.516 0.437 0.4 0.344
% Difference -23.00% -27.10%
Constant Speed * * * *
60% Variable Speed 0.386 * * 0.374 *
% Difference
Input Specific Energy Consumption (SEC, kW/TR) at varying ECWT

Johnson Controls at DC Dialogue 3rd Edition, 2019

 Performance Comparison

CSD Vs VSD
600,000 6,000
Adjsuted baseline CSD AED Actual VSD AED CSD Avg TR

VSD Avg TR CSD Equi. Load Hrs. VSD Equi. Load Hrs.
500,000 5,000

EQUIVALENT LOAD HOURS

ELECTRICITY COST, AED

400,000 4,000
16.3%

AVERAGE TR
13.7% 24.4% 21.9%
300,000 3,000
15.9%
22.7% 28.8%

13.5%
200,000 2,000

100,000 1,000

- 0
Sep-18 Oct-18 Nov-18 Energy
Mar-19 Savings
Dec-18 Jan-19
Apr-19 Feb-19

in 8 months
Savings 68,503 49,337 30,817 51,006 70,271 96,614 101,972 85,833
~ 1.8M kWh
~ AED 554,353
Johnson Controls at DC Dialogue 3rd Edition, 2019
 Apprehension’s Mitigated !

!  MV Variable Speed Drives are !  MV-VSD costs and size, both have
expensive, with un-attractive reduced with improved technology and its
payback time to evaluate the payback

!  District Cooling Plants always !  DCP’s seldom see full Delta T. As such,
operate at Full Load Conditions chillers are loaded between 60% and
90%

!  Use for Thermal Storage
means the chillers will always
be operating at full design load.
!  Again, limited by the low Delta T. Also,
Thermal Storage Tank is always charged
at off peak conditions and hence at low
WB temp it will benefit most with VSD
technology.

!  Chillers must be evaluated for !  “Real” World conditions will always see
Full Load Efficiency at “Design” reduced ECWT’s and lower loads. Off
Conditions design performance of Chillers is critical.

Johnson Controls at DC Dialogue 3rd Edition, 2019

 But What’s the
Control Strategy ?

Johnson Controls at DC Dialogue 3rd Edition, 2019

Traditional Central Utility Plant Operations

Most plants are operated by:

"  Very talented plant engineers and

operators based on their past Chilled water
temperature Time to turn
experience & intuition is too high on another
chiller
"  Site-specific sequences of operation
based on IF>THEN rules
"  Highly conservative constraints
"  The manner that causes the fewest
complaints

Johnson Controls at DC Dialogue 3rd Edition, 2019

1/6

1/4

2/6

1/2

4/6

3/4

5/6 CENTRAL PLANT OPTIMIZATION

DATA DRIVEN BOTTOM LINE BENEFITS
18 Johnson Controls, Inc.
Johnson Controls at DC Dialogue 3rd Edition, 2019
 Truly minimizing utility cost while ensuring reliability

•  Staging of chillers, water side

economizers and cold
storage systems
Total System
•  Chilled water temperature set
Cooling Output points
Ton
•  Evaporator Flow
Management
Cooling Tower Condenser Chiller Vane Chilled Water Air Handler
Fan Speed Pump Speed & Speed Pump Speed Fan Speed •  Condenser water
temperature set points
•  Chilled water differential
pressure set points
•  Sequencing and speed
control of chilled water and
Total System condenser pumps
Energy Input
Power
•  Sequencing of cooling towers
and cooling tower fan speed
control

Johnson Controls at DC Dialogue 3rd Edition, 2019

Model Predictive Control (MPC) provides a math-based
and physics-based “classic optimization” approach vs
rules-based supervisory control

Controls the variables based on

sophisticated rules: Supervisory Control
•  Reset Sequences of AND Optimization
Operation
•  Iterative Step & Wait
•  Relational Control, and/or
•  Natural Curve Fit / Equal
Marginal Principle

Applies “classic” optimization
procedures with objective
functions (e.g. minimize cost)
Supervisory Control subject to constraints (e.g. laws
(Rules-based) of physics)

Johnson Controls at DC Dialogue 3rd Edition, 2019

CPO Operational Tool System Architecture

Johnson Controls at DC Dialogue 3rd Edition, 2019

CPO Evaluation + Implementation Process

Johnson Controls at DC Dialogue 3rd Edition, 2019

In Review….

Johnson Controls at DC Dialogue 3rd Edition, 2019

1/6

1/4

2/6

1/2

4/6

Johnson Controls
3/4

We combine technology with insights to build

5/6 purposeful solutions that help the world progress,
meeting today’s needs and shaping better tomorrows.
Johnson Controls at DC Dialogue 3rd Edition, 2019