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ler Plant Optimization
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Optimizing The Chiller Plant —- A
White Paper
Why Optimize a Chiller Plant?
Chiller Plant En...
The chiller plant can now be optimized for
maximum efficiency at part load as well as full
load operation. Annual operating savings are
significant and wear and tear is reduced with
lower pressure operation.
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The typical design only optimizes a chiller plant
for maximum load with the cooling towers and
| contact
the condenser water pumps sized and set-up for
maximum load operation and design conditions. Energy Technology
Engineering
While the chiller may have good part load San Jose, CA
performance, the rest of the plant is not PH: (408) 439-8818
effectively “re-tuned” to operate at part load,even though cooling tower fans do turn down
based on a fixed condenser water temperature
set point.
This less then optimum chiller plant design only
uses a control algorithm based on a simple
temperature measurement, set-point, and
control mechanism.
Properly matching all the component operations
under various load and operating conditions will
save significant amounts of energy. Total
average annual plant energy savings of 25% are
possible with water cooled chiller plants.
The following control strategies, properly
applied,
The Chiller Plant Optimizer™ w
increase your operating savings.
izes a patented
methodology to apply sophisticated adaptive
control routines to continuously adjust / tune
control parameters for optimal energy demand.
Condenser Water Temperature Reset
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page id=33)
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Achiller’s maximum capacity is effected by a
pressure requirement to “push” a given mass
flow rate of refrigerant from the compressor
through the condenser to the evaporator.
Typically there is a limiting orifice or valve
between the condenser and evaporator. The
chiller design matches the condensing pressure
Emai
william.henry@sbeglob
alnet
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chiller-plant-with-
proven-strategies),
(https:/icoolenergytech
performance-
enhancements!)
(httpss/coolenergytech
.com/partnering-
opertunities/)to this pressure requirement. This is what
defines the design condensing temperature for
maximum load.
At maximum load the condensing pressure /
temperature which is designed as noted above
defines the required condenser water
temperature. So you find condensing water
requirements in the range of 80 to 85°F.
During operation of the chiller, If the condensing
water temperature is below the design
temperature, the capacity of the chiller is
reduced because the mass flow capability of
refrigerant is reduced. On the other hand, the
efficiency of the chiller increases with lower
condensing water temperature.
A control strategy that reduces the condensing
water temperature when the chiller is operating
at part load will significantly improve the
chillers operating performance at that load and
can lead to significant savings. This control
strategy is defined as Condenser Water
Temperature Reset.
This savings is not pure, that is to say more fan
energy is required to provide the lower
condenser water temperature under most
operating conditions due to the outside wet bulb
temperature. It is conceivable that with small
chiller loads, the fan energy usage could be
greater then the chiller energy savings.The Chiller Plant Optimizer™
(httpi//facilityenergy.coolenergytech.com/?
page id=123) has a unique method that readily
achieves the right balance between cooling
tower and chiller operation for greater savings
benefit. Using advanced logic and adaptive
control computer routines prepackaged in a
stand alone control unit installation costs are
minimized and unit configuration to match the
specific chiller plant is accomplished offsite.
Cooling Tower Temperature Relief
(httpi//facilityenergy.coolenergytech.com/?
page id=107)
A typical chiller plant is designed for best
efficiency when operating near or at 100%
operation with the condenser pumps and
cooling towers. When operating at part load
capacity the cooling tower and pump still have
the maximum operation capability.
A simple example; the chiller plant is 85%
loaded but the outside conditions (humidity) are
maximum. The cooling tower fan will be
required to operate at full speed to achieve the
desired condenser water temperature set point.
With lower part load situations and lower
outside conditions, the cooling tower fan will
still be required to work harder then necessary
to achieve the desired set point. But, if under
these conditions the maximum fan speed islimited, the savings in cooling fan energy will
outweigh the slightly increase energy usage of
the chiller.
A control strategy that is designed to achieve
this balance is called Cooling Tower
Temperature Relief. An intui
ive example would
be to consider a plant that is designed to
operate at a lower load and note that the design
considerations could provide a smaller cooling
tower or the same cooling tower with smaller
motor and a smaller condenser water pump.
The patented Chiller Plant Optimizer™ uses a
unique method including advanced control logic
and adaptive control routines to determine the
ideal limits for cooling tower fan operation.
Chilled Water Temperature Reset vs Condenser Water
Temperature Reset
It is readily recognized that re setting or raising
the chilled water temperature, will save some
energy. The typical savings for this strategy is
limited, and there are many situations where it
is not possible, nor wise to use this strategy.
Raising the chilled water one degree results in
nearly the same efficiency improvement as
lowering the condenser water temperature one
degree. Condenser water temperatures can belowered down to 60 degrees F. for many chillers
while the opportunity to raise chilled water
temperature is about 5 to 7 degrees F. at max.
led Water
Still, when it is feasible applying C!
Temperature Reset should not be overlooked.
Several different strategies are available from
various vendors, and the results can be mixed.
Generally when it is clear chilled water reset is
not problematic, and savings will be achieved,
then the implementing strategy is straight
forward and uncomplicated.
Variable Condenser Water Flow
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page _id=114)
Varying the flow rate of the condenser water
can be important addition with the above
strategies for a total energy savings. Published
papers of actual performance tests by a major
chiller manufacturer show us that condenser
water flow rates can be significantly reduced
without impairment to the chiller. ASHRAE
publishes minimum recommended condenser
water flow rates to prevent mineral buildup.
Design compromise (remember price to
performance ratio) dictate the typical design
flow velocities that range for 2 to 3 times the
ASHARE minimum,Some engineers feel that to design a control
strategy to save energy by varying the flow rate
and motor speed is not worth the effort. a)
Many real world chiller plants have much larger
condenser water pumps than the theoretical
design requirements. b) When the individual
pumps are paralleled on a common distribution
header they are sized, and balanced to provide
flow and pressure significantly higher then in a
single circuit system. c) Also, it is not always
feasible to have a short run between the plant
systems. d) Finally, since the Chiller Plant
Optimizer™ has been designed for additional
optional algorithms, implementation costs are
kept to a minimum.
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