TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES

Ayala Blvd., Ermita, Manila

COLLEGE OF ENGINEERING
Department of Mechanical Engineering

ACTIVITY NO. 3
Chiller Efficiency

Barachina, Aldrian

Soriano, Ramon Mathew

Ramirez, Dennis Karl E.

Cariño, Mark Lorenz

Ariola, Jose Luis

Lim, Marc Gean

Domingo, Marc Lester

Zabala, Nico Dale

Crucillo, Raymund Mark

Ocheda, Roecca B.

BSME-NS4A

TEAM 6

ENGR. RODELIO PADRIQUE

PROFESSOR
I. Definition of Chiller

A chiller (cooling water circulation device) is a device that regulates

temperature by circulating a cooling liquid, such as water or a heat medium,
whose temperature is controlled by the refrigerant cycle. It is used for air
conditioning in buildings and industries, as well as controlling the temperature
of different industrial devices and laboratory instruments, equipment, and
apparatuses at a steady level. It's called a "chiller" since it's frequently used for
chilling.

A chiller may continually provide cooled water while circulating water in a

cooling unit. It is widely used as a suitable device for cooling heat-generating
parts and air-conditioning equipment such as laser processing devices and
high-frequency heating devices at a constant temperature, and it solves a
variety of cooling problems while also lowering operating costs and increasing
energy efficiency.

II. The Operating Principles of the Chiller

A chiller operates on the

vapor compression or vapor
absorption concept. Chillers
deliver a steady stream of
coolant to the cold side of a
process water system at a
temperature of around 50°F
(10°C). The coolant is then
pumped through the process,
removing heat from one portion
of the facility (e.g., machinery,
process equipment, etc.) and
returning it to the process water
system's return side.

A chiller is a mechanical refrigeration system that employs vapor

compression and links to the process water system via an evaporator. A
chiller's evaporator, compressor, condenser, and expansion device all circulate
refrigerant. Each of the chiller's components undergoes a thermodynamic
process. The evaporator acts as a heat exchanger, transferring heat from the
 process coolant flow to the refrigerant. The refrigerant evaporates during heat
transfer, transforming from a low-pressure liquid to vapor, while the
temperature of the process coolant decreases.

The refrigerant is then sent to a compressor, which performs a variety of

tasks. To begin, it removes refrigerant from the evaporator and ensures that
the evaporator's pressure is low enough to absorb heat at the proper pace.
Second, it increases the pressure in the departing refrigerant vapor to
guarantee that the temperature of the vapor remains high enough to release
heat when it reaches the condenser. At the condenser, the refrigerant reverts
to a liquid condition. A cooling medium transports the latent heat released when
the refrigerant transitions from vapor to liquid away from the environment (air
or water).

III. Types of Chillers

A chiller takes heat away from and cools the target device. The extracted heat
must be evacuated by the chiller itself, and there are two types of heat exhaust
methods: those that utilize refrigerants and those that employ water circuits to
circulate water. Air-cooled and water-cooled cooling methods are two
examples of cooling methods.

A.) Air-Cooled Chiller - This is a system that sends wind to the heat exchanger
and uses air to cool the refrigerant. Although the chiller has a built-in fan
motor that is simple to install, because exhaust heat is created in the room,
exhaust equipment may be necessary in small areas. A condenser
(radiator) cools and liquefies the gas compressed by the freezer
(compressor). It has a refrigerant gas cycle and a circulating water cycle,
 with refrigerant gas serving as a heat medium for cooling the circulating
water.

The pressure of liquefied gas is decreased when it passes through the

expansion valve, and it becomes a cooling gas. A water cooler (heat
exchanger) exchanges heat with the circulating water to cool it. Aquarium
cleaning is simple since there is no freezing or blockage. When rainwater
comes into contact with the cooling tower when it rains, the heat of
vaporization from the evaporation of rainwater lowers the temperature of
the radiator, and because the temperature drops due to the evaporation of
rainwater around the air-cooled chiller, the cooling efficiency can be
maintained regardless of the rise in humidity, so the cooling efficiency
improves even when the humidity is high.

B.) Water-Cooled Chiller - A cooling tower is used to chill water in this sort of
system. Refrigerator cooling water is necessary, but it has several
advantages, including good cooling efficiency and the absence of exhaust
heat in the room.

A natural chiller (absorption chiller) is a water-cooled chiller that employs

water, which is active in the field of large-scale air conditioning, as a
refrigerant and is used as a heat source refrigerator for central air
conditioning of air conditioning equipment for medium and large-scale
buildings. An evaporator, absorber, regenerator, and condenser make
chilled water (hot water) under pressure control by circulating refrigerant
sealed in the apparatus (cooling water circulation device). It is a cooling
cycle, but chilled water (hot water) is created by altering the composition of
the refrigerant in the equipment to gas and liquid (latent heat transfer) inside
 an airplane. It can run continuously throughout the year and has a tiny
design that allows it to be fitted in tight areas.

IV. Energy Utilization Involved in the Chiller

Chillers use more than 40% of the total energy needed for space cooling in
commercial and industrial buildings. The energy consumption of chillers and
chilled water pumps, condenser pumps, and fan motors has been evaluated in
this report using data from a walkthrough energy audit of the University of
Malaya's 16 faculties. For various percentages of loadings, chillers and the
motors and pumps used in chillers are predicted to use 10,737 MWh (or 51
percent of total energy consumption). Variable speed drives are used in chillers
to minimize energy consumption because they are big energy consumers. It is
projected that
adopting efficient
chillers at various
loadings can save
roughly 8368
MWh of yearly
energy. It was
also shown that
matching needed
speeds utilizing
variable speed
drives for 60
percent speed
reduction may
save roughly 23,532 MWh of yearly energy for chilled water supply pumps,
condenser pumps, and cooling tower fan motors. Using energy efficient chillers
at 50% load might save around 1,274,692 kg of CO2. It was also shown that
adopting variable speed drives for 60 percent speed decreases may save
roughly 2,426,769 kg CO2. Variable speed drives in chilled water pumps,
condensers, and fan motors were shown to have short payback times of only
a few months.
V. Performance Parameters of the Chiller Related to Energy Efficiency

Chillers are one of a building's major energy users, which has a significant
influence on operating expenses. As a result, it's critical to keep an eye on your
chillers to assess their efficiency and assure peak performance. So, in this post,
we'll look at how to calculate a chiller's efficiency. The efficiency of a chiller may
be calculated very easily. It is expressed in terms of "COP," which stands for
Coefficient of Performance.

The Coefficient of performance is simply a ratio of the cooling effect

generated by the chiller to the quantity of electrical energy used to create this
effect. Both units should be measured in Kilowatts (kW); let us see how this is
done. Consider a chiller that produces 2,500kW of cooling, or 8,533,364BTU/h
in metric units. The chiller's electrical power consumption to generate this is
460kW.

The metric computation would be as follows:

2,500kW / 460kW = 5.4, resulting in a COP of 5.4. This means that for every
1kW of power fed into the machine, 5.4kW of cooling is produced.

The imperial calculation would be as follows:

To begin, convert BTUs to kWs.
8,533,364BTU/s / 3412.142 = 2,500kW
2,500kW / 460kW = 5.4, resulting in a COP of 5.4. This means that for every
1kW of power fed into the machine, 5.4kW of cooling is produced

It is critical to remember that the COP of a chiller changes with cooling load
and that each chiller has a distinct COP. To detect performance difficulties, the
chiller manufacturer should be able to supply the COP design data, which you
may compare to the performance of your chiller. Conventional single speed
chillers typically achieve their highest COP at or near maximum load, but most
chillers operate at part load 98
percent of the time. If this is the
case, contact a specialist to see if
a variable frequency drive (VSD)
can be retrofitted to the motor
controls, which reduces the
rotation speed of the compressor,
lowering electrical demand and
increasing the COP at part load.
VI. Baseline Efficiency Level of the Chiller

The utilization of existing equipment in calculating the baseline for making

project savings claims is a typical challenge for many chiller initiatives. The
explanation that follows illustrates why this is not necessarily the proper
baseline.

Consider three key replacement possibilities to build an adequate baseline

(Fagan et al. 2011):
• Early replacement. Existing equipment has an usable life remaining
(RUL).
• Replace-on-burnout. The present equipment's effective usable life
(EUL) has passed.
• Natural turnover. Equipment replacement for purposes other than
energy savings.
Apply a dual baseline (Ridge et al. 2011) for the first scenario (early
replacement), as indicated in Figure 1. Establish a hypothetical baseline that
employs a new chiller that meets the appropriate energy-efficiency requirement
for the applicable jurisdiction for the latter two scenarios. The hypothetical
baseline should also take into account industry best practices and current
equipment, which may have better efficiency levels than the applicable energy-
efficiency criteria.

There are two unique baseline eras, as depicted in Figure 1.

• Period 1. The current equipment is protected for the length of the RUL
of existing equipment.
• Period 2. Use a hypothetical baseline for the remaining EUL of new
equipment.
 When available, utilize the program defined EUL for chiller equipment or
review regional technical reference manuals (TRM); if neither is accessible,
consult other secondary sources. Similarly, utilize the program's algorithm to
estimate the RUL of baseline chiller equipment. If this has not already been
established, consider defining RUL as the difference between the EUL and the
chiller's present age (or number of years since its last rebuild).

VII. Factors That Contribute to Energy Losses and Inefficiencies

Building chillers are the single biggest energy-consuming component in

most academic, commercial, and industrial establishments. Building chillers
account for more than half of the yearly power consumption at many
institutions. As a result, appropriate building chiller operation and maintenance
should be a top concern in any facility energy management program.

However, it is surprising how frequently chillers are run or maintained

inefficiently or ineffectively, resulting in increased energy expenditures, worse
system performance and dependability, and shorter equipment life.

While there are several causes that lead to decreasing chiller efficiency, the
five most prevalent are: improper operating procedures, ignored or postponed
maintenance, ignored cooling tower maintenance, oversizing, and disregarding
alternate-fuel chillers. While each of these causes constitutes a genuine and
severe danger to chiller efficiency, maintenance managers may readily reduce
or remove them.

Poor operating practices - might reduce not just chiller efficiency but also
chiller longevity. Most of such behaviors are the result of one of two situations:
attempting to force a chiller to do something it was not meant to do or failing to
grasp the repercussions of a certain operation.

For example, increasing the rate of chilled water flow via the chiller is a
frequent approach when trying to offer additional cooling water to a facility.
More cooling water is thought to be available with a greater flow rate.

In actuality, however, exceeding the manufacturer's recommended flow rate

through a chiller diminishes the chiller's working efficiency. Flow rates higher
than those suggested also accelerate the rate of erosion in the chiller's tubes,
resulting in early tube collapse.
 Ignored Maintenance - While appropriate maintenance procedures are
essential for the optimal running of all building equipment, few areas are more
visible than in the maintenance of building chillers. Consider the effect that
proper maintenance may have on chiller efficiency.

The majority of modern, high-efficiency centrifugal chillers have a full-load

efficiency rating of around 0.50 kW per ton. If that chiller is carefully maintained,
it should have a full-load efficiency of 0.55-0.60 kW per ton after five years.

If the same chiller's maintenance was neglected, it would not be shocking

to discover that the full-load efficiency had dropped to 0.90 to 1.0 kW per ton.
This indicates that a badly maintained chiller will consume 20-25 percent more
energy each year to deliver the same cooling.

Ignoring Cooling Towers - Cooling towers are key components of chiller

system efficiency. In most circumstances, the operation of the cooling tower
greatly influences the operational efficiency of the chiller. Towers in good
shape, correctly managed, and carefully maintained enable chillers to run at
optimal efficiency.

Even little changes in cooling tower performance will have a significant

influence on chiller efficiency. For example, each degree Fahrenheit increase
in condenser-water supply from the tower reduces chiller efficiency by an
average of 2%.

Because cooling towers are exposed to the weather, they acquire dirt,
leaves, and other material that can obstruct air and water passageways.
Furthermore, the warm, wet atmosphere in which they work encourages
biological development, which can clog spray nozzles and diminish heat-
transfer efficiency. Solids buildup in cooling tower water can also choke spray
nozzles and water passageways.

Oversizing - Because chiller efficiency reduces fast with decreasing load,

properly sizing a chiller is also vital for its effective functioning. When the facility
was new, the chiller was probably somewhat enlarged to allow for some
expansion in cooling demands without having to replace the chiller.

However, given the condition of facility churn, the loads that a chiller
experiences after only a few years might be drastically different from those for
 which it was intended. This is especially true if a facility has been changed to
increase its energy efficiency.

Installing new windows or energy-efficient lighting systems, for example,

frequently leads in significant reductions in cooling loads. As cooling loads fall,
the number of hours per year that a chiller runs at decreased load and, thus,
reduced efficiency rises, resulting in a loss in yearly operational efficiency.

Ignoring Alternative-fuel Chillers - When chillers ultimately wear out, a

straightforward one-for-one replacement is a typical error. A management
replaces an old chiller with a new electric-drive centrifugal unit if it was an
electric-drive centrifugal unit. While the type of chiller built 15 to 20 years ago
may have made sense at the time, far too many factors have changed since
then to presume that the same type of chiller is still the best choice for the
facility today.

Deregulation, real-time power pricing, and technological advancements

have all contributed to managers having more options when it comes to
replacing aging building chillers. Electricity deregulation and real-time pricing
provide managers with an incentive to regulate their energy usage. The flatten
the load, especially at peak hours, decreasing the cost of power.

VIII. New or Advanced Technologies, Practices, and Approaches to Enhance

the Efficiency of the Chiller.

There are tons of practices or approach on how to enhance the efficiency

of a chiller, here are some examples of it:

1.) Consider variable speed retrofits. Variable speed drives will benefit
the majority of components in a chilled water system. In fact, VFDs are required
by most contemporary energy standards for these components in new systems
and substantial retrofits. VFD costs have also dropped considerably in recent
years.

The constant and variable speed chiller efficiency figures on page 38

demonstrate that VFDs for chillers have a significant effect, but only if
condenser water temperature relief is also applied.

Cooling tower fans are another area where VFDs might help you conserve
electricity. Variable speed fan motors not only reduce fan energy owing to fan
law benefits (a fan at 50% speed takes 12.5 percent of the power of a fan
running at 100% speed), but also provide more consistent temperature
regulation when loads and outdoor wet-bulb temperature fall.

Variable speed pumping can give a chance for energy savings, but it needs
a detailed examination of other components of the system. A constant to
variable flow retrofit of chilled water may necessitate extensive and costly
upgrades of control valves and control sequences. Additionally, the variable
flow capabilities of current chillers must be examined. Low chiller flow
restrictions may affect the economic viability of variable chilled water pumping.
Variable flow management on the condenser water side may be limited by
chiller flow needs or cooling tower fouling/freezing problems. However, if the
pumps on a constant flow system are large, balancing pump flow by decreasing
speed against flow limitation using a balancing value may offer a significant
return even if variable flow is not added during system operation.

2.) More is less: Running multiple parallel devices optimizes savings.

Part-load operation of chiller plant equipment is often more efficient. Chillers,
for example, can operate at optimum efficiency between 40% and 60% of peak
capacity. Cooling tower fans and system pumps piped in parallel may benefit
from a control method that works more pieces of equipment at lower speeds,
as opposed to a staging plan that enables operational equipment to reach full
capacity before staging on the next unit. Running additional cooling towers and
chillers enhances heat transfer surface area at all operating stages, increasing
efficiency and reducing pressure drops. Taking advantage of pump legislation
savings and running at optimum pump efficiency points is critical for pumps.
(The pump law is analogous to the fan law in that when pump speed is lowered,
energy consumption is reduced by the cube of the speed reduction.) Any
control scheme adjustment, however, must take into account minimum chiller
and cooling tower flow restrictions.

3.) Raise the temperature of the supply. Most commercial systems are
constructed with chilled water supply temperatures ranging from 40 to 45
degrees Fahrenheit. During peak periods, this typically provides for proper
dehumidification and an acceptable supply air temperature in occupant areas.
These peak weather and load circumstances, however, are uncommon.

Supply air temperature reset control can conserve energy in a variety of

ways. First, boosting supply temperatures can assist prevent over-
dehumidification of areas and unnecessary latent cooling when cold supply air
 temperatures are not required (appropriate humidity levels and no zones at
peak load). More crucially, greater supply air setpoints allow chilled water
supply temperature to be raised, enhancing chiller efficiency significantly. In
general, increasing the chilled water supply temperature by one degree
increases chiller efficiency by around 2%.

To maximize energy savings, further design and control aspects should be

examined. As previously stated, VFDs on all or some components should be
considered. In addition, setpoints, temperature resets, and other minor control
sequence adjustments are frequently effective and inexpensive.

IX. Example of Calculations that Focuses on Energy Efficiency

Beside from the calculations that are given above, here are some
calculations that focuses on energy efficiency of a chiller:

Q: 0.07 x Cb x γb x Lbx （Tout－Tin）

Q: Cooling capacity (impossible capacity) (kw)
Cb: Specific heat of circulating water (cal/g℃)
*Water is approx. 1.0 cal/g℃
γb: Density of circulating water (g/m³)
*Water is approx. 1.0 g/m³
Lb: Circulating water amount (ℓ/min)
Tout: Load outlet temperature (℃)
Tin: Load inlet temperature (℃)