Back to Basics Chiller Plant Applications Melbourne 28 th April 2016 - - PowerPoint PPT Presentation

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Back to Basics Chiller Plant Applications Melbourne 28 th April 2016 - - PowerPoint PPT Presentation

Oct 02, 2023 459 likes •857 views

Back to Basics Chiller Plant Applications Melbourne 28 th April 2016 Johnson Controls - Proprietary Many Considerations Climate Accessibility Comfort Redundancy Criticality Water Energy Noise Indoor space Outdoor space Marketing

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SLIDE 1

Back to Basics Chiller Plant Applications

Melbourne 28th April 2016

Johnson Controls - Proprietary

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SLIDE 2

Many Considerations

Water

2

Criticality Redundancy Energy Noise Indoor space Outdoor space Comfort Accessibility Climate Marketing Codes/Standards

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SLIDE 3

Consumables + Water + Maintenance + ENERGY Chiller Plant Operating Costs =

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Holistic Chiller Plant Approach Energy Cost of Plant = Load Hours Efficiency Rate Structure

X X X

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SLIDE 4

Measure & Verify Optimize System Automate System Apply components effectively, optimally Select components effectively, optimally Design system infrastructure to max efficiency potential

Operating Decisions Design Decisions

Maintain

Automation is a key component of the optimization process but optimization is not just smart controls

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SLIDE 5

Design Energy Vs. Annual Energy

Design Performance

Chiller 58% Tower 5% Fans 24% Pumps 13%

Annual Energy Usage

Pumps 22% Tower 2% Chiller 33% Fans 43% Johnson Controls - Proprietary & Confidential

Sustainability Life Cycle Flexibility Efficiency

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SLIDE 6

Air cooled vs Water cooled

Heat rejection medium Air Water Performance dry bulb based wet bulb based Full Load Efficiency Lower Higher Part load efficiency Lower# Higher Chiller Size larger baseline Water usage NO* YES Location Outdoors Indoors (plant-room) Installation Less complex More complex Maintenance Less complex More complex

* Power generating stations use water to produce electricity

# Plant efficiencies are dependent on climate, control, and other factors Johnson Controls - Proprietary

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SLIDE 7

4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 10 20 30 40 50 60 70 80 90 100

COP % Capacity

YK CSD Constant CEFT YK CSD AHRI Relief YK VSD AHRI Relief YMC2 AHRI Relief

Chillers operate for 85% of the time within this capacity range

Constant Speed, Constant CEFT Constant Speed, AHRI Relief Variable Speed, AHRI Relief Variable Speed, AHRI Relief + oil-free

VSD technology unlocks efficiency benefit of natural weather conditions

Note: Above is based on water cooled centrifugal compressor technology

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SLIDE 8

The design process

  • Minimize ‘transport’ energy
  • Maximize the economics of high

efficiency components

  • Optimize ‘lift’

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SLIDE 9

Metering device

1 6

condenser

pressure

Pressure- enthalpy diagram

2 3 5 4

compressor

enthalpy

evaporator

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SLIDE 10

Pressure Enthalpy Lift or Differential Pressure

12.2° C 6.7° C 29.4° C

Water cooled chillers

Standard design lift condition

35° C

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SLIDE 11

What is Heat Recovery? ASHRAE Handbook (2008):

  • “In many large buildings, internal heat gains require year-round chiller
  • peration. The chiller condenser water heat is often wasted through a cooling

tower”…“[Heat recovery] uses otherwise wasted heat to provide heat at the higher temperatures required for space heating, reheat, and domestic water heating”

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Heat recovery creates and uses energy at higher chiller lift condition to improve overall building efficiency

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SLIDE 12

Boiler Condenser

Expansion Valve Cooling Tower

Evaporator

What is Heat Recovery?

Heat Recovery Compressor Motor

Building with Energy Recovery

(12.2ºC) (6.7ºC) (35ºC) (40ºC)

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Example – reheat cooled and de-humidified O/A to neutral condition for use with a passive chilled beam system with site recovered energy

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SLIDE 13

Why use a heat recovery chiller? Social / Environmental Advantages

  • CO2 reductions
  • Reduced water consumption

Economic Advantages

  • Operational savings

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Coincident heating and cooling Cooling capacity 680 kWr Heat rejection 820 kWr Power input 140 kWe Total COP = 1500 / 140 = 10.7

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SLIDE 14

1 4

Lower tower water temps Higher chilled water temps

What is lift relief ?

AND / OR Less compressor work = lower input kWe

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SLIDE 15

Reduce lift

Capitalizing on ‘off-design’ conditions -most of the time

Evaporator Compressor Condenser Pressure Enthalpy

Reduces Energy Consumption

Lift

Lowering Condenser Water Temperature Reduces Compressor Work Lowers the Lift

Expansion

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SLIDE 16

Reduce lift

Capitalizing on ‘off-design’ conditions -most of the time

Evaporator Compressor Condenser Pressure Enthalpy

Reduces Energy Consumption

Lift

Raising Chilled Water Temperature Reduces Compressor Work Lowers the Lift

Expansion

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SLIDE 17

50% 0%

ENERGY

Evaporator Temp. Condenser Temp.

Off- Design Lift

Load (weight of rock) 12.8°C ECWT 44°F (6.7°C) LCHWT 29.40 C ECWT

How does lower LIFT (compression ratio) impact efficiency ?

Variable Speed Chiller Energy Usage Analogy -

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100%

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SLIDE 18

1 8

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SLIDE 19

1 9

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Legionella growth is dormant below 20C York chillers can operate at low condenser water temperatures

Cold tower water assists to control Legionella growth

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SLIDE 20

2

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Water Consumption is a function of TOTAL HEAT REJECTION. HEAT REJECTION = Cooling Capacity + Shaft Power + Condenser Pump Power Thus, Lower Shaft Power = Lower Water Consumption!

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SLIDE 21

2 1

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Benefits of Cold Cond. Water on High Temp Chiller (i.e. 14C leaving evap. YMC2)

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SLIDE 22

Opportunities for Lower Lift

2 2

Lower Condenser Water Temperature

  • Lower CW Design Temperatures
  • Oversize Towers
  • Climate wet bulb relief
  • Control Strategy
  • Chiller / Tower optimization
  • Series Counter-flow

Higher Chilled Water Temperature

  • Higher CHW Design temperatures
  • Climate wet bulb relief
  • Control strategy
  • chilled water reset
  • Series & Series Counter-flow
  • Multiple CHW loops
  • HT loop & LT loop

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SLIDE 23

6 deg C 10 deg C 14 deg C

Series chillers

Lift is reduced 4 degrees C

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SLIDE 24

Evaporator Condenser Evaporator Condenser

ECWT LCWT ECHWT LCHWT

Evaporator 1 Compressor 1 Condenser 1

Pressure Enthalpy

Lift 1

Evaporator 2 Compressor 2 Condenser 2

Lift 2

Evaporator Compressor Condenser

Pressure Enthalpy

Enhanced efficiency through series counter-flow

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140 C 100 C 60 C 290 C 350 C 320 C

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SLIDE 25

Enhanced efficiency through series counter-flow

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Parallel Chillers SCF Chillers Total Capacity (kWr) 2 x 1500 2 x 1500 Evap Flow Total (L/s) 44.7 x 2 = 89.4 89.4 Evap DP (kPa) 82.4 78.9 Cond Flow Total (L/s) 69.8 x 2 = 139.6 138.7 Cond DP (kPa) 76.9 54.2 R134a Charge (kg) 2 x 603 = 1206 2 x 438 = 876 Cost ($) BASE Less than BASE VPF Evap min (L/s) 13 22 Load (kWr) Parallel (kWe) SCF (kWe) Saving (kWe) % 3000 471.0 446.5 24.5 5.2% 2700 378.0 355.5 22.5 6.0% 2400 297.8 276.3 21.5 7.2% 2100 229.4 210.0 19.4 8.5% 1800 171.5 154.4 17.1 10.0% 1500 122.7 108.6 14.1 11.5% 1200 100.2 87.5 12.7 12.7% 900 80.9 69.5 11.4 14.1% 600 65.2 56.9 8.3 12.7% 300 75.4 66.0 9.3 12.4%

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SLIDE 26

Today’s and tomorrow’s challenge

Additional component-level efficiency gains will be insufficient.

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"...we are reaching maximum technological limits at a component level and that in the future the industry will have to look at the full HVAC system for further improvements. AHRI is in the process

  • f forming a new working group to address systems approaches for

efficiency improvements and will work closely with Standard 90.1.”

  • Dick Lord, co-writer of addendum ‘ch’ to ANSI/ASHRAE/IES

Standard 90.1-2010, ASHRAE Press Release, December 12, 2012

Johnson Controls - Proprietary

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SLIDE 27

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Primary / Secondary System

Know the benefits and limitations

  • f the system type

P/S System: Recommend to Size Primary Pumps for more flow than Secondary Pumps VPF System: Pump Head of Low Load Chiller

Primary/Secondary System VSD & VPF System

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SLIDE 28

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Variable Chilled Water Flow

VSD & VPF System

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SLIDE 29

Johnson Controls - Proprietary

The role of controls in the optimization process

Best-in-class algorithms that take a holistic, system-level approach All variable speed plant

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SLIDE 30

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SLIDE 31

Most Energy Efficient Chiller Plant Design

JEM is identified as the “Greenest Building” in Singapore (2013)

+ + + = 6.7 Plant COP

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SLIDE 32

System efficiency targets …

Singapore Green Mark v4 Platinum rating @ 0.55 kW/Ton = 6.4 plant COP Low temp loop = 9/18 deg C with 2 x YORK YK series counter-flow CSD chiller pairs High temp loop = 15/20 deg C with 2 x YORK YK VSD chillers Traditional chiller plant COP JEM Project delivering 0.527 kW/TR system efficiency:

Johnson Controls - Proprietary

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SLIDE 33

18 C 9 C 13.5 C AHU(s) LT CHW loop VPF DOAS VPF 20 C 15 C

Efficient System Design Concepts applied to HVAC system …

HT CHW loop

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SLIDE 34

Today’s variable speed chillers with optimized control strategies deliver outstanding real world plant-room efficiencies !

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W.A>

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SLIDE 35

BMS Johnson Controls Metasys CPO Internet Connection

Pump VSD’s Fan VSD’s Hardwired devices

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SLIDE 36

Currently used HFC and Natural refrigerants

R134a R410a R245fa R717 Hydrocarbon

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H20

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SLIDE 37

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Legislation has driven refrigerant direction. Investments are long-term and require thoughtful insight to how the equipment will be used and operated throughout its lifetime.

2017 2004 1987 1970’s 1930’s 1830’s Address greenhouse gas emissions Eliminate ozone depleting CFC’s & HCFC’s Make it safe & efficient Make it work HFOs* Lower GWP HFCs

(i.e. R-410A, R-134a, R32)

HFCs

(i.e. R-410A, R-134a, R-404A, R-507)

HCFCs

(i.e. R-22, R-123)

CFCs

(i.e. R-11, R-12)

Natural Refrigerants

(i.e. CO2, ammonia, water, hydrocarbons)

Available Chemicals

(Ethers, Ammonia, Water, CO2, Methylene Chloride, etc.)

Towards the end of this decade we will start to see the introduction of new low GWP refrigerants (HFO) . HFC’s with an acceptable GWP such as R134a will continue to be available

Johnson Controls - Proprietary

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SLIDE 38

QUESTIONS ? SUMMARY

Optimization is a process. Innovative design is the foundation. Chiller & Plant COP is improved when lift is reduced. Where energy is recovered and used, Plant COP can be improved when lift is increased. Further efficiency increases are currently being delivered at the system level. JCI offers responsible refrigerant solutions for numerous applications. R&D is progressing with next generation refrigerants.