Ways to Improve Chiller

Efficiency
Energy Consumption

25 - 30%
Building Energy
Energy Consumption

25 - 30%
Building Energy
Initial Considerations
Initial Considerations
Proper maintenance procedures
Initial Considerations
Proper maintenance procedures
Accurate operating logs
Major Savings Opportunities
Component related
System related
Retrofit related
Major Savings Opportunities
Component related
System related
Retrofit related
#1

Chilled Water Reset

Mild outdoor temperatures
Lower outdoor humidity levels
Less need for dehumidification
Adequate cooling at higher chilled water temps
#1

Chilled Water Reset

Mild outdoor temperatures
Lower outdoor humidity levels
Less need for dehumidification
Adequate cooling at higher chilled water temps
#1

Chilled Water Reset

Energy Savings

Drive Type Savings / Degree Increase

Constant speed 0.5 - 0.75%
Variable speed 2.0 - 3.0%
#2

Maintaining Proper
Refrigerant Charge
Too much or too little
Limits heat transfer capacities
Increases head pressure
Increases energy consumption FREON
#3

Eliminate Refrigerant Leaks

High-Pressure
#3

Eliminate Refrigerant Leaks

Refrigerant
Refrigerant

High-Pressure
#3

Eliminate Air Leaks

Low-Pressure
#3

Eliminate Air Leaks

Air & Moisture

Air & Moisture

Low-Pressure
#4

Maintaining Compressor
Motor Efficiency
Lack of cooling decreases efficiency
Increased current draw w/o increased voltage
#4
Open-Drive Motor

Maintaining Compressor
Motor Efficiency
#4
Open-Drive Motor
Air Cooled

Maintaining Compressor
Motor Efficiency
Inadequate ventilation
Obstructed air intake Air Cooled
Obstructed exhaust openings
Loose/corroded electrical connection
#4

Hermetic Motor

Maintaining Compressor
Motor Efficiency
#4

Hermetic Motor

Maintaining Compressor
Motor Efficiency
Restricted refrigerant flow
Clogged refrigerant filter
Refrigerant Cooled
Loose/corroded electrical connection
#5

Reduce Condenser Tube Fouling

Sedimentation, slime and algae growth
#5

Reduce Condenser Tube Fouling

Sedimentation, slime and algae growth
#5

Reduce Condenser Tube Fouling

Sedimentation, slime and algae growth
Inefficient heat exchange
Compressor works harder
Increases energy consumption
1% per 1F increase in small temp. difference
Major Savings Opportunities
Component related
System related
Retrofit related
Major Savings Opportunities
Component related
System related
Retrofit related
#6

Reduced Entering Condenser

Water Temperature
#6

Mr. Compressor
#6

85 Condenser Water

Mr. Compressor
#6
High
Head
85 Condenser Water

Mr. Compressor
#6
High
Head
Lower Condenser
Water Temperatures

Mr. Compressor
#6
High
Head
Lower Condenser
Water Temperatures

Low
Head
Mr. Compressor
#6 0.65

0.60

0.55

0.50
kW / ton

0.45

0.40

0.35

0.30

0.25
85 F 80 F 75 F 70 F 65 F 60 F
Entering Condenser Water Temperature
#6 0.65
Competitor
0.60 60% Load
100% Load
0.55 80% Load

0.50
kW / ton

0.45

0.40

0.35

0.30

0.25
85 F 80 F 75 F 70 F 65 F 60 F
Entering Condenser Water Temperature
#6 0.65
Competitor
0.60 60% Load
100% Load
0.55 80% Load

0.50
kW / ton

YORK
0.45 60% Load
100% Load
80% Load
0.40

0.35

0.30

0.25
85 F 80 F 75 F 70 F 65 F 60 F
Entering Condenser Water Temperature
#6 0.65
Competitor
0.60 60% Load
100% Load
0.55 80% Load

0.50
kW / ton

YORK
0.45 60% Load
100% Load
80% Load
0.40

0.35 YORK w/ Variable Speed

100% Load
0.30 80% Load
60% Load

0.25
85 F 80 F 75 F 70 F 65 F 60 F
Entering Condenser Water Temperature
#7

Proper Condenser Water Flow Rate

Partially closed valves High
Clogged cooling tower nozzles Head
Dirty strainers and filters
Mud in condenser tubes
Air in water piping
#7

Proper Condenser Water Flow Rate

#7

Proper Condenser Water Flow Rate

20% Flow reduction

#7

Proper Condenser Water Flow Rate

20% Flow reduction

Results in 5% energy increase

#8
Controlling Demand Charges
100 w/o Demand Limiting

80
% Full-load Amps

60

40

20

0
0 2 4 5 6 7 8 10 12 14 16 18 20

Minutes
#8
Controlling Demand Charges
100 w/o Demand Limiting

80
% Full-load Amps

60

40

20

0
0 2 4 5 6 7 8 10 12 14 16 18 20

Minutes
#8
Controlling Demand Charges
100 w/o Demand Limiting
w/ Demand limiting

80
% Full-load Amps

60

40

20

0
0 2 4 5 6 7 8 10 12 14 16 18 20

Minutes
#9
Operate Chillers in Proper Sequence
Evaluate part-load and full-load efficiencies
Determine optimum chiller sequence
#9
Operate Chillers in Proper Sequence
1.3

1.1
kW / ton

0.9 Constant Speed

0.7

0.5

0.3
100% 80% 60% 40% 20%
Load
#9
Operate Chillers in Proper Sequence
1.3

1.1
kW / ton

0.9 Constant Speed

0.7

0.5

0.3
100% 80% 60% 40% 20%
Load
#9
Operate Chillers in Proper Sequence
1.3

1.1
Efficiency begins dropping
kW / ton

0.9 Constant Speed

0.7

0.5

0.3
100% 80% 60% 40% 20%
Load
#10

Optimizing Pump Operation

Shutdown pumps serving idle chillers
2 speed-motor
Variable speed drives
Investigate primary and secondary systems
#11

Use of Power Factor

Correction Capacitor
Ideal power factor = 1.0
Practical = 0.8 - 0.95
Better P.F. reduces demand on utility
Many utilities offer incentives for higher P.F.
#12

Chiller Plant Automation

D.D.C. energy management system
Operate chiller plant at peak efficiency
Demand limiting
Chiller water reset
Time of day start/stop
Optimized sequencing
24-hour electronic chiller plant monitoring
#13

Variable Speed Drives

Pumps
Cooling tower fans
Centrifugal chillers
#13

Variable Speed Centrifugal Chillers

Constant speed capacity control
Prerotation vanes to throttle refrigerant flow
Variable speed capacity control
Controlling motor speed
Optimizing prerotation vane position
#13
Variable Speed Centrifugal Chillers
1.3

1.1

Constant Speed
kW / ton

0.9 Variable Speed

0.7

0.5

0.3
100% 80% 60% 40% 20%
Load
#13
Variable Speed Centrifugal Chillers
1.3

1.1

Constant Speed
kW / ton

0.9 Variable Speed

0.7

0.5

0.3
100% 80% 60% 40% 20%
Load
#13
Variable Speed Centrifugal Chillers
1.3

1.1

Constant Speed
kW / ton

0.9 Variable Speed

0.7

0.5 30% Energy Savings

0.3
100% 80% 60% 40% 20%
Load
Major Savings Opportunities
Component related
System related
Retrofit related
Major Savings Opportunities
Component related
System related
Retrofit related
#14

Retrofit w/ Smaller Driveline

Oversized chiller with respect to building load
Match chiller plant to cooling profile
Take advantage of large heat exchangers
Reduces energy costs
#14
BANK OF AMERICA
San Francisco

Before After

1750 tons 1035 tons

2000 HP motor 900 HP motor
R-12 R-134a

$86,000 utility rebate

$65,000 annual operating savings
4 year payback
#14

Other Benefits
Inaccessible chiller location
Eliminate CFCs
Reduce maintenance costs
#15

Why Replace a Chiller?

#15

Why Replace a Chiller?

High energy costs
#15

Why Replace a Chiller?

High energy costs
Increasing maintenance costs
#15

Why Replace a Chiller?

High energy costs
Increasing maintenance costs
Parts obsolescence
#15

Why Replace a Chiller?

High energy costs
Increasing maintenance costs
Parts obsolescence
Unreliable operation
#15

Why Replace a Chiller?

High energy costs
Increasing maintenance costs FREON

Parts obsolescence
Unreliable operation
CFCs
#15

Improvements in Chiller Technology

Better tube performance
Increased surface area
More efficient compressors
Higher efficiency motors
Use of variable speed drive
#15

New Chiller Choices

Steam Absorption
Direct-Fired Absorption
Gas-Engine-Driven Centrifugal
#15

Life Cycle Cost Analysis

Energy costs
Maintenance
First cost
#15

Life Cycle Cost Analysis

Energy costs
Maintenance
First cost
#15
Summary of Monthly Total Cost of Operation
Project : ABC Hospital
Engineer: XYZ Engineering

Jan Feb Mar Apr

Atlanta, GA
01-Feb-95

May June
Energy Costs
Centrifugal Ch-1 $4458 $5067 $6741 $9112 $11441 $12572
Centrifugal Ch-2 $4458 $5067 $6741 $9112 $11441 $12572

Jul Aug Sept Oct Nov Dec

Centrifugal Ch-1 $4458 $5067 $6741 $9112 $11441 $12572

Centrifugal Ch-2 $4458 $5067 $6741 $9112 $11441 $12572
Tptal Ton-hr Eq. FL SPLV Partload Comp 0.85 kW/ton
Centrifugal
$12572
Ch-1 $108470 $5067 $6741 $9112 $11441
vs.
Centrifugal Ch-2 $157792 $5067 $6741 $9112 $11441
$12572
Weather City: Atlanta, GA
Computer Load Line Development
0.60 kW/ton
Loadline Input Data Temp Total Ch-1 Ch-2

Max Des Temp: 100 95-99 486 486 486

Peak Block: 500 90-94 386 386 386
Econ Temp: 47 85-89 286 286 286
Tons of Econ: M 80-84 186 186 186
Ld Line Type: Y 75-79 486 486 486
Computer: 500 70-74 486 486 486
Ch1: 300 65-69 486 486 486
Ch2: 70 60-64 486 486 486
#15
Summary of Monthly Total Cost of Operation
Project : ABC Hospital
Engineer: XYZ Engineering

Jan Feb Mar Apr

Atlanta, GA
01-Feb-95

May June
Energy Costs
Centrifugal Ch-1 $4458 $5067 $6741 $9112 $11441 $12572
Centrifugal Ch-2 $4458 $5067 $6741 $9112 $11441 $12572

Jul Aug Sept Oct Nov Dec

Centrifugal Ch-1 $4458 $5067 $6741 $9112 $11441 $12572

Centrifugal Ch-2 $4458 $5067 $6741 $9112 $11441 $12572
Tptal Ton-hr Eq. FL SPLV Partload Comp 0.85 kW/ton
Centrifugal
$12572
Ch-1 $108470 $5067 $6741 $9112 $11441
vs.
Centrifugal Ch-2 $157792 $5067 $6741 $9112 $11441
$12572
Weather City: Atlanta, GA
Computer Load Line Development
0.60 kW/ton
Loadline Input Data Temp Total Ch-1 Ch-2

Max Des Temp: 100 95-99 486 486 486

Peak Block: 500 90-94 386 386 386
Econ Temp: 47 85-89 286 286 286
Tons of Econ: M 80-84 186 186 186
Ld Line Type:
Computer: 500
Y 75-79
70-74
486
486
486
486
486
486 $157,792 - $108,470 = $49,322
Ch1: 300 65-69 486 486 486
Ch2: 70 60-64 486 486 486
#15

Maintenance Cost
Short Term
Preventative maintenance
#15

Maintenance Cost
Short Term
Preventative maintenance
Long Term
Scheduled teardown
Hermetic burnout
#15

Maintenance Cost
Short Term
Preventative maintenance
Long Term
Scheduled teardown
Hermetic burnout
#15

Life Cycle Cost Analysis

Energy costs
Maintenance
First cost
#15

Life Cycle Cost Analysis

Energy costs
Maintenance
First cost
#15

First Cost
Equipment
Installation
Other system components
#15

Life Cycle Cost Formula

+ First cost
- Utility rebates
- Energy savings
- Reduced maintenance cost

= Financial Payback
#15
York Project Investment Analysis

Focus on Big Picture

01-Feb-95

Common Information Alt. One Desrip. Existing

Chiller

Simple/discounted payback Project Name ABC Hospital

Location Atlanta, GA Warranty
Bldg 27
554335

Chiller # 1 Post warranty 6542

Project cost Utility 5% Utility rebate 9809
Oper Sav $55322 Cost

Utility cost/rebates 109809

Payback 2.9 Project Cost 8209809

Utility escalation Cash Flow Financial Analysis

Proj Utility Reclaim Other Utility Maint Total

Maintenance cost 1996
1997
13121
0
29831
0
2031
0
0
0
398497
298097
7384
2384
3902940
3902940

1998 0 0 0 0 298097 2384 3902940

Maintenance escalation 1999
2000
0
0
0
0
0
0
0
0
298097
298097
2384
2384
3902940
3902940
2001 0 0 0 0 298097 2384 3902940

Proj Utility Reclaim Other Utility Maint Total

2002 13121 29831 2031 0 398497 7384 3902940
2003 0 0 0 0 298097 2384 3902940
2004 0 0 0 0 298097 2384 3902940
2005 0 0 0 0 298097 2384 3902940
2006 0 0 0 0 298097 2384 3902940
2007 0 0 0 0 298097 2384 3902940
#15

FLEXIBILITY
Refrigerant choice
Open-drive technology
Electric motor
Steam turbine
Gas engine
Compressors and shells
#15
R-134a
Centrifugal
R-123 R-22

Screw R-134a
R-22 R-22

Reciprocating R-134a
R-22
ParaFlow
Absorption Water

IsoFlow
Absorption Water

R-134a
TurboMaster
R-22

Ammonia AMMONIA

TONS 100 400 700 850 1000 1250 1500 2100 5500 8500
Summary
 Summary
Thorough maintenance program
 Summary
Thorough maintenance program
Daily/accurate log records
 Summary
Thorough maintenance program
Daily/accurate log records
Evaluate component opportunities

FREON
 Summary
Thorough maintenance program
Daily/accurate log records
Evaluate component opportunities
Evaluate system opportunities
#8
Controlling Demand Charges
100 w/o Demand Limiting
#9 w/ Demand limiting

Operate Chillers in Proper Sequence 80

% Full-load Amps
60
1.3

40
#13 1.1

Efficiency begins dropping 20

Variable Speed Centrifugal Chillers Constant Speed
kW / ton

0.9
0
1.3 0 2 4 5 6 7 8 10 12 14 16 18 20
0.7
Minutes
1.1
0.5

Constant Speed
kW / ton

0.9 Variable Speed

0.3

0.7 100% 80% 60% 40% 20%

Load

0.5 30% Energy Savings

0.3
100% 80% 60% 40% 20%
Load
 Summary
Thorough maintenance program
Daily/accurate log records Centrifugal
R-134a

R-123 R-22

Evaluate component opportunities Screw R-134a

R-22 R-22

Reciprocating R-134a

Evaluate system opportunities ParaFlow

Absorption
R-22

Water

Investigate retrofit and replacement IsoFlow

Absorption Water

R-134a
TurboMaster
R-22

Ammonia AMMONIA

TONS 100 400 700 850 1000 1250 1500 2100 5500 8500
 Summary
Thorough maintenance program
Daily/accurate log records FREON

Evaluate component opportunities

Evaluate system opportunities
Investigate retrofit and replacement
Apply as many strategies as possible
R-134a
Centrifugal
R-123 R-22

Screw R-134a
R-22 R-22

Reciprocating R-134a
R-22
ParaFlow
Absorption Water
#8
IsoFlow
Absorption Water Controlling Demand Charges
R-134a 100 w/o Demand Limiting
TurboMaster w/ Demand limiting
R-22
80
#9

% Full-load Amps
Ammonia AMMONIA Operate Chillers in Proper Sequence 60

40
TONS 100 400 700 850 1000 1250 1500 2100 5500 8500 1.3

20
1.1

Efficiency begins dropping 0

Constant Speed 0 2 4 5 6 7 8 10 12 14 16 18 20
kW / ton

0.9
#13
Minutes
Variable Speed Centrifugal Chillers 0.7

1.3 0.5

1.1 0.3

Constant Speed 100% 80% 60% 40% 20%

kW / ton

0.9 Variable Speed Load

0.7

0.5 30% Energy Savings

0.3
100% 80% 60% 40% 20%
Load