Method to test HVAC equipment at part load conditions

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1 IPLV Method to test HVAC equipment at part load conditions For water cooled chillers: 100% load ( % hrs) + 75% ( Hrs ) + 50% ( Hrs ) + 25% ( Hrs ) = IPLV value Manufacturer can favor this number by tweaking design Better to get data from 100% down to 10% from manufacturer

2 IPLV Do computer model to simulate actual building part load performance, then you have actual load in 10% increments with wet bulb data Insert manufacturer data with hours Much closer to actual usage vs one single IPLV number

3 Chilled Water Systems Two or more Chillers Three different Pumping methods

4 Single-Chiller System air-cooled chiller pump coil three-way valve

5 Chillers Piped in Parallel Single Pump off 54 F [12.2 C] 54 F [12.2 C] on 42 F [5.6 C] 48 F [8.9 C]

6 Chillers Piped in Parallel Dedicated Pumps off on 42 F [5.6 C] 54 F [12.2 C] 60% to 70% of system flow coil starved for flow

7 Chillers Piped in Parallel Dedicated Pumps 2 pumps head pressure 1 pump system curve 65% 100% percent flow

8 Chillers Piped in Series absorption chiller electric chiller three-way valve

9 Three-Way Valve Control airflow three-way modulating valve bypass pipe

10 Primary-Secondary Configuration production pumps production loop distribution pump distribution loop two-way valve

11 Primary-Secondary System Rules The bypass or de coupler pipe should be free of restrictions Sized for minimal pressure drop Avoid random mixing of supply- and return-water streams No check valve Sized for the flow of only one chiller Bi directional flow meter

12 Two-Way Valve Control airflow two-way modulating valve

13 Production Loop production pumps supply tee return tee

14 Manifolded Production Pumps production pumps isolation valves

15 Distribution Loop supply tee distribution pump return tee two-way valve

16 Multiple Distribution Pumps distribution pumps return from loads supply to loads

17 Tertiary Pumping distribution pump tertiary pump two-way valve bleed line

18 Distribution Loop Characteristics Reduced pump energy use Distribution loop sized for system diversity Higher returnwater temperatures

19 System Operation production loop supply tee return tee distribution loop

20 Deficit Flow 1,000 gpm at 42 F [63 L/s at 5.6 C] 1,000 gpm at 56 F [63 L/s at 13.3 C] 1,200 gpm at 44.3 F [76 L/s at 6.8 C] 1,200 gpm at 56 F [76 L/s at 13.3 C]

21 Excess Flow 2,000 gpm at 42 F [126 L/s at 5.6 C] 2,000 gpm at 54.6 F [126 L/s at 12.6 C] 1,800 gpm at 42 F [114 L/s at 5.6 C] 1,800 gpm at 56 F [114 L/s at 13.3 C]

22 Variable-Primary-Flow Systems variable-flow pumps check valves control valve two-way valve optional bypass with three-way valve

23 Critical VPF System Requirements Chillers must handle variable evaporator flow new chillers and panels System must include a bypass System-level controls must limit the rateof-flow change Adequate time to design and commission controls Operator must understand the system

24 Critical VPF System Requirements Must keep the evaporator flow between the manufacturers min and max flow. Staging is the critical time in chiller sequencing both adding and subtracting. Consider One Large CW Pump (with Standby) vs a pump for each chiller. Some of the modular chiller manufacturers actually remove evaporators as the stage down in variable flow applications.

25 Heat-Recovery Chiller heat-recovery condenser standard condenser evaporator

26 Chiller Heat Pump Any water cooled chiller is a heat pump within certain temperature limits Some can be designed and selected for high temperature hot water applications Screws and Scrolls are easiest for high lift duty Centrifugals are harder to get high lift, two compressors in series

27 Chiller Heat Pump Work with the manufacturer on product selection MUST have an evaporator load to make heat, so be very careful if this chiller is expected to run at part load

28 Application Outside Range of Chiller air-cooled chiller 240 gpm at 45 F [15 L/s at 7.2 C] 240 gpm at 56.7 F [15 L/s at 13.7 C] 80 gpm at 80 F [5 L/s at 26.7 C] 80 gpm at 45 F [5 L/s at 7.2 C] process load

29 Free Cooling Cool Chilled Water System with the Cooling tower water Outdoor WB dependent Chillers can be off or supplement the system Plate & Frame heat exchanger rated to AHRI

30 Waterside Economizer Plate-and-Frame Heat Exchanger distribution pump plate-and-frame heat exchanger

31 Waterside Economizer Refrigerant Migration from compressor to compressor condenser liquid flow shutoff valve shutoff valve vapor migration evaporator

32 Chilled Water Plant Control Temperature Flow Load KW or Amps Critical Zone or CW Valve Position

33 Load Indicators Temperature supply-water temperature return-water temperature chiller-plant controller

34 Load Indicators Flow chiller-plant controller flow meter

35 Load Indicators Capacity return-water temperature flow meter supply-water temperature chiller-plant controller

36 Chiller Rotation equal-capacity chillers

37 Improving Chiller/System Efficiency Maintenance is the first place to start Leak Check, Brush Condenser Tubes, Clean Air Cooled Condensers Lower Cooling Tower Water temperature BUT not so low that Oil Pressure differential is lost Be careful on W/C screw chillers as so don t have an electric oil pump.

38 System Optimization Chiller Decrease condenser-water temperature Increase chilled-water temperature Chilled-water pump (variable-flow system) Increase chilled-water T Cooling tower Increase condenser-water temperature Condenser-water pump (variable-flow system) Increase condenser-water T

39 Chilled Water Reset Pros Reduces chiller energy Can work in constant-flow systems Cons Increases pump energy in variableflow systems Can cause loss of space humidity control Complicates chiller sequencing control

40 Trend Toward Lower Flow Rates electric-driven chiller evaporator flow rate leaving chilled-water temperature condenser flow rate entering condenser-water temperature yesterday 2.4 gpm/ton [0.043 L/s/kW] 44 F [6.7 C] 3.0 gpm/ton [0.054 L/s/kW] 85 F [29.4 C] today 1.5 gpm/ton [0.027 L/s/kW] 41 F [5 C] 2.0 gpm/ton [0.036 L/s/kW] 85 F [29.4 C]

41 Low-Flow Systems annual energy consumption, kwh 750, , , ,000 chiller 150,000 pumps 0 cooling tower fans base case low flow

42 Control of Condensing Pressure condenser evaporator control panel

43 Evaporative Condenser fan refrigerant vapor condenser coil liquid refrigerant sump subcooler pump

44 Cooling Tower propeller fan sprays fill outdoor air sump 85ºF [29ºC] to condenser from condenser 95ºF [35ºC]

45 Condensing Temperature Control flow-regulating valve condenser water pump condenser

46 Vary Condenser Water Flow Rate cooling tower cooling tower variable-speed drive condenser diverting valve bypass pipe condenser

47 Vary Entering Water Temperature variablespeed drive cooling tower cooling tower condenser bypass pipe condenser diverting valve

48 Cooling Tower Bypass 40ºF [4ºC] cooling tower 55ºF [13ºC] bypass pipe condenser diverting valve 65ºF [18ºC]

49 Condenser-Water Temperature annual energy consumption, kwh 300, , , F [29.4 C] 70 F [21.1 C] 55 F [12.8 C] optimal control condenser-water temperature set point cooling tower chiller

50 Chilled Water Plants Look at chilled water plant kw/ton, not just chiller kw/ton Add chiller, chilled water pumps, condenser water pumps and cooling tower fans together to get the plant kw/ton Need a good and accurate flow meter

51 Thermal Storage Cooling Can be designed or added to a chilled water system Chilled water tanks, 1 BTU is 1 lb of water changed 1 degree F, larger in size Ice storage, 144 BTU is 1 lb of water changed from liquid to water at 32 degree F, smaller in size

52 On-Peak and Off-Peak Periods 100 cooling load, % of design off peak on peak off peak 0 midnight 6 a.m. noon 6 p.m. midnight

53 On-Peak Cooling with Ice 100 cooling load, % of design make ice melt ice 0 midnight 6 a.m. noon 6 p.m. midnight

54 Ice Storage Tank

55 Ice Storage Tank water ice heat-transfer fluid inside tube near beginning of freezing process near end of freezing process

56 Positive-Displacement Compressors Impact on Chiller Capacity operating leaving-fluid refrigerant refrigerant mode temperature temperature density* cooling 40 F 36 F lb/ft³ (4.4 C) (2.2 C) (15.6 kg/m³) ice-making 22 F 15 F lb/ft³ (-5.6 C) (-9.4 C) (10.2 kg/m³) *HFC-134a

57 Small Air-Cooled System bypass valve pump cooling coil with three-way control valve ice valve air-cooled chiller ice storage tanks

58 Large Water-Cooled System cooling coil with two-way control valve ice pump bypass pipe VFD ice storage tanks load pump VFD water-cooled chiller chiller pump

59 Intermediate Heat Exchanger ice storage tanks cooling coil load pump VFD chiller pumps heat exchanger ice valve existing chillers ice-making chiller ice pump

60 Maintenance Suggested basic maintenance plan In all cases, refer to the manufacturer s data for their exact requirements Be aware of maintenance requirements for warranty Electric Chillers-Scroll, Recip, Screw and Centrifugal Absorption

61 Maintenance Considerations Mechanical Components Required maintenance Compressor and motor: no maintenance required Controls: no maintenance or calibration required Recommended maintenance Visually inspect overall unit Inspect safety controls and electrical components Tighten electrical connections Check for leaks Meg Electric Motors

62 Maintenance Considerations Mechanical Components Other design-specific requirements Change oil when oil analysis dictates Replace oil filter periodically Replace filter drier periodically Clean oil strainers annually Check shaft alignment annually Check coupling annually Replace shaft seal every 2 to 4 years Compressor teardown inspection every 5 to 10 years

63 Maintenance Considerations Heat Transfer Surfaces Recommended maintenance Use a qualified water treatment specialist Clean condenser tubes as needed Clean water-side strainers Test tubes every 3 years with Eddy Current

64 Heat Transfer Surfaces Log and track the approach temperature Approach temp is the difference between the refrigerant temperature in the heat exchanger to the leaving water temp i.e., evaporator refrigerant temp is 40 F and chilled leaving water temp is 42 F so the approach temp is 2 F

65 Fluid Analysis Oil analysis Conduct annual analysis to verify system integrity Measure oil pressure drop to determine if filter needs changing Measure charge Refrigerant charge Conduct analysis of refrigerant Inspect purge system

66 Oil Analysis Why perform regular oil analysis? Helps reduce maintenance costs Detects problems without compressor disassembly Extends service life of oil charge Reduces environmental problems related to oil disposal Helps maintain compressor efficiency and reliability Helps lower refrigerant emissions

67 Maintenance Water-Cooled Care must be taken on chillers with Brazed Plate Heat Exchangers to ensure long life with good filtration and water treatment as they are not mechanically cleanable. If they are fouled, reverse flow cleaning, acid cleaning OR replace!!

68 Absorption Chiller Types singleeffect doubleeffect directfired

69 Absorption Refrigeration Cycle reject heat heat energy in D C condenser generator expansion device pump A evaporator absorb heat B absorber reject heat

70 Absorption Refrigeration Cycle 1 psia [6.9 kpa] 1.5 psia [10.3 kpa] 5 psia [34.5 kpa] 15 psia [103.4 kpa] B C D concentration 0.1 psia [0.69 kpa] A F E 50 F [10 C] 100 F [37.8 C] 150 F [65.6 C] solution temperature 200 F [93.3 C] LiBr solution

71 Absorption Refrigeration Cycle steam or hot water generator evaporator heat exchanger absorber B D E C F A cooling water condenser chilled water expansion device

72 Single-Effect Chiller condenser generator evaporator absorber

73 Double-Effect Chiller low-temperature generator high-temperature generator condenser evaporator absorber

74 Direct-Fired Chiller condenser low-temperature generator evaporator absorber high-temperature generator

75 Direct-Fired Burner Daily maintenance Verify proper operation Seasonal maintenance Inspect burner firing rate, blower, linkage, and safety controls Test run with alternate fuel, if dual-fuel burner

76 Heat Transfer Surfaces Recommended maintenance Use a qualified water treatment specialist Clean absorber and condenser tubes as needed Clean waterside strainers Test tubes every 3 years with Eddy Current

77 Corrosion Inhibitors Absorbent solution analysis Conduct annually or semiannually Verifies corrosion inhibitor levels Verifies performance additive levels Refrigerant analysis Conduct annually

78 Mechanical Components Recommended maintenance Pump teardown and inspection every 5 to 10 years Controls: no maintenance or calibration required Visually inspect overall unit Inspect safety controls and electrical components Meg Electric Motors

79 Purge System Weekly maintenance Check level of liquid refrigerant in purge condensing unit Check vacuum pump oil Semiannual maintenance Inspect purge condensing coil and clean as necessary Change vacuum pump oil as needed

80 Credits for Seminar Trane Air Conditioning Clinic Series ASHRAE Handbooks, Standards and Guidelines AHRI Standards Climacool Corp Emerson Electric Calmac Ice Storage

81 Helpful Websites

82 Closing Comments Questions Future of HVAC Industry Future for Arizona Future for Electric Utility Industry Future of Energy Costs

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