carrier chiller retrofit - ice group · carrier retrofit | chiller #1 — cost analysis 750 ton...
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Jeff Figueroa EMCOR Services Mesa Energy
Rod Kraft EMCOR Services Mesa Energy
Carrier Chiller Retrofit
2019 Operations & Applied Peer Group Meeting
Carrier 19EF, 19EX and 19XR Chiller Retrofit
• Customer inquired about replacing their Carrier 19EF 1350 ton chiller to a smaller 750 ton chiller.
• Old Data Center built in the 1970’s
• High heat load
• 2018 — Reduced load due to increased office space and more efficient Data Center equipment Continuously running unloaded at
roughly 300-400 tons.
.95 Kw/ton operating at 650 tons.
2019 Operations & Applied Peer Group Meeting
Why Retrofit vs. Replace The Chiller?
Replacing the chiller was considered but after review of the installation cost, Retrofit was recommended.
– It would cost approximately $1 million a day to crane up the new chiller and shut down the cable transit system.
– Installation cost increased payback. No Water Side Piping needed to retrofit.
2019 Operations & Applied Peer Group Meeting
Strategy Behind The Proposal
JOB DETAILS Replace the 1350 ton 19FA compressor with a new 750 ton 19XR; upgrade the PIC controller and installing a VFD for the compressor.
– Carrier thought they had the job sole sourced.
– Carrier would not sell us the compressor so we priced in an entire basic 19XR chiller.
– Risk – No Warranty from Carrier.
Awarded the job!!
2019 Operations & Applied Peer Group Meeting
Carrier Chiller Retrofit Kick Off
New chillers arrived.
Compressor and PIC controller were removed at the shop.
Evaporator and condenser were scrapped.
2019 Operations & Applied Peer Group Meeting
Removal of Old Carrier Compressor/Rigging of New
Rigged and removed the 19FA compressor from the 19EF chiller.
Purchased and modified moving dollies, welding support rods underneath the motor for further support.
Compressor and cart were rigged onto stake bed truck and delivered to the jobsite.
2019 Operations & Applied Peer Group Meeting
Compressor Rigging
Rigged new 19XR 6000lb compressor up through a service elevator and across the roof into chiller room.
Entrance to 11th floor mechanical room shown.
Rigged compressor up mechanical room stairs and rolled into place used modified carts.
2019 Operations & Applied Peer Group Meeting
New Compressor Installation
19XR compressor ready to rig into place.
2019 Operations & Applied Peer Group Meeting
Piping of Suction Elbow and Discharge
Suction elbow and discharge line fabricated, fitted and welded into place.
2019 Operations & Applied Peer Group Meeting
Piping of Oil Recovery, Motor Cooling & Refrigerant Drain Lines
Compressor in place.
Oil recovery line installed.
Motor cooling lines piped in.
Motor Insulated.
Refrigerant drain line piped in.
2019 Operations & Applied Peer Group Meeting
Electrical Rerouted to Motor and Complete
2019 Operations & Applied Peer Group Meeting
Suction Elbow Insulated
2019 Operations & Applied Peer Group Meeting
Piped Up and Ready!
2019 Operations & Applied Peer Group Meeting
Starter Conversions
Old Benshaw Solid State Starter.
2019 Operations & Applied Peer Group Meeting
Starter Conversion
Removed old Benshaw starter, left enclosure and breaker.
Installation of new ABB ACH 550 VFD next to old starter.
2019 Operations & Applied Peer Group Meeting
Starter Conversions – VFD Installation
VFD Installation with starter work.
Able to go with smaller HP VFD due to the 750 ton compressor used.
2019 Operations & Applied Peer Group Meeting
PIC Controller Upgrade
Original 32SM controller removed.
New Carrier PIC controller installed.
Had to add wells for sensors.
Input parameters.
2019 Operations & Applied Peer Group Meeting
Carrier Retrofit | Chiller #1 — Performance
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950
Chiller Performance Evaluation
Chiller 1 Chiller 1 (Old) Chiller 2 Chiller 3 Chiller 4
2019 Operations & Applied Peer Group Meeting
Carrier Retrofit | Chiller #1 — Performance
Kw/ton at various loads
Tons of Cooling Chiller #1 Chiller #1 Old Chiller #2 Chiller #3 Chiller #4
950 0.71 0.47
900 0.74 0.44
850 0.41 0.77 0.42 0.76
800 0.35 0.81 0.4 0.76
750 0.29 0.84 0.39 0.78 0.61
700 0.27 0.9 0.4 0.82 0.625
650 0.25 0.95 0.48 0.86 0.624
600 0.25 1 0.52 0.9 0.68
550 0.26 1.05 0.59 0.98 0.72
500 0.27 1.1 0.61 1.05 0.77
450 0.28 1.2 0.69 1.1 0.82
400 0.29 1.31 0.74 1.2 0.88
350 0.29 1.4 0.84 1.3 0.95
300 0.3 1.45 0.93 1.4 1.1
250 0.36 1.15
200 0.4
2019 Operations & Applied Peer Group Meeting
Carrier Retrofit | Chiller #1 — Cost Analysis
750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate
Chiller KW Ton Load Hours Total KWH KWH Price Total Cost
1,380 0.54 600 3,132 1,014,768 $0.18 $182,658.24
750 0.346 600 3,132 650,203.2 $0.18 $117,036.58
Savings Annually $65,621.66
Tons KW Ton Load KW Usage Hours Per Year Total KWH Price Per KWH Total Cost
1,380 0.8 375 300 5,628 1,688,400 $0.18 $303,912.00
750 0.377 375 141.375 5,628 795,658.5 $0.18 $143,218.53
Savings Annually $160,693.47
Hours Per Year Total Annual Savings $226,315.13
Weekends 104 24 2,496
Weekdays 261 12 3,132 Project Cost $311,860.00
Total Hours 5,628
Payback in Years 1.38
2019 Operations & Applied Peer Group Meeting
Carrier Retrofit | Chiller #1 – Operating!
2019 Operations & Applied Peer Group Meeting
Carrier Chiller Retrofit | Chiller #1
Success!
2019 Operations & Applied Peer Group Meeting
Carrier 19EX Retrofit | Chiller #1
Due to the performance of Chiller #4, we received notice to proceed on the second chiller.
New 19XR compressor in chiller room and ready to go.
2019 Operations & Applied Peer Group Meeting
Installation of new 19XR Compressor
19XR compressor with stator removed.
2019 Operations & Applied Peer Group Meeting
19EX Compressor Removed
Carrier chiller with 19EX compressor removed.
2019 Operations & Applied Peer Group Meeting
Compressor Rigging
Carrier 19XR compressor rigged into place.
2019 Operations & Applied Peer Group Meeting
Installation of Piping
Stator now rigged into place and suction piping started.
2019 Operations & Applied Peer Group Meeting
Installation In Progress
2019 Operations & Applied Peer Group Meeting
Controller and Electrical
PIC Controller installed.
Electrical ready to run.
2019 Operations & Applied Peer Group Meeting
Piping
Suction line flange installed.
Capped off economizer vent line.
2019 Operations & Applied Peer Group Meeting
Suction Elbow and Discharge Installed
Suction and discharge lines piped in.
PIC controller installed.
2019 Operations & Applied Peer Group Meeting
View Piped In
2019 Operations & Applied Peer Group Meeting
View Piped In
2019 Operations & Applied Peer Group Meeting
Ready to Energize!
2019 Operations & Applied Peer Group Meeting
Water Side Conversion
Converted piping from variable primary to variable primary secondary system.
2019 Operations & Applied Peer Group Meeting
Pump Installation View
2019 Operations & Applied Peer Group Meeting
Primary Pumps Installed
New Primary Pumps.
2019 Operations & Applied Peer Group Meeting
Piping View
2019 Operations & Applied Peer Group Meeting
Carrier 19XR Retrofit | Chiller #2
19XR Chiller
2019 Operations & Applied Peer Group Meeting
Carrier Retrofit | Chiller #2
Rigging and removal of old stator.
2019 Operations & Applied Peer Group Meeting
Carrier 19XR Retrofit | Chiller #2
19XR Compressor Ready for rigging.
2019 Operations & Applied Peer Group Meeting
Carrier Retrofit | Chiller #2
19XR Compressor in place and rigging in of new stator.
2019 Operations & Applied Peer Group Meeting
Carrier Retrofit | Chiller #2
19XR Compressor Installed.
2019 Operations & Applied Peer Group Meeting
Carrier 19EF, 19EX and 19XR Chiller Retrofit
Total plant running at .44Kw/ton.
$1.5M total project sell, 25% actual GP%.
Questions?
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