carrier chiller retrofit - ice group · carrier retrofit | chiller #1 — cost analysis 750 ton...

45
Jeff Figueroa EMCOR Services Mesa Energy Rod Kraft EMCOR Services Mesa Energy Carrier Chiller Retrofit

Upload: others

Post on 25-Aug-2020

34 views

Category:

Documents


0 download

TRANSCRIPT

Page 1: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

Jeff Figueroa EMCOR Services Mesa Energy

Rod Kraft EMCOR Services Mesa Energy

Carrier Chiller Retrofit

Page 2: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 3: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 4: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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!!

Page 5: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 6: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 7: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 8: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

New Compressor Installation

19XR compressor ready to rig into place.

Page 9: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Piping of Suction Elbow and Discharge

Suction elbow and discharge line fabricated, fitted and welded into place.

Page 10: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 11: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Electrical Rerouted to Motor and Complete

Page 12: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Suction Elbow Insulated

Page 13: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Piped Up and Ready!

Page 14: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Starter Conversions

Old Benshaw Solid State Starter.

Page 15: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 16: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 17: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 18: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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

Page 19: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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

Page 20: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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

Page 21: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Carrier Retrofit | Chiller #1 – Operating!

Page 22: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Carrier Chiller Retrofit | Chiller #1

Success!

Page 23: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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.

Page 24: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Installation of new 19XR Compressor

19XR compressor with stator removed.

Page 25: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

19EX Compressor Removed

Carrier chiller with 19EX compressor removed.

Page 26: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Compressor Rigging

Carrier 19XR compressor rigged into place.

Page 27: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Installation of Piping

Stator now rigged into place and suction piping started.

Page 28: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Installation In Progress

Page 29: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Controller and Electrical

PIC Controller installed.

Electrical ready to run.

Page 30: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Piping

Suction line flange installed.

Capped off economizer vent line.

Page 31: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Suction Elbow and Discharge Installed

Suction and discharge lines piped in.

PIC controller installed.

Page 32: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

View Piped In

Page 33: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

View Piped In

Page 34: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Ready to Energize!

Page 35: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Water Side Conversion

Converted piping from variable primary to variable primary secondary system.

Page 36: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Pump Installation View

Page 37: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Primary Pumps Installed

New Primary Pumps.

Page 38: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Piping View

Page 39: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Carrier 19XR Retrofit | Chiller #2

19XR Chiller

Page 40: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Carrier Retrofit | Chiller #2

Rigging and removal of old stator.

Page 41: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Carrier 19XR Retrofit | Chiller #2

19XR Compressor Ready for rigging.

Page 42: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Carrier Retrofit | Chiller #2

19XR Compressor in place and rigging in of new stator.

Page 43: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

2019 Operations & Applied Peer Group Meeting

Carrier Retrofit | Chiller #2

19XR Compressor Installed.

Page 44: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

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%.

Page 45: Carrier Chiller Retrofit - ICE Group · Carrier Retrofit | Chiller #1 — Cost Analysis 750 Ton Chiller Cost Analysis & Payback Remaining Week Day Operating Hours Estimate Chiller

Questions?