K Y YowDir, Technical Center of ExcellenceTrane, Ingersoll Rand

Latest Trends in Chiller System Technologies

IGBC Conference 2016Grand Hyatt ,Mumbai 06-08 Oct 2016

Agenda

� Chiller vs Chiller Plant

� ASHRAE GreenGuide - Performance Goals of Chiller Pl ant

� Distribution Efficiency – Low Resistance and Low Flo w/Rt

� Design For Low Pump Head

� Variable Primary Flow

� Singapore case Studies ( GreenMark Platinum Plants)

� Recommended Key Technologies ( Product & System)

Chiller is just a part of Chiller System

Chiller

PLANT

Chiller

PLANT

Pumps

Chiller

Chillers

Cooling Towers

Controls

High Performance Chiller High Performance Chiller System

Multi-stage/Multiple/VSD/compressorDirect drive / Gear drive/Oiless (MB, Ceramics)Adaptive Controls

Holistic Approach to Building efficiency

(0.48 to 0.52 kw/Rt at AHRI conditions) (0.52 to 0.60 kw/Rt at Operating conditions)

M&V

(Product level Technologies)

Energy efficient HVAC systems are the key

Key: Energy Efficiency of HVAC System

Every Building can be a High Performance Building

By Design Through Upgrade

Good for business & Responsible to environment

Without compromising comfort or productivity

Energy Use Cost Emis sions

Chiller Plant Performance Goals

Big opportunity to Reduce KWI of Ancillary Equipment

( ASHRAE GreenGuide)

Reduces2/3

Ancillary

Reduces 1/3 Energy

Both NEW & Existing

ASHRAE GreenGuide

( DT : 7C-11C)

( DT : 7C-10C)

LOW FLOW Design => Low Distribution Energy

*ASHRAE 90.1(2016) will have Addendum :15F (8.3C) DT as a Prescriptive Requirement ( Exceptions Apply)

Chilled Water Pump : Kw/Rt is function of (Flow per RT) and Head

Head(m)

Kw per /M3/S

STD

LARGE

2.40 GPM/RT to 1.67 GPM/RT => Low Pumping Kw/Rt (0. 02)

Pumping Energy Performance Index Table

( Maintain same pipe size)

Delta T

Deg C Gpm/Rt Lps/Rt 10 15 20 25 30 40

127 190 253 316 380 506

3 4.45 0.280 0.035 0.053 0.071 0.089 0.106 0.142

4 3.34 0.210 0.027 0.040 0.053 0.066 0.080 0.106

5 2.67 0.168 0.021 0.032 0.043 0.053 0.064 0.085

5.56 2.40 0.151 0.019 0.029 0.038 0.048 0.057 0.077

6 2.22 0.140 0.018 0.027 0.035 0.044 0.053 0.071

7 1.91 0.120 0.015 0.023 0.030 0.038 0.046 0.061

8 1.67 0.105 0.013 0.020 0.027 0.033 0.040 0.053

9 1.48 0.093 0.012 0.018 0.024 0.030 0.035 0.047

10 1.33 0.084 0.011 0.016 0.021 0.027 0.032 0.043

Flow/Rt Pump Kw/Rt at different Heads

Hd varies with GPM 1.8

Smaller Pump/Electricals : Savings re-invest in Higher EFF Chillers

Condenser Water Pump :

Hd(m)

Kw per /M3/S

3.0 GPM/Rt to 2.0 GPM/Rt => Low Pumping Kw/Rt (0.02 4)

STD

LARGE

Delta T

Deg C Gpm/RtLps/Rt 10 15 20 25 30 35

127 190 253 316 380 443

3 5.30 0.334 0.042 0.063 0.084 0.106 0.127 0.148

4 3.98 0.250 0.032 0.048 0.063 0.079 0.095 0.111

5 3.18 0.200 0.025 0.038 0.051 0.063 0.076 0.089

5.3 3.00 0.189 0.024 0.036 0.048 0.060 0.072 0.084

6 2.65 0.167 0.021 0.032 0.042 0.053 0.063 0.074

7 2.27 0.143 0.018 0.027 0.036 0.045 0.054 0.063

8 1.99 0.125 0.016 0.024 0.032 0.040 0.048 0.055

9 1.77 0.111 0.014 0.021 0.028 0.035 0.042 0.049

10 1.59 0.100 0.013 0.019 0.025 0.032 0.038 0.044

Flow/Rt Pump Kw/Rt at different Heads

Smaller Pumps/Electricals and Smaller Cooling Tower ( due to Bigger Range)

LOW FLOW Condenser :

Hd(m)

Kw per /M3/S

Benefit of Low Flow Expands at partload Conditions

STD

LARGE

Delta T

Deg C Gpm/RtLps/Rt 10 15 20 25 30 35

127 190 253 316 380 443

3 5.30 0.334 0.042 0.063 0.084 0.106 0.127 0.148

4 3.98 0.250 0.032 0.048 0.063 0.079 0.095 0.111

5 3.18 0.200 0.025 0.038 0.051 0.063 0.076 0.089

5.3 3.00 0.189 0.024 0.036 0.048 0.060 0.072 0.084

6 2.65 0.167 0.021 0.032 0.042 0.053 0.063 0.074

7 2.27 0.143 0.018 0.027 0.036 0.045 0.054 0.063

8 1.99 0.125 0.016 0.024 0.032 0.040 0.048 0.055

9 1.77 0.111 0.014 0.021 0.028 0.035 0.042 0.049

10 1.59 0.100 0.013 0.019 0.025 0.032 0.038 0.044

Flow/Rt Pump Kw/Rt at different Heads

At Constant Flow, STD 3.0 GPM/RT Design can hit >0.1 Kw/Rt at 50-60% load

GPM/RT increases during chiller Partload => Higher Kw/Rt

KWI Savings Expands at Part Load

Design for LOW Pressure Resistance CHW/CW SystemGoal : Max 15 - 20m ( CHW)

Max 10 -12m ( CW)

� Low WPD Chiller Evap/Cond ( <4m)

� Avoid 90 Deg Bends in Piping� Over Size Riser Pipe where

justified� Avoid use of Balancing Valve� Locate CT near plantroom� Elevate Pumps to same elevation

as chiller connection

� Replace 4 X 650Rt with 3 X 700 RT� Relocate Chiller plant to Carpark� Locate new CTs next to plant� Re-design with VPF (existing Pri-Sec)� Remove Balancing Valves

Green Energy Management (GEM) Project by Grand Hyatt Spore (1999)

1.0 Kw/Rt to 0.59 Kw/Rt

Case Study 1 : Hotel

A/C A/C

BAS

Airside

Existing Air-cooled Chiller plant >1.3 Kw/RT

Case Study 2 : Existing Office Building

Operating0.56 Kw/rt

Retrofit : ( 2 x 500 RT ) 0.514 Kw/RT

Ancillary Kw/Rt = 0.041 ( 8% of System)

8C CHW(select at6.7C)

Case Study 3 : Existing Commercial Bldg

3.5 Million Sq Ft Business Park Development ( 7,000 RT)

Sustaining 0.58 Kw/RT since completion in 2010 ( 6Y operation)

Case Study 4 : Existing Business Park Performance Audit after 6 Yrs

Meeting the GreenGuide Goals of 0.55 Kw/Rt Plant ?

6.2 C , Tropics Temperate Climate

0.503

0.015

0.024

0.005

Site

0.547

Case Study : A Singapore Site ( 3600 RT at 6,2C)

Singapore Project achieving 0.55 Kw/Rt ( Average 0 .57 )

M+V Captures and Display All Essential Data for Analytics

Ministry of the Environment and Water Resources, Si ngapore

Energy saving system design

Improvement 35%(0.86 to 0.57 Kw/Rt)

Scope: • 1 x 850RT Low-pressure Centrifugal Chillers (0.48 Kw/Rt) replacing existing 2 X 500 RT R134a chiller( 8 yrs Old)• New chilled water and condenser water pumps c/w VSD• System efficiency of <0.60kW/RT

GreenMark Platinum

Case Study 5 : Govt Building

2012 Energy Retrofit ( Guaranteed Energy Savings Performance)

Energy Retrofit is more than one-to-one chiller Cha nge-out

Re-configure Pumping ( Pri-Sec to VPF)Re-Engineer Piping layout to Minimise Friction Loss

STRAIGHT CW PIPE CONNECTION TO CHILLER

CWS PIPE NOZZLE

Many pipe bends and turns – high frictional loss CHW/CW water

distribution system

Balancing valve - high

∆∆∆∆P

BEFORE AFTER

Components Recommended Performance

System Optimisation( New/Existing Plants)

Chillers 0.48-0.52 Kw/Rt (rated at AHRI conditions)Low Water pressure Drop (<3m)

Optimise ( Not one-to-one changeout)Large DT ( CHW 7-11C)/ (CW 7-10C) Convert to Variable Primary FlowCHW Temp: 5 to 7.5C Can consider Reset (Operation).

Pumps/Motors Min 85% (P) /93%(M) Eff CHW/CW Kw/Rt < 0.03CHW Head <20mCW Head <15m

VSD for CHW PumpsVSD for CW Pumps (optional)

Cooling Towers Kw/Rt <0.03Exceeds 90.1 Rating requirement

Equipped with VSDProvide Extra CTs if possible(Good for Optimisation)

Piping LOW Resistance Retrofit to :Avoid 90 Deg. BendsAvoid Bal ValvesLayout Piping first

M+V Investment Grade (SS591/IPMVP STDS)

Continuous Monitoring and Optimisation

Designing High Performance Chiller Plant ( Better than 0.60 Kw/Rt)

Recommended Technologies For Designing better than 0.60 Kw/Rt Plant

Simple Technologies for Breakthrough Performance in Existing Buildings

<0.60Kw/Rt

PLANT

<0.60Kw/Rt

PLANT

Pumps

Chillers

Cooling Towers

Controls

M&V

Thank You