Download - Trane 4 Chiller Plant Controls
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Chiller Plant Control
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Introduction to Trane Control Systems2 © 2010 Trane
What We Will Cover
• Factory-integrated controls on chillers
• Chiller plant control strategies
• Tracer control features
• Reliability and serviceability
• Chiller plant optimization
• Additional discussion
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Introduction to Trane Control Systems3 © 2010 Trane
Trane AdaptiView™ Control System4th Generation Microprocessor Chiller Control
• Adaptive control – Reliable operation through difficult
operation conditions
• Feed-forward control– Accurate and stable control under
the most dynamic system transients
• Sophisticated diagnostics
• Fast restarts
• Operator tested – informative display
• Multiple open protocol communication options
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Introduction to Trane Control Systems4 © 2010 Trane
Feed-forward control enables the chiller to respond
faster to load changes
• Feed-forward control uses flow change and entering water
temperature as an indication of load change
• It proactively compensates for load changes
Trane AdaptiView™ Control SystemFeed-forward Control
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Introduction to Trane Control Systems5 © 2010 Trane
PID Feedback
42º?º
Typical Controller
Trane
UC800/AdaptiView
UC800 Feedback
40º56º
Feedforward
ΣΣΣΣ
DP
627 gpm
• Return Water Temp• Evaporator Flow
Trane AdaptiView™ Control SystemFeed-forward Control
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Introduction to Trane Control Systems6 © 2010 Trane
• Directly measures chilled water flow
• Enhances leaving water temperature control during rapid flow rate changes of up to 50%/min.
– >30 % /min commercial control
– 10% /min precision process control
• Auto-tunes control gains to maintain stability and accuracy over chiller’s full range of flow rates.
Trane AdaptiView™ Control SystemVariable Flow Compensation
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Introduction to Trane Control Systems7 © 2010 Trane
What Do Customers Really Care About ?
• Reliable chilled water flow
• Operating cost (energy efficiency)
• Operator safety
• Environmental awareness
• Reduced maintenance cost
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Introduction to Trane Control Systems8 © 2010 Trane
Tracer Chiller Plant Control• Repeatability – performance from plant to plant
– Maximize the use of pre-engineered features
– Minimize on-site customization
• Flexibility – supports a variety of:– Plant layouts
– Chiller types
– Control strategies
• Maximized energy savings
– Load matching
– Chiller tower optimization
– Distributed pump pressure optimization
– Thermal ice storage
– Minimize manual intervention
• Minimized operational costs
– Minimize manual intervention, but anticipate it
– Maintain chilled water flow and temperature
– Minimize service surprises
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Introduction to Trane Control Systems9 © 2010 Trane
LoadDetermination
Chiller Plant Control
ChillerSequencing
Chiller Plant Control
UserInterface
SystemOptimization
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Introduction to Trane Control Systems10 © 2010 Trane
Plant Layout FlexibilityConstant Flow
Chiller #1
Chiller #2
CW SupplyTemp
CW ReturnTemp
UCP2UCP2
UCP2UCP2
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Introduction to Trane Control Systems11 © 2010 Trane
Plant Layout FlexibilityVariable Flow - Decoupled
Air Handling Units
Control Valves
Variable-Speed
Drive
Pressure Differential Controller or Transmitter
Production
DistributionBypass Line
SU
PP
LY
DE
MA
ND
Chiller #1
Chiller #2UCP2
UCP2
UCP2UCP2
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Introduction to Trane Control Systems12 © 2010 Trane
Plant Layout FlexibilityVariable Primary Flow
Air Handling Units
Control Valves
Production
DistributionBypass Line
SUP
PLY
DE
MA
ND
Variable-Speed Drive
Flow
Meter
UCP2UCP2
UCP2UCP2
Differential Pressure Sensor or
Transmitter
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Introduction to Trane Control Systems13 © 2010 Trane
Pre-engineered Features
• Load determination
• Capacity matching
• Rotation
• Chiller setpoint control
• Failure recovery
• User interface
Installation and operating reliability and efficiency
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Introduction to Trane Control Systems14 © 2010 Trane
Load Determination (when to add or subtract a chiller)
What is the optimal sequencing for chillers?
• Should I run one chiller at 100% or two chillers at 50%?
• The givens…– whether you run one chiller or two…
� The building load does not change
� The outside wet bulb temperature does not change
– When you run two chillers…
� You may double the number of pumps
� You may double the number of tower cells
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Introduction to Trane Control Systems15 © 2010 Trane
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
0 20 40 60 80 100
Percent Load
kW
/to
n
One Chiller at 100%? orTwo Chillers at 50%?
Constant Speed Centrifugal ChillerUnloading at constant condenser water temperature
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Introduction to Trane Control Systems16 © 2010 Trane
Capacity Matching(turn the right chiller on)
Dependent on chiller plant design
• Normal - identical chillers
• Base - heat recovery/super efficient
• Pea - back up/alternate energy source/inefficient
• Swing - match the load!
• Custom - mix and match/nested CPC objects
Reduce operating costs
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Introduction to Trane Control Systems17 © 2010 Trane
UCP2
450 Ton Chiller (Swing) 900 Ton Chiller
(Normal-1)
900 Ton Chiller (Normal-2)
UCP2
UCP2
0 2250450 18001350900
UCP2
Building Load (Tons)
Reduce operating costs
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Introduction to Trane Control Systems18 © 2010 Trane
Flexible Rotation Which chiller is next?
• Schedule based
• Run-time
• Manual operator decision
• Customized
– Number of starts
– Other?
Reliable chilled water
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Introduction to Trane Control Systems19 © 2010 Trane
Unload Before StartKeep chillers online
• Ride out flow transients on startups
– Deals with less sophisticated chiller controllers
• Variable flow / multiple pump systems
• Low supply water temperatures
Reliable chilled water
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Introduction to Trane Control Systems20 © 2010 Trane
Failure Recovery Keep chilled water flowing
• No manual intervention required
• Follow the standard sequence
• Multiple failure inputs
– Chiller level
– System level
Reliable chilled water
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Introduction to Trane Control Systems21 © 2010 Trane
Intuitive User Interface
• Minimize training time
• Minimize undesirable manual control
• Maximize operator efficiency
Reduced Operational Costs
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Introduction to Trane Control Systems22 © 2010 Trane
Chiller - Tower Optimization Tower Setpoint Optimization
• Load
• Condenser watertemperature
• Wet bulb
• Tower design
• Load
• Condenser watertemperature
• Chiller design
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Introduction to Trane Control Systems23 © 2010 Trane
Chiller - Tower Optimization Chiller–Tower Interaction
Condenser Water Temperature, °°°°F
400
74
En
erg
y C
on
su
mp
tio
n, kW
76 78 80 8272
300
200
100
084
Tower
Optimalcontrol point
Chiller
Total
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Introduction to Trane Control Systems24 © 2010 Trane
Chiller - Tower OptimizationNorth America
350K
An
nu
al
Op
era
tin
g C
os
t, $
US
D
300K
250K
200K
150K
100K
50K
0Mexico City Orlando San Diego Toronto
55°°°°F Lvg Tower
Optimal Control
Design ECWT
Control Strategy
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Introduction to Trane Control Systems25 © 2010 Trane
Air Handling Units
Control
Valves
Pressure
Differential
Controller or
Transmitter
• Critical valve reset
• Benefits
– Reduced pump energy
– Better coil control
– Extend pump life
Distribution Pumping Critical Valve Pressure Control
Reduce operating costs
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Introduction to Trane Control Systems26 © 2010 Trane
Chiller Plant Dashboard Details
Daily Average MetricsPump Pressure
Pump Status
System and Chiller Status
Chilled Water Temps
Tower Water Temps
System Load
System Efficiency
Pump Flow
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Introduction to Trane Control Systems27 © 2010 Trane
Summary
Key points to remember
• Integrated chiller controls
– Factory quality; better performance, efficiency and serviceability; lower risk
• Performance
– Temperature control; reliability; extended equipment life; automatic failure response
• Efficiency
– Lower energy and maintenance costs
• Sustainability
– Maintain performance over time
– Document performance
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Thank you!