Introduction to Improving Energy

Efficiency in Chiller Systems

Riyaz Papar, PE, CEM
Director, Global Energy Services
Hudson Technologies Company
rpapar@hudsontech.com
November 2013

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Acknowledgments

Texas Industries of the Future (TXIOF)

Texas State Energy Conservation Office (SECO)

Energy Industries in Ohio

Joe Longo & Derrick Shoemake, Hudson

Technologies

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Webinar Agenda

The Systems Approach

Fundamentals of Refrigeration

Chiller Plant Actual Operating Performance

Predictive and Preventive Maintenance

BestPractices

Energy Conservation Measures (ECMs)

Conclusions

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Chiller System Energy Cost?

1,000 Refrigeration Tons chiller plant load

Chiller System performance = 0.75 kW/ton
Bundled power cost = $0.085/kWh
600,000
500,000
Operating Cost ($)

400,000
300,000
200,000
100,000
4 months

6-8 months

All year round

Operating hours
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The Systems Approach

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The Systems Approach

Establish current system conditions,

operating parameters, and system energy use

Investigate how the total system presently

operates

Identify potential areas where system

operation can be improved

Analyze the impacts of potential

improvements to the plant system

Implement system improvements that meet

plant operational and financial criteria

Continue to monitor overall system

performance
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A Chilled Water Plant Systems Approach

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Main Driving Force for Change

Energy
Reliability
Maintenance
Productivity
Quality
Cost avoidance
Emissions reductions

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Fundamentals of
Refrigeration

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The Refrigeration Cycle

P [psia]

10

R134a

Condensation / SubCooling

10

105F

2
Expansion

Compression

40F
Ev aporation (Boiling)

0.2

10

0.6

0.4

0.8

25

50

75

100

125

150

h [Btu/lbm]
State Point
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Single Stage Chiller System

HGBP (Hot Gas ByPass)

Compressor
Condenser

Cooling Water

Evaporator

Chilled Water

HGBP

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A Centrifugal
A Water-Cooled
Chiller Chiller System

Condenser

Compressor

Evaporator (Chiller Barrel)

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Two Stage Chiller System

HGBP

Compressor
Condenser

Cooling Water

Evaporator

Economizer

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Chilled Water

HGBP
(Hot Gas ByPass)

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LiBr-Water Absorption Chillers

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The Air, Water and Refrigerant Cycle

The Systems Approach

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Chiller Plant - Actual

Operating Performance

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Chiller Capacity

Definition of Refrigeration Ton (RT)

The

amount of thermal energy to be

removed from 1 Ton (2,000 lbs) of
water at 32F to make it into ice at 32F
in one day (24 hr) is known as 1 RT

1 RT = 12,000 Btu/hr = 3.517 kW

Chiller capacity (size or tonnage) is the
amount of full load cooling capacity
provided by the chiller at certain design
conditions
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Chiller Performance Metrics

Most standard rating in the US - kW/RT

(hp/RT)

Amount of compressor power (kW or

hp) required to produce 1 RT of cooling
or refrigeration

Compressor Power (kW )

kW / RT
Cooling Load ( RT )

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Chiller Full Load Design Specifications

Obtained from the Chiller Manufacturer

Chiller ID: Chiller #6

Chiller Manufacturer: ZZZZZZZ

Year Commissioned: 1990

Chiller Type: Constant Speed Centrifugal

Model Number: XXXXXXXXXX

Serial Number: AAAAAAAA

Refrigerant Type: R-134a

Capacity (Tonnage): 2,000

Efficiency (kW/Ton): 0.625

IPLV / NPLV: .541

Full Load Amps (FLA): 198

Volts: 4160

Evaporator Entering Water Temperature: 54.37F

Evaporator Leaving Water Temperature: 44F

Condenser Entering Water Temperature: 85F

Condenser Leaving Water Temperature: 94.4F

Evaporator Delta Temperature: 10.37F

Condenser Delta Temperature: 9.4F

Evaporator GPM: 4,627

Condenser GPM: 6,000

Evaporator Pressure Drop (psig): 9.9

Condenser Pressure Drop (psig): 8.1

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Overall Chiller Plant Performance

Information required

Total tonnage
Total kW

Compressor Power
Pumping Power
Cooling Tower Fan Power
Other (as defined in the scope)

Plant Performance

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kW
n
Chiller Tons
m
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Overall Chiller Plant Performance

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Chiller Plant Efficiency Metrics

Overall chiller plant performance

Individual chiller efficiency

Lift is defined as the difference between the refrigerant

saturated condensing and evaporating temperatures

Individual compressor isentropic efficiency

Chiller tonnage
Compressor kW

Individual Chiller Lift

Total tonnage
Total kW (including chillers and auxiliaries)

Suction and discharge temperatures

Suction and discharge pressures

Individual heat exchanger effectiveness

Approach temperatures
T on chilled water and cooling tower water
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Predictive & Preventive

Maintenance
BestPractices

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First Things First Fluid Management

Understanding Cause and Effect is very

important for Root Cause Analysis
This enhances system reliability and reduces
unplanned shutdown
Significant savings in Maintenance costs
Most Maintenance BestPractices are testingbased

Refrigerant, Oil and Water Testing

Rotating equipment monitoring

Vibration analysis

Eddy-current testing

In chiller systems, contaminants affect

efficiency & capacity

Chemistry Based Solutions

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Blood Chemistry

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Chiller Chemistry

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Refrigerant Analysis Criteria

Moisture
Oil
Particulate
Chlorides
Acid
Purity
Non-Condensables
Other Contaminants

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Nonferrous cutting wear

Severe sliding wear

Copper alloy
sliding wear

Ferrography
Oil Analysis

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Water Testing and Analysis

Cooling Tower Water testing and analysis

Open loop evaporation of water

Control of corrosion, scale and biological activity
Material of construction plays a very important role
Testing conducted for pH, TDS, Conductivity, Hardness,
Alkalinity, Chlorides, Silica, Bacteria, etc.

Chilled Water testing and analysis

Closed loop generally less issues
Lower temperatures

Working with a water chemist / treatment

company
Periodic testing program
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Energy Conservation
Measures (ECMs)

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3 Methods of Maximizing Chiller Plant Efficiency

Preventive

Restorative

Identify problems before they become expensive

(cost avoidance)
Maintain optimum chiller plant efficiency
Identify heat transfer problems, i.e., off-design
water flow, fouling or scaling, etc.
Remove non-condensable gases
Maintain proper refrigerant levels

Opportunity

Identify optimal chilled water set points

Proper chiller sequencing and load balancing
Proper tower basin water management
Peak demand management
Condition-based maintenance versus scheduled
preventive maintenance
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Implement ECWT management

Optimize settings for ChWST
Eliminate all refrigerant leaks
Maintain design water flow rates
in evaporator / condenser
Eliminate refrigerant stacking
Remove non-condensable gases
and moisture
Reclaim refrigerant
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No Cost / Low Cost

ECMs

List of ECMs

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Clean fouled and scaled heat

exchangers
Sequence multiple chillers to optimize
efficiency
Maintain compressor isentropic
efficiency
Improve drive efficiency
Investigate application of variable
frequency drives
Undertake peak load management
strategy
Install water-side economizers
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Higher Cost
ECMs

Medium Cost
ECMs

List of ECMs (continued)

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Implement ECWT Management

ECWT Entering Cooling Water Temperature

Approach

The approach is the difference in temperature between

the cooled-water temperature and the entering-air wet
bulb temperature
Since the cooling towers are based on the principles of
evaporative cooling, the maximum cooling tower
efficiency depends on the wet bulb temperature of air

Wet Bulb

Wet bulb temperature is the lowest temperature that

can be reached by the evaporation of water only
It is determined by the atmospheric pressure, ambient
temperature and the relative humidity
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Concept of Lift

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Implement ECWT Management

80F ECWT drops to 70F ECWT

kW/ton drops from 0.7 to 0.47 (33% improvement)

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Optimize Settings for ChWST

ChWST Chilled Water Supply Temperature

Approach / RAT

The approach (RAT) is the difference in temperature

between the chilled-water supply temperature and the
refrigerant saturated temperature in the evaporator
It provides the driving force to transfer the heat from
the water to the refrigerant

Load control

Cooling required is controlled by bypassing chilled

water flow
Alternate methodology variable pumping

Primary
Secondary
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Optimize Settings for ChWST

Chiller Performance (kW/RT)

0.475
0.45
0.425
0.4
0.375
0.35
0.325
0.3
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42

43

44

45

46

47

CWST (F)

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Clean Fouled and Scaled Evaporator

Fouling in the evaporator / cooler

Refrigerant-side
Water-side

Refrigerant-side fouling Excess Oil

Refrigerant-side fouling Water

Water-side fouling

High makeup (leaks) in the closed loop system

Iron fouling from corrosion, microbiological growth and
scale due to insufficient chemical protection

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Fouled/Scaled Evaporator

Iron Oxide Scaled

Condition
After tube brushing

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Fouled/Scaled Condenser
March

July

Sept

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Reclaim Refrigerant

Over time and operations, the refrigerant in the

chiller gets contaminated and results in

Fouling of heat exchangers

Reductions in heat transfer coefficients

The process of recovering the refrigerant and

bringing it back to AHRI-700 specification
standard is known as Reclamation
Reclaiming a refrigerant improves overall
operating performance and in most cases
increases chiller tonnage (capacity)
Periodic sampling and testing of refrigerants in
chiller systems is key to ensuring that the chiller
chemistry is well maintained

Analogous to maintaining water chemistry in boilers

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Reclaim Refrigerant

Moisture in
refrigerant
Presence of Oil
in refrigerant
Particulate in
refrigerant
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Impact on Capacity

Reclaim Refrigerant
SUMMARY of RESULTS & COST SAVINGS
Total System

Design P/L

Design F/L

Refrigerant

Tons = 1,502 [RT]

1,502 [RT]

2,002 [RT]

Design: R134a

com pHP = 1,219 [HP]

1,503 [HP]

2,360 [HP]

Currently Used:

HPTon = 0.81 [BHP/RT]

1.001 [HP/Ton]

1.18 [BHP/RT]

Steam Rate = 12.02 [lb/hr-HP]

R134a

12.03 [lb/hr-HP]

Superheat Capacity Penalties

NC% = 0.0 [% ]
Balance Syste m = 0.0 [% ]

Com ponent Balances

Capacity Loss (RT)

2.8

0.1

Evaporator

Balance Evap = 0.0 [% ]

Balance SubCoole r = ???? [% ]

Potential Savings Opportunities

Pressure Ratio (current):

Annual Energy Costs

Steam Cost = 14.48 [$/1000lb]

2.6

Evaporator

Condenser

System

New Ratio

2.3

2.6

2.3

Savings (% )

13.1

0.0

13.1

Hours = 4,000 [Hr]

LFC = 0.80 [kW/ton]
Cost ($)

NC Penalty ($)

678,871

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Impact of Oil, Particulate

& Moisture in refrigerant
on energy efficiency &
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costs

Eliminate Refrigerant Stacking

Refrigerant stacking impacts heat transfer efficiency

in both the evaporator and condenser - higher
kW/Ton and energy costs

Leads to reduced compressor capacity

Chiller surging or stalling

Shut down on low refrigerant temperature

(pressure)

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Refrigerant Stacking

Raise
ECWT
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Sequence Multiple Chillers to Optimize Efficiency

All chillers will have an optimal operation range

(best efficiency point)

When multiple chillers are operating, the overall

plants composite operating curve maybe very
different from the individual chillers curve

It is important to know how each of the chillers

operate under different load conditions

Pick the best chiller operating combination for

the current operating conditions Dynamic
Optimization problem (NOT Easy)
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Investigate Application of Variable

Frequency Drives (VFD)

Replacing old chillers with newer energy efficient systems

most new packaged chillers will come with a VFD option

VFDs take advantage of lower ambient temperatures (lower

lift) and correspondingly lower cooling loads (lower
refrigerant flow rates)

VFD pumps and fans can play a very important role in

reducing total system energy consumption

VFD efficiency is extremely high (99%) and more

importantly, it offers a benefit on the drive side by providing

Soft start capability

Power factor correction
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Comparison of Constant Speed & VFD

Chiller Performance

Chiller Performance (kW/RT)

0.75
0.7
Constant Speed

0.65

Variable Frequency

0.6
0.55
0.5
0.45
0.4
0.35
0.3
20

30

40

50

60

70

80

90

100

Cooling Load (% )

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Install Water-side Economizers

This ECM is applicable only in certain

geographical areas but can have a huge
impact on energy savings

Installing a water-side economizer allows for

free cooling during times of the year when
the outdoor ambient conditions allow for
very low wet-bulb temperatures

The cooling tower water provides all (or

some portion) of the chilled water plant load
and reduces the amount of chillers required
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Undertake a Peak Load Management Strategy

Peak demand charges can become excessive

depending on chiller plant management and
operational strategy

There are 3 ways to manage peak demand

regarding chillers
Thermal energy storage
Optimize chiller efficiency to lower kW usage of running
chillers
Take a chiller off-line

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Conclusions

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Next Steps

Develop a simple schematic of your Chiller Plant /

Refrigeration system and define the boundaries

Use a systems approach to complete an initial assessment to

understand operations and load profile

Undertake a simple gap analysis to identify any potential

improvement opportunities

Evaluate each ECM and prioritize based on quantified savings

opportunities

Put a program in place to ensure that there is proper

Predictive and Preventive Maintenance BestPractices

Implement an effective Chiller Plant Performance Monitoring,

Diagnostics and Optimization system
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1-Day Training Workshop

Introduction to Energy Efficiency in
Chiller Plant Systems
December 17, 2013
8 am 4 pm
Houston Business RoundTable
5213 Center Street
Pasadena, TX 77505
Facilitator: Riyaz Papar, PE, CEM
Hudson Technologies Co.
Registration Information:
Kathey Ferland
Texas Industries of Future
kferland@mail.utexas.edu
http://TexasIOF.ceer.utexas.edu

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Contact Information
Technical Information
Riyaz Papar, PE, CEM
Hudson Technologies Co.
rpapar@hudsontech.com
http://www.hudsontech.com

Program Information
Kathey Ferland
Texas Industries of Future
kferland@mail.utexas.edu
http://TexasIOF.ceer.utexas.edu

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