AIRAH ( QLD ) presentation

AIRAH ( QLD ) presentation
To efficiency and beyond

Introductory Concepts:
Design load vs Annual load
Chiller rating tools ‐ COP & IPLV
Bin weather data & NPLV

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 Chiller
58% Chiller
Fans 33%
43%

Fans Tower
24% Tower 2%
Pumps 5% Pumps
13% 22%
Design Performance Annual Energy Usage

A historical focus on chiller full load efficiency [COP/EER]
y
Increased focus today on‐
1. Chiller part load efficiency [IPLV / NPLV]
2. Reduction of air and water ‘transport’ energy

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 Tools used to identify appropriate chiller technology 

Constant condenser vs AHRI relief (IPLV)
Load % time entering condenser water temperature
IPLV without  AHRI relief with AHRI relief

100% 1 29 5
29.5 29 5
29.5

75% 42 29.5 23.9

50% 45 29.5 18.3

25% 12 29.5 18.3

Constant high ambient wb climates
h h b b l Seasonal climates

What is the weather data and load profile for the jobsite location ? => NPLV

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 YorkCalc BIN WEATHER DATA – Brisbane AUSTRALIA

temperature bin canberra melbourne adelaide perth sydney brisbane cairns

deg F deg C HRS WB HRS WB HRS WB HRS WB HRS WB HRS WB HRS WB
105-109 40.6- 42.8 6 21.7
100-104 37.8- 40 1 20 1 21.7 27 21.1 2 22.2 4 22.2 3 23.3 3 25
95 99 35-
95-99 35 37
37.22 17 19 4
19.4 12 21 1
21.1 55 20 17 21 1
21.1 6 21 1
21.1 15 22 2
22.2 14 25 6
25.6
90-94 32.2- 34.4 50 18.9 22 20.6 116 19.4 42 21.1 18 20.6 131 23.3 94 25.6
85-89 29.4- 31.7 112 17.8 50 20 215 18.3 14 20.6 40 21.1 643 21.7 781 25
80-84 26.7-28.9 193 17.2 96 18.9 313 17.8 37 21.1 158 20.6 1374 20.6 1620 23.3
75-79 23.9- 26.1 332 16.1 160 18.3 477 16.7 151 20.6 618 20.1 1744 18.9 2513 22.2
70-74 21.1-23.3 480 15.6 276 17.2 696 15.6 612 20.1 1493 18.3 1814 16.7 1984 20.1
65-69 18.3- 20.6 725 14.4 485 16.7 1013 14.4 1478 18.3 1975 16.1 1307 14.4 1163 17.8
60-64 15.6- 17.8 1096 13.3 958 15.1 1495 12.8 1966 16.1 1772 13.9 913 12.2 344 15.6
55-59 12.8- 15 1316 11.1 1650 13.3 1852 11.1 1764 13.9 1383 11.1 484 9.4 107 12.8
50 54 10-
50-54 10 12
12.22 1307 89
8.9 1938 11 1
11.1 1522 94
9.4 1384 11 1
11.1 852 89
8.9 223 72
7.2 23 10 1
10.1
45-49 7.2- 9.4 1160 6.7 1776 8.9 702 7.8 853 8.9 397 6.7 65 5.1 2 7.8
40-44 4.4-6.7 859 4.4 930 7.2 218 5.6 396 6.7 38 5.1 11 2.8
35-39 1.7- 3.9 547 2.2 277 5.1 38 2.8 38 5.1 1 1.1 0.6
30-34 ((1.1)) - 1.1 307 0.1 50 2.8 1 0.6 1
25-29 (3.9)-(1.7) 137 -2.8 4
20-24 (6.7)-(4.4) 27 -5.1 0.6
15-19 (9.4)-(7.2) 1 -7.2 66% annual operating hours full mechanical cooling
56% annual operating hours 19‐24
56% annual operating hours 19 24 deg c tower water
deg c tower water
30%  potential for integrated economizer assist
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 Review
• Variable speed drives are widely applied today to motors used in HVAC 
plant applications as a cost effective means to reduce energy use.

• Chilled water plants typically operate only 1% of the time at full load, design 
conditions.

• IPLV (integrated part load value) is a useful tool to evaluate chillers, but is 
based on a single chiller plant using standard AHRI water temperatures and 
average US weather data.

• NPLV (non‐standard part load value) can be used where the standard AHRI 
chilled and condenser water temperatures, load profile, and weather data 
do not apply.

• Brisbane bin weather data indicates there is opportunity for significant 
chiller operating hours at reduced off‐design entering condenser water.

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Chiller full load efficiency trends

COP=7 Chiller COP trend ((>7.0)

0)
(6.50)
COP=6
COP 5
COP=5
COP=4

1970 1980 1990 2000 2010

Recent gains through cycle efficiency

Since 1980, average chiller efficiency has improved  
over 35%, despite using less efficient refrigerants.

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• Significant gains in full load efficiency through advances in 
h h d l ffi i i
heat exchanger, compressor, motor, and cycle efficiencies.

• The biggest single gain however has been in part load 
efficiency with the adoption of the variable speed drive.

R ifi
Rectifier DC Inverter M
Motor
L
L1 U1
V1    V3    V5
L2 V1
Supply C U M3
W
L3 V4   V6    V2

Control electronics
Monitoring Control
Control, monitor, and communication

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Over 30 years of VSD technology development for chillers

Generation 5 (2010s)

Generation 4 (2000s)

Generation 3 (1990s)

Generation 2 (1986)

Significant innovation in 
Generation 1 (1979)
VSD technology since 1979

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 Real World Energy @ Lower Lift
Capitalizing on ‘off‐design’
Capitalizing on  conditions – 99% of the time
off design  conditions  99% of the time
Lowering Condenser Water 
Pressure Temperature

Condenser
d L
Lowers the Lift
th Lift
Lift  Expansion Compressor

Evaporator
Reduces Compressor Work

Enthalpy
Reduces Energy 
Consumption

Direct Indirect

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 How does LIFT impact efficiency ?
Chiller Energy Usage Analogy ‐
gy g gy Constant Speed Driven Chillers 
p

100% Condenser Temp.
85°F (29.5°C) ECWT

Design Lift
Lift
RGY  

(height of mountain)
ENER

Load
(weight of rock)

0% Evaporator Temp.
44°F (6.7°C) LCHWT

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 How does LIFT impact efficiency ? 
Chiller Energy Usage Analogy ‐
gy g gy Constant Speed Driven Chillers 
p

Condenser Temp.
85°F (29.5°C) ECWT

70%
RGY  

55°F (12.8°C) ECWT

n Lift
Off‐ Design
ENER

Load
(weight of rock)

0% Evaporator Temp.
44°F (6.7°C) LCHWT

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 How does LIFT impact efficiency ? 
Chiller Energy Usage Analogy ‐
gy g gy Variable Speed Driven Chillers 
p
Condenser Temp.
85°F (29.5°C) ECWT

Variable
Speed
Drive 
50%
RGY  

55°F (12.8°C) ECWT

n Lift
Off‐ Design
ENER

Load
(weight of rock)

0% Evaporator Temp.
44°F (6.7°C) LCHWT

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How Can You Save Energy in an HVAC Central Plant ?

YK Chiller with VSD Performance

COP
Loading has little effect
4.7 on efficiency
5.5 [~ 10%]

6.6
8.3
11

17
33

Entering condenser water
29.5 C 18.3 C
24.0 C 12.8 C

13
Johnson Controls ‐ Proprietary & Confidential
How Can You Save Energy in an HVAC Central Plant ?

YK Chiller with VSD Performance

COP
Loading has little effect
4.7 on efficiency
5.5 [~ 10%]

6.6
Lift has significant
8.3 effect on efficiency
11 [~ 50%]

17
33

Entering condenser water
29.5 C 18.3 C
24.0 C 12.8 C

14
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Variable Speed Drives save energy and reduce noise

Constant Speed

Variable Speed

1
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Variable Speed Drives
Low Voltage Liquid Cooled Unit Mounted VSD
g q

YMC²²
YVAA Magnetic VSD 
VSD Screw air cooled Centrifugal

415V
YVWA YK
VSD Screw water cooled Open VSD 
Centrifugal

1
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Variable Speed Drives
Medium Voltage (MV) VSD
g ( )

3.3 kV & 6.6 kV
YK
VSD Open 
Centrifugal

11 kV YK ‐EP
VSD Open Centrifugal 
with Economizer

1
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The Purpose of Variable Speed Drives

 Starts & stops the motor

 Significantly reduces inrush current to < than full load amps

 Corrects power factor close to unity

 Reduces utility demand charge

Regulates compressor speed to provide the most efficient 
chiller operation, reducing part load energy consumption

1
8
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Low inrush current with VSD < 100% FLA 

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 Superior power factor
0.95 power factor  (std VSD)
0.98 power factor VSD with active IEEE electronic filter

power factor non VSD (fixed speed)  

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 100 KW actual work

Consumed energy to  PF = 0.86
total energy  59 KVAR
59 KVAR generate magnetic field
i fi ld
provided  116 KVA
from supply

100 KW actual work

Consumed energy to 
total energy 
total energy 33 KVAR
33 KVAR generate magnetic field
PF = 0.95
PF  0.95
provided  105 KVA
from supply

100 KW actual work
Consumed energy to 
20 KVAR generate magnetic field
total energy  PF = 0.98
PF  0.98
provided 
from supply
102 KVA

what power factor means
p

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Why VSD ? ‐ Comparative Energy Performance
Comparison at AHRI condenser ‘relief’
Comparison at AHRI condenser  relief

No VSD VSD
% Load
% Load ECWT LWT COP COP %SAVED
100 29.5 6.7 6.17 6.11 ‐1.0
90        27.2 6.7 6.73 6.89 2.2
80 25.0 6.7 7.14 7.82 8.7
70 22.8 6.7 7.42 8.86 16.2
60 20.6 6.7 7.59 10.24 25.9
50 18.3 6.7 7.65 11.42 33.0
40 18.3  6.7 7.11 11.17 36.4
30
30          18 3
18.3  67
6.7 6 36
6.36 10 34
10.34 38 5
38.5
20         18.3  6.7 5.17 9.26 44.1
15 18.3  6.7 4.41 8.01 45.0

Significant savings ….and with more possible
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 Opportunities for Lower Lift

Lower Condenser  Higher Chilled Water 
g
Water Temperature Temperature
• Climatic Conditions
Climatic Conditions • Chilled Water Reset
Chilled Water Reset
• Control Strategy • Chilled Beam Systems
• Oversize Towers
Oversize Towers • UFAD Applications
UFAD Applications
• Series Counter‐flow • Series Counterflow

2
3
 Unit Mounted Low 
Voltage Solid State Starter

Unit Mounted Low 
Voltage Variable Speed 
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Efficiency breakthrough – low lift magnetic VSD chillers

+   8% COP
+ 13% IPLV

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 YVAA 0345EXV50 (1175 kWr)
Air-CooledVariable Speed ScrewChiller
YVAA Series % load Ambient COP
100 35.0 3.2
90 31.7 3.6
80 28.3 4.2
70 25.0
25 0 4.8
48
60 21.7 5.4
50 18.3 6.3
40 15.0 7.6
30 12.8 9.3
20 12.8 7.6

YVAA Key Technology Elements

Hybrid Falling  Variable Speed Variable Speed Micro‐channel  Variable Speed 

Film Evaporator Drive Screw Compressor Condenser Coils  Fans

VSD technology offers huge efficiency 
gy g y
gains with air cooled chillers

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 Fixed speed (conventional) staging Variable speed staging

100% 100%

90% 90%

80% 80%

70% 70%

60% 60%

50% 50%

40% 40%
Average chiller load
A hill l d
30% 1 chiller = 57% 30%
2 chiller = 67%
20% 3 chiller = 75% 20%
4 chiller = 83%
10% 5 chiller = 88% 10%

0% 0%

min%
min%  33% 67% 100% min% 26%
min%     26%         52%
52% 100%
Building load Building load
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 All variable speed plant ‐ key CPO functions

1. Energy based staging algorithms

2 Condenser water set‐point reset 
2. Condenser water set point reset

3. Chilled water set‐point reset Reduce chiller lift

4. Series / Series counter‐flow chillers

5. Variable chilled water flow (VPF) with large delta T

6 System  differential pressure set‐point reset
6. System differential pressure set point reset Reduce pump energy
Reduce  pump energy

7. Variable condenser water flow

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Metasys screenshot of YK VSD chiller installed on jobsite Chiller COP=16.9 !

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Metasys screenshot of tower at same chiller load Cooling load 516 kWr

Total fan energy 3.8 kW
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8.6
An instantaneous delivered plant COP of 8.6 !!

Chiller Input 
Chiller Input 30 kW
30 kW
Chw Pumps  8.5 kW
Condenser Pump  18 kW
Tower Fans   3.8 kW
/
Plant COP =  516/ 60.3 = 8.6

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 High Efficiency
VSD chillers

Minimize LIFT

Design to minimize
‘transport’ energy

System level control 
optimization

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