3 ChillerOptimizationStrategies

Cooling Plant Control Optimization
An Overview
Why Optimize Cooling Plant Control?
• Chillers/Pumps/Cooling Towers Are Largest Energy Consumers1
• Chillers Operate At Part-Load 95% Of The Time
• Chillers Become Progressively Less Efficient At Lower Load Levels
• A Small Increase In Percent Efficiency Results In Big Savings
• Maintenance Is Difficult To Anticipate And Plan
• Many Interrelated Variables Affect Plant Efficiency
1. See the following slides for a breakdown of the percentage of energy of a building’s total energy usage that is devoted to running chillers, chilled
water and condenser water pumps, and cooling tower fans for different regions of the country.
Slide 2 Company Confidential

Building Aggregate Percentage of Energy Devoted Operating a
Chiller Plant – South Region
100%
90% Communication
80% 10% 1%
Process Heat
70%
5%
60% 10%
Comfort Heat
50%
40% Cooling
30%
Power
20%
10% Lighting
0%
Offices Schools Industry Hospitals
(Comfort)
Source: „Energieverbrauch der Privaten Haushalte“; und des Sektors Gewerbe, Handel und Dienstleistaungen, Projektnummer
17/02; Abschlussbericht;
What Benefits should a Chiller Plant
Optimization Program have?
• Ability To Model Part Load Equipment Performance
• Endorsed algorithms for:
– Optimal sequencing of multiple chillers
– Optimal condenser water temperature
– Optimal cooling tower fan sequencing
• Savings Of 10 To 15 % On Annual Plant Power Consumption2
• Centralized Reporting And Monitoring Of Plant Parameters
• Automatic Recording Of Cumulative Energy Savings
• Optional Graphical Presentation Of Energy Savings and Plant Performance Parameters possible
• Avoidance Of Costly Breakdowns
• SBT US has this algorithm, called “CPOP”, for determining optimal chilled water supply and cooling coil
discharge air temperatures patented
• The North American CPOP uses ASHRAE3 endorsed algorithms as above
3 See 2003 ASHRAE HVAC Applications Handbook, pgs, 41.12 – 41.16 and 41.21 – 41.25.
2 For North American systems; the weather and humidity conditions can be different in Europe; so the figures above shall provide a range of potential savings.

Typical Instrumentation: Primary-Secondary Chilled
Water Plant with Parallel Chillers
S/S S/S S/S
T
LEGEND
S/S S/S S/S.......Start/Stop Control
KW S/S AO from EMS T..........Temperature sensor
T KW.......Kilowatt transducer and sensor
FM........Flow meter
S/S S/S FM
KW S/S T
T
2-way control valves
T S/S S/S c c c c
KW S/S
T FM S/S
V/S pump

Instrumentation and Data Point List
Analog Inputs Analog Outputs

• Condenser Water Inlet Temperature • (Chiller Inlet Guide Vane Controllers)
• Chilled Water Supply and Return • Cooling Tower Bypass Control
Temps Across Each Chiller • Variable Speed Pump Drive Controller
• Chilled Water Supply and Return
Header Temps
• Chilled Water Flow
• Chiller KW or Amp Transducers
Digital Outputs
• Chilled Water Terminal Unit
Δ Pressure • On/Off:
– Each Chiller
– Each CHW and CW Pump
– Each Tower Fan
Digital Inputs
– Each Variable Speed Pump
• ON/OFF Status Proofs for Chillers, – CHW and CW Isolation Valves
Pumps, Cooling Tower Fans on Each Chiller
• End Switches for Isolation Valves
• Chiller Alarms

What are main Cooling Plant Optimization
Control Strategies?
• Soft Load Chillers (after having been OFF for a long period of time)
• Demand Limit Chillers
• Optimize Condenser Water Temperature

– Considers dynamics between chillers and towers
• Optimize Multiple Chiller Sequencing

– Dynamic Updating of Part-Load Curves
– Performed via Direct Commands or Operator Advisory Messages

… more Cooling Plant Optimization Control Strategies
• Optimization Of Chilled Water Temperature2

– Performed via a mathematical model of chillers, CHW pumps, and air handler
fans
– Considers dynamics of chilled water pumps and air handler fans (variable
speed or constant speed) with the chiller
• Optimization of discharge air temperature from cooling coils
• Multiple, Parallel Variable Speed Pump Switchover
• Multiple Chiller Load Allocation
2 The technique of determining and controlling for optimal chilled water and coil discharge air temperature
in a DDC Controller has been patented. (U.S. Patent # 5,963,458: Digital Controller for a Cooling and
Heating Plant Having Near-Optimal Global Set Point Control Strategy, October 5, 1999).

What influences the Optimized Control of
Chillers ?
• Efficiency (COP) and Power Draw of Chiller(s)

• Efficiency and Power Draw of Peripherie such as Variable Speed
Pump(s), Cooling Towers, and Air Handlers (if applicable)
• Set Points for Chilled Water, Coil Discharge Air, Air Handler Fan
Static Pressure, and Pump Diff Pressure
• Chilled/Condenser Water Temperature And Flow
• Evaporator Tube Fouling
• Outdoor Ambient Wet Bulb Temperature
• Air Flow Through Cooling Tower
• Cleanliness Of Cooling Tower
• Condenser Tube Fouling

What is the overall Goal of Optimization
Control Strategies?
Minimize total chiller plant operating costs
– Includes analysis and programming logic that considers the

interaction that pumps, cooling towers, and air handler fans have on
the total cost of running the plant
– In all-electric chilled water plants, this reduces to minimizing the

chiller plant power input per ton (kW for Europe) of refrigeration
Slide 10
What Limitations Constrain Chiller Plant
Optimization?
• Chiller Refrigerant Head Above A Minimum Value

• Condenser Water Temperature Above Low Limit Temperature and
Below High Limit Temperature
• Primary Versus Secondary Flow
• Limit on Upward Reset of CHW Temp

The Five Optimal Control Strategies…
1/ Multiple Chiller Sequencing

2/ Determining Switchover Flow Points for Multiple, Parallel V/S Pumps
3/ Optimizing Condenser Water Temperature
4/ Optimizing Chilled Water Temperature Considering CHW Pump and
AHU Fan Power
5/ Multiple Chiller Load Allocation (Optimal Load Balancing of Parallel
Chillers)

Optimal Parallel
2/ Optimal Variable-Speed
Parallel Pump
Variable-Speed Sequencing
Pump Sequencing
• Pumps have the same head/flow characteristics
• Options range from simple strategy for sequencing to sequencing

pumps based on maintaining minimum pump KW
• For minimum pump KW strategy, the sequencing decision is based on

predicted KW with one more pump / one less pump operating,
compared to current configuration KW
• Pump ‘wire-to-water’ efficiencies might be considered

Optimal Parallel Variable-Speed Pump Sequencing
You remember how Pump and System Curves look like?
100
Pump Curve
Total 80 Control Curve
Head System Curve
In 60
m Natural Operating Point
40
20
Maintained Differential
Head Across Sub Circuits
20 40 60 80 100 120 140
m3 per hour

Ho do the curves look for Parallel Pump
Operating Points ?
m HEAD
60 Point of operation with
with both pumps running
50 Control curve
40
Piping Head Loss
30 Curve
Operation point of each
20 pump when both pumps
Run Operating point for
10 single pump operation
20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
m3/hr x 100

… and how for Variable Speed Operating Points:
A, B, C, D, E ?
m HEAD
40 100% speed
90%
30
80% A Piping head loss curve
20 70% B
60% C
10 D
E Control curve
20 40 60 80 100 120 140 160 180 200 220 240 260
m3/hr x 100

Single-Pump Versus Two-Pump Operation Ranges
for Variable Speed Pumps In Parallel
m HEAD
60
Two-pump operating band
50 Control curve
100% s 100% speed
40
Piping head loss
30 Single pump curve
operating band
20 60% s
60% s
10 End-of-curve operation
20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
m3 per hour

Determining Multiple, Parallel V/S Pump
Switch-Over (Simple Strategy)
60
50
40
30
20
10
20 40 60 80 100 120 140 160 180

1/ Multiple
Multiple Chiller
Chiller Sequencing
Sequencing
It all starts with: Typical Chiller Manufacturer Published Part Load Performance Curves

Multiple Chiller Sequencing
Typical Chiller Part-Load Performance Curve
COP
5.0
4.0
3.0
2.0
1.0
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
% CHILLER LOAD

Modeling Typical Chiller Part-Load Performance
Curve with LSQ2 and LSQDAT Statements
Q& ch ,i [ kW ]
COP =
( Pch ,i + Pchwp + Pcwp )[ kW ]
where : Pch ,i = a 0 ,i + a 1,i (T cwr ,i − T chws ,i ) + a 2 ,i (T cwr ,i − T chws ,i ) 2 + a 3 ,i Q& ch ,i + a 4 ,i Q& 2 ch ,i + a 5 ,i (T cwr ,i − T chws ,i )Q& ch ,i
5.0
4.0
3.0
2.0
1.0
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
% CHILLER LOAD
Slide 21
COP Versus Load Characteristic Curves
500 kW Chiller Part-Load Performance
8
7
6
5
COP
4
COP (Chiller + Pumps)
3
2 COP (Chiller Only)
1
0
0 100 200 300 400 500 600
kW output

Hybrid Chiller Plants - Onpeak
(e.g. electric-driven chillers and steam-driven chillers)
ON-Peak €/kWh(th) Vs. % Load

20
Chiller Only
15
€/kWh
10
Chiller + Pumps
5 + Towers
0
0 50 100 150
Percent Cooling Load
Hybrid Chiller Plants – Off Peak
OFF-Peak €/kWh(th) Vs. % Load

0.05
0.04 Chiller Only
0.03
€/kWh
0.02
Chiller + Pumps
0.01 + Towers
0.00
0 50 100 150
Percent Cooling Load

Consideration of CHW and CW
Pumps in Staging Decisions
COP
5.0
4.0
3.0
2.0
COP a = Includes pump power
COP a
= One chiller operation
1.0
= Two chiller operation
200 400 600 800 1000

Switch over point without considering Switch over point considering
pump power pump power
CHILLER LOAD

Optimum Chiller Combination Selections
(consider previous slide)
• Based on Proportionate Sharing of the Facility Cooling Load Among

Multiple Chillers Using Actual Part-Load Curves
• Chiller Combination with Minimum Predicted Power Draw Selected

ONLY When Another Chiller is Needed
• Chiller Combinations Must Be Valid

– Load ratio range must lie between 30% (adjustable) - 100%
– Chiller(s) cannot be in alarm
– Chiller(s) cannot be locked-out

Predicted Chiller KW Draw for Different Chiller Combinations
Plant kW Cooling

Method of Determining COP Sequence Order of Chillers
(used for chiller shut-down logic)
COP
5.0
slope = 0 when x=-B/2A
4.0 Max COP
3.0
COP = Ax*x+Bx+C
2.0
x = % chiller load
Load at which
1.0
max COP occurs
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
% CHILLER LOAD

Condenser Water Temperature Optimization
Considers Interaction of Chiller and Cooling Tower
• First Priority: - Maintain condenser water temp and CW flow per

cell between high and low limits
• Second Priority: - Cycle tower fans to maintain minimum chiller

plus tower power

The Pressure Enthalpy Diagramm - Basics and Control Strategies
(log P)
subcooling
condension
expansion compression
evaporation
superheat
Enthalpy
Control Constraints On Condenser Water Temperature:
• Maintain Above A Low Limit Temp/ Below A High Limit Temp

• Maintain Between A Low and High Limit CW flow per cell
– Maintain above low limit to avoid poor heat transfer and tower fouling
– Maintain below a high limit to avoid tower nozzle and header damage
• Increase Tower Fan Speed

– At High Limit Value of Condenser Water Temperature
– When Maximum Chiller Power Is Reached

DDC Algorithm for Optimizing Tower Air Flow
• Open Loop Tower Fan Control Concept

– Advantages
• Based on ASHRAE paper by Braun and Diderrich (1990)

– Optimize tower fan sequencing
– Optimize tower fan air flow
RAFtwr = 1 − γ twr ( PLRtwr, cap − PLR) PLRfreecooling < PLR < 1. 0

[
RAFtwr = 4PLR1 − γ twr (PLRtwr,cap − PLRfreecooling ) PLR < 0.25 ]
Optimum Tower Air Flow: Parameter Calculations
Parameter Single-Speed Fans Two-Speed Fans Variable-Speed Fans

PLRtwr, cap PLR0 2 ⋅ PLR0 3 ⋅ PLR0
γ twr 1 2 1
PLRtwr, cap 3⋅ PLRtwr, cap 2⋅ PLRtwr, cap
1
PLR0 =
⎛ Pch,des ⎞
⎜ ⎟ ⋅ S ⋅ (atwr,des + rtwr,des )
⎜P ⎟
⎝ twr,des ⎠
where:
⎛ Pch,des ⎞
⎜ ⎟ = the ratio of the chiller power to cooling tower fan power at design conditions
⎜P ⎟
⎝ twr,des ⎠
(changein chiller power)
S = Sensitivity=
(changein condenserwater temperature) × (chiller power)
(atwr,des + rtwr,des ) = the sum of the tower approach and range at design conditions

Tower Fan Sequencing Rules for Optimal Operation
• Variable Speed Fans

– Open tower cells sequentially with fans at minimum speed.
Then, operate all cells with fans at equal speeds.
• Multi-Speed Fans
– Increment the lowest speed fans first when adding tower fan
capacity. Reverse for removing capacity.
• Variable/Multi-Speed Fans
– Operate all cells with variable speed fans first
– Control all variable speed fans at equal speeds
– Increment lowest speed fans first when adding tower capacity
– Command a multi-speed fan to SLOW when all variable speed
fans match the SLOW speed when either incrementing or
decrementing tower capacity
– Decrement variable speed fans first when removing tower fan
capacity

Optimal Chilled Water and Cooling Coil Discharge Air
Temp Control
Control Strategy:
• Reset Chilled Water Temperature Upward Until:
Ptot = Pcomp + Ppump + PAHU
(log P)
is minimized
subcooling condension
expansion
compression
evaporation
superheat

Temp Control
Enthalpy
Mathematical Models of Cooling Plant Components
• Chiller Pchlr = K comp ⋅ ΔTchw

3
⎛ 1 ⎞
• Chilled water pump Ppump = K pump ⎜⎜ ⎟⎟
⎝ ΔTchw ⎠
• Air handler fan
3 3
⎛ 1 ⎞ ⎛ 1 ⎞
Pfan = K fan ⎜⎜ ⎟⎟ = K ' fan ⎜⎜ ⎟⎟
⎝ ΔTair ⎠ ⎝ ΔTchw ⎠

Temp Control
Chilled Water Temperature Optimization –
Problem Formulation
Ptot = ∑P comp
+ ∑P pump
+ ∑P fan
The optimum Δ T chw is found by :

d ( Ptot )
=0
d ( Δ T chw )
3( ∑ K + ∑K )
⇒ Δ T chw , opt = 4 pump fan
∑K comp
The optimum chilled water su pply temp is :

T chws , opt = T chwr − Δ T chw , opt

Temp Control
Relationship Between Chiller, CHW Pump, and AHU Power
Consumption, with CHW Temperature and Load
Power Consumption Vs. CHW Delta T
8000
7000 Chiller Pow er
6000
Power (KW)
5000 CHW Pump Pow er

4000
3000 AHU Fan Pow er
2000
1000 Total Pow er
0
0 5
2.5°C 10
5°C 15
7.5°C
CHW Delta T (°C)

Calculating Optimum Coil Discharge Air Temperature
RH
• First, calculate optimum CHW
supply temp
• Assume air-water energy balance
at coil at each steady-state load
• Solve for return CHW temp from
Tma Tda
each coil
C
• Calculate optimum discharge air
temp from:
C
– Measured values of CFM, Tma and
Tchws Tda, CHW supply temp
– Calculated values of coil CHW
flow, ω, Topt,chws

Multiple Chiller Load Allocation
(Optimal Load Balancing of Parallel Chillers)
€/hr dC A dC B dCC
Necessary Condition : = =
50 dx A dxB dxC
40 Constraint : L = xA + xB + xC
CC = aC xC + bC xC + cC
B 2
30 A C
C A = a A x A + bA x A + c A
2
C B = a B xB + bB xB + cB
2
20
10
100 200 300 400 500 600 700 800 900 1000
CHILLER LOAD

Summary
• Chiller Performance Is A Function Of Many Interrelated Variables
• Continuously Optimizing Control Performance Over Time Requires

Adaptive Algorithms
• DDC Controllers Can Use Methods Such As:

– Storing Part-Load Equipment Performance as Data Points
– Altering Stored Part-Load curves from Actual Data Points
– Least Squares Curve Fitting of Equipment Performance Data Points
– Calculating Minimum Value of Parabolic Performance Curves
• Adaptive Chiller Control Algorithms Are Superior Because Energy

Savings Are Continuously Optimized

3 ChillerOptimizationStrategies

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Cooling Plant Control Optimization

• Chillers/Pumps/Cooling Towers Are Largest Energy Consumers1

• Chillers Operate At Part-Load 95% Of The Time

• Chillers Become Progressively Less Efficient At Lower Load Levels

• A Small Increase In Percent Efficiency Results In Big Savings

• Maintenance Is Difficult To Anticipate And Plan

• Many Interrelated Variables Affect Plant Efficiency

Slide 2 Company Confidential

Slide 4 Company Confidential

S/S S/S S/S

Slide 5 Company Confidential

Analog Inputs Analog Outputs

Slide 6 Company Confidential

• Demand Limit Chillers

• Optimize Condenser Water Temperature

• Optimize Multiple Chiller Sequencing

Slide 7 Company Confidential

• Optimization Of Chilled Water Temperature2

Slide 8 Company Confidential

• Efficiency (COP) and Power Draw of Chiller(s)

Slide 9 Company Confidential

Minimize total chiller plant operating costs

– Includes analysis and programming logic that considers the

– In all-electric chilled water plants, this reduces to minimizing the

• Chiller Refrigerant Head Above A Minimum Value

Slide 11 Company Confidential

1/ Multiple Chiller Sequencing

Slide 12 Company Confidential

• Pumps have the same head/flow characteristics

• Options range from simple strategy for sequencing to sequencing

• For minimum pump KW strategy, the sequencing decision is based on

• Pump ‘wire-to-water’ efficiencies might be considered

Slide 13 Company Confidential

20 40 60 80 100 120 140

Slide 14 Company Confidential

Slide 15 Company Confidential

20 40 60 80 100 120 140 160 180 200 220 240 260

Slide 16 Company Confidential

Slide 17 Company Confidential

20 40 60 80 100 120 140 160 180

Slide 18 Company Confidential

Slide 19 Company Confidential

Slide 20 Company Confidential

500 kW Chiller Part-Load Performance

Slide 22 Company Confidential

ON-Peak €/kWh(th) Vs. % Load

OFF-Peak €/kWh(th) Vs. % Load

0.04 Chiller Only

Slide 24 Company Confidential

200 400 600 800 1000

Slide 25 Company Confidential

• Based on Proportionate Sharing of the Facility Cooling Load Among

• Chiller Combination with Minimum Predicted Power Draw Selected

• Chiller Combinations Must Be Valid

Slide 26 Company Confidential

Slide 27 Company Confidential

4.0 Max COP

Slide 28 Company Confidential

• First Priority: - Maintain condenser water temp and CW flow per

• Second Priority: - Cycle tower fans to maintain minimum chiller

Condenser Water Temperature Optimization

• Maintain Above A Low Limit Temp/ Below A High Limit Temp