Professional Documents
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
an
Engineers
Newsletter Live
telecast
© 2005 American Standard Inc.
Today’s Topics
Fundamentals
Chiller–tower interaction
Cooling-tower terminology, operation
Design conditions
Cooling-tower control options
System optimization
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 1
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Today’s Presenters
Cooling tower
fundamentals
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 2
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Refrigeration Cycle
2-stage
compressor
condenser
evaporator
economizer
expansion expansion
© 2005 American Standard Inc.
device device
Pressure–Enthalpy
(p-h) Chart
subcooled
liquid
liquid
pressure
+ vapor mix
superheated
A B vapor
5 psia
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 3
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
6 condenser 4
Pc
expansion 5
pressure
economizer
devices 2-stage
P1 8 compressor
3 2
7
Pe
evaporator 1
9
© 2005 American Standard Inc.
enthalpy
condenser
4'
Pc
expansion 4
pressure
devices 2-stage
P1 economizer compressor
Pe
evaporator 1
© 2005 American Standard Inc.
enthalpy
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 4
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
chiller–tower interaction
Heat Rejection
Tower determines return condenser
water temperature
electrical input
× motor efficiency
chiller–tower interaction
Heat Rejection, Q
or
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 5
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
electric chiller
Heat Rejection Example
For 1 ton of evaporator load:
Q = 12,000 Btu/h × (1 + 1/6.10)
= 12,000 Btu/h × (1 + 0.16)
= 13,967 Btu/h
© 2005 American Standard Inc.
electric chiller
Heat Rejection Example
T = Q (Btu/h) / (500 × gpm)
… 9.3°F at 3 gpm/ton
T = 13,967 / (500 × 3) = 9.3F
… 14.0°F at 2 gpm/ton
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 6
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
chiller–tower interaction
Heat Rejection
Condenser water warms in proportion
to heat rejection and condenser water
flow rate
Cooling Tower
“Heat transfer device, often tower-like,
in which atmospheric air cools warm
water, generally by direct contact
(evaporation).”
ASHRAE Terminology of HVAC&R
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 7
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
cooling tower
Components
propeller fan
sprays
louvers
outdoor fill
air
© 2005 American Standard Inc.
sump
to from
condenser cold water hot water condenser
cooling tower
Performance Factors
Ambient wet-bulb temperature drives
tower design and selection
ASHRAE Fundamentals Handbook,
“Evaporation”
0.4% value is most conservative …
exceeded ~35 hours/year
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 8
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
cooling tower
Performance Factors
hot water
temperature
range
tower
flow rate
cold water
temperature
approach
© 2005 American Standard Inc.
cold water
temperature
Cooling Technology Institute (CTI)
approach > 5°F may certify tower performance
© 2005 American Standard Inc.
ambient 60°F–90°F WB
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 9
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Design WB, °F 78
Approach, °F 7
Cold water, °F 85
Fan power, hp 40
© 2005 American Standard Inc.
range = 14°F
2 gpm/ton
82°F
cold water
approach = 4°F
© 2005 American Standard Inc.
78°F WB
design ambient
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 10
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Design WB, °F 78 78
Approach, °F 7 4
Cold water, °F 85 82
Fan power, hp 40 40
© 2005 American Standard Inc.
range = 14°F
2 gpm/ton
85°F
cold water
approach = 7°F
© 2005 American Standard Inc.
78°F WB
design ambient
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 11
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Design WB, °F 78 78 78
Approach, °F 7 4 7
Cold water, °F 85 82 85
Fan power, hp 40 40 25
© 2005 American Standard Inc.
12.0
approach = 7
8.0
100% load
approach = 4
0.0
© 2005 American Standard Inc.
50 60 70 80
ambient wet bulb, °F
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 12
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
12.0
approach = 7
8.0
100% load
0.0
© 2005 American Standard Inc.
50 60 70 80
ambient wet bulb, °F
12.0
8.0
100% load
approach = 9
4.0 50% load
approach = 4
0.0
© 2005 American Standard Inc.
50 60 70 80
ambient wet bulb, °F
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 13
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Design
conditions
© 2005 American Standard Inc.
a design issue
Flow Rates
Past rule of thumb: 3 gpm/ton
10° F ΔT for older, less efficient chillers
~9°F ΔT for currently produced chillers
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 14
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
a history of
Chiller Performance
8.0 centrifugal
>600 tons
chiller efficiency, COP
screw
6.0 150-300 tons
scroll
<100 tons
4.0
reciprocating
<150 tons
2.0
0.0
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 15
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Condenser water
pump
Cooling tower
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 16
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
gpm × P
hp =
3960 × pump efficiency
0.746 × hp
kW =
motor efficiency
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 17
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
a Trane Engineers Newsletter Live
Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 18
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
a Trane Engineers Newsletter Live
Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Base
design
© 2005 American Standard Inc.
Base
design
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 19
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Base
design
Base
design
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 20
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Base Reduced
design flow
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 21
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Base Reduced
design flow
Base Reduced
design flow
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 22
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Base Reduced
design flow
condenser pump
250 chiller
200
150
100
50
0
3.0 2.0 3.0 2.0 3.0 2.0 3.0 2.0
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 23
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
What if it was
© 2005 American Standard Inc.
0 ft of head?
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 24
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
condenser pump
250 chiller
*piping PD = 0 ft
200
150
100
50
0
3.0 2.0 3.0 2.0 3.0 2.0 3.0 2.0
© 2005 American Standard Inc.
DuPont, Greenville
Cost savings: $45,000 excavation, concrete
6.5% operation
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 25
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
DuPont, Greenville
Cost savings: $45,000 excavation, concrete
6.5% operation
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 26
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Chiller Plant
Analyzer
TRACE™ 700
DOE 2.1
HAP
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 27
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
The meter is on
the BUILDING
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 28
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
a win-win-win situation
Saving Energy–And More
“In addition to the electric energy savings,
this chiller plant will have prevented the
emissions of 1.1 million lb of CO2 per year,
8,800 lb of SO2 per year, and 3,100 lb of
NOx per year. This is an overall win-win-win
situation where the first cost is reduced,
operating cost is minimized, plus significant
environmental benefits are realized as an
additional benefit.”
© 2005 American Standard Inc.
Cooling-tower
control options
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 29
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
chiller–tower optimization
Control
Capacity
Design requirements
Tower control options
Sequence to conserve energy
System protection
Chiller requirements
Tower requirements
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 30
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
be on/off
• Fans that serve multiple refrigeration
circuits
• Climates with >7,200 cooling-degree days
© 2005 American Standard Inc.
cooling tower
Capacity Control
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 31
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
cooling tower
Capacity vs. Airflow
100
80
airflow, %
60
40
20
© 2005 American Standard Inc.
0
0 20 40 60 80 100
capacity, %
cooling tower
Control Options
Fan control
Cycling single-speed fan
Two-speed fan
Variable-speed drive
Modulating dampers
Centrifugal two-speed fan
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 32
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
60
40
20
variable-
speed drive
© 2005 American Standard Inc.
0
0 20 40 60 80 100
capacity, %
two-speed fan:
100% and 50%
60 two-speed fan:
100% and 67%
40
20
© 2005 American Standard Inc.
0
0 20 40 60 80 100
capacity, %
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 33
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
1 single-speed fan,
1 two-speed fan
60
40
20
© 2005 American Standard Inc.
0
0 20 40 60 80 100
capacity, %
60
40
20
© 2005 American Standard Inc.
0
0 20 40 60 80 100
capacity, %
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 34
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
cooling tower
Rules for Capacity Control
ASHARE 90.1 requirements
make sense
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 35
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
chiller–tower optimization
Control
Capacity
Design requirements
Tower control options
Sequence to conserve energy
System protection
Chiller requirements
Tower requirements
© 2005 American Standard Inc.
system protection
Chiller Head Pressure
cooling
tower Condenser pressure set
41.8°F by leaving-condenser water
temperature
condenser
40°F
P
Evaporator pressure set
water-cooled
chiller by leaving-evaporator water
temperature
P evaporator
44°F
© 2005 American Standard Inc.
cooling
load
46°F
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 36
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
system protection
Chiller Requirements
Achieve and maintain sufficient
“head” pressure
Pressure and time required varies by
chiller type …
Oil return
Refrigerant flow (through expansion
devices)
Motor cooling
© 2005 American Standard Inc.
Oil supply
system protection
Chiller Head Pressure
cooling
tower Condenser pressure set
41.8°F by leaving-condenser water
temperature
condenser
40°F
P
Evaporator pressure set
water-cooled
chiller by leaving-evaporator water
temperature
P evaporator
44°F
© 2005 American Standard Inc.
cooling
load
46°F
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 37
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
system protection
Chiller Head Pressure
Measure evaporator–condenser P
or condenser pressure or water temperatures …
then:
Control entering water temperature
Fan control
Reduce water flow over tower—
e.g., 3-way bypass into sump (not preferred)
Reduce flow through condenser
2-way valve
© 2005 American Standard Inc.
system protection
Diverting Valve at Tower
cooling Tower bypass with 3-way
tower or 2-way valves
41.8°F
Constant flow through
chiller
condenser
40°F
P NOT PREFERRED
water-cooled Longer lag time makes
chiller control difficult
P evaporator
44°F
© 2005 American Standard Inc.
cooling
load
46°F
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 38
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
system protection
Throttling Valve
cooling Throttling valve
tower modulates based on
60.0°F refrigerant P
Low-cost alternative
condenser Short periods with
40°F
P low flow over tower
water-cooled
chiller
P evaporator
44°F
© 2005 American Standard Inc.
cooling
load
46°F
system protection
Diverting Valve at Chiller
cooling Chiller bypass with 3-way
tower 41.8°F or 2-way valves
Constant flow over tower
More precise control
condenser
40°F
P
water-cooled
chiller
P evaporator
44°F
© 2005 American Standard Inc.
cooling
load
46°F
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 39
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
system protection
VFD on Pump
cooling Enables more efficient
tower water balancing
60.0°F
Short periods with
low flow over tower
VFD
condenser
40°F Most efficient method
P of controlling chiller
water-cooled head pressure
chiller
P evaporator
44°F
© 2005 American Standard Inc.
cooling
load
46°F
system protection
Sequence of Operation
… for chiller head pressure:
1. The BAS shall monitor the refrigerant
pressure in each chiller’s evaporator and
condenser. The BAS shall use PID-based
DDC control of the [chiller-condenser-pump
VFD][cooling-tower bypass valve][chiller-
condenser bypass valve] to maintain no
less than the minimum pressure differential
specified by the chiller manufacturer.
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 40
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Trane literature
Condenser Water Control
CTV-PRB006-EN
Condenser Water Temperature
Control for CenTraVac Centrifugal
Chiller Systems
RLC-PRB017-EN
Water-Cooled Series R Chiller
Models RTHB & RTHD Condenser
Water Control
© 2005 American Standard Inc.
system protection
Flow Limits: An Example
500-ton 500-ton
Flow chiller cooling tower
Design 1000 gpm 1000 gpm
Maximum 2469 gpm 1290 gpm
Minimum 449 gpm 780 gpm
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 41
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
system protection
Tower Flow Limits
Flow violation Result
Too low “Holes” in fill coverage
Lost efficiency
Mineral deposits
System
optimization
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 42
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Cold?
e.g., 55°F, minimizes chiller
energy consumption
Optimized?
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 43
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
300
chiller
optimal
200 control point
100
tower
© 2005 American Standard Inc.
0
72 74 76 78 80 82 84
condenser water temperature, °F
chiller–tower optimization
An Example …
720,000 ft² hotel
Control strategies
Make leaving-tower water
cold as possible (55F)
Optimize system operation
Entering-condenser
setpoint equals design …
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 44
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
200K
150K
100K
50K
© 2005 American Standard Inc.
0
Mexico City Orlando San Diego Toronto
300K
200K
100K
© 2005 American Standard Inc.
0
Dubai Paris Sao Paulo Singapore
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 45
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
chiller–tower optimization
Operating Cost Savings
14
Orlando
12
operating cost savings, %
Singapore
Sao Paulo
Toronto
10
Dubai
Mexico City
8
San Diego
6
4
Paris
2
© 2005 American Standard Inc.
0
location
chiller–tower optimization
Perspective on Savings
For centrifugal chillers ≥ 300 tons,
ASHRAE 90.1 requires …
0.576 kW/ton at full load
0.549 kW/ton at IPLV
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 46
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
chiller–tower optimization
Perspective on Savings
Equivalent
Savings, % chiller efficiency
0.0 0.576
2.8 0.560
4.5 0.550
6.2 0.540
14.0 0.495
© 2005 American Standard Inc.
chiller–tower optimization
Documented Savings
Braun, Diderrich: ASHRAE Transactions
(1990)
(July 2004)
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 47
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
800.0
T t
600.0
200.0
© 2005 American Standard Inc.
0.0
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
Condenser Water Setpoint (°F)
SOURCE: Hydeman, et al. Pacific Gas and Electric. Used with permission.
chiller–tower optimization
What’s the “Catch”?
The chiller works harder
Takes advantage of chiller COP
Tower fans consume less energy
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 48
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
“Near optimal
chiller–tower operation”
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 49
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
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Cooling Towers and Condenser Water Systems: Design and Operation • 2005
chiller–tower optimization
Finding “Near Optimal”
Tower design
(flow rate, range, approach)
Chiller design
Refrigeration cycle
(vapor compression vs. absorption)
Compressor type
Capacity control (variable-speed drive)
© 2005 American Standard Inc.
Changing conditions
(chiller load, ambient wet bulb)
chiller–tower optimization
Necessities
System-level
controls
Variable-
frequency drive
on tower fans
High-quality
relative humidity
sensor
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 50
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
a Trane Engineers Newsletter Live
Cooling Towers and Condenser Water Systems: Design and Operation • 2005
chiller–tower optimization
Calculating the Savings
Available tools include
TRACE™ 700, Chiller Plant Analyzer,
System Analyzer™
© 2005 American Standard Inc.
chiller–tower optimization
Specification Chart
% Wet bulb Tower Chiller +
Full load (deg F) setpoint tower kW
100 78
75 71
50 60
50 71
© 2005 American Standard Inc.
25 60
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 51
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
a Trane Engineers Newsletter Live
Cooling Towers and Condenser Water Systems: Design and Operation • 2005
100 71
75 65
50 57
50 65
© 2005 American Standard Inc.
25 57
chiller–tower optimization
Summary
Coldest condenser
water is not better
Optimal control
saves money
Real, quantifiable
savings
Proven control
strategy that’s more
than 10 years old
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 52
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
a Trane Engineers Newsletter Live
Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Limiting factors:
Tower static lift
Proper water distribution
throughout tower fill
(nozzles)
Required flow through
© 2005 American Standard Inc.
condenser
Reduced speed/flow:
Increases chiller power
(warmer water leaving
condenser)
Alters heat-transfer
effectiveness of tower
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 53
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
a Trane Engineers Newsletter Live
Cooling Towers and Condenser Water Systems: Design and Operation • 2005
No definitive answer
… yet
Control strategy varies with
each installation based on
chiller and tower selections
© 2005 American Standard Inc.
Answers to
your questions
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 54
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
a Trane Engineers Newsletter Live
Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Summary
Tower fundamentals
Larger range (lower flow rate) reduces
tower size or approach
Approach increases as ambient wet bulb
decreases
Summary
Cooling-tower control options
Invest in VFDs on all tower fans
Head pressure control is critical
to reliability
Chiller–tower optimization
Minimize system energy consumption
Offers significant operating-cost savings
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 55
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.
a Trane Engineers Newsletter Live
Cooling Towers and Condenser Water Systems: Design and Operation • 2005
Bibliography
© 2005 American Standard Inc.
Upcoming Broadcasts
May 25 Energy analysis–
LEED™ modeling
Nov 16 Demand-controlled
ventilation based on CO2
© 2005 American Standard Inc.
Trane, in proposing these system design and application concepts, assumes no responsibility for the performance or desirability of any 56
resulting system design. Design of the HVAC system is the prerogative and responsibility of the engineering professional.