Chiller Plant Optimization: A Case Study
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1 Presentation of Chiller Plant Optimization: A Case Study Presented by Michael S. Conway
2 The site Large pharmaceutical client 5 MW cogen 88,000 PPH of boiler capability 8,200 tons of chiller capability Free cooling Diverse chillers 4 MW of diesel peak shaving
3 The site
4 Plant layout Boilers Cogen Chillers Peak Shaving Diesels
5 Background Plant control system was upgraded to PLCs in 2001 System design was/is robust Flow meters on both sides of each chiller Variable position control valves Pressure, flow, and temperature at critical points in the plant Flow meters on all towers Variable position control valves on all towers Real time KW available from some equipment
6 Background Overall the system was in good shape Site operation is largely outsourced Several chillers had been replaced in recent years Cooling tower had been replaced and changed from a four cell to six cell tower VFDs added to five of nine chilled water pumps
7 Visibility/Controllability ABC Company
8 Visibility/Controllability ABC Company
9 Visibility/Controllability ABC Company
10 What the client was considering A very large investment in a third party chiller optimization program
11 Our advice They already had the tools to optimize The plant had substantial control flexibility Updates would probably be minor That someone needed to dig into the details They could still consider a larger and more complex project, if warranted
12 First step Spend time in the plant working with staff to understand current operations Review the original sequence (2001) Review how new equipment was integrated into the original sequence
13 Second step (minor capital spend) Move the differential pressure sensors from the plant to the most remote location Install VFDs on the four remaining pumps client had left over VFDs from another project! Install KW transducers on the condenser water pumps - all energy associated with the chiller plant would now be available in real time Total capital investment of $93,000
14 Third step Document, implement, test Plant PLC automatically selects the lowest remote DP, failure modes programmed Pump control algorithm updated to fully utilize all eight VFD pumps Tower sequence updated to actively control flow to all six cells (smart to flow) Counter flow tower used for winter mode Corrected tower winter mode selection, which had been looking at wet bulb Free cooling: all interlocks removed; corrected the logic which was forcing the system out of plate and frame mode when temperature was below 18 degrees Automatic chilled water reset instituted Automatic condenser water reset instituted Condenser water pump selection updates Duct burner control and chiller/steam dump logic improved
15 CHW Pump Savings Winter Mode with Plate and Frame On Line-Base Case ABC Company
16 CHW Pump Savings Winter Mode with Plate and Frame On Line-Revised Sequence ABC Company
17 CHW Pump Savings Shoulder Season with Two Chillers On Line Base Case ABC Company
18 CHW Pump Savings Shoulder Season with Two Chillers On Line Revised Case ABC Company
19 Cooling tower sequence improvements Shoulder Season One Chiller On Line Base Case ABC Company
20 Cooling tower sequence improvements Shoulder Season One Chiller On Line Revised Case ABC Company
21 Cooling tower sequence improvements Summer Season Multiple Chillers On Line Base Case ABC Company
22 Cooling tower sequence improvements Summer Season Multiple Chillers On Line Revised Case ABC Company
23 Not chilled water related Simultaneous operation of the steam dump while duct firing ABC Company
24 Not chilled water related Steam dump and duct burner interlocked ABC Company
25 Savings Cooling tower sequence $104,000 Chilled water pumping $ 61,000 Reset schedules $ 59,000 Free cooling $ 39,000 Duct burner control $ 23,000 TOTAL $286,000
26 Summary No two situations are alike Client had the tools The ability to adequately manage water Free cooling capability during the winter Single VFD chiller operation for extended periods Minor upgrades were required Relocation of DP sensors Addition of three VFDs Updated programming Operator training Ability to track auto versus manual Project ROI of.3 years Avoided capital cost of $900K
27 Next steps Monitor and trend system performance Program guidance for chiller staging Evaluate savings associated with additional VFDs
28 Contact Mike Conway Energy Management Optimization (c) David M. Ferro Director of Energy Management Services (c)
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