5_Chiller Plant Control

1Chiller Plant Control

Introduction to Trane Control Systems2 2010 Trane

What Do Customers Really Care About ?

Operator safety Reliable chilled water flow Environmental awareness Operating cost (energy efficiency) Maintenance cost


What We Will Cover

Chiller plant control strategies Tracer control features Reliability and serviceability Chiller plant optimization Factory-integrated controls on chillers Additional discussion


Tracer Chiller Plant Control Repeatability performance from plant to plant

Maximize the use of pre-engineered features Minimize on-site customization

Flexibility supports a variety of: Plant layouts Chiller types Control strategies

Maximized energy savings Load matching Chiller tower optimization Distributed pump pressure optimization Thermal ice storage Minimize manual intervention

Minimized operational costs Minimize manual intervention, but anticipate it Maintain chilled water flow and temperature Minimize service surprises


LoadDetermination

Chiller Plant Control

ChillerSequencing

Chiller Plant Control

UserInterface

SystemOptimization


Chiller Plant Layout

Variable Primary Flow Using Control System with

adaptive control Chillers Chillers w/ feed-forward controls &

flow compensation

Decoupler System

Air Handling Units

Control Valves

Variable-Speed

Drive

Pressure Differential Controller or Transmitter

Production

DistributionBypass Line

SU PPL YD E

MAN D

UCP2UCP2

UCP2UCP2

Air Handling Units

Control Valves

Production


SUPPLY

DEM

AND

Variable-Speed Drive

Flow

Meter

UCP2UCP2

UCP2UCP2

Differential Pressure Sensor or

Transmitter


Pre-engineered Features

Load determination Capacity matching Rotation Chiller setpoint control Failure recovery User interface

Installation and operating reliability and efficiency


Load Determination (when to add or subtract a chiller)

What is the optimal sequencing for chillers? Should I run one chiller at 100% or two chillers at 50%?

The givens whether you run one chiller or two

The building load does not change The outside wet bulb temperature does not change

When you run two chillers You may double the number of pumps You may double the number of tower cells


0.40.50.60.70.80.9

11.11.21.31.4

0 20 40 60 80 100Percent Load

k

W

/

t

o

n

One Chiller at 100%? orTwo Chillers at 50%?

Constant Speed Centrifugal ChillerUnloading at constant condenser water temperature


Capacity Matching(turn the right chiller on)

Dependent on chiller plant design

Normal - identical chillers Base - heat recovery/super efficient Peak - back up/alternate energy source/inefficient Swing - match the load! Custom - mix and match/nested CPC objects

Reduce operating costs


UCP2

450 Ton Chiller (Swing) 900 Ton Chiller

(Normal-1)

900 Ton Chiller (Normal-2)

UCP2UCP2

0 2250450 18001350900

UCP2

Building Load (Tons)Reduce operating costs


Flexible Rotation Which chiller is next?

Schedule based Run-time Manual operator decision Customized

Number of starts Other?

Reliable chilled water


Unload Before StartKeep chillers online

Ride out flow transients on startups Deals with less sophisticated chiller controllers

Variable flow / multiple pump systems Low supply water temperatures



Failure Recovery Keep chilled water flowing

No manual intervention required Follow the standard sequence Multiple failure inputs

Chiller level System level



Intuitive User Interface

Minimize training time Minimize undesirable manual control Maximize operator efficiency

Reduced Operational Costs


Reduced Operational Costs

Chiller Plant Status Screen - Tracer Summit

Easy to OperateEasy to Operate


Alarm ManagementChiller Operating Parameters & Diagnostic Messages

Direct high level link to chiller panel Workstation displays and logs all chillers

Operating parameters Diagnostic messages

Useful for chiller diagnosis and preventive maintenance


Alarm ManagementChiller Operating Parameters & Diagnostic MessagesAlarm ManagementChiller Operating Parameters & Diagnostic Messages


Diagnostics and Reports

Standard status reports Diagnostic reporting and message routing

Series R Rotary Liquid Chillers - Air Cooled Standard Report

Current Value

Chiller Name Chiller East Wing #1 Present Value Occupied Communication State Up Operating Mode Run: Normal

Chilled Water Leaving Temp - deg F 47.30 Chilled Water Entering Temp - deg F 57.70 Chilled Water Setpoint - deg F 41.00

Air Cooled Condenser Data Ckt 1 Sat Refrig Temp - deg F 74.00 Ckt 2 Sat Refrig Temp - deg F 74.30

Current Draw - % RLA 47 Current Limit Setpoint - % RLA 0

Compressor(s) Running? Yes

Ice Making? No Outdoor Air Temperature - deg F 82.20

RTA/RTW 70-125 Ton Unit: Compressor A Run Time - hrs 4271 Compressor A Starts 19 Compressor B Run Time - hrs 111 Compressor B Starts 18

RTA 240 to 400 Ton Unit (Add'l): Compressor C Run Time - hrs 0 Compressor C Starts 0

RTA 300 to 400 Ton Unit (Additional): Compressor D Run Time - hrs 0 Compressor D Starts 0

Chiller Plant Control Standard Report

Current Value

Chiller Plant Name Building Plant #1

System Mode Normal

System Data: Supply Water Setpoint 38.00 Supply Water Temp 47.30 Return Water Temp 57.70

Chilled Water Pump On Chilled Water Flow Flow Bypass Pipe Flow Not Used

System Operation: Failure Exists No Number of Chillers Enabled 1 Active Operation Confirming Chiller Off

Add Information: Next Chiller to Add 2 Add Delay Timer 6 Add Request Yes Add Temperature 39.50

Subtract Information: Subtract Method Temperature Subtract Delay Timer 20 Chilled Water Delta Temp 10.40 Subtract Delta Temperature 9.50 Subtract Flow Threshold 0.00 Excess Flow Percentage 20.00

Rotation Information: Rotation Type Day of Week Next Rotation Date & Time 03/21/04 00:01:00

Chiller 1: Chiller Control On Chiller Status On Chilled Water Setpoint 40.00 Leaving Chilled Water Temp 47.30 Chilled Water Pump On Chilled Water Flow Flow Current Limit Setpoint 120.00 Chiller Failure None Sequence Number Base Chiller Available Yes

Reduced Maintenance Cost


Chiller Plant Dashboard Details

Daily Average MetricsPump Pressure

Pump StatusSystem and

Chiller Status

Chilled Water Temps

Tower Water TempsSystem

Load

System Efficiency

Pump Flow


Chiller - Tower Optimization Tower Setpoint Optimization

Load Condenser water

temperature Wet bulb Tower design

Load Condenser water

temperature Chiller design


Chiller - Tower Optimization ChillerTower Interaction

Condenser Water Temperature, C

400

25

E

n

e

r

g

y

C

o

n

s

u

m

p

t

i

o

n

,

k

W

26 27 28 2924

300

200

100

030

Tower

Optimalcontrol point

Chiller

Total


Cooling Tower OptimizationResults

Minimumtemperature

Design CW WB + 5degrees

Optimized$47,500.00

$48,000.00

$48,500.00

$49,000.00

$49,500.00

$50,000.00

$50,500.00

$51,000.00

Minimumtemperature

Design CW WB + 5degrees

Optimized

Chiller+Tower Yearly Estimated Operating Cost

EarthWise


Plant Layout FlexibilityVariable Primary Flow

Air Handling Units

Control Valves

Production


SUPPLY

DEMAN D

Variable-Speed Drive

Flow Meter

UCP2UCP2

UCP2UCP2

Differential Pressure Sensor or

Transmitter


Energy OptimisationVariable Primary Chilled Water Flow Control

UCP2UCP2

UCP2UCP2

F

AHU

P

UCP2UCP2

VSD

VSD

VSD

Advanced

Variable

Primary Chilled Water

Flow Control


Trane AdaptiView Control System4th Generation Microprocessor Chiller Control

Adaptive control Reliable operation through difficult

operation conditions Feed-forward control

Accurate and stable control under the most dynamic system transients

Flow Compensation Sophisticated diagnostics Fast restarts Operator tested informative display Multiple open protocol communication options


Feed-forward control is an open loop predictive control strategy which enables the chiller to respond faster to load changes

Feed-forward control uses flow change and entering water temperature as an indication of load change

It proactively compensates for load changes

PID Feedback

7?

UC800 Feedback

712

Feedforward

DP40 l/s

Typical Controller

AdaptiView Controller

Trane AdaptiView Control SystemFeed-forward Control


Figure 1: Temperature Control w ith out Feedforward

30

40

50

60

70

80

90

100

0:00:00 0:30:00 1:00:00 1:30:00 2:00:00 2:30:00 3:00:00 3:30:00 4:00:00 4:30:00Tim e (hour:min:sec)

T

e

m

p

[

d

e

g

F

]

Condenser Entering W ater Temperature

Evaporator Entering W ater Temperature

Evaporator Leaving W ater Temperature Chiller CycledOff, Low W aterTem perature

Temperature Control


Feedforward ControlFigure 2: Temperature Control w ith Feedforward

30

40

50

60

70

80

90

100

0:00:00 0:30:00 1:00:00 1:30:00 2:00:00 2:30:00 3:00:00 3:30:00 4:00:00 4:30:00Time (hour:min:sec)

T

e

m

p

[

d

e

g

F

]

Condenser Entering W ater Temperature

Evaporator Entering W ater Temperature

Evaporator Leaving W ater Temperature


Directly measures chilled water flow Enhances leaving water temperature control during

rapid flow rate changes of up to 50%/min. >30 % /min commercial control 10% /min precision process control

Auto-tunes control gains to maintain stability and accuracy over chillers full range of flow rates.

Trane AdaptiView Control SystemVariable Flow Compensation


Capacity Controlw/o Water Flow Compensation

30

40

50

60

70

80

90

100

110

120

130

0:00:00 0:10:00 0:20:00 0:30:00 0:40:00 0:50:00Time (hour:min:sec)

W

a

t

e

r

T

e

m

p

[

d

e

g

F

]

-500.00

-300.00

-100.00

100.00

300.00

500.00

700.00

900.00

1,100.00

1,300.00

1,500.00

W

a

t

e

r

F

l

o

w

[

g

p

m

]

Evaporator W ater Flow

Evap Entering W ater Temp

Evap Leaving W ater TempChiller off Chiller

off

Chiller on

50% Flow Reduction


With CompensationCapacity Control

with Water Flow Compensation

30

40

50

60

70

80

90

100

110

120

130

0:00:00 0:10:00 0:20:00 0:30:00 0:40:00 0:50:00Time (hour:min:sec)

W

a

t

e

r

T

e

m

p

[

d

e

g

F

]

-500.00

-300.00

-100.00

100.00

300.00

500.00

700.00

900.00

1,100.00

1,300.00

1,500.00

W

a

t

e

r

F

l

o

w

[

g

p

m

]

Evaporator W ater Flow

Evap Entering W ater Temp

Evap Leaving W ater Temp

Introduction to Trane Control Systems33 2010 Trane33

Trane Chiller Plant Control & Optimization

F

P

VSD

VSD

VSD

UCP2UCP2

UCP2UCP2

UCP2UCP2

VSD VSD VSD

WB T

SMS

Energy Optimization

Flexible & Reliable Op

Better Plant Mgmt


Landmark East

Four Seasons Hotel

Tai Tung Building

Oriental Press

AIA Building

DHL Asia Hub

Major Job Reference


Landmark East

Project Developer USI Property Management Ltd.

E & M Consultant TAP

Project Category HVAC Control System

BACnet Interface with BMS


Project Scenario

30,000 Points

6 chiller plants (18 nos. Trane Chillers)

3,000 nos. VAV/CAV boxes (Trane)


Four Season Hotel

Project Developer SHK / Four Seasons

Group E & M Consultant

JRP/SHK Project Category

HVAC Control System

Four Season Hotel

Project Developer SHK / Four Seasons

Group E & M Consultant

JRP/SHK Project Category

HVAC Control System


Project Scenario

10,000 Points


800 nos. VAV/CAV boxes (Trane Controller)

3,500 nos. FCUs (Trane)

104 AHU/PAUs (Trane)

10,000 Points





Project Scenario

10,000 Points






Project Developer Tak Shing Property

E & M Consultant Rankin & Hill

Project Category BMS Supplier

BMS System Integration

Tai Tung Building


Project Scenario

8,000 Points 4 nos. Trane Chillers 500 nos. Trane VAV boxes 30 AHU/PAUs (Trane)


Oriental Press

Project Developer Oriental Press

E & M Consultant Hang Foong

Project Category BMS Supplier

BMS System Integration


Project Scenario

4,000 Points 7 nos. Trane Chillers Tube Cleaning System 600 nos. FCUs (Trane) 18 AHU (Trane)


200 Points4 Chillers20 AHUsBMS System

Integration

AIA Building


1,000 Points2 Chillers10 AHUs70 VAVsBMS System

Integration

DHL Asia Hub


Tracer Summit GraphicTracer Summit Graphic

55

Thank you!

Date post:	20-Oct-2015
Category:	Documents
Upload:	gerardo-zamorano
View:	39 times
Download:	2 times

5_Chiller Plant Control

Documents