Chiller Plant Control

1
 What We Will Cover

• Factory-integrated controls on chillers

• Chiller plant control strategies
• Tracer control features
• Reliability and serviceability
• Chiller plant optimization
• Additional discussion

2 Introduction to Trane Control Systems © 2010 Trane

 Trane AdaptiView™ Control System
4th 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
• Sophisticated diagnostics
• Fast restarts
• Operator tested – informative display
• Multiple open protocol communication options

3 Introduction to Trane Control Systems © 2010 Trane

 Trane AdaptiView™ Control System
Feed-forward Control

Feed-forward control 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

4 Introduction to Trane Control Systems © 2010 Trane

 Trane AdaptiView™ Control System
Feed-forward Control

PID Feedback
Typical Controller

?º 42º

Feedforward UC800 Feedback

Trane • Return Water Temp

Σ
UC800/AdaptiView • Evaporator Flow

56º 40º

DP
627 gpm

5 Introduction to Trane Control Systems © 2010 Trane

 Trane AdaptiView™ Control System
Variable Flow Compensation

• 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 chiller’s full range of flow rates.

6 Introduction to Trane Control Systems © 2010 Trane

 What Do Customers Really Care About ?

• Reliable chilled water flow

• Operating cost (energy efficiency)
• Operator safety
• Environmental awareness
• Reduced maintenance cost

7 Introduction to Trane Control Systems © 2010 Trane

 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

8 Introduction to Trane Control Systems © 2010 Trane

 Chiller Plant Control

Chiller Plant Control

Load Chiller User System

Determination Sequencing Interface Optimization

9 Introduction to Trane Control Systems © 2010 Trane

 Plant Layout Flexibility
Constant Flow

CW Return UCP2
UCP2
CW Supply
Temp Temp
Chiller #2

UCP2
UCP2

Chiller #1

10 Introduction to Trane Control Systems © 2010 Trane

 Plant Layout Flexibility
Variable Flow - Decoupled

UCP2
UCP2
Chiller #2

UCP2
UCP2

Production

SUPPLY
Pressure
Chiller #1 Air Handling Units Differential
Controller or
DE MAND
Bypass Line
Distribution Transmitter

Variable-Speed Control
Drive Valves

11 Introduction to Trane Control Systems © 2010 Trane

 Plant Layout Flexibility
Variable Primary Flow

UCP2
UCP2

Variable-Speed
Drive Differential Pressure
UCP2
UCP2 Sensor or
Flow Transmitter

S UPPLY
Production
Meter
Air Handling Units

DE MAND
Bypass Line
Distribution

Control Valves

12 Introduction to Trane Control Systems © 2010 Trane

 Pre-engineered Features

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

Installation and operating reliability and efficiency

13 Introduction to Trane Control Systems © 2010 Trane

 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

14 Introduction to Trane Control Systems © 2010 Trane

 One Chiller at 100%? or
Two Chillers at 50%?

Constant Speed Centrifugal Chiller

Unloading at constant condenser water temperature
1.4
1.3
1.2
1.1
1
kW/ton

0.9
0.8
0.7
0.6
0.5
0.4
0 20 40 60 80 100
Percent Load

15 Introduction to Trane Control Systems © 2010 Trane

 Capacity Matching
(turn the right chiller on)

Dependent on chiller plant design

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

Reduce operating costs

16 Introduction to Trane Control Systems © 2010 Trane

 UCP2
UCP2

450 Ton Chiller 900 Ton Chiller

(Swing) 900 Ton Chiller (Normal-2)
(Normal-1)

0 450 900 1350 1800 2250

Building Load (Tons)

Reduce operating costs

17 Introduction to Trane Control Systems © 2010 Trane

 Flexible Rotation
Which chiller is next?

• Schedule based
• Run-time
• Manual operator decision
• Customized
– Number of starts
– Other?

Reliable chilled water

18 Introduction to Trane Control Systems © 2010 Trane

 Unload Before Start
Keep chillers online

• Ride out flow transients on startups

– Deals with less sophisticated chiller controllers
• Variable flow / multiple pump systems
• Low supply water temperatures

Reliable chilled water

19 Introduction to Trane Control Systems © 2010 Trane

 Failure Recovery
Keep chilled water flowing

• No manual intervention required

• Follow the standard sequence
• Multiple failure inputs
– Chiller level
– System level

Reliable chilled water

20 Introduction to Trane Control Systems © 2010 Trane

 Intuitive User Interface

• Minimize training time

• Minimize undesirable manual control
• Maximize operator efficiency

Reduced Operational Costs

21 Introduction to Trane Control Systems © 2010 Trane

 Chiller - Tower Optimization
Tower Setpoint Optimization

• Load • Load
• Condenser water • Condenser water
temperature temperature
• Wet bulb • Chiller design
• Tower design

22 Introduction to Trane Control Systems © 2010 Trane

 Chiller - Tower Optimization
Chiller–Tower Interaction

400
Total
Energy Consumption, kW

300

Chiller
Optimal
200 control point

100
Tower

0
72 74 76 78 80 82 84
Condenser Water Temperature, °F

23 Introduction to Trane Control Systems © 2010 Trane

 Chiller - Tower Optimization
North America

350K
Control Strategy
300K 55°°F Lvg Tower
Annual Operating Cost, $ USD

Optimal Control
250K Design ECWT

200K

150K

100K

50K

0
Mexico City Orlando San Diego Toronto

24 Introduction to Trane Control Systems © 2010 Trane

 Distribution Pumping
Critical Valve Pressure Control

• Critical valve reset

• Benefits
– Reduced pump energy
– Better coil control
– Extend pump life Pressure
Differential Air Handling Units
Controller or
Transmitter

Control
Valves

Reduce operating costs

25 Introduction to Trane Control Systems © 2010 Trane

 Chiller Plant Dashboard Details

System and
Chiller Status
Pump Status

System
Chilled Water Temps Efficiency

System
Tower Water Temps Load

Pump
Flow

Daily Average Metrics

Pump Pressure

26 Introduction to Trane Control Systems © 2010 Trane

 Summary
Key points to remember
• Integrated chiller controls
– Factory quality; better performance, efficiency
and serviceability; lower risk
• Performance
– Temperature control; reliability; extended equipment life;
automatic failure response
• Efficiency
– Lower energy and maintenance costs
• Sustainability
– Maintain performance over time
– Document performance

27 Introduction to Trane Control Systems © 2010 Trane

 Thank you!

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