HIGH

EFFICIENCY
CHILLER PLANT

12 August 2021
Rangga Tirtanegara,
Singapore Certified Green Mark Facility Manager
Contracting Application Manager
PT. Trane Indonesia
 AGENDA

• Introduction
• High Efficiency Chiller Plant System Benchmark
• Typical Chiller Plant System Design
• Optimizing Chiller Efficiency
• Optimizing Pump Efficiency
• Optimizing Cooling Tower Efficiency
• Trane Tracer Chiller Plant Control & Energy Management System
• Measurement & Verification
• Trane Contracting Solution
Introduction
TYPICAL BUILDING ENERGY CONSUMPTION
IN TROPICAL COUNTRIES
Life Cycle Cost of Chiller System
 Centralized HVAC System

Airside Chilled Refrigeration Condenser

Loop Water Loop Loop
Loop
 What is Chiller System Efficiency
“ Efficiency is often measured as the ratio of useful output (TR) to total input (kW) “

Room Heat Heat + Total Plant Work

Chiller
Plant
Cooling (TR)
Output
Electrical
Energy
(kW) Input

“ Energy cannot be created or destroyed in an isolated system”

-Law of Conservation of Energy-
 High Efficiency Chiller
Plant System Benchmark
 ASHRAE Benchmark

New Technology High-efficiency Conventional Chiller Plants with

Older Chiller
All-Variable Speed Optimized Code Based Correctable Design or
Plants
Chiller Plants Chiller Plants Chiller Plants Operational Problems

EXCELLENT GOOD FAIR NEEDS IMPROVEMENT

kW/ton 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

C.O.P. (7.0) (5.9) (5.0) (4.4) (3.9) (3.5) (3.2) (2.9)
AVERAGE ANNUAL CHILLER PLANT EFFICIENCY IN KW/TON (C.O.P.)
(Input energy includes chillers, condenser pumps, tower fans and chilled water pumping)

Based on electrically driven centrifugal chiller plants in comfort conditioning applications with
42F (5.6C) nominal chilled water supply temperature and open cooling towers sized for 85F
(29.4C) maximum entering condenser water temperature and 20% excess capacity.
Local Climate adjustment for North American climates is +/- 0.05 kW/ton
Singapore Greenmark Benchmark
 ASHRAE Green Guide
75% : 25% 87% : 13%

Efficient Plant Typically has ratio of 85% : 15% to 90% : 10% between
Chiller : Ancillary Equipment
Typical Chiller Plant
System Design
 Constant Primary Flow
7 deg
• Simple 35 deg
Configuration 500 gpm
• Pump Energy 30 deg 12 deg
Remain the
same during
part load 500 gpm

500 gpm

300 gpm

1200 gpm
 Constant Primary Variable Secondary Flow
Constant Flow Pump
35 deg 7 deg
• Constant Flow 500 gpm
Pump at
Production Loop
30 deg 12 deg
• Variable Flow
Pump at
Distribution Loop 500 gpm
• Reduce secondary
pump energy at
part load
Variable Flow
300 gpm Pump

1200 gpm
VFD
 Variable Primary Flow
7 deg
• Reduce pump 35 deg
energy at part 400 gpm
load
• Variable Flow 30 deg 12 deg
Compatible
Chiller
400 gpm
• Chiller Plant
Optimizer
400 gpm

0 gpm
VFD

1200 gpm
Trane Enhanced Flow Management
Optimizing Chiller
Efficiency
 Chiller Efficiency

• Compressor Efficiency
• Compressor Type
• Compressor Design (Single Screw, Twin Screw, etc)
• Constant or Variable Speed Control
• Drive Train Efficiency
• Geared or Direct Drive
• Steel Bearing, Magnetic Bearing, Ceramic Bearing
• Refrigerant Efficiency
• R134A, R123, R514A, 1233zd, 1233ze, R22 etc.
• Heat Exchanger Efficiency
• Heat Exchanger Type (Shell and Tube, Plate Heat Exchanger)
• Number of tubes or plates
• Tubes Design (Smooth, Inner Groove, Outer Grove, etc)
• Tubes Material (Copper, Titanium, etc)
• Tubes Thickness (0.025”, 0,030”,0.035”)

Scroll Compressor
Positive Displacement
Capacity :
Low Tonnage up to 100 TR
Common Application :
Small Air-Cooled Chiller
Variable Refrigerant Flow
Water Cooled Package Unit
Heat Pump
Compressor Type
Screw Compressor
Positive Displacement
Capacity :
Medium Tonnage up to 400 TR
Common Application :
Air Cooled Chiller
Water Cooled Chiller
Heat Pump
Low Temp Application
Centrifugal Compressor
Dynamic Compression
Capacity :
Large Tonnage up to 3000 TR
Common Application :
Water Cooled Chiller
District Cooling
 Trane Chiller Product Line
Scroll Compressor Screw Compressor Centrifugal Compressor
Air Cooled Chiller Air Cooled Chiller Water Cooled Single Compressor
• CGAM • RTAC • CVHE /CVHF/ CVHG
• CGAP • RTAD • CVHS/M
• CGAK • RTAF • CVHH
• CXAJ • RTAG • CVHL
• ACS • ACRB • HDWA
• HSWA
Water Cooled Package Unit Water Cooled Chiller Water Cooled Double Compressor
• SWUT • RTHD • CDHG
• WCVS • RTHF • CDHH
• RTWD • CDHF
• RTWS
• RTWF

Please contact us for the best chiller selection for your application
 Vapor Compression Cycle

High
Pressure

Low
Pressure
LIFT = Chilled Water Leaving Temp (A) –
Low Temperature High Temperature Condenser Water Leaving Temperature (D)
 Fixed Speed Centrifugal Chiller
1.0
design
chiller performance (kW/ton)

selection

pressure rise
85°F Capacity Control
75°F Inlet Guide Vane
65°F
55°F
0.0
0 50 100
chiller capacity (%) flow rate - capacity (cfm - tons)

Lift Line
 Variable Speed Centrifugal Chiller
1.0
chiller performance (kW/ton)

surge
best efficiency
boundary

85°F

pressure rise
fully
75°F
open
65°F Capacity
55°F Control
IGV + VFD
0.0
0 50 100
chiller capacity (%) flow rate - capacity (cfm - tons)

Lower Lift
Less Steep
 Fixed Speed vs Variable Speed
Centrifugal Chiller
• Performance
Comparison at
900-ton chiller selections at 44°/85°F Equivalent Price
1.0 Design Point Performance
VS @ 0.585 kW/ton • At design temperature
chiller performance (kw/ton)

FS @ 0.513 kW/ton (-12.4%) (85 deg C), Fixed

speed perform better
at full load and part
load
85°F
75°F
variable-speed • At low lift (55 deg C),
65°F fixed speed slightly
55°F fixed-speed better at full load, but
variable speed
perform better
0.0 significantly at part
0 100 load.
chiller capacity (%) Price difference can
be used to invest in
better chiller
2017 ASHRAE Meteo Climate Data
Jakarta Climate

New York Climate

 Fixed Speed Screw Chiller

1.0
chiller performance (kw/ton)

Capacity Control
85°F Slide Valve
75°F
65°F
55°F

0.0
0 100
chiller capacity (%)

Lift Line
 Variable Speed Positive Displacement Chiller

1.0
chiller performance (kw/ton)

85°F
75°F
65°F Capacity
55°F
Control
Slide Valve
+ VFD
0.0
0 100
chiller capacity (%)

Low Load Eff improve

significantly
 Fixed Speed vs Variable Speed
• Performance
Comparison at
@ equivalent price
Equivalent Price
chiller performance (kw/ton)

1.0
• Both at design
temperature (85 deg
C) & low lift
85°F variable-speed
condition, Variable
75°F Speed perform much
65°F better at Part Load
55°F slide valve Condition,

0.0
0 100
chiller capacity (%)
 Variable Speed Centrifugal vs Rotary

Centrifugal Rotary Screw

1.0 1.0
chiller performance (kW/ton)

85°F

75°F

65°F

55°F

0.0
0.0
0 100 0 100
chiller capacity (%) chiller capacity (%)

Suitable Low Lift Suitable Low Lift &

Application Low Load Application
Optimizing Pump
Efficiency
 Combined Pump Efficiency
• Pump Efficiency (Pump Type, Design)
• Hydraulic Efficiency
• Volumetric Efficiency
• Mechanical Efficiency
• Coupling Efficiency
• Motor Efficiency
• Motor IE Rating
• Drive Efficiency
 Understanding Pump Curve

System
Pressure
Calculation

Pump Power
Cross Section of
(Flow x Head) Match Chiller
Flow Design
 Pump & Fan Affinity Law
With Impeller diameter (D) held constant :
Law a. Flow (Q) is proportional to shaft speed (N)
• The volume
flow decrease
by 10%
• The head
Law b. Head (H) is proportional the square of shaft speed (N) decrease by
21%
• The power
decrease by
33%
Law c. Power (P) is proportional to the cube of shaft speed (N):
 Reduce Pump Flow

Ton of Refrigeration = (US Gpm) x (T out – T in)

24
Standard Design (6.67 -12.2 C)
1 TR = 2.4 gpm x (54 F – 44 F) / 24
500 TR chiller = 1200 gpm

Low Flow Design (High Delta T) (6.67 -14.6 C)

1 TR = 1.6 gpm x (58.4 F – 44 F) / 24
500 TR = 833 gpm
(31% Flow Reduction)
 Typical Chilled Water System

Closed Loop System

Open Loop System

Closed System Pump Head Design
Open System Pump Head Design
Friction Loss in Pipe
Fittings Pressure Drop Coefficient
Low Flow Design
• Increase delta T
• Lower pump flow
• Bigger pipe size
• Shorter pipe
length
• Reduce number of
fittings
• Proper usage of
pipe accessories
• Reduce chiller /
coil pressure drop
• Reduce cooling
tower height
Installation Example
Pipe First then Equipment
Variable Flow Pressure Control
IE Motor
Efficiency
Rating
@11 kW
IE1 87.6%
IE2 89.8%
IE3 91.4%
IE4 93.3%
Optimizing Cooling
Tower Efficiency
Cooling Tower Performance
• Inlet Water Temperature (Ti)
• Outlet Water Temperature (To)
• Ambient Air Wet Bulb
• Water Flow Rate

• Approach = Temp Outlet – Ambient Air

Wet Bulb.

• Range = Temp Inlet – Temp Outlet

Rate of Sensible (Temperature)

• Bigger Cooling Tower

• Higher Entering Cooling Tower Temperature
• Lower Ambient Dry Bulb Temperature
Rate of Latent (Evaporation)

• Bigger Cooling Tower

• Lower Relative Humidity of Ambient
Air
 Cooling Tower Triangle
1. As much / big cooling Height
tower as possible.
2. Shortest cooling
tower as possible
3. Lowest fan power as Cooling Tower
possible Capacity

Area Fan Power

(Width x Length)
Cooling Tower Part Load Control
Pump / Fan Affinity
Law

• The air flow decrease by 10%

• The static pressure decrease by 21%
• The power decrease by 33%
 3 Cooling tower with 1 Chiller
Run 3 Cooling Tower
at 25 Hz (min)

1 CT @ 50 Hz
vs
3 CT @ 25 Hz

Run 1 Chiller

Constant Entering Temperature Control VFD

Approach Control VFD
Enough Space for Cooling Tower

Short Circuit Cooling Tower will increase

Ambient Wet Bulb Temperature
Trane Tracer Chiller Plant
Control & Energy
Management System
 Trane Tracer SC & Ensemble
Chiller Plant Control & Energy Management System

• Load determination
• Energy Efficiency Optimization
• Rotation & Scheduling
• Setpoint control
• Alarm & Failure recovery
• Data Logging
• Measurement & Verification
 Tracer System Schematics
Common CPOS Expanded CPOS solution with
System Tracer ES SQL Server
Measurement & Verification system

SMS modem Advantech Uno Operator Interface

Level
Ethernet LAN
BACnet
Building Control
Tracer SC Level
Agilent
Data Logger
Unit Controller
AdaptiView Multiplexer
Card

Digital Power Meter

Unit Control
Level,
high accuracy sensors
LonTalk/Modbus
‣
 Why Trane Tracer
Chiller Plant Control
• Factory Programmed Chiller Plant
Control Application Logic.
• Vast knowledge of HVAC System.
• Large number of Project Reference.
• Has successfully applied in different
types of building and projects.
• Mixed Used
• Office
• Apartment
• Hotel
• Data Center
 Tracer System Schematics

Legend VSD VSD VSD

WB T
• Flow Meter Weather
Station

• Temperature F T T T
• Variable Speed Drive T
VSD
T
• Motorized Valve UCP2
UCP2

• Differential Pressure Transmitter VSD

VSD

• Wet Bulb / Temperature VSD

UCP2
UCP2

VSD

UCP2
UCP2
VSD
Types of Chiller Plant
T M
• Constant Flow
T T
• Variable Primary Flow DP

• Primary Secondary F
Trane Tracer Display
Trane Tracer Display
Measurement &
Verification
 Quote of&the
Why Measure Day
Verification

Peter Drucker was celebrated by BusinessWeek magazine as

“the man who invented management.”
M & V Green Mark Standard
 Trane Tracer Benefit
• Optimize MEP Operation
equipment based on Load Profile
• Identify Inefficient Equipment or
System
• Focusing capex investment
• Actual Return of Investment
Calculation
• Estimate cost of operation at
different time
• Future Investment benchmark
• Generate saving for Building
Owner.
20th Century 21st Century
Trane Contracting
 Trane Contracting Solution

• Chiller Plant Audit

• New Chiller Plant Design & Build
• Existing Chiller Plant Retrofit
• Air Cooled / Water Cooled Chiller Plant Conversion
• Chiller Plant Optimization
• Specialty Project (Process, Air Tunnel, Ice Skating,
Snow world, Data Center)
 Project Reference
• Kuningan City
• JW Marriot Surabaya
• Sinarmasland Tower
• Mandarin Oriental Jakarta
• Bandung International Convention Center
• Trans Cibubur Ifly
• Pakubuwono Menteng Apartment
• Thamrin Nine Mixed Use Development
• Plaza UOB
• Jotun Factory
• Siemens RSPAD MRI Project
• etc
 Rangga Tirtanegara
(rangga.tirtanegara@trane.com)
(+62 815 864 20 874)

THANK YOU Dedi Sarwanto

Q&A (dedi.sarwanto@trane.com)
(+62 811 1996 886)