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15 Ways To Improve Chiller Efficiency3
15 Ways To Improve Chiller Efficiency3
Efficiency
Energy Consumption
25 - 30%
Building Energy
Energy Consumption
25 - 30%
Building Energy
Initial Considerations
Initial Considerations
Proper maintenance procedures
Initial Considerations
Proper maintenance procedures
Accurate operating logs
Major Savings Opportunities
Component related
System related
Retrofit related
Major Savings Opportunities
Component related
System related
Retrofit related
#1
Maintaining Proper
Refrigerant Charge
Too much or too little
Limits heat transfer capacities
Increases head pressure
Increases energy consumption FREON
#3
High-Pressure
#3
Refrigerant
Refrigerant
High-Pressure
#3
Low-Pressure
#3
Low-Pressure
#4
Maintaining Compressor
Motor Efficiency
Lack of cooling decreases efficiency
Increased current draw w/o increased voltage
#4
Open-Drive Motor
Maintaining Compressor
Motor Efficiency
#4
Open-Drive Motor
Air Cooled
Maintaining Compressor
Motor Efficiency
Inadequate ventilation
Obstructed air intake Air Cooled
Obstructed exhaust openings
Loose/corroded electrical connection
#4
Hermetic Motor
Maintaining Compressor
Motor Efficiency
#4
Hermetic Motor
Maintaining Compressor
Motor Efficiency
Restricted refrigerant flow
Clogged refrigerant filter
Refrigerant Cooled
Loose/corroded electrical connection
#5
Mr. Compressor
#6
85 Condenser Water
Mr. Compressor
#6
High
Head
85 Condenser Water
Mr. Compressor
#6
High
Head
Lower Condenser
Water Temperatures
Mr. Compressor
#6
High
Head
Lower Condenser
Water Temperatures
Low
Head
Mr. Compressor
#6 0.65
0.60
0.55
0.50
kW / ton
0.45
0.40
0.35
0.30
0.25
85 F 80 F 75 F 70 F 65 F 60 F
Entering Condenser Water Temperature
#6 0.65
Competitor
0.60 60% Load
100% Load
0.55 80% Load
0.50
kW / ton
0.45
0.40
0.35
0.30
0.25
85 F 80 F 75 F 70 F 65 F 60 F
Entering Condenser Water Temperature
#6 0.65
Competitor
0.60 60% Load
100% Load
0.55 80% Load
0.50
kW / ton
YORK
0.45 60% Load
100% Load
80% Load
0.40
0.35
0.30
0.25
85 F 80 F 75 F 70 F 65 F 60 F
Entering Condenser Water Temperature
#6 0.65
Competitor
0.60 60% Load
100% Load
0.55 80% Load
0.50
kW / ton
YORK
0.45 60% Load
100% Load
80% Load
0.40
0.25
85 F 80 F 75 F 70 F 65 F 60 F
Entering Condenser Water Temperature
#7
80
% Full-load Amps
60
40
20
0
0 2 4 5 6 7 8 10 12 14 16 18 20
Minutes
#8
Controlling Demand Charges
100 w/o Demand Limiting
80
% Full-load Amps
60
40
20
0
0 2 4 5 6 7 8 10 12 14 16 18 20
Minutes
#8
Controlling Demand Charges
100 w/o Demand Limiting
w/ Demand limiting
80
% Full-load Amps
60
40
20
0
0 2 4 5 6 7 8 10 12 14 16 18 20
Minutes
#9
Operate Chillers in Proper Sequence
Evaluate part-load and full-load efficiencies
Determine optimum chiller sequence
#9
Operate Chillers in Proper Sequence
1.3
1.1
kW / ton
0.7
0.5
0.3
100% 80% 60% 40% 20%
Load
#9
Operate Chillers in Proper Sequence
1.3
1.1
kW / ton
0.7
0.5
0.3
100% 80% 60% 40% 20%
Load
#9
Operate Chillers in Proper Sequence
1.3
1.1
Efficiency begins dropping
kW / ton
0.7
0.5
0.3
100% 80% 60% 40% 20%
Load
#10
1.1
Constant Speed
kW / ton
0.7
0.5
0.3
100% 80% 60% 40% 20%
Load
#13
Variable Speed Centrifugal Chillers
1.3
1.1
Constant Speed
kW / ton
0.7
0.5
0.3
100% 80% 60% 40% 20%
Load
#13
Variable Speed Centrifugal Chillers
1.3
1.1
Constant Speed
kW / ton
0.7
0.3
100% 80% 60% 40% 20%
Load
Major Savings Opportunities
Component related
System related
Retrofit related
Major Savings Opportunities
Component related
System related
Retrofit related
#14
Before After
Other Benefits
Inaccessible chiller location
Eliminate CFCs
Reduce maintenance costs
#15
Parts obsolescence
Unreliable operation
CFCs
#15
May June
Energy Costs
Centrifugal Ch-1 $4458 $5067 $6741 $9112 $11441 $12572
Centrifugal Ch-2 $4458 $5067 $6741 $9112 $11441 $12572
May June
Energy Costs
Centrifugal Ch-1 $4458 $5067 $6741 $9112 $11441 $12572
Centrifugal Ch-2 $4458 $5067 $6741 $9112 $11441 $12572
Maintenance Cost
Short Term
Preventative maintenance
#15
Maintenance Cost
Short Term
Preventative maintenance
Long Term
Scheduled teardown
Hermetic burnout
#15
Maintenance Cost
Short Term
Preventative maintenance
Long Term
Scheduled teardown
Hermetic burnout
#15
First Cost
Equipment
Installation
Other system components
#15
= Financial Payback
#15
York Project Investment Analysis
FLEXIBILITY
Refrigerant choice
Open-drive technology
Electric motor
Steam turbine
Gas engine
Compressors and shells
#15
R-134a
Centrifugal
R-123 R-22
Screw R-134a
R-22 R-22
Reciprocating R-134a
R-22
ParaFlow
Absorption Water
IsoFlow
Absorption Water
R-134a
TurboMaster
R-22
Ammonia AMMONIA
TONS 100 400 700 850 1000 1250 1500 2100 5500 8500
Summary
Summary
Thorough maintenance program
Summary
Thorough maintenance program
Daily/accurate log records
Summary
Thorough maintenance program
Daily/accurate log records
Evaluate component opportunities
FREON
Summary
Thorough maintenance program
Daily/accurate log records
Evaluate component opportunities
Evaluate system opportunities
#8
Controlling Demand Charges
100 w/o Demand Limiting
#9 w/ Demand limiting
% Full-load Amps
60
1.3
40
#13 1.1
0.9
0
1.3 0 2 4 5 6 7 8 10 12 14 16 18 20
0.7
Minutes
1.1
0.5
Constant Speed
kW / ton
0.3
100% 80% 60% 40% 20%
Load
Summary
Thorough maintenance program
Daily/accurate log records Centrifugal
R-134a
R-123 R-22
Reciprocating R-134a
Water
R-134a
TurboMaster
R-22
Ammonia AMMONIA
TONS 100 400 700 850 1000 1250 1500 2100 5500 8500
Summary
Thorough maintenance program
Daily/accurate log records FREON
Screw R-134a
R-22 R-22
Reciprocating R-134a
R-22
ParaFlow
Absorption Water
#8
IsoFlow
Absorption Water Controlling Demand Charges
R-134a 100 w/o Demand Limiting
TurboMaster w/ Demand limiting
R-22
80
#9
% Full-load Amps
Ammonia AMMONIA Operate Chillers in Proper Sequence 60
40
TONS 100 400 700 850 1000 1250 1500 2100 5500 8500 1.3
20
1.1
0.9
#13
Minutes
Variable Speed Centrifugal Chillers 0.7
1.3 0.5
1.1 0.3
0.7
0.3
100% 80% 60% 40% 20%
Load