Chiller Plant Control

What Do Customers Really Care About ?

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

Introduction to Trane Control Systems

2010 Trane

What We Will Cover

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

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

Introduction to Trane Control Systems

2010 Trane

Chiller Plant Control

Chiller Plant Control

Load Determination Chiller Sequencing User Interface System Optimization

Introduction to Trane Control Systems

2010 Trane

Chiller Plant Layout

UCP2 UCP2

Variable Primary Flow Using Control System with

adaptive control Chillers Chillers w/ feed-forward controls & flow compensation

Decoupler System
UCP2 UCP2

Production

S U PP L Y

Air Handling Units

Distribution

Bypass Line

Pressure Differential Controller or Transmitter

DE M AND

UCP2 UC P2

Variable-Speed Drive
UCP2 UC P2

Variable-Speed Drive

Control Valves

Flow Meter

Bypass Line

Differential Pressure Sensor or Production Transmitter Air Handling Units Distribution

Introduction to Trane Control Systems

S U PP LY

DE MAND

Control Valves

2010 Trane

Pre-engineered Features

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

Installation and operating reliability and efficiency

7 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

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 kW/ton 1 0.9 0.8 0.7 0.6 0.5 0.4 0 20 40 60 Percent Load 80 100

Introduction to Trane Control Systems

2010 Trane

Capacity Matching
(turn the right chiller on) Dependent on chiller plant design

Normal Base Peak Swing Custom

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

Reduce operating costs

10 Introduction to Trane Control Systems 2010 Trane

U C P2 U C P2 450 Ton Chiller (Swing) 900 Ton Chiller (Normal-2)

900 Ton Chiller (Normal-1)

450

900 1350 Building Load (Tons)

1800

2250

Reduce operating costs

11 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

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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

13 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

14 Introduction to Trane Control Systems 2010 Trane

Intuitive User Interface

Minimize training time Minimize undesirable manual control Maximize operator efficiency

Reduced Operational Costs

15 Introduction to Trane Control Systems 2010 Trane

Chiller Plant Status Screen - Tracer Summit

Reduced Operational Costs

16

Introduction to Trane Control Systems

Easy Easy to to Operate Operate

2010 Trane

Alarm Management
Chiller 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

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Introduction to Trane Control Systems

2010 Trane

Alarm Management
Chiller Operating Parameters & Diagnostic Messages

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Introduction to Trane Control Systems

2010 Trane

Diagnostics and Reports

Standard status reports Diagnostic reporting and message routing

Series R Rotary Liquid Chillers - Air Cooled Standard Report
Chiller Plant Control Standard Report Current Value Chiller Plant Name System Mode System Data: Supply Water Setpoint Supply Water Temp Return Water Temp Chilled Water Pump Chilled Water Flow Bypass Pipe Flow System Operation: Failure Exists Number of Chillers Enabled Active Operation Add Information: Next Chiller to Add Add Delay Timer Add Request Add Temperature Subtract Information: Subtract Method Subtract Delay Timer Chilled Water Delta Temp Subtract Delta Temperature Subtract Flow Threshold Excess Flow Percentage Rotation Information: Rotation Type Next Rotation Date & Time Chiller 1: Chiller Control Chiller Status Chilled Water Setpoint Leaving Chilled Water Temp Chilled Water Pump Chilled Water Flow Current Limit Setpoint Chiller Failure Sequence Number Chiller Available Building Plant #1 Normal 38.00 47.30 57.70 On Flow Not Used No 1 Confirming Chiller Off 2 6 Yes 39.50 Temperature 20 10.40 9.50 0.00 20.00 Day of Week 03/21/04 00:01:00

Current Value Chiller Name Present Value Communication State Operating Mode Chilled Water Leaving Temp - deg F Chilled Water Entering Temp - deg F Chilled Water Setpoint - deg F Air Cooled Condenser Data Ckt 1 Sat Refrig Temp - deg F Ckt 2 Sat Refrig Temp - deg F Current Draw - % RLA Current Limit Setpoint - % RLA Compressor(s) Running? Ice Making? Outdoor Air Temperature - deg F RTA/RTW 70-125 Ton Unit: Compressor A Run Time - hrs Compressor A Starts Compressor B Run Time - hrs Compressor B Starts RTA 240 to 400 Ton Unit (Add'l): Compressor C Run Time - hrs Compressor C Starts RTA 300 to 400 Ton Unit (Additional): Compressor D Run Time - hrs Compressor D Starts Chiller East Wing #1 Occupied Up Run: Normal 47.30 57.70 41.00 74.00 74.30 47 0 Yes No 82.20 4271 19 111 18 0 0 0 0

Reduced Maintenance Cost

On On 40.00 47.30 On Flow 120.00 None Base Yes

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Introduction to Trane Control Systems

2010 Trane

Chiller Plant Dashboard Details

System and Chiller Status

Pump Status System Efficiency System Load

Chilled Water Temps

Tower Water Temps

Pump Flow Daily Average Metrics

20 Introduction to Trane Control Systems

Pump Pressure
2010 Trane

Chiller - Tower Optimization

Tower Setpoint Optimization

Load Condenser water

Load Condenser water

temperature Wet bulb

Tower design

temperature
Chiller design

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Introduction to Trane Control Systems

2010 Trane

Chiller - Tower Optimization

ChillerTower Interaction
400

Total Energy Consumption, kW

300

Chiller
200

Optimal control point

100

Tower

0 24 25 26 27 28 29 30

Condenser Water Temperature, C

22 Introduction to Trane Control Systems 2010 Trane

Cooling Tower Optimization Results

Chiller+Tower Yearly Estimated Operating Cost

$51,000.00

$50,500.00

$50,000.00

$49,500.00

$49,000.00

$48,500.00

$48,000.00

$47,500.00 Minimum temperature Design CW WB + 5 degrees Optimized

EarthWise

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Introduction to Trane Control Systems

2010 Trane

Plant Layout Flexibility

Variable Primary Flow
UC P2 UCP2

Variable-Speed Drive
UC P2 UCP2

Flow Meter Bypass Line

Production

Differential Pressure Sensor or Transmitter Air Handling Units

PPLY SU

DE MAND

Distribution

Control Valves

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Introduction to Trane Control Systems

2010 Trane

Energy Optimisation
Variable Primary Chilled Water Flow Control

Advanced Variable Primary Chilled Water

UC P2 UC P2

UC P2 UC P2

Flow Control
VSD
UC P2 UC P2

VSD

VSD

F
AHU

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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

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

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Introduction to Trane Control Systems

2010 Trane

Trane AdaptiView Control System

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

Typical Controller
PID

Feedback

Feed-forward control uses flow

change and entering water temperature as an indication of load change

AdaptiView Controller
Feedforward
UC800

It proactively compensates for

load changes

Feedback

12 DP
27 Introduction to Trane Control Systems

7 40 l/s
2010 Trane

Temperature Control
Figure 1: Tem perature Control w ith out Feedforw ard
100

90

C ondenser Entering W ater Tem perature

80

Temp [degF]

70
Evaporator Entering W ater Tem perature

60

50

40

E vaporator Leaving W ater Tem perature

C hiller C ycled O ff, Low W ater Tem perature

30 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

4:30:00

T im e (hour:m in:sec)

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Introduction to Trane Control Systems

2010 Trane

Feedforward Control
Figure 2: Tem perature Control w ith Feedforw ard
100 90 Condenser Entering W ater Tem perature

80

Temp [degF]

70

Evaporator Entering W ater Tem perature 60

50

40 Evaporator Leaving W ater Tem perature

30 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

4:30:00

Tim e (hour:m in:sec)

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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 chillers full range of flow rates.

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Introduction to Trane Control Systems

2010 Trane

50% Flow Reduction

130 1,500.00 120

Capacity Control w /o W ater Flow Compensation

1,300.00

110

1,100.00

100
Evaporator W ater Flow

900.00

Water Temp [degF]

80

500.00

70

300.00

60
Evap Entering W ater Tem p

100.00

50

-100.00

40
Chiller on
Evap Leaving W ater Tem p

-300.00
Chiller off Chiller off

30 0:00:00

0:10:00

0:20:00

0:30:00

0:40:00

-500.00 0:50:00

Time (hour:min:sec)

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Introduction to Trane Control Systems

2010 Trane

Water Flow [gpm]

90

700.00

With Compensation
130 1,500.00 120

Capacity Control w ith Water Flow Compensation

1,300.00

110

1,100.00

100 Water Temp [degF]

900.00

90

Evaporator W ater Flow

700.00

80

500.00

70

300.00

60

Evap Entering W ater Tem p

100.00

50

-100.00

40
Evap Leaving W ater Temp

-300.00

30 0:00:00

0:10:00

0:20:00 0:30:00 Time (hour:min:sec)

0:40:00

-500.00 0:50:00

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Introduction to Trane Control Systems

2010 Trane

Water Flow [gpm]

Trane Chiller Plant Control & Optimization

Energy Optimization

VSD

VSD

VSD WB T

S SM

Flexible & Reliable Op

Better Plant Mgmt VSD

UCP2 UCP2

VSD

UCP2 UCP2

VSD

UCP2 UCP2

F
33 Introduction to Trane Control Systems

33

2010 Trane

Major Job Reference

Landmark East Four Seasons Hotel Tai Tung Building Oriental Press AIA Building DHL Asia Hub
34 Introduction to Trane Control Systems 2010 Trane

Landmark East
Project Developer
USI Property Management Ltd. E & M Consultant TAP Project Category HVAC Control System BACnet Interface with BMS

35

Introduction to Trane Control Systems

2010 Trane

Project Scenario
30,000 Points 6 chiller plants (18 nos. Trane Chillers) 3,000 nos. VAV/CAV boxes (Trane)

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Introduction to Trane Control Systems

2010 Trane

Four Season Hotel

Project Developer
SHK / Four Seasons Group E & M Consultant JRP/SHK Project Category HVAC Control System

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Introduction to Trane Control Systems

2010 Trane

Project Scenario
10,000 Points 1 chiller plants (5 nos. Trane Chillers) 800 nos. VAV/CAV boxes (Trane Controller) 3,500 nos. FCUs (Trane) 104 AHU/PAUs (Trane)

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Introduction to Trane Control Systems

2010 Trane

Tai Tung Building

Project Developer
Tak Shing Property E & M Consultant Rankin & Hill Project Category BMS Supplier BMS System Integration

39

Introduction to Trane Control Systems

2010 Trane

Project Scenario

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

40

Introduction to Trane Control Systems

2010 Trane

Oriental Press
Project Developer
Oriental Press E & M Consultant Hang Foong Project Category BMS Supplier BMS System Integration

41

Introduction to Trane Control Systems

2010 Trane

Project Scenario

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

42

Introduction to Trane Control Systems

2010 Trane

AIA Building
200 Points 4 Chillers 20 AHUs BMS System Integration

43

Introduction to Trane Control Systems

2010 Trane

DHL Asia Hub

1,000 Points 2 Chillers 10 AHUs 70 VAVs BMS System Integration

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Tracer Summit Graphic

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Introduction to Trane Control Systems

2010 Trane

Thank you!

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