Trane 4 Chiller Plant Controls

Chiller Plant Control
What We Will Cover

Factory-integrated controls on chillers Chiller plant control strategies Tracer control features Reliability and serviceability Chiller plant optimization Additional discussion
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
2010 Trane

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
2010 Trane

Feed-forward Control
PID
Feedback
Typical Controller ? 42
Feedforward
UC800
Feedback
Trane UC800/AdaptiView 56
Return Water Temp Evaporator Flow 40
DP 627 gpm
5 Introduction to Trane Control Systems 2010 Trane

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.
2010 Trane
What Do Customers Really Care About ?

Reliable chilled water flow Operating cost (energy efficiency) Operator safety Environmental awareness Reduced maintenance cost
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
2010 Trane

Load Determination Chiller Sequencing User Interface System Optimization
2010 Trane
Plant Layout Flexibility

Constant Flow
CW Return Temp
UC P2 UCP2
Chiller #2
UC P2 UCP2
CW Supply Temp
Chiller #1
10
2010 Trane

Variable Flow - Decoupled
UC P2 UCP2
Chiller #2
UC P2 UCP2
Production
SUPPLY
Chiller #1 Bypass Line
Air Handling Units

Distribution
Pressure Differential Controller or Transmitter
Variable-Speed Drive
DE MAND
Control Valves
11
2010 Trane

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
12
2010 Trane
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
14
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
15
2010 Trane
Capacity Matching
(turn the right chiller on) Dependent on chiller plant design

Normal Base Pea 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

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

Flexible Rotation
Which chiller is next?

Schedule based Run-time Manual operator decision Customized

Number of starts Other?
Reliable chilled water
18
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

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

Chiller - Tower Optimization

Tower Setpoint Optimization
Load Condenser water
Load Condenser water
temperature Wet bulb

Tower design
temperature
Chiller design
22
2010 Trane

ChillerTower Interaction
400
Total Energy Consumption, kW

300
Chiller
200
Optimal control point
100
Tower
0 72 74 76 78 80 82 84
Condenser Water Temperature, F


North America
350K
Control Strategy
Annual Operating Cost, $ USD
300K 250K 200K 150K 100K 50K 0
55F Lvg Tower Optimal Control Design ECWT
Mexico City
Orlando
San Diego
Toronto
2010 Trane
24
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

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

26 Introduction to Trane Control Systems
Pump Pressure
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
2010 Trane
Thank you!
28

Trane 4 Chiller Plant Controls

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Trane 4 Chiller Plant Controls

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Chiller Plant Control

What We Will Cover

Introduction to Trane Control Systems

Trane AdaptiView Control System

Introduction to Trane Control Systems

Trane AdaptiView Control System

It proactively compensates for load changes

Introduction to Trane Control Systems

Trane AdaptiView Control System

Return Water Temp Evaporator Flow 40

Trane AdaptiView Control System

Auto-tunes control gains to maintain stability and

Introduction to Trane Control Systems

What Do Customers Really Care About ?

Introduction to Trane Control Systems

Tracer Chiller Plant Control

Flexibility supports a variety of:

Maximized energy savings

Minimized operational costs

Introduction to Trane Control Systems

Chiller Plant Control

Chiller Plant Control

Introduction to Trane Control Systems

Plant Layout Flexibility

Introduction to Trane Control Systems

Plant Layout Flexibility

Chiller #1 Bypass Line

Air Handling Units

Pressure Differential Controller or Transmitter

Introduction to Trane Control Systems

Plant Layout Flexibility

Flow Meter Bypass Line

Differential Pressure Sensor or Transmitter Air Handling Units

Introduction to Trane Control Systems

Installation and operating reliability and efficiency

Introduction to Trane Control Systems

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

Introduction to Trane Control Systems

Normal Base Pea Swing Custom

Reduce operating costs

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

900 Ton Chiller (Normal-1)

900 1350 Building Load (Tons)

Reduce operating costs

Schedule based Run-time Manual operator decision Customized

Reliable chilled water

Introduction to Trane Control Systems

Unload Before Start

Ride out flow transients on startups

Deals with less sophisticated chiller controllers

Variable flow / multiple pump systems Low supply water temperatures

Reliable chilled water

Chiller level System level

Reliable chilled water

Intuitive User Interface

Reduced Operational Costs

Chiller - Tower Optimization

Load Condenser water

Load Condenser water

temperature Wet bulb

Introduction to Trane Control Systems

Chiller - Tower Optimization

Total Energy Consumption, kW