EFFICIENCY

VERMONT
Successful
Cooling System
Energy
Optimization
Topics for Discussion

ΠCommercial Energy Consumption

ΠEquipment Evaluation
‹ Full-load efficiency
‹ Integrated part-load values
ΠElectric utility charges
ΠPower Factor

Help you understand how to evaluate an air-cooled

system with regard to bottom-line implications.
Commercial Energy Consumption

U.S. DOE Electrical End-Use Estimates

“Commercial Buildings Energy Consumption Survey”
 Electric Utility Charges

• Customer Charge
• Electric Fuel Charge Adjustment
– Fuel Charge Adjustment
• Environmental Surcharge
• Energy Charge
• Kilowatt (kW) Demand/Delivery Charge
• Power Factor Adjustment/Penalty
 ASHRAE 90.1-2001 (Mandatory Provisions)
• Full Load (FL)
– Predicts performance at a single operation point
• Doesn’t anticipate how equipment will respond
during off-design conditions
• Equipment with excellent full-load characteristics
may have less than satisfactory part-load
characteristics
• Integrated Part Load Value (IPLV)
– Predicts performance over a defined range of
operating points
• Provides a more accurate account of actual
equipment operation
Equipment Evaluation
Air-Conditioning & Refrigeration Institute
• Provides programs to certify manufacturer’s
published equipment data
– Verified through random testing
• Equipment labeled when in compliance
ARI Standard 550/590-98
ΠStandard defining the testing and rating
requirements for all chillers
ΠProvides an equal baseline for all
manufacturers
‹ Defines testing conditions for real-world,
chiller performance
 ARI Standard 550/590-98
• Developed through real-world studies
– 1992 U.S. Department of Energy Study
• DOE/EIA-0246(92)
– 1995 Building Owner’s & Managers Assn.
• 1995 BEE Report

• Developed Weighted Average for:

– Building types, Buildings with/without economizer, Chiller
operational hours, etc.

• Determined 1% of a chiller’s operating hours spent at full

load design conditions.
– With such few hours spent at FL operation, an analysis
comparing FL only would be completely inaccurate.
Equipment Evaluation
ARI Standard 550/590-98
IPLV = .01A + .42B + .45C + .12D
A = EER @ 100% load (95°F Ambient)
B = EER @ 75% load (80°F Ambient)
C = EER @ 50% load (65°F Ambient)
D = EER @ 25% load (55°F Ambient)

12
kW / ton =
EER
Equipment Evaluation
A/C Chillers w/Condenser
Minimum Efficiencies
COP EER kW / TON
2.80 FL 9.56 FL 1.26 FL
3.05 IPLV 10.41 IPLV 1.15 IPLV
IPLV Comparison
A/C Chiller A = 12.5 EER A/C Chiller B = 15.2 EER
kW/ton12.5 = 12/EER kW/ton15.2 = 12/EER
= 12/12.5 = 12/15.2
= 0.96 kW/ton = 0.79 kW/ton

0.17 kW/TON difference!

Equipment Evaluation
Approximate Annual Energy Costs (dollars)

ASHRAE IPLV Comparison

Minimum Efficiency IPLV (EER)
10.41 12.5 15.2
kW / ton 1.15 0.96 0.79
Avg. Load 109 109 109
Op. Hours 5000 5000 5000
Rate 0.0813 0.0813 0.0813
AEC $50,955 $42,536 $35,003

$15,952
difference!
System Considerations
Air-cooled system Water-cooled system
• Low maintenance Œ Higher maintenance
• Low installation and
equipment costs ΠHigh-efficiency
• Higher Energy Œ High installation costs
Consumption ΠLow sound
• Water Scarcity

A/C Chiller W/C Chiller

How do you know
when your
cooling system is
optimized?
Step 1: Begin with
the end in mind.
Decide what components
you are going to
optimize.
Look at the system.
Cooling System Energy:
• Chillers
• Tower fans
• Primary Chilled Water and
Condenser Water Pumps
• Sum of the kWh
consumption of the
above.

Possibly also consider:

secondary pumps, AHU
fan energy.
2A: The Chiller:
Do you know your
chiller matrix?
 Chiller Efficiency Matrix
Entering Condenser Water Temperature
Percent Capacity
Load Tons 55 60 65 70 75 80 85
kW/ton usage
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Const Speed Chiller Effy Matrix
Percent Load Entering Condenser Water Temperature
55 F 65 F 75 F 85 F
kW/ton usage
10% 1.140 1.180 1.220
20% 0.700 0.740 0.810 0.900
30% 0.547 0.587 0.653 0.747
40% 0.470 0.515 0.585 0.675
50% 0.428 0.476 0.544 0.632
60% 0.400 0.450 0.517 0.607
70% 0.383 0.437 0.503 0.591
80% 0.375 0.425 0.493 0.580
90% 0.371 0.420 0.484 0.573
100% 0.368 0.416 0.482 0.564
Const Speed Chiller Effy Curves
1.200

1.100

1.000
Entg Cond
0.900 Wtr Temp
0.800 55 F
kW/ton

0.700 65 F
75 F
0.600 85 F
0.500

0.400

0.300

0.200
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Pct Load
VAR SPEED Chiller Efficiency Matrix

Percent Load Entering Condenser Water Temperature

55 F 65 F 75 F 85 F
kW/ton usage
10% 0.520 0.680 1.100
20% 0.320 0.430 0.660 0.900
30% 0.260 0.353 0.527 0.753
40% 0.235 0.320 0.475 0.670
50% 0.220 0.308 0.444 0.612
60% 0.210 0.303 0.420 0.577
70% 0.209 0.311 0.423 0.569
80% 0.233 0.325 0.428 0.558
90% 0.249 0.340 0.442 0.560
100% 0.270 0.360 0.460 0.576
VAR SPEED Chiller Efficiency Curves
1.200

1.100

1.000
Entg Cond
0.900 Wtr Temp

0.800 55 F
kW/ton

65 F
0.700
75 F
0.600 85 F

0.500

0.400

0.300

0.200
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Pct Load
Cooling tower entering condenser
water bin hours for Burlington Vt.:
• 85F ECWT = 10 hrs
• 75F ECWT = 1000 hrs
• 65F ECWT = 1450 hrs
• 55F ECWT and below = 6300 hrs
Chiller Performance Generalities:
• Lower lift = less compressor
energy (Compressor lift is the
difference between the suction and
discharge pressure).
• Capacity has less affect on
compressor performance than lift.
• Different chillers have different
minimum lifts due to design
differences…
 Compressor

Flooded
Evaporator
Condenser
@ 44F
@ 85F leaving
ECWT chilled water
Refrigerant Refrigerant
pressure= pressure =
19.1 psia 6.1 psia

Orifice: 13# differential pressure

 Compressor

Flooded
Evaporator
Condenser
@ 44F
@ 55F leaving
ECWT chilled water
Refrigerant Refrigerant
pressure= pressure =
10.4 psia 6.1 psia

Orifice : 4.3 # differential pressure

 “stacking” phenomenon

Compressor Flooded
Evaporator
@ 44F
leaving
Condenser
chilled water
@ 55F
Refrigerant
ECWT
pressure =
Refrigerant 6.1 psia
pressure=
Tubes not
10.4 psia
covered by
liquid

Orifice : 4.3 # differential pressure

 Motor cooling and oil loss problems stem from
the same phenomenon; low internal differential
pressure for systems which rely on a differential
Compressor Flooded
pressure to operate. Evaporator
@ 44F
leaving
Condenser
chilled water
@ 55F
Refrigerant
ECWT
pressure =
Refrigerant 6.1 psia
pressure=
Tubes not
10.4 psia
covered by
liquid

Orifice : 4.3 # differential pressure

2B: The Tower:
• Raising the tower setpoint
will save fan energy but
penalize the chiller.
• Two-speed fan motors
better than single speed.
• Variable speed is best for
energy and control.
2C: The pumps:
• Condenser water flow:
Reducing the condenser water
flow will save on the pump
energy but penalize the chiller
(similar to holding up the
entering condenser water
temperature).
Performance Matters
First Cost Advantage of Air Cooled Chillers
Easy Installation – 20% less than Water Cooled Equivalent
No Cooling Tower, Tower pumps, Tower and Pump Starters
No equipment room required for the chillers
Multiple Circuits for redundancy – not multiple chillers
Mounted starters
Maintenance Advantage of Air Cooled Chillers
Easy Maintenance – vs. Water Cooled
No on site Systems Engineer required
No water treatment or make up water required
No leaks on the roof
No cooling tower, condenser pumps, associated
starters
Performance –
The Traditional Trade-off for Air Cooled Chillers
Energy
‹Full Load typically 65% more than Water Cooled system
‹9.6 EER = 1.25 kW/TR (ASHRAE 90.1 Tier 1 requirement)
‹10.2 EER = 1.17 kW/TR (ASHRAE 90.1 Tier 2)
‹Part Load typically 100% more than Water Cooled system
‹12.5 EER = .96 kW/TR
Performance –
The Traditional Trade-off for Air Cooled Chillers
Sound
‹Multiple Compressors and Condenser fans
‹Typical full load sound levels often 100+ dBA
‹Lower nighttime sound regulations can be limiting factor

‹Required acoustical treatments drive up first cost

‹Sound blankets (-1 dBA) = 2-3% of first cost
‹Unit enclosures (-3 to 5 dBA) ~$10 K
 How Latitude changes the balance
• All the best of today’s air cooled chillers
– ASHRAE 90.1 energy level compliance up to 10.3 EER
– R-134a environmentally sound HFC refrigerant
– Compact single package design (150 – 260 TR)
– Simple maintenance requirements
– Dual Circuit design for redundancy

Œ PLUS YOU NO LONGER COMPROMISE ON PERFORMANCE…

‹ World class IPLV performance – real world savings during the other
New 98% of the operating time vs. 90.1 requirements
z 15.2 EER

New ‹ Part load sound levels 5-6 dBA lower than competitors
New ‹ load shedding software for noise level management
‹ Soft Start Capabilities for increased motor life
New
New ‹ Reduced Full load amps for a reduction in wire sizing
 Performance matters

The power of
off design on
Energy - 98%
of operating
hours are at
off design
conditions

Latitude delivers 15-25% Real World kWh Savings

 Performance matters
Annual Energy Savings due to part load efficiency
$14,000
180 TR Chiller
180 TR
– ARI Chiller
IPLV part
$12,000

$10,000
load points

Annual Savings
5000vshours
– 5000
12.5 15.2 IPLV
$8,000
hours
$7500/year
– savings
$.0813/kWh
$6,000

$7500/year savings $4,000

(2003 DOE National
$2,000
Average)
3000 hours $-

$4500/year savings 2000 2500 3000 3500 4000 4500

Operating Hours
5000 5500 6000

150 TR 180 TR 200 TR 250 TR

Latitude’s part load performance is tested & ARI certified

 Electrical Characteristics
• Soft Start
• Power factor
• First Costs – Electrical
installation
– Wire and circuit breakers
reduced by 1-2 sizes
– 5-15% Generator cost
savings
• Operating Costs
– .95 Power Factor
throughout operating range
 Performance through Technology
• 25 years of real world experience with
varying compressor motor speeds
• Logical Extension of Variable Speed Drive
technology for compressor motor
applications
• Eliminates Slide valve and associated
inefficiencies, and reduces compressor
moving parts by 50%
• Solid State unit mounted starter
 Lowest Total Cost of Ownership

• First Cost savings = 10-15%

Latitude
– Electrical Savings can save you 10% of the
– Elimination of sound attenuation equipment
cost of the chiller…….
• Operating Costs Savings = 15-
25% Every year it operates!
– 15 Year equipment life
– 5000 hours per year operation
– National Average $$/kWh ($0.0813)

Performance that delivers real world

savings every year of operation