Chiller Optimization Workshop September 18, 2003

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Chiller Optimization WorkshopSeptember 18, 2003

• Fran Boucher
• Senior Energy Engineer

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New England Territories
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Who is here today?
o

• Process / industrial
• Institutions
• Office and commercial space
• Up to 100 Tons
• 100 to 300 tons
• Over 300 tons

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Utility Conservation Programs

• Utilities provide
• Technical Assistance
• Incentive funds
• Customers pay of cost

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Utility Conservation Programs

• Types of Projects
• New construction
• New equipment loads
• Replacement for efficiency
• Replacement due to age

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Utility Conservation Programs

• NOT JUST CHILLERS
• Cooling towers
• Optimization controls
• Base load chiller
• Pumping
• Reducing load Lighting efficiency, etc.
• Eliminating inappropriate loads

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Utility Conservation Programs

• Inappropriate process chiller loads
• Air compressors
• Hydraulic pumps
• Process loads with high leaving water
  temperature (70plus)

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Personal Care Products Manufacturer
Example 1

• Planned to add an additional 400 ton chiller
• Used load reduction through our program
• Avoided purchase of chiller
• Cut projected annual electric cost by 201,500!
• Utility incentive over 700k
• Payback as low as two years!

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Printed Circuit Board Manufacturer
Example 2

• Installed heat exchanger to pre-cool with city
  water
• Eliminated need for 25 ton chiller addition
• Shut chillers down all winter
• 37,000 Incentive
• 2 year payback
• Saved annual 26,900 dollars electricity costs

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Massachusetts Manufacturer
Example 3

• Inappropriate use of Chilled water
• Replaced 75 Hp water cooled air compressor. Now
  air cooled
• Compressor cooled with chiller
• Saved 15,800 per year on chiller operation
• Payback 2 years

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Incentive Programs

• Two paths for Chillers
• Prescriptive
• Simple, no engineering
• Fits chiller only projects
• Custom
• Engineering study required
• Explore complimentary ECMs

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Incentive Programs

• Two Custom Programs
• Retrofit (Energy Initiative)
• New Construction/ New Equipment / End of Life
  (Design 2000plus)

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Incentive Program

• Retrofit (Energy Initiative)
• Pay 50 of FULL cost
• 2 year payback limit
• Examples
• Load reduction
• Inappropriate use
• Waterside economizer
• New controls

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Incentive Program

• New Facility/Equip. (Design 2000plus)
• Pay 75 of Incremental Cost
• 1.5 year payback limit
• Examples
• New / replacement chillers
• Beyond code improvements
• Variable pumping
• More efficient towers
• Optimization controls

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Incentive Program

• Technical Assistance
• Modeling key to optimize chiller
• TA Study for modeling
• Solid numbers for management
• Program Volume
• 25 to 30 chillers a year

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Comprehensive Chiller Program
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Comprehensive Chiller Program

• Premium Chiller Replacement Program
• Eligibility
• Replacement of 300 ton or larger chiller
• Three demand side measures
• All lighting upgraded
• Complete energy model
• Not for industrial refrigeration
• Reward 90 or 1 yr. payback
• Note Mix of incremental and full cost

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Hospital Opportunities

• 2 Comprehensive Chiller Projects in 2003
• Hospital A
• Lighting, EMS, misc. DX to CHW conversion
• 240,000 incentive
• 66,000 electric savings
• 1 yr. payback (incremental cost)
• Hospital B
• 750,000 Incentive
• lt 2 yr payback

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Comprehensive Chiller

• Case Study Plastics Manufacturer
• Situation
• Immediate need to replace 1 of 2 cooling towers
  (Design 2000plus)
• Plan to install free cooling for air
  compressors (payback under 2 years)
• Available incentives lt50,000
• Their budget 200,000
• Plan to replace 1 old 250 ton chiller 1 year
  later

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Comprehensive Chiller
(Continued)

• Revised Approach
• Replaced 2 cooling towers
• Added waterside economizer to whole plant
• Replaced oversized CHW pumps
• Several VSDs 30 Hp. each
• EMS Chiller plant automation
• New 400 Ton chiller

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Comprehensive Chiller
(Continued)

• Project cost 589,770
• Utility Incentive 393,081
• Customers cost 196,698
• Still under 200k budget!
• Electric Savings 87,372
• Simple Payback 2.3 years
• NO BRAINER!!!!!!!!!!!

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Light Commercial Case Study

• The Building (New Construction)
• 60,000 SF
• Light Commercial
• 5 days, 12 hours/day
• 250 ton peak load 277,000 Ton hours
• Customer Criteria
• Efficiency / value
• Redundancy preferred

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Chiller Options
(Continued)

• Air Cooled Code min. Non-qualifying
• Single water cooled screw Qualifying
• Two water cooled screws Qualifying
• Centrifugal Qualifying
• VSD centrifugal Qualifying
• All 270 tons except 3 with 2_at_ 135 tons

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Chiller Comparison Case Study
Cost is net cost compared to Air Cooled chiller
base case
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Case Study Wrap Up

• Modeling is the key to a good decision
• Your results likely different
• We assist with the modeling
• Single water cooled screw saves 5000 per year
  and 1.5 year payback even without an incentive
  program!
• VSD economics improve with longer hours and
  larger machines

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Energy Conservation Opportunities

• Favorable Opportunities
• Long hours multiple shifts and weekends
• Year-round chiller load
• Process and computer room loads
• Multiple chillers without automation controls

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Utility programs are your friend!
Thank you!
Fran Boucher, CEM 508-421-7299