1Chiller Plant Control
Introduction to Trane Control Systems2 2010 Trane
What Do Customers Really Care About ?
Operator safety Reliable chilled water flow Environmental awareness Operating cost (energy efficiency) Maintenance cost
Introduction to Trane Control Systems3 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 Systems4 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 Systems5 2010 Trane
LoadDetermination
Chiller Plant Control
ChillerSequencing
Chiller Plant Control
UserInterface
SystemOptimization
Introduction to Trane Control Systems6 2010 Trane
Chiller Plant Layout
Variable Primary Flow Using Control System with
adaptive control Chillers Chillers w/ feed-forward controls &
flow compensation
Decoupler System
Air Handling Units
Control Valves
Variable-Speed
Drive
Pressure Differential Controller or Transmitter
Production
DistributionBypass Line
SU PPL YD E
MAN D
UCP2UCP2
UCP2UCP2
Air Handling Units
Control Valves
Production
DistributionBypass Line
SUPPLY
DEM
AND
Variable-Speed Drive
Flow
Meter
UCP2UCP2
UCP2UCP2
Differential Pressure Sensor or
Transmitter
Introduction to Trane Control Systems7 2010 Trane
Pre-engineered Features
Load determination Capacity matching Rotation Chiller setpoint control Failure recovery User interface
Installation and operating reliability and efficiency
Introduction to Trane Control Systems8 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 Systems9 2010 Trane
0.40.50.60.70.80.9
11.11.21.31.4
0 20 40 60 80 100Percent Load
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One Chiller at 100%? orTwo Chillers at 50%?
Constant Speed Centrifugal ChillerUnloading at constant condenser water temperature
Introduction to Trane Control Systems10 2010 Trane
Capacity Matching(turn the right chiller on)
Dependent on chiller plant design
Normal - identical chillers Base - heat recovery/super efficient Peak - back up/alternate energy source/inefficient Swing - match the load! Custom - mix and match/nested CPC objects
Reduce operating costs
Introduction to Trane Control Systems11 2010 Trane
UCP2
450 Ton Chiller (Swing) 900 Ton Chiller
(Normal-1)
900 Ton Chiller (Normal-2)
UCP2UCP2
0 2250450 18001350900
UCP2
Building Load (Tons)Reduce operating costs
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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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Unload Before StartKeep 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
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Failure Recovery Keep chilled water flowing
No manual intervention required Follow the standard sequence Multiple failure inputs
Chiller level System level
Reliable chilled water
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Intuitive User Interface
Minimize training time Minimize undesirable manual control Maximize operator efficiency
Reduced Operational Costs
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Reduced Operational Costs
Chiller Plant Status Screen - Tracer Summit
Easy to OperateEasy to Operate
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Alarm ManagementChiller 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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Alarm ManagementChiller Operating Parameters & Diagnostic MessagesAlarm ManagementChiller Operating Parameters & Diagnostic Messages
Introduction to Trane Control Systems19 2010 Trane
Diagnostics and Reports
Standard status reports Diagnostic reporting and message routing
Series R Rotary Liquid Chillers - Air Cooled Standard Report
Current Value
Chiller Name Chiller East Wing #1 Present Value Occupied Communication State Up Operating Mode Run: Normal
Chilled Water Leaving Temp - deg F 47.30 Chilled Water Entering Temp - deg F 57.70 Chilled Water Setpoint - deg F 41.00
Air Cooled Condenser Data Ckt 1 Sat Refrig Temp - deg F 74.00 Ckt 2 Sat Refrig Temp - deg F 74.30
Current Draw - % RLA 47 Current Limit Setpoint - % RLA 0
Compressor(s) Running? Yes
Ice Making? No Outdoor Air Temperature - deg F 82.20
RTA/RTW 70-125 Ton Unit: Compressor A Run Time - hrs 4271 Compressor A Starts 19 Compressor B Run Time - hrs 111 Compressor B Starts 18
RTA 240 to 400 Ton Unit (Add'l): Compressor C Run Time - hrs 0 Compressor C Starts 0
RTA 300 to 400 Ton Unit (Additional): Compressor D Run Time - hrs 0 Compressor D Starts 0
Chiller Plant Control Standard Report
Current Value
Chiller Plant Name Building Plant #1
System Mode Normal
System Data: Supply Water Setpoint 38.00 Supply Water Temp 47.30 Return Water Temp 57.70
Chilled Water Pump On Chilled Water Flow Flow Bypass Pipe Flow Not Used
System Operation: Failure Exists No Number of Chillers Enabled 1 Active Operation Confirming Chiller Off
Add Information: Next Chiller to Add 2 Add Delay Timer 6 Add Request Yes Add Temperature 39.50
Subtract Information: Subtract Method Temperature Subtract Delay Timer 20 Chilled Water Delta Temp 10.40 Subtract Delta Temperature 9.50 Subtract Flow Threshold 0.00 Excess Flow Percentage 20.00
Rotation Information: Rotation Type Day of Week Next Rotation Date & Time 03/21/04 00:01:00
Chiller 1: Chiller Control On Chiller Status On Chilled Water Setpoint 40.00 Leaving Chilled Water Temp 47.30 Chilled Water Pump On Chilled Water Flow Flow Current Limit Setpoint 120.00 Chiller Failure None Sequence Number Base Chiller Available Yes
Reduced Maintenance Cost
Introduction to Trane Control Systems20 2010 Trane
Chiller Plant Dashboard Details
Daily Average MetricsPump Pressure
Pump StatusSystem and
Chiller Status
Chilled Water Temps
Tower Water TempsSystem
Load
System Efficiency
Pump Flow
Introduction to Trane Control Systems21 2010 Trane
Chiller - Tower Optimization Tower Setpoint Optimization
Load Condenser water
temperature Wet bulb Tower design
Load Condenser water
temperature Chiller design
Introduction to Trane Control Systems22 2010 Trane
Chiller - Tower Optimization ChillerTower Interaction
Condenser Water Temperature, C
400
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26 27 28 2924
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100
030
Tower
Optimalcontrol point
Chiller
Total
Introduction to Trane Control Systems23 2010 Trane
Cooling Tower OptimizationResults
Minimumtemperature
Design CW WB + 5degrees
Optimized$47,500.00
$48,000.00
$48,500.00
$49,000.00
$49,500.00
$50,000.00
$50,500.00
$51,000.00
Minimumtemperature
Design CW WB + 5degrees
Optimized
Chiller+Tower Yearly Estimated Operating Cost
EarthWise
Introduction to Trane Control Systems24 2010 Trane
Plant Layout FlexibilityVariable Primary Flow
Air Handling Units
Control Valves
Production
DistributionBypass Line
SUPPLY
DEMAN D
Variable-Speed Drive
Flow Meter
UCP2UCP2
UCP2UCP2
Differential Pressure Sensor or
Transmitter
Introduction to Trane Control Systems25 2010 Trane
Energy OptimisationVariable Primary Chilled Water Flow Control
UCP2UCP2
UCP2UCP2
F
AHU
P
UCP2UCP2
VSD
VSD
VSD
Advanced
Variable
Primary Chilled Water
Flow Control
Introduction to Trane Control Systems26 2010 Trane
Trane AdaptiView Control System4th 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
Introduction to Trane Control Systems27 2010 Trane
Feed-forward control is an open loop predictive control strategy which 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
PID Feedback
7?
UC800 Feedback
712
Feedforward
DP40 l/s
Typical Controller
AdaptiView Controller
Trane AdaptiView Control SystemFeed-forward Control
Introduction to Trane Control Systems28 2010 Trane
Figure 1: Temperature Control w ith out Feedforward
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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 4:30:00Tim e (hour:min:sec)
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Condenser Entering W ater Temperature
Evaporator Entering W ater Temperature
Evaporator Leaving W ater Temperature Chiller CycledOff, Low W aterTem perature
Temperature Control
Introduction to Trane Control Systems29 2010 Trane
Feedforward ControlFigure 2: Temperature Control w ith Feedforward
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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 4:30:00Time (hour:min:sec)
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Condenser Entering W ater Temperature
Evaporator Entering W ater Temperature
Evaporator Leaving W ater Temperature
Introduction to Trane Control Systems30 2010 Trane
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.
Trane AdaptiView Control SystemVariable Flow Compensation
Introduction to Trane Control Systems31 2010 Trane
Capacity Controlw/o Water Flow Compensation
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0:00:00 0:10:00 0:20:00 0:30:00 0:40:00 0:50:00Time (hour:min:sec)
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Evaporator W ater Flow
Evap Entering W ater Temp
Evap Leaving W ater TempChiller off Chiller
off
Chiller on
50% Flow Reduction
Introduction to Trane Control Systems32 2010 Trane
With CompensationCapacity Control
with Water Flow Compensation
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0:00:00 0:10:00 0:20:00 0:30:00 0:40:00 0:50:00Time (hour:min:sec)
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Evaporator W ater Flow
Evap Entering W ater Temp
Evap Leaving W ater Temp
Introduction to Trane Control Systems33 2010 Trane33
Trane Chiller Plant Control & Optimization
F
P
VSD
VSD
VSD
UCP2UCP2
UCP2UCP2
UCP2UCP2
VSD VSD VSD
WB T
SMS
Energy Optimization
Flexible & Reliable Op
Better Plant Mgmt
Introduction to Trane Control Systems34 2010 Trane
Landmark East
Four Seasons Hotel
Tai Tung Building
Oriental Press
AIA Building
DHL Asia Hub
Major Job Reference
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Landmark East
Project Developer USI Property Management Ltd.
E & M Consultant TAP
Project Category HVAC Control System
BACnet Interface with BMS
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Project Scenario
30,000 Points
6 chiller plants (18 nos. Trane Chillers)
3,000 nos. VAV/CAV boxes (Trane)
Introduction to Trane Control Systems37 2010 Trane
Four Season Hotel
Project Developer SHK / Four Seasons
Group E & M Consultant
JRP/SHK Project Category
HVAC Control System
Four Season Hotel
Project Developer SHK / Four Seasons
Group E & M Consultant
JRP/SHK Project Category
HVAC Control System
Introduction to Trane Control Systems38 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)
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)
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)
Introduction to Trane Control Systems39 2010 Trane
Project Developer Tak Shing Property
E & M Consultant Rankin & Hill
Project Category BMS Supplier
BMS System Integration
Tai Tung Building
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Project Scenario
8,000 Points 4 nos. Trane Chillers 500 nos. Trane VAV boxes 30 AHU/PAUs (Trane)
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Oriental Press
Project Developer Oriental Press
E & M Consultant Hang Foong
Project Category BMS Supplier
BMS System Integration
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Project Scenario
4,000 Points 7 nos. Trane Chillers Tube Cleaning System 600 nos. FCUs (Trane) 18 AHU (Trane)
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200 Points4 Chillers20 AHUsBMS System
Integration
AIA Building
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1,000 Points2 Chillers10 AHUs70 VAVsBMS System
Integration
DHL Asia Hub
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Tracer Summit GraphicTracer Summit Graphic
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