Chilled Water Plant Statement of Capabilities

Transcription

1 ENGINEERED ENERGY SOLUTIONS INC. 166 West Ed Avenue Somerville, NJ Phone: (908) Fax: (908) Chilled Water Plant Statement of Capabilities

2 Table of Contents S E C T I O N 1 History of the Company S E C T I O N 2 Chilled Water Plant Automation S E C T I O N 3 Sample Projects

3 SECTION 1 History of the Company Engineered Energy Solutions, Inc. Engineered Energy Solutions (EES) was founded in 1982 with a mission to conserve the energy required to operate building systems. This mission has led the company to have direct influence on the energy use for major buildings in the Northeast. EES has been instrumental in improving operation, increasing reliability and life span, and reducing energy use for a number of Fortune 500 companies. EES is a control systems integrator specializing in the efficient use of energy as it relates to the design and control of building systems. EES has the unique ability to conceive, design, install, supervise, start-up, commission, and service the solution. The engineering and service teams have years of experience dealing with the complexities of building systems, management and operations to achieve quality control systems that pay for themselves. The EES staff of professionals is available to work as an extension of a client s engineering department or as designated consultants. On the basis of this team-generated program, EES Automation Engineers complete an analysis of the total system requirements and then apply the latest concepts with proven electrical instrumentation, control and information technology. By working closely with clients during the definition, design, implementation and operational phases of the project, EES provides a control and information system that meets the project objectives, budget and schedule. EES has, in addition to Chiller Plant Control System design, a very strong expertise in field implementation and functional performance testing. Types of systems in which we have developed complete solutions include: Chilled Water Systems Boiler Systems Automatic Free Cooling Systems (Use of Cooling Tower for Winter Cooling) Air Handling Systems Clean Room Systems

4 Sterile Core Airflow Control Production HVAC and Warehousing Terminal HVAC Systems (Reheat, VAV, Double Duct, Radiation, Induction, Fan Coil, etc) Co-Generation Lighting Building Automation using distributed stand-alone control Metering Electrical & Thermal with Facility Cost Allocation Demand Control Strategic Energy Use - determine which energy supply to use depending on cost/energy unit Remote Monitoring and Alarm Systems Tunnel Ventilation - Redundant Processor (Hot Back/Up) Systems In addition to our project expertise, we are a Certified Member of the Control System Integrators Association. This certification requires EES to go through an audit every three years to qualify our technical and management abilities in the area of control system engineering. Measured areas include project management, software engineering, documentation, project risk analysis, business operations, configuration management and quality assurance. This assures that we will provide accurate levels of documentation for commissioning and troubleshooting of our systems. EES is also a Provider Firm Member in the Building Commissioning Association. The purpose of building commissioning is to provide a quality building that is fully documented and easily maintained. The sustainability and total cost of ownership of a facility are taken into account. Because of our extensive HVAC experience, we have been exposed to numerous building systems and are familiar with the potential pitfalls. The goal of our projects is to provide full documentation to the client with controls in an open platform that allow for ease of maintainability by the owner s personnel. Building Control Systems Integration Geographical Experience EES is a regional company with the majority of its projects located on the East Coast. We have done work in Connecticut, Pennsylvania, New Jersey, New York, as well as in Georgia and South Carolina. We have an office in Puerto Rico to serve our pharmaceutical clients in the Caribbean. We have designed and installed control systems throughout Canada and the U.S. for a major financial client.

5 EES Project Team and Collaboration The success of a project is dependant on the level of communication and collaboration between the project team members. Understanding this need, EES has incorporated the use of the Grandview project management system. Each project team member (EES, owner, CM, engineer, electrician, etc.) will have a password for remote access into the system. Through this remote access, the project team can view milestones, track material, view project status, check invoicing, transfer documentation more effectively and increase the overall level of communication between the team members. In this manner, EES is able to execute projects more efficiently from any location in the world. The method of remote access is via the Internet using Internet Explorer. No additional software is needed. The diagram below highlights the system. It has enabled EES to provide more solutions to remote locations while performing project functions in our Somerville, NJ facility.

6 SECTION 2 Chilled Water Plant Automation PROCOS is our fully automated chiller plant control system. PROCOS is an acronym for Programmable Chiller Optimization System. We utilize PLC-based hardware and industrial grade instrumentation in our systems. There are several reasons why this hardware and programming software is used. Reliability of the components with a high Mean Time Between Failure (MTBF) results in more automatic operation and increases the overall system reliability. Lower quality instrumentation leads to garbage in = garbage out syndrome. This can translate to as much as 20% inefficiency in plant operation and increased service costs due to poor sensor information. Hardware is backward compatible which eliminates the need for upgrades. Control flexibility for use in mixed tonnage chiller plants, multi-fuel chiller plants, heat exchanger optimization, multiple pumping configurations, and control strategies. Ability to use EES algorithms in a plug-and-play fashion to customize the installation. Use standard code to customize the system for any mechanical configuration. Higher analog resolution on I/O eliminates overshoot and inconsistent control which ultimately saves energy. Ability to simulate the system and perform a Factory Acceptance Test to eliminate excessive field rework. We provide full documentation so that the owner can maintain the system. This removes the need for service contract agreements which lower the total cost of ownership of the system. This includes AutoCAD drawings, loop drawings, O&M Manuals, fully documented PLC code listing, and fully documented HMI code listing.

7 We provide full training so that the owner can maintain and troubleshoot the system with in-house personnel. We remove the need for service contracts which decreases the total life cycle cost of the system. PLC hardware can be serviced by any system integrator which promotes competition. Other system vendors use territorial alignments to control service areas. PROCOS is expandable to include our Strategic Utilities Management algorithms. 50% 35% 12% 3% Incremental Spending for PLCs Concept Non-Recurring Costs Design & Build Install & Commission Savings Opportunities with PLCs Operation & Support Since EES methodology is to put more effort up front during the concept, design, and build phases, we end up saving the client money on the back end with start up and operations. This investment in the initial cost will save the client time and money on a life cycle basis. This creates an asset for the owner. Through our experience, we have seen that each chilled water plant is unique in its configuration. We have the ability to conceive, design, provide the software, and build chiller plant control systems for multiple mechanical configurations. We have experience with campus chilled water plants and distribution systems. We focus on the reliability and energy savings that can be realized. Our systems are designed to be fully automated. Some of the EES control strategies include: Stage chillers based on load criteria with the ability to weight certain areas based on critical loads Chiller setpoint reset to optimize chiller efficiency Automatic backup in the event a chiller fails Chiller staging based on efficiency

8 Automatic flow control through the chiller Automatic CHW pump and CDW pump staging Automatic backup for in the event a pump fails Chiller head pressure control for automated heat exchanger operation Auto changeover from mechanical cooling to free cooling Cooling tower optimization Heat recovery chiller control Load shedding and demand control Optimized load differential pressure control Thermal storage systems Primary / secondary control with VFDs Evasive action for reliability in production environments We develop the PROCOS system to provide plant floor to top floor information. Energy usage and load profile analysis software from EES can be included to identify chilled water consumers. This information can be valuable in determining cost allocations for buildings / departments, identifying excessive energy use, and marginal cost accounting on production areas. We have also installed systems that utilize our Strategic Utility Management (SUM) algorithms to determine which equipment is the most efficient to run based on the price of fuel. A heat exchanger can be utilized whenever a facility has a need for 24/7/365 cooling. Facilities of this type include computer centers, pharmaceutical, food packaging, and manufacturing companies. EES has extensive experience with the implementation of heat exchanger projects and can perform a complete turnkey installation. We use algorithms which will optimize the use of the heat exchanger. Using a heat exchanger during winter months is obvious but there are also times during the spring and fall where a heat exchanger can be utilized. We have even installed systems where the heat exchanger was in full use during June. The efficient and reliable operation of a chilled water plant requires not only control expertise but also mechanical experience and the ability to quantify the savings that would be realized. EES has also installed heat exchanger controls in various facilities where the needs are quite diverse. The heat exchanger can be placed in a myriad of mechanical arrangements including parallel, series, or dual plant. We have worked on installations that have a common cooling tower arrangement and others that have a dedicated cooling tower for the heat exchanger. In some installations, the heat exchanger is used as a method of free cooling. In other installations, the heat exchanger provides an added level of reliability and back up. When a heat exchanger is used in a parallel arrangement, it is on a headered chilled water system and acts as another chiller in the system. EES heat exchanger automation system will determine if a heat exchanger can be utilized. The control system will then maintain the running chillers while the heat exchanger is readied for operation. When a heat exchanger is in a series arrangement, it is placed on the chilled water return line. The heat exchanger can either precool the chilled water return temperature or take on the entire chilled water load depending on the outside air and load conditions.

9 Dual plant arrangements are found on larger facilities or campus systems where multiple chilled water plants can serve a chilled water loop. A heat exchanger can be placed on one plant so that, when outside air and load conditions are correct, it can be readied for operation with minimal effect on the other plants. The cooling tower side of the heat exchanger can drop the cooling tower water supply without affecting the operation of the chillers because the chillers would be running on a different cooling tower system. Regardless of the mechanical arrangement, the switch to free cooling will occur automatically without operator intervention. Decisions in the industrial PLC controller will ensure a smooth transition. Also, the use of an industrial controller lends itself to customization and flexibility for any system. We have installed heat exchanger automation systems that provide a level of backup and ride through when chiller(s) would fail. This has been useful in the pharmaceutical and computer industry where downtime is not an option.

10 SECTION 3 Sample Chilled Water Plant Automation Projects This section lists seven (7) completed projects. These projects represent different mechanical configurations with different goals for each. For four (4) of the projects we have done a heat exchanger energy analysis. Project #1 Organon, West Orange, NJ Industry Pharmaceutical Primary Goal Reliability Secondary Goal Energy Savings This facility is a pharmaceutical production environment with a chilled water loop serving air handling units located in various areas in the facility. The PROCOS system and heat exchanger automation has been fully functional for over ten years. Each chiller has a dedicated chilled water pump, condenser water pump, and cooling tower. The discharge of each chiller flows into a common header for distribution throughout the building. The heat exchanger is located on the common return to the chillers in a series arrangement so it can precool the chilled water return temperature or take over the entire chilled water load depending on conditions. With this mechanical configuration, the dedicated cooling tower for one chiller is used to cool the cooling tower water supply temperature. We also control the head pressure on this chiller so that as the cooling tower water supply is lowered, this chiller will remain on line. When the heat exchanger automation system has determined that the heat exchanger can assume the load, the chiller is turned off automatically via the PROCOS system. Various process loads are attached to the chilled water system. A loss of cooling and/or chilled water flow for any period of time can cause downtime and lost product. Fail safe programming has been put in place to engage the heat exchanger so that in the event no chillers are running, the heat exchanger will attempt to maintain the load under the proper outside air conditions. The heat exchanger energy savings report for this facility highlights the savings, in energy, that Organon has realized. The heat exchanger can run as standalone or in chiller assist. As can be seen, more savings are realized when the heat exchanger is used in

11 standalone mode without any chillers running. This facility has a very tight tolerance on its chilled water supply and chilled water return temperature needs. The control that EES installed has been customized with these tolerances in mind. The amount of product that has been saved due to the installation of this system has not be quantitatively calculated There have been several instances where the system has enabled heat exchanger cooling due to chiller electrical failures. This resulted in product being brought to market rather than being discarded. Project #2 Bellcore (Telcordia), Piscataway, NJ Industry Telecommunications Primary Goal Reliability Secondary Goal Energy Savings This facility is a computing center for Telcordia. There are two separate chilled water plants with one loop serving the office space and another loop serving the computer center. During the winter, the office chillers are turned off because the air handling units run on an economizer cycle. The computer center requires cooling 24/7/365. The PROCOS chilled water plant control system has been fully functional for over seven years. The computer chillers are headered on both the condenser and chilled water side. Pumps on the chilled water and condenser loops are also headered so that any pump can run with any chiller. The heat exchanger is located on the computer chilled water plant in a parallel arrangement. The head pressure is controlled on the computer chillers so that as the cooling tower water supply is lowered, the running chillers will remain on line. When the heat exchanger automation system has determined that the heat exchanger can assume the load, the chillers are turned off automatically via the PROCOS system and the heat exchanger assumes the load. Since this is a computer center, chilled water flow and/or temperature cannot be lost for more than two minutes or the computer systems will shut down and disrupt communications. Fail safe programming has been put in place to engage the heat exchanger so that in the event no chillers are running, the heat exchanger will attempt to maintain the load under the proper outside air conditions. Project #3 AT&T Bell Labs (Avaya), Lincroft, NJ Industry Telecommunications Primary Goal Energy Savings Secondary Goal Reliability This facility is a computing center for Avaya. There is one chilled water plant but the chillers are valved to serve the computer chilled water loop and the office chilled water loop. During the winter, the load decreases because the air handling units run on an economizer cycle. The computer center requires cooling 24/7/365. The PROCOS chilled water plant control system has been fully functional for over fifteen years. The chillers

12 are headered on both the condenser and chilled water side. Pumps on the chilled water and condenser loops are also headered so that any pump can run with any chiller. The heat exchanger is located in a parallel arrangement. The head pressure is controlled on the chillers so that as the cooling tower water supply is lowered, the running chillers will remain on line. When the heat exchanger automation system has determined that the heat exchanger can assume the load, the chillers are turned off automatically via the PROCOS system and the heat exchanger assumes the load. In this facility, the heat exchanger will run in standalone or chiller assist mode. The automation system is programmed so that the heat exchanger and chiller do not run in assist mode for extended periods of time due to the fact that this is not very efficient. The heat exchange has run about 33% of the yearly cooling plant run hours. This facility is able to run more heat exchanger hours due to the fact that there is more flexibility with the chilled water supply and return temperatures. As a result, EES incorporated this into the control system to allow more free cooling capability which has afforded more energy cost savings to Avaya. Project #4 AT&T Bell Labs, Middletown, NJ Industry Telecommunications Primary Goal Energy Savings Secondary Goal Reliability This facility is a computing center for AT&T. There is one central chilled water plant which serves the entire facility. During the winter, the load decreases because the air handling units run on an economizer cycle. The computer center requires cooling 24/7/365. The PROCOS chilled water plant control system has been fully functional for over fifteen years. The chillers are headered on both the condenser and chilled water side. Pumps on the chilled water and condenser loops are also headered so that any pump can run with any chiller. This facility also has an emergency chiller which provides additional cooling reliability during the summer. The heat exchanger is located in a parallel arrangement. The head pressure is controlled on the chillers so that as the cooling tower water supply is lowered, the running chillers will remain on line. When the heat exchanger automation system has determined that the heat exchanger can assume the load, the chillers are turned off automatically via the PROCOS system and the heat exchanger assumes the load. The heat exchanger energy savings report for this facility highlights the savings, in energy, that AT&T has realized. In this facility, the heat exchanger will run in standalone or chiller assist mode. The automation system is programmed so that the heat exchanger and chiller do not run in assist mode for extended periods of time due to the fact that this is not very efficient. The heat exchange has run about 33% of the yearly cooling plant run hours. This facility is able to run more heat exchanger hours due to the fact that there is more flexibility with the chilled water supply and return temperatures. As a re-

13 sult, EES incorporated this into the control system to allow more free cooling capability which has afforded more energy cost savings to AT&T. Heat Exchanger ON - No Chiller Assist Average Load: 250 Tons KW - Chiller Cooling Only 383 KW - Heat Exchanger Cooling Only -220 KW - Savings 163 Run Hours - Heat Exchanger 2281 KWHR - Savings $/KWHR - Electrical Rate $0.08 $ Savings $29, SAVINGS $29, Project #5 New York Life Insurance Company, New York, NY Industry Financial Primary Goal Reliability Secondary Goal Energy Savings This facility is a computing center for New York Life Insurance Company. There is one central chilled water plant which serves most of the facility. There are two heat exchangers on a smaller, dedicated chilled water system which serves the main computer center and support offices. The computer center requires cooling 24/7/365. The PROCOS chilled water plant control system and has been fully functional for over ten years. The chillers are headered on both the condenser and chilled water side. Pumps on the chilled water and condenser loops are also headered so that any pump can run with any chiller. The heat exchangers are installed in a parallel arrangement. The head pressure is controlled on the chillers so that as the cooling tower water supply is lowered, the running chillers will remain on line. When the heat exchanger automation system has determined that the heat exchanger can assume the load, the chillers are turned off automatically via the PROCOS system and the heat exchanger assumes the load. This facility is unique because there is a backup heat exchanger for redundancy. In the event the lead heat exchanger fails (i.e. valve does not function), the backup heat exchanger will be started. This exemplifies the customization and flexibility designed into EES heat exchanger control systems.

14 Project #6 Pfizer Pharmaceuticals, Groton, CT Industry Pharmaceutical Primary Goal Reliability and Campus Loop Control Secondary Goal Energy Savings This facility is pharmaceutical manufacturing and research facility for Pfizer Pharmaceuticals. There is one central chilled water plant which serves a campus chilled water loop. There are four (4) 1500 ton absorption chillers and four (4) 1500 ton centrifugal chillers. The PROCOS chilled water plant control system has been fully functional for over ten years. The chillers are headered on both the condenser and chilled water side. Pumps on the chilled water and condenser loops are also headered so that any pump can run with any chiller. The cooling towers are located next to the chiller building. The plant utilizes automated flow and pressure control to vary the flow through the chiller bundles. VFDs on the condenser and chilled water pumps are also control by the PROCOS system. An individual chiller control panel was placed on each chiller and networked with a central plant controller to eliminate wiring costs and create a distributed system. The loads are monitored for chilled water usage and the plant is operated to maximize the loading on the running chillers. Absorption chillers are used as a base load since they require more time to get up and running. The centrifugal chillers are used to trim the load requirements as needed. Project #7 World Trade Center, New York, NY Industry Financial Primary Goal Monitoring Secondary Goal Energy Usage EES installed the original central chilled water plant monitoring system the WTC site. The system was used on a campus chilled water loop that served the two towers and the other buildings in WTC complex. The total tonnage of the plant was tons. We supplied all instrumentation, PLC equipment, and HMI computers for monitoring by the operators and Port Authority personnel. The facility utilized Hudson River water for condenser relief on the chillers. EES installed a monitoring package on river water usage for EPA reporting. The loads were monitored on the campus loop and in the towers for chilled water usage. Reports were generated for management decisions and cost accounting. Project #8 Dubai Health Care City, Dubai UAE Industry District Cooling Primary Goal Energy Savings and Efficiency Secondary Goal Reliability

15 EES provided the automation system design engineering, programming, start up and commissioning of a district cooling plant in Dubai, UAE. The plant served medical offices, hospitals, and commercial space through the use of energy transfer stations (ETS) at each building. The total tonnage of the district plant is tons. The control system was designed for lights out automation to run the district plant as required to meet the load in the most efficient manner. The overall plant efficiency was reduced to 0.95 kw/ton with EES PROCOS controls in place. This efficiency included all chillers, cooling towers, primary chilled water pumps, secondary chilled water pumps, condenser pumps and all associated plant HVAC equipment.we supplied all instrumentation, PLC equipment, and HMI computers for monitoring by the operators and Port Authority personnel. The loads were monitored on the district cooling loop and the ETSs were controlled to deliver the required chilled water. Reports were generated for management decisions and cost accounting. V:\SALES\SALES LITERATURE\Statement of Capabilities\CHW Plant statement of capabilities green.doc