CHLLED WATER SYSTEMS OPTIMIZATION AN OVERVIEW

Transcription

1 CHLLED WATER SYSTEMS OPTIMIZATION AN OVERVIEW APEM July 20, 2004

2 OPTIMIZATION The process of obtaining the most favorable conditions or amounts.

3 CHILLED WATER SYSTEMS OPTIMIZATION Pump Less Water

4 THE PROCESS Initial Assessment (Go-No Go) Financial Issues Operations Engineering Capital Projects Commissioning Training Continuous System Tuning

5 INITIAL ASSESSMENT

6 Initial Assessment System Data Delta T & Flow/Load System Configuration Pumping Energy Controls Develop Initial Optimization Plan Estimated Savings Go-No-Go

7 FINANCIAL ISSUES

8 Financial Issues Meet with the CFO Existing Utilities Model Capital Projects Model What are the Required Parameters for Project Approval?

9 Financial Issues Funding Existing Operations Cash Flow Utility Participation Financing Implementation Continued Operations Phasing Deferred Capital Costs Distribution System Production System

10 OPERATIONS

11 Operations Existing System Operations Automation/Lack thereof System Issues Operating Parameters Optimized System Operations Automated Control Resolve System Issues New Operational Way of Life

12 Operations Expansion Issues Infrastructure Requirements New Load Vs Installed Cooling Capacity Production/Distribution System Flow Capacity Alternate Project Site Locations New Project Design Criteria» Coil Delta T = Plant Delta T» 25 psig Delta P Bldg Dist. System» Pressure Independent, High Rangeability, Industrial Grade Two Way Control Valves

13 ENGINEERING

14 Engineering Systems Optimization 1. Data 2. Evaluation & Analysis 3. Capital Projects 4. Continuous System Tuning Virtual Facilities Engineer

15 Engineering Data Operational Data Physical Data

16 Manual Trends BCS Trends Engineering Operational Data BCS Historians PI (Real Time Performance Management RTPM osisoft.com) Benchmarking

17 Engineering Physical Data System Survey Piping Ladder Diagram & Hydraulic Model Piping size, lengths & routing Piping Components Equipment (Name Plate Data)

18 Engineering Evaluation & Analysis System Optimization Opportunities Piping Ladder Diagram Physical Conflicts Hydraulic Profile (Model) Hydraulic Issues System Pumping Energy Remove Pumps VFD Hydraulically most remote point Delta T Performance Optimize System Delta T Flow Limited Plant Eliminate via Delta T Optimization

19 Piping Ladder Diagram Secondary Pump Chillers Primary Pumps Building Load Control Valve

20 4 " 6 " 3 " 4 " 3 " 3 " P-1 P-2 P-1 P F0 T G/ PH MD FT/HD 400 GPM FT/HD 470 GPM FT/HD 470 GPM 1 0 " C H W S 1 1 BLDG.1 2 \ " 2 \ " 3 " 3 " BLDG P FT/HD GPM 70FT/HD 450 GPM P250 GPM - 3 BLDG " P-2 5" 5" 50 FT/HD 4 " 4 " 2 \ " 5" 5 " 2 \ " 5" BLDG P250 -GPM 4 50FT/HD WEST LOOP GPM P-4 70FT/HD 6 " BLDGS. 5, 7 & 7A P-2 3 " P F0 T G7/ P8H M5D FT/HD 350 GPM P F0 T G/ PH MD 350 GPM FT/HD 4 " 2 \ " 2 \ " 2 \ " 2 \ " IN-LINE PUMP 50 GPM P-3 30FT/HD " 1 6 " P P HP 1 6 " 1 6 " HP 1 6 " 1 2 " 6 " HWS P P-13 P H P 1 6 " 1 6 " 1 6 " 1 6 " GPM70FT/HD 1 0 " 1 2 " BLDG.13 CHWP-2 CHWP-1 CHWP GPM 7 0 F T / H D 1500GPM 70FT/HD GPMFT/HD 1 6 " " P-25 10HP P HP 5" 5 " 1 C H W R " 5 " 5" 5 " 5" 5 " 1 2 " 5" CHWP FT/HD GPM CHWP FT/HD GPM 3\" 6 " 3\" BLDG CHWP-1 2HP S Y M ABBREVIATION B O L C H W S SHUT-OFF AUTOMATICCONTROLVALVE (GATE) SHUTOFFVALVE (BUTTERFLY) (BALLVALVE) CHECK VALVE C H W P CHILLEDWATERPUMP WATER RETURN C H W S CHILLED DELTA "P" CONTROL WATER VALVE SUPPLY 2-WAY NO NC LEGEND C H W R CS ET CW TYP DESCRIPTION ARROWINDICATESDIRECTIONOFFLOW CIRCUIT DOMESTIC SETTER COLD WATER EXPANSIONTANK FMFS FLOW METERTCH SWI NORMALLYCLOSEDOPEN TEMPERATURE SENSOR PUMP PRESSUREGAUGE SHWPS C H W P SECONDARYCHILLEDWATERPUMP SECONDARYHEATINGWATERPUMP S. O. V. SHUT-OFFVALVE NOTES: STRAINER (COMBINATION) STRAINER/S.O.V. SUCTIONDIFFUSER TEMPERATURE GAUGE TYPICAL TRIPLEDUTYVALVE REDUCER WEST LOOP NORTHWEST LOOP CENTER LOOP CENTER LOOP EAST LOOP EAST LOOP EAST LOOP EAST CAMPUS LOOP 2 0 " C H W S " 20" 20" C H W S C H W S 2 0 " C H W S 2 0 " 5" 3 " CENTRAL PLANT BLDG. 42 BLDG.39 C H W S C H W S " C H W S 1 20" 2 0 " 20" 20" 2 0 " N.C. N.C. 1 C H W R " " N. C. 1 N.C. 1 4 " 8 " N.C " " " C H W S 8 " 8 " " " 1 8 " BLDG. 33 BLDG.31 BLDG.35 BLDG.37 6 " " 1 2 " BLDG.2 BLDG. 6 BLDG.48 BLDG. E 3 4 BLDG. E 2 5 BLDG. E25 BLDG. E25 BLDG. E " 6 " BLDG. 24 BLDG.34 BLDG.26 BLDG. 8 BLDG.4 BLDG. 12 BLDGS.6 &6A BLDG.14 BLDG. 18 BLDG.54 BLDGS.16 &56 1 BLDG. 1 4 " " BLDGS.17,18,19 1 \ " BLDG. 45 BLDG.36 BLDG.38 BLDG. E40 (EAST CAMPUS CUP) BLDG. E51 BLDG. E52 BLDG. E53 BLDG. E2 BLDG. E38 BLDG. E32 BLDG. 2 PUMP IN-LINE HP 2 4 " CHWP-2 W15 BLDG. W16 BLDG. W20 BLDG. W34 BLDG. NW12 & 13 BLDG. NW15 BLDG. NW " 30" 6 " 6 " 8 " N.C. 1 0 " 1 0 " 1 2 " 1 2 " " 2 \ " FT/HD 100 GPM HWS 2 " 2 CHWP CHWP-2 CHWP CHWP C H W P CHWP CHWP CHWP CHWP-2 CHWP C H W P - 3 CHWP-2 CHWP-1 PUMPSLOCATED INBSMNTBLDG.8 CHWP-1 3 " 1 0 " 1 0 " 1 0 " CHWP-1 CHWP-4 -GPM -FT/HD IN-LINE- CHW P-1 CHW P-1 6 " 1 0 " 1 6 " HWS P-1 P-2 4 " CHWP- 4 C H W P - 3 N.C. CHWP- 2 CHWP " 1 2 " " 7CHWP CHWP-2 10GPM PARTLOAD F5 T G/ PH MD CHWP CHWP FT/HD GPM 70FT/HD 350 GPM F0 T G/ PH MD 20GPM70FT/HD FT/HD GPM 70FT/HD 700 GPM F5 T G/ PH MD 45FT/HD 150 GPM F0 T G/ PH MD FT/HD GPM 95FT/HD GPM 7CHWP FT/HD GPM N. C. CHW-P3A CHW-P3 4 " GPM 65FT/HD CHWP CHWP FT/HD 1GPM GPMFT/HD FT/HDGPM 350GPM50FT/HD 50FT/HD 350 STND-BY GPM CHWP-1 CHWP-8 15HP HP CHWP STND-BY CHWP FT GPM HD N.C. 20HP 20 HP 40FT/HD FT/HD GPM 70FT/HD 40 GPM 4 " 4 " 58FT/HD 1000GPM P FT/HD 3215GPM 75FT/HD 600 GPM CHWP-31 CHWP " 4 " IN-LINE P-2 P FT/HDGPM CHWP CHWP CHWP CV-1 CV HP CHWP CHW/HW SECOND CHWP F GT PH MD IN-LINE PUMP PUMP6,6A,7 6 " 6 " CHWP-3 CHWP-1 10HP P-2 CHW-P4A C H W - P 4 6 " 1 2 " 1 \ " 6 " 4 " CHWP CHWP G P M CSTND-BY H W P CHWP GPM CHWP GPM CHWP G P M C H W P CHWP-15 4 " (NOT IN-LINEIN USE) [HP IN-LINE 37FT/HD 33 IN-LINE GPM 2HP IN-LINE 5 HP. 45FTHD1 4 0 G P M 45FTHD140GPM 7.5HP. 185FTHD 8 5 G P M BACK-UP FT GPM HD 7.5 HP GPM FT HD CHWP-1 IN-LINEPUMP ( 81300GPM 5 T FYT P / H3 D) 4 " 798FT/HD 1001GPM CHWP-2 100FT/HD GPM " 710HP " 1 0 " 1 0 " 8 " STND-BY 65FT/HD 440 GPM 8 5 F T / H D 80FT/HD FT/HD GPM 50FT/HD 8 0 F T / H D STND-BY GPM CHWP-1 CHWP-2 CHWP-3 CHWP-4 IN-LINE IPUMPS 250 GPM 6 " 4 " PUMP 7.5HP. 6 " CHWP-2 60FT/HD GPM \" PUMPIN-LINE 3 " 100FT/HD 400 GPM 1 0 " 4 " 1 0 " 8 " 1 2 " \ " 2 \ " 1\" 6 " 80FT/HD PUMPSIN-LINE 2 " 4 " HWR 5" 7\HP7 CHWP CHWP FT/HD290GPM 1\" HCHILLEDWATER/ RIVER E X 3HP 1 0 " 8 " 8 " 1 0 " 6 " 4 " 75 HP 75HP HP 760HP " BOILER BOILER BOILER 1 " IN-LINE 6 " H E X W 7\ HP 3 " 1 " 3 " FROMH.W. SYSTEM IN-LINE P - 5 P-6 CHW P-3 CHW 2 P- CHW P " 4 " 6 " N. C. 1 0 " 1 2 " N.C. N.C. HWS N.C.H W S N.C. HWS PUMP [HP. 3 " 1 2 5" 2 " 1\" 3 " 1\" 1 " 1 " 1 " 1 \ " 3 " GPM 2 SPEED SPED GPM 2 \ " 2 \ " 4 " 6 " 46 2 F5 T G/ PH MD 42FT/HD 625 GPM 46FT/HD 260 GPM 6 " 4 " N.C. 5 " HWS 4 " 3 " 1\" 3 " 5" 5" 1 2 " 1 2 " 1 8 " 1 8 " 2 INBLDG.8A PUMPSLOCATED 120FT/HD 120 FT/HD 3 " 2 \ " 2 \ " 1 " 1\" 1\" 1\" 1 \ " 5 " 5" 6 " 5" 5" 6 " IN-LINE IN-LINE IN-LINE 2 \ " N. C " 1 " CHWP CHWP- 4 C H W P 1\" 6 " N.C. 8 " 1 0 " 1 0 " 1 1 PUMP 30GPM (2HP) PUMP 90 GPM (3 HP) P60 GPM U M P ( 2 H P ) N.C " 51FT/HD 98 GPM 51FT/HD 98 GPM HP 5" C.W. MAKE-UP 7 3 F T / H D 65FT /HD 63FT /HD PUMP 1\" CHWP FT/HD GPM CHWP-4 STD-BY CHWP GPM 160FT/HD C2 H4 W" P \ " 1 SECOND. CHW/HW 1\" CHWP GPM CHWP GPM CHWP GPM 7500GPM 160FT/HD " 155FT/HD 155FT/HD 160FT/HD FUT. 5 " 2 " HE 3 " " 6 " 1 \ " 4 " 2 \ " 2 \ " 1 \ " 5" 5" 5" 5" 6 " 5" 5" 2 \ " 3 0 " 1 " 3 " 1\" 3 " 1\" 3 " 1 " 4 " 6 " 1 0 " 8 " 1 4 " 6 " 5 " 2 " 3 " 1\" 1 4 " 1 4 " " 1 " 1 " 2 \ " 1 " 1 \ " 2 \ " 2 \ " 4 " 6 " HE-1 HE-2 HE-3 6 " 4 " 4 " 6 " 1 " 5" 5" 6 " 4 " 2 30" 2 " 3 " 1 2 " 6 " 1\" 4 " MAKE-UP 3 " 1 0 " 1 2 " 1 0 " BOILER BOILER BOILER HWS N.C. 63 PSI 4 " 1 8 " 2 4 " " 4 " 6 " N.C. HWR N.C. H W R N.C. HWR ABANDONED 2 \ " 3 " 6 " 4 " 3 " IN-LINE 2HP PUMP 2 4 " 6 " 8 " 2 4 " " 1 HWR 6 " 6 " 1 0 " 6 " 1 N.C. 1 2 " N.C. 1 2 " 1 2 " 5" N. C. 3 " 8 " C H W R " 1 20" 2 0 " 20" 20" C H W R C H W R C H W R C H W R C H W R C H W R 1 6 " 20" N.C. 2 0 " 2 0 " 2 0 " C H W R C H W S 1 C H W R C H W S C H W R C H W S C H W R 8 " C H W R C H W R 1 4 " 1 2 " N.C. CHILLED WATER SYSTEMS OPTIMIZATION

21 Hydraulic Profile (Pipe Flow) Production/Distribution/Building Systems Hydraulic Modeling Software System Hydraulic Optimization (Configuration & Control) Facilities Planning (Infrastructure Impact) Operational Planning (What-if Scenarios) System trouble shooting Virtual Facilities Engineer

22 Hydraulic Profile (Model) PUMP VFD CONTROL Speed Response is Flat or Set Point Reset is required Differential Pressure Sensor Location Plant wall Across the pump Physically most remote system point (s) *Hydraulically most remote point (points low select)

23 Hydraulic Profile (Model) Head Bldg Load Typical Production Distribution Building Distance

24 DISTANCE (FEET) N N048 HEAD LOSS (FT. HEAD) SECONDARY PUMPS N051 N571 N572 N065 N579 AHU-12B N137 N139 N176 N178 N660 N140 N070 N771 N157 N772 N158 AHU-8 R AHU AT NEW HIGHRISE (LOCATED IN BASEMENT) N111 N069 N066 N067 N084 AHU-11 N161 N160 N832 N071 N082 N601 AHU-3 N075 N076 N078 N605 N606 N613 AHU-7B N153 N602 N603 N616 AHU-5 TERTIARY PUMP "BLDG. "A" EAST EXPANSION (FURTHEST MOST HYDRAULICLY REMOTE POINT) N155 N163 FURTHEST REMOTE FAN COIL, BLDG. "A" N001 N028 N102 N088 N086 N087 N136 N831 N083 N614 EAST EXPANSION 70 N N002 CHILLERS PRIMARY PUMPS FCR-22 (RISER AT NEW HIGHRISE 2ND STORY CASINO AREA 40 N316 N339 N003 N317 N N027 N338 HEX 20 AHU-1-1 N340 N402 N418 N N SHEET NOTE : PROFILE WITH NEW PUMPS, NO DIVERSITY, AND SYSTEM BALANCED TO DELIVER 5300 GPM. HYDRAULIC PROFILE WITH PRIMARY PUMP FLOW AT GPM, 103 FT/HD EACH. HYDRAULIC PROFILE WITH SECONDARY PUMP FLOW AT 1330 GPM, 133 FT/HD EACH. POINTS OF PRIORITY INTERESTS ARE PLOTTED ONLY, FOR CLARITY PURPOSES. EG D AVIDA IST EREDPROFESS MEC HAN ION AL E NGINEER.ROGERS ICAL IA S T ATEOFCALIFORN CHILLED WATER HYDRAULIC PROFILE PEPPERMILL RENO, NEVADA CHILLED WATER DISTRIBUTION SYSTEM INVESTIGATION ATTACHMENT C CHILLED WATER SYSTEM HYDRAULIC PROFILE

25 System Pumping Energy Head Bldg Load Typical Production Distribution Building Distance

26 Delta T Performance Distribution System Delta T Profile Optimized Systems Delta T Maximum Block Load Delta T Coil Design Delta T Non Optimized Systems Load

27 Flow Limited Plant 1500 gpm 1500 gpm 1000 ton load/16 degree Chillers = 1500 gpm each 0 gpm 625 ton load/10 degree delta T = 1500 gpm 1500 gpm Production 1500 gpm Distribution

28 Flow Limited Plant 1500 gpm 1680 gpm 1000 ton load/16 degree Chillers = 1500 gpm each 1320 gpm 700 ton load/10 degree delta T = 1680 gpm 1500 gpm Production 1680 gpm Distribution

29 CHILLED WATER SYSTEMS OPTIMIZATION Flow Limited Plant Existing Conditions Future Projects Distribution Flow GPM/Load Tons Delta T Distribution Flows Typical Load Profile Production Tons Typical Production Flow Typical Year

30 Capital Projects Control Valves Return Water Temperature Sensors Controls Data Historian System Reconfiguration Piping Pumping Heat Exchangers Chillers/Towers Etc. Commissioning Training

31 Capital Projects

32 Capital Projects University of California Davis Medical Center Sacramento University of Iowa Massachusetts Institute of Technology

33 Commissioning Control Valves Pumps & VFD s Controls

34 Training Systems Approach Know your System Piping Ladder Diagram Hydraulic Profile Delta T & Flow Trouble Shooting Fix the problem, Don t treat the Symptom

35 Continuous System Tuning The Virtual Facilities Engineer

36

37 The Virtual Facilities Engineer PI Software Pipeflo Software

38 The Virtual Facilities Engineer PI (VFE Server) Real Time Performance Management - RTPM Collect, Aggregate & Store Data Across the Enterprise (Multiple Control Systems) ICE Interactive Configurable Environment Web Based ACE (Advanced Computing Engine) Wizard, Manger, Scheduler Data Link ( spread sheet data link) Process Book (graphical front end using VBA)

39 Green-Delta T =15F, Yellow-Delta T F, Red-Delta T<12F

40 The Virtual Facilities Engineer Real Time Performance Analysis Control Valve Performance Chiller Performance Pump/VFD Performance System Performance (COP; Kw/ton; etc) Establish & Verify Campus Building Chilled Water Charges

41 The Virtual Facilities Engineer Real Time Flow Modeling (Pipeflo Engineered Software) Building Interface DP Control Valve DP Pump Staging Hydraulically Most Remote Point VFD DP Set Point

42 The Virtual Facilities Engineer Component Diagnostics Cooling Coil/Control Valve Delta T Performance Chiller Staging Load/Flow Pump Staging Hydraulic Model Building Differential Pressure Performance Hydraulic Model Hydraulically Most Remote Point Hydraulic Model

43

44 I GET IT!