Bilfinger Efficiency GmbH Energy efficiency of cooling systems: Optimization through precise energy monitoring Thomas Theiner ACHEMA 2015, Frankfurt am Main June 15-19, 2015
On the way to new efficiency potentials 1. Cooling systems: the unknown entity 2. Energy monitoring: value added for cooling technology 3. Development of a cooling system 4. Key measurement points 5. Findings from energy monitoring 6. Savings potential in cooling systems 7. Practical examples Bilfinger Efficiency GmbH page 2
Cooling systems: the unknown entity Broad utilization: Higher Energy requirement: cooling systems have a diverse range of applications in various industries and properties The energy requirements for cooling systems is about 14% of the entire energy requirement in Germany. Enormous potential: Efficiency potential of between at least 10 and 50% Complexity: Interaction among many different individual components in a refrigeration supply system (compressor, ventilators, heat exchangers, pumps, control technology) Interaction among the individual components with impact on energy consumption Precise energy monitoring of the individual components for the implementation of the correct measures is necessary Bilfinger Efficiency GmbH page 3
Recognizing potentials through energy monitoring Energy monitoring systems make energy consumption transparent localize the causes of increased energy consumption identify savings potential optimize energy consumption increase the efficiency of the systems in question Value added Reliable data through ongoing monitoring Overview and control through detailed and comprehensive analyses Optimized use and provision of energy Reduced energy costs Increase in economic efficiency and competitiveness Bilfinger Efficiency GmbH page 4
Development of a cooling system Circulation pump Bilfinger Efficiency GmbH page 5
Key measurement points Electricity meters Volume flow electricity Circulation pump Pressure sensor Temperature sensor Bilfinger Efficiency GmbH page 6
Transparency through precise measurement data Pressure and temperature measurement figures Measurement of the temperature difference in the vaporizer and condenser Determining the efficiency level of the compressor Switching off pumps, ventilators and water intake of the heat exchangers Automatic determination of efficiency key figures (EER, SEI) Dependencies between cooling need and outside temperature or production Information on the current and expected cooling need Conclusions for defects on expansion valve Avoiding excess or insufficient filling of the cooling circulation with coolant Conclusions for use, design and dirtying of heat exchangers Potential for the reduction of condensation or increase in the vaporization temperature Categorizing the compressor efficiency in comparison to modern compressors Recognizing wear and tear or damage to the compressor Transparency of useless operating modes for components and avoidable consumption Defining efficient conditions for liquefaction (dry, moistened) Cooling machine requirements on the basis of the highest level of efficiency for the application case (EER) Optimization of the control strategy on the basis of overall system efficiency (SEI) Utilization-dependent control of the cold water temperature Setting up automatic notification when expected need is exceeded Shifting requirements for the optimization of the partial load behavior of the machinery or for the optimization electricity procurement (grid fees, control energy marketing) Bilfinger Efficiency GmbH page 7
Reasons for the introduction of energy monitoring Procedure for the introduction Troubleshooting Measure Mobile measurement Monitoring system Global access Preventive maintenance and service Energy efficiency enhancement Analyze Optimize Evaluation software Data charts and diagrams Fixed installation of the monitoring Optimization of the control Installation of control technology Exchange of plant components Performance inspection in accordance with EU guideline Commissioning and guarantee inspection Save 0 to 7 year amortization period 10% to 50% savings potential Bilfinger Efficiency GmbH page 8
Overview of savings potential 1 LIQUEFIER +/- 10% 2 WRG 25 50 % 1 2 4 4 6 3 4 COMPRESSOR ECONOMIZER 3 15% +/- 6% Savings potential 10-50% 5 3 7 5 VAPORIZER +/- 10% 6 DISTRIBUTION 5 15% 7 CONSUMPTION 5 15% Bilfinger Efficiency GmbH page 9
Trailblazer for success: Energy monitoring for cooling systems Success factors: Optimized energy efficiency key figures (EER, SEI) Identification of the efficiency measures based on measurement results Energy savings of guaranteed > 10% and up to 50% of electricity volumes previously consumed Amortization periods for the efficiency measures of between 0-7 years Implementation of the defined measures for reduced investment costs Comprehensive insight into the cooling system Ongoing accounting of electricity consumption, pressures and temperatures of the cooling system Ongoing monitoring of the efficiency for the entire cooling system page 10
Practical example: producers of frozen foods Implemented measures (selection) 1 General reduction of the condensation pressure Additional reduction of the condensation pressure through change in the compressor control Optimized selection of the RKW and control of air volumes An energy savings of 27% is guaranteed! 1 2 3 Optimization and development of existing WRG of the oil cooling Conversion of the performance 2 5 control of a compressor Adjustment of the vaporizer pressure 100,000 per year 6 5 3 Change to the machine sequence (following review of the side load) 6 3 6 Reduction of distribution losses Bilfinger Efficiency GmbH page 11
Bilfinger Efficiency GmbH An der Gehespitz 50 63263 Neu-Isenburg www.efficiency.bilfinger.com efficiency@bilfinger.com