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HPAC ENGINEERING LIVE WEBINAR

Engineering Study: The Future of Chilled Water Plants and

Waterside Economizers

Presented by Spencer Fuller May 19, 2016

Johnson Controls, Inc. 2016

Introduction

Spencer Fuller
Global YORK Chiller Product Manager,
Johnson Controls

The YORK Chiller Team

Craig Campbell, Christine Detz, Seth Gladfelter, Nick Staub, Jill Woltkamp

2 Johnson Controls, Inc. 2016

Agenda

Out of this world capabilities

of the YMC2 chiller!!

Traditional Chilled Water

System Design

New Chilled Water System

Design
Capabilities
Benefits

What to do Next?

3 Johnson Controls, Inc. 2016

 POLL QUESTION

What is the lowest entering condenser

water temperature a chiller a handle?

A. 65 F (18 C)
B. 55 F (12 C)
C. 50 F (10 C)
D. 36 F (2.2 C)

4 Johnson Controls, Inc. 2016

 POLL ANSWER

What is the lowest entering condenser

water temperature a chiller a handle?

A. 65 F (18 C)
B. 55 F (12 C)
C. 50 F (10 C)
D. 36 F (2.2 C)

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 Can efficiency values
below 0.1 kW/ton
be achieved?

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Out of this World Capabilities

17.58 COP

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Out of this World Capabilities
YMC2 Chiller Performance Below 0.1 kW/Ton
kW/Ton

66% Variation!!

% Load

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Out of this World Capabilities
YMC2 Chiller Performance Below 0.1 kW/Ton
kW/Ton

66% Variation!!

IPLV Points

ECWT Entering Condenser

Water Temperature

% Load

9 Johnson Controls, Inc. 2016

Out of this World Capabilities
YMC2 Chiller Performance Below 0.1 kW/Ton
kW/Ton

66% Variation!!

IPLV Points

ECWT Entering Condenser

Water Temperature

% Load

10 Johnson Controls, Inc. 2016

Out of this World Capabilities

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Out of this World Capabilities

250 Ton Efficiency =

~22 kW

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 POLL QUESTION

What has a greater impact on chiller

efficiency?

A. Load
B. Lift

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 POLL ANSWER

What has a greater impact on chiller

efficiency?

A. Load
B. Lift

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Impact of Lift
YMC2 Chiller Performance Below 0.1 kW/Ton
kW/Ton

66% Variation!!

IPLV Points

ECWT Entering Condenser

Water Temperature

% Load

15 Johnson Controls, Inc. 2016

 What is the traditional
chilled water system
design?

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Traditional Design

Base Chiller Waterside Economizer

ASHRAE 90.1 Path B (variable Other possible term used: Free

speed drive chillers) Cooling Heat Exchanger

Chiller
Waterside
Economizer

17 Johnson Controls, Inc. 2016

Traditional Operation

Tower Building
Load

Chiller

Waterside
Economizer

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Traditional Operation
Mechanical Cooling Mode - Chiller

Tower Building
Load

Chiller

Waterside
Economizer

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Traditional Operation
Free Cooling Mode - Water Side Economizer

Tower Building
Load

Chiller

Waterside
Economizer

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 What if the waterside
economizer could
be removed?

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Out of this World Capabilities

With The YORK YMC2

Magnetic Bearing Centrifugal
Chiller it CAN be removed!

22 Johnson Controls, Inc. 2016

AHRI Conditions Traditional Chiller Operation

Tower Building
Load

Condenser
44F
85F (6.7C)
(29C)
Evaporator

AHRI Conditions: Flow Rate

Evaporator Flow Rate: 2.4 gpm/ton (0.043 lps/kW)
Condenser Flow Rate: 3.0 gpm/ton (0.054 lps/kW)

23 Johnson Controls, Inc. 2016

YMC2 Chiller Inverted Duty

YMC2 is the first chiller in the world to continuously operate in inverted duty
Inverted Duty: condenser water return is lower than the chilled water
supply temperature

Tower Building
Load

The YMC2 Chiller

Condenser
44F
85F (6.7C)
(29C)
Evaporator
36F
(2.2C)
Flow Rate is Constant Per Design Condition

24 Johnson Controls, Inc. 2016

How can the YMC2 Operate in Inverted Duty?
Permanent
Oil-Free Magnetic Motor & Outstanding
Variable Orifice
Operation Active Magnetic Performance
Bearing

Ensures adequate
Chiller can adjust refrigerant flow
speed to operate in from the
a wide range of condenser to the
conditions evaporator to avoid
starving the
evaporator

Eliminates
concerns about oil
return to the Providing highest
compressor chiller efficiency on
the market

25 Johnson Controls, Inc. 2016

 What were the results of the
engineering study?

26 Johnson Controls, Inc. 2016

Background on the Engineering Study

Completed by outside 3rd party Consulting Engineering Firm

Various load profiles completed

This presentation will focus on:

1000 Ton (3510 kW) new office building (2x 500 ton
chillers)
200 Ton (700 kW) internal base load
Variable primary flow chilled water
Constant speed condenser pump
Optimized (VSD) tower control

27 Johnson Controls, Inc. 2016

Background on the Engineering Study

Three Locations
Dallas ASHRAE Climate Zone 3A warm, moist
Chicago - ASHRAE Climate Zone 5A cool, moist
San Francisco Bay Area ASHRAE Climate Zone 3C warm, marine

28 Johnson Controls, Inc. 2016

Energy Cost Savings

Annual Energy
Cost
Electricity
Location Base Chiller and
Rate ($/kWh)
Waterside
Economizer
Chicago $0.089 $70,900
Dallas $0.078 $98,000
San
Francisco $0.156 $125,900
Bay Area

Modeling Assumptions
ASHRAE 90.1-2013
The chilled water plants are modeled according to the Appendix G baseline with variable speed chillers and primary-only,
variable flow chilled water loops
eQUEST simulation program utilized to obtain hourly chilled water load profiles
Theoretical Optimal Plant Performance approach in obtaining the chilled water plant performance
Flat electricity rates are assumed based on the Energy Information Administration average price database

29 Johnson Controls, Inc. 2016

Energy Cost Savings

Annual Energy Cost

Energy
Electricity
Location Base Chiller and Cost
Rate ($/kWh) The YORK YMC2
Waterside Savings
Chiller
Economizer
Chicago $0.089 $70,900 $69,700 $1,200
Dallas $0.078 $98,000 $87,400 $10,600
San
Francisco $0.156 $125,900 $112,300 $13,600
Bay Area

Modeling Assumptions
ASHRAE 90.1-2013
The chilled water plants are modeled according to the Appendix G baseline with variable speed chillers and primary-only,
variable flow chilled water loops
eQUEST simulation program utilized to obtain hourly chilled water load profiles
Theoretical Optimal Plant Performance approach in obtaining the chilled water plant performance
Flat electricity rates are assumed based on the Energy Information Administration average price database

30 Johnson Controls, Inc. 2016

Cost of Waterside Economizer System -
Dallas Plant Costs Example

Plate and Frame Installation, Piping,

Controls
Heat Exchanger and Accessories

$25,275 $151,232 $35,000

Dont Forget About the Routine Maintenance Costs

31 Johnson Controls, Inc. 2016

Upfront Cost Savings

Annual Energy
Cost Associated with
Location Cost Savings of Payback
Waterside Economizer
the YMC
Chicago $149,752 $1,200 INSTANT
Dallas $211,507 $10,600 INSTANT
San Francisco
$199,261 $13,600 INSTANT
Bay Area

Modeling Assumptions
Costs Estimates are based on data provided by contractors and suppliers for the plant configurations
Total installed costs are adjusted based on city cost indexes from the RS Means Mechanical Cost Data

32 Johnson Controls, Inc. 2016

Other Advantages

Mechanical Save on Accommodate

Fewer Water
Plant Footprint Routine for Increased
Leak Points
Savings Maintenance Building Load

Less pipe
Fewer Investment for
bypass/isolation the future
valves

Photo courtesy of Burns & McDonnell- Projects Designer

Cleaning of plate
and frame heat
Space can be exchanger
used for business Sensor
investment calibration

33 Johnson Controls, Inc. 2016

Retrofit or Increased Building Load?

Tower Building
Load

20+ year old

Existing chiller
Chiller Increases
due to
expansion

Waterside
Economizer

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Retrofit or Increased Building Load?

Tower Building
Load

Existing Chiller Increases

due to
expansion

Waterside
Economizer
WSE can no longer
meet the free
35 Johnson Controls, Inc. 2016
cooling needs
Retrofit or Increased Building Load?
An installed YMC2 can
accommodate the increased
Tower building load Building
Load

20+ year
The 2 Chiller
YMCold chiller Increases
due to
expansion

Waterside
Economizer
While the WSE is
being used for free
36 Johnson Controls, Inc. 2016
cooling
 What about ASHRAE 90.1?

37 Johnson Controls, Inc. 2016

Complying with ASHRAE Standard 90.1
1 2
Simplified Approach
There are 17
requirements in this path
Laid out as a simple
checklist for documenting
38 Johnson Controls, Inc. 2016
Three Path Options
3
Non-Prescriptive Path
Prescriptive Path (Energy Cost Budget
Method)
Tables for documenting Requires a list of energy-
the equipment efficiency related features that
exceed the standards
10 general requirements requirements
and five special
mandatory requirements Also need a list of
features that are being
traded off
90.1 Compliance Support Materials

Description of Each Path/Approach to 90.1

https://www.energycodes.gov/resource-center/ace/compliance/step2
http://www.csemag.com/single-article/documenting-ashrae-901-
compliance/275aae2f4c30bf85951a68913f0103a7.html

Example of how the Energy Cost Budget Method was performed- http://hpac.com/air-
conditioning/using-standard-901-energy-savings-and-leed-credits

ASHRAE 90.1 Energy Cost Budget method instructions -

https://www.google.com/webhp?sourceid=chrome-instant&ion=1&espv=2&ie=UTF-
8#q=ECB+method+instructions

ASHRAE 90.1 Energy Cost Budget method compliance report -

https://www.google.com/webhp?sourceid=chrome-instant&ion=1&espv=2&ie=UTF-
8#q=ECB+method+compliance+report

39 Johnson Controls, Inc. 2016

 Do you want to save
upwards of $500,000?

40 Johnson Controls, Inc. 2016

Out of this World Capabilities

Design your system with the

YORK YMC2 chiller

41 Johnson Controls, Inc. 2016

In Conclusion

Maximize your building

efficiency
Save upfront costs
Save annual energy costs
Simplify your system
Achieve 36 F (2.2 C)
Entering Condenser Water
Temperature Capability
See performance ratings below 0.1 kW/ton
Own the first chiller in the world to continuously operate inverted

42 Johnson Controls, Inc. 2016

Additional Resources / Links

Learn more about the YMC2 Chiller

www.york.com/mars

Contact
Read the study summary
http://www.york.com/for-your-workplace/chilled-water- jci@bay
systems/engineering-study
market
Access the recording of this webinar
http://event.on24.com/r.htm?e=1172609&s=1&k=9B238 force.com
4BD2448268D9174C4FE56463757 with questions.

Related Resources
Cold Weather Operation of Cooling Towers ASHRAE
Journal Article - https://www.ashrae.org/resources--publications/periodicals/ashrae
journal/features/cold-weather-operation-of-cooling-towers
Central Plant Optimization - http://www.johnsoncontrols.com/buildings/services-and-
support/optimization-and-retrofit-services/central-plant-optimization

43 Johnson Controls, Inc. 2016

 Questions & Answers

44 Johnson Controls, Inc. 2016