A Study On An Optimal Approach Temperature Control Strategy of Condensing Water Temperature For Energy Saving
A Study On An Optimal Approach Temperature Control Strategy of Condensing Water Temperature For Energy Saving
A Study On An Optimal Approach Temperature Control Strategy of Condensing Water Temperature For Energy Saving
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Article history: An optimal approach temperature (OAT) control strategy is proposed for resetting the
Received 12 June 2010 condensing water temperature hourly, so to maximize the performance of the combined
Received in revised form water chiller and cooling tower system. A system performance factor is introduced for
15 September 2010 evaluation of the system performance. A regression function is presented for the calcula-
Accepted 4 January 2011 tion of an optimal condensing water temperature at each hour of air-conditioning opera-
Available online 9 January 2011 tion. The parameters in the regression function include the ambient wet bulb temperature,
the chiller load ratio at the hour, and a dimensionless relative efficiency of chiller and
Keywords: cooling tower. The regression function has an R2 close to 1 compared to the computed
Cooling tower results. When applied to two cities in Taiwan, the OAT control strategy has a potential to
Energy saving save energy more than 4% on an annual basis. The OAT control strategy is most advan-
Temperature tageous when applied to regions with large seasonal variation of wet bulb temperature.
Wet bulb ª 2011 Elsevier Ltd and IIR. All rights reserved.
* Corresponding author. Department of Energy and Refrigerating Air-Conditioning Engineering, 1, Sec. 3, Chung-Hsiao E. Rd. Taipei 10608,
Taiwan, ROC. Tel.: þ886 2 27712171x3508; fax: þ886 2 87733713.
E-mail address: yhtsai@ntut.edu.tw (Y.-K. Chuah).
0140-7007/$ e see front matter ª 2011 Elsevier Ltd and IIR. All rights reserved.
doi:10.1016/j.ijrefrig.2011.01.001
i n t e r n a t i o n a l j o u r n a l o f r e f r i g e r a t i o n 3 4 ( 2 0 1 1 ) 8 1 6 e8 2 3 817
consumption. It was found that the lowest possible condensing annual wide range of wet bulb temperature as typical in
water temperature might not always save the most energy due subtropical regions would provide high potential to save
to high cooling tower fan power. Ahn and Mitchell (2001) used energy by the control of the condensing water temperature.
a quadratic regression scheme to predict the total energy Therefore, it is appropriate to consider chiller and cooling
consumption of an air-conditioning system. In the study they tower as a system for the evaluation of the effects of
found that the ambient wet bulb temperature is an important condensing water temperature control. This study introduces
factor on the optimal supervisory control of the condensing a new optimal control so to maximize the system perfor-
water temperature. Briley (2003) suggested that the operating mance of the chiller and the cooling tower. The optimal
efficiency of a refrigeration system could be increased by approach temperature (OAT) control as proposed would
operating the system at lowest possible condensing water minimize the total power of chiller and cooling tower at each
temperature. Briley suggested condensing water temperature hour using the hourly operating conditions.
can be controlled according to ambient wet bulb temperature.
Crowther and Furlong (2004) used adjustment of condensing
water temperature to measure the total power of chillers and 2. OAT control scheme
cooling tower fans, and used the adjustment to seek an optimal
temperature setting. The results showed for three different The approach temperature is the difference between the
cities in the United States that optimization of chiller-cooling ambient wet bulb temperature and the condensing water
tower was possible to save energy significantly. temperature. The past literature often used a simple fixed
Lu et al. (2004) used a modified genetic algorithm to mini- approach temperature (FAT) control (Crowther and Furlong,
mize the total energy consumption of the condenser water 2004; Ma et al., 2008; Yu and Chan, 2008) that used only
loop. The model considered the interaction constraints of ambient wet bulb temperature as the parameter to control the
cooling tower air flow rate, water flow rate and condensing condensing water temperature. In difference to the FAT
water temperature to optimize all equipment energy. Ma et al. control, the OAT control considers four parameters, namely,
(2008) used the simplified semi-physical models of chiller and ambient wet bulb temperature, chiller load ratio, chiller and
cooling tower to predict the system energy performance under cooling tower fan performance characteristics.
various conditions and condensing water temperature control
strategies. Then Ma et al. developed a model based supervisory 2.1. Chiller and cooling tower energy performance
control strategy using performance map and exhaustive search
(PMES) based technique for online control and operation the Fig. 1 shows the performance data of two types of chillers
system. Morris and Blaine (2008) presented a chiller plant (screw and centrifugal) and also two types of cooling towers
spreadsheet model to predict the energy consumption at any (cross flow and counter flow), provided by international brand
operating conditions. The spreadsheet included optimizer tool suppliers in Taiwan. Power ratios (CPR, TPR) with respect to
to determine the minimum chiller plant energy consumption. the rated power of chillers and cooling towers are shown in
The results showed that lower energy control for the condenser Fig. 1 under two different wet bulb temperatures, with chilled
system (pumps and cooling towers) might have a consequence water setting at 6.7 C.
of much higher energy use for the chillers. Yu and Chan (2008) The performance data at different load ratios and con-
used thermodynamic chiller and cooling tower models to densing water temperatures can be obtained from Fig. 1.
evaluate chiller system COP under different condensing water Variable speed fan modulation is used in Fig. 1 for the
temperature control logics. They also considered the range calculation of the cooling tower power ratio (TPR). In Fig. 1,
temperature of the condensing water kept constant with CLR and TLR are respectively the chiller load ratio and the
varying condensing water flow rate. tower load ratio (with respect to the rated capacity) as
The above discussion indicates that the ambient wet bulb described in Equation (1). Qe is the chiller load, Qchr is the
temperature is an important factor for the optimal control of rated chiller capacity, Qc is the heat rejection load and Qctr is
the condensing water temperature. It is then obvious that the the rated heat rejection capacity of cooling tower. The CPR
818 i n t e r n a t i o n a l j o u r n a l o f r e f r i g e r a t i o n 3 4 ( 2 0 1 1 ) 8 1 6 e8 2 3
Screw chiller Centrifugal chiller Cross flow tower Counter flow tower
a WB=15°C b WB=25°C
1 1
T LR=1
TLR=0
T LR= 0
T LR=0
TLR=0
T LR = 0
T LR=1
T LR=0
T LR=0
T LR=0
CLR=1
.6
.2
.8
.2
.4
.6
.8
.4
0.8 0.8 CLR=1
CLR=0.8
CLR=0.8
C PR o r TPR
C PR o r TPR
0.6 0.6
CLR=0.6
CLR=0.6
0 0
16 18 20 22 24 26 28 30 24 26 28 30
CWT (°C) CWT (°C)
Fig. 1 e Performance of chiller and cooling tower at different condensing water temperatures, (a) at wet bulb [ 15 C, (b) at
wet bulb [ 25 C.
and TPR are respectively the ratios of chiller and cooling TLR are all operating conditions, and the controllable factor is
tower power against the rated powers (Pchr and Pctr) as des- CWT. Therefore, the maximum SPF can be obtained by
cribed in Equation (2) resetting CWT according to the operating conditions. Using
the performance data of chillers and cooling towers such that
CLR ¼ Qe =Qchr ; TLR ¼ Qc =Qctr (1)
in Fig. 1, an OAT control scheme is presented to seek for the
maximum SPF as follows:
CPR ¼ Pch =Pchr ; TPR ¼ Pct =Pctr (2)
It can be seen in Fig. 1(a and b) that the power ratios are Step 1: Obtain the cooling load ratio (CLR) of the chillers from
significantly affected by the condensing water temperature the real time operation using Equation (1), usually
(CWT), under different ambient wet bulb (WB) conditions. obtained from measured operating data.
Moreover, similar trends are observed for the different types Step 2: The real time ambient wet bulb temperature is used to
of chillers and cooling towers. It can be seen that the chiller determine the low limit constraint of CWT, as shown
power ratio decreases with lower condensing water temper- in Fig. 1.
ature. In reverse, the cooling tower power ratio increases with Step 3: From the low limit of CWT, obtain CPR for every 0.1 C
lower condensing water temperature. Therefore, these increase in CWT.
different trends of energy performance for the chillers and the Step 4: CPR obtained in step 3 is used with Equation (2) to
cooling towers necessitate an optimal control to achieve calculate chiller power (Pch).
minimum energy consumption. Step 5: Energy balance constraint ðQc ¼ Qe þ Pch Þ is used with
It can also be seen in Fig. 1 that there is a limit for the Equation (1) to calculate TLR, and then tower fan
condensing water temperature. As shown in cross flow cool- power (Pct) with Equation (2).
ing tower for WB at 15 C, the lowest possible condensing
water temperature is 22 C for TLR equals to 1.0. However,
when TLR equals to 0.2, the lowest possible condensing water
5.2
temperature is 17.2 C.
10
Table 1 e Office building composition.
Building type Office
8 Floor area (m )2
18,000
Floor height (m) 4
Predicted OAT (oC )
5 5
SPF
SPF
WB=15 C, CTF=1.058
WB=15 C, CTF=1.116
4 4
WB=15 C, CTF=1.174
WB=25 C, CTF=1.047 WB=25 C, CTF=1.058
WB=25 C, CTF=1.094 WB=25 C, CTF=1.116
3 WB=25 C, CTF=1.141 3 WB=25 C, CTF=1.174
Fig. 4 e Variation of OAT control SPF with CLR, (a) at CPFr [ 4.45, (b) at CPFr [ 5.5.
820 i n t e r n a t i o n a l j o u r n a l o f r e f r i g e r a t i o n 3 4 ( 2 0 1 1 ) 8 1 6 e8 2 3
As mentioned earlier the optimization also rests on the CT,3 CT,2 CT,1
rated power consumption of the cooling tower fan against the
rated chiller power. Therefore, another factor, CTF (cooling
tower factor) is introduced in the computation of OAT. The
definition of CTF is shown in Equations (6) and (7).
CPFr
CTF ¼ 1þ (6)
TPFr
Condenser water loop
CPFr ¼ Qchr =Pchr ; TPFr ¼ Qchr =Pctr (7)
CH,1
In the OAT control scheme, as the heat rejection load (Qc) is
related to the chiller load (Qc ¼ Qe þ Pch ), CLR and TLR are
related. So the optimal condensing water temperature is reset at Chilled water loop
each hour according to the operating WB and CLR. Then the
optimal approach temperature can be predicted using a regres- CH,2
sion function of WB, CLR and CTF as shown in Equation (8).
600
3.1. Description of the building case
Op e ra tin g h ou rs
8
< Calculate OAT at each operating hour using Equation ð8Þ
max SPF ¼ CWTopt ¼ WB þ OAT (9)
:
If CWTopt < 18:3 C then CWTopt ¼ 18:3 C
a April b July
7 32 6
28 32
6
5
24
Temp. ( C)
Temp. ( C)
5
SPF
SPF
28
o
4
20
4
16
3
3 24
12
Mon. Tues. Wed. Thur. Fri. Mon. Tues. Wed. Thur. Fri.
Fig. 7 e Weekly variation of SPF in April and July, (a) April, (b) July.
822 i n t e r n a t i o n a l j o u r n a l o f r e f r i g e r a t i o n 3 4 ( 2 0 1 1 ) 8 1 6 e8 2 3
Table 3 e Comparison of annual energy consumption of chiller-cooling tower system using different CWT control
strategies in Taipei city.
Case CWT control Tower Chiller Total Energy saving
strategy (kWh yr1) (kWh yr1) (kWh yr1) (%)
a Typical year weather data for Hong Kong and Miami obtained from http://www1.eere.energy.gov/buildings.
b 2007 hourly measured weather data of Taipei and Kaohsiung.
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3.4. Apply OAT control strategy to another subtropical strategy of cooling systems in climatic regions with large
city variation of ambient wet bulb.