Chiller Plant Performance Monitoring via Heat Rejection Modeling
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Solution Overview
Problem
Current chiller plant performance evaluation methods are inefficient due to the lack of adequate instrumentation and data collection systems, leading to complex and costly measurements that are not regularly consulted, and existing methods focus solely on compressor components without evaluating the entire chiller plant effectively.
Innovation Solution
A method using fewer points of instrumentation to determine chiller performance by measuring the heat rejected by the chiller, employing a computerized analyzer with programmable logic controllers to calculate refrigeration load and efficiency in real-time, allowing for real-time comparisons and customized modeling based on actual operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional performance evaluation methods are used with comprehensive instrumentation, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts only the essential measurement parameters needed for chiller performance evaluation, specifically focusing on heat rejection measurements rather than comprehensive monitoring of all system parameters. This selective extraction reduces instrumentation complexity while maintaining measurement accuracy for the critical performance metric.
Solution Approach 2:
The patent uses a modeled representation of chiller performance based on heat rejection data, creating a simplified copy of the complex thermal processes. This modeling approach allows accurate performance evaluation without requiring direct measurement of all intermediate thermal parameters, thereby reducing instrumentation requirements.
2Loss of information
If comprehensive data collection systems are implemented, then information completeness is improved, but ease of operation deteriorates due to difficulty in consulting and analyzing the data
Solution Approach 1:
The patent extracts and focuses on the single most critical performance indicator - heat rejection - rather than collecting and analyzing comprehensive datasets. This extraction approach maintains essential performance information while dramatically simplifying data analysis and interpretation for operators.
Solution Approach 2:
The patent changes the fundamental parameter being measured from multiple operational parameters to a single heat rejection parameter. This parameter transformation simplifies the information structure, making it easier to consult and analyze while retaining the ability to evaluate chiller performance effectively.
3Device complexity
If kW/ton measurement method is used, then performance evaluation is simplified, but reliability deteriorates due to variability from operating conditions
Solution Approach 1:
The patent changes the measurement parameter from kW/ton (which varies with operating conditions) to heat rejection, which provides a more stable and reliable basis for performance evaluation. This parameter change maintains evaluation simplicity while improving reliability by reducing sensitivity to varying operating conditions.
Solution Approach 2:
The patent implements a measurement approach that provides direct feedback on heat rejection, enabling more reliable performance assessment. This feedback mechanism allows for better comparison against benchmarks and improved reliability in evaluating chiller performance across different operating scenarios.
4Measurement precision
If multiple sensors are deployed throughout the chiller plant, then measurement precision is improved, but manufacturing precision and cost increase
Solution Approach 1:
The patent extracts the essential measurement need down to a single heat rejection measurement point, eliminating the requirement for multiple sensors throughout the plant. This extraction approach maintains sufficient measurement precision for performance evaluation while dramatically reducing implementation cost and manufacturing complexity.
Solution Approach 2:
The patent makes the heat rejection measurement serve multiple evaluation purposes simultaneously, replacing the need for multiple specialized sensors for different parameters. This multi-functionality approach maintains comprehensive performance monitoring capability while reducing the total number of measurement devices required.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach provides real-time performance evaluation with reduced instrumentation costs, enabling effective comparison and optimization of chiller plant operations, and allows for customized algorithms to determine refrigeration load and efficiency, promoting energy savings through condenser water reset control.
Implementation Method 1
The refrigeration process of cooling the CHW creates heat that is rejected into a separate cooling fluid
Implementation Method 2
Heat is removed from the CW by a cooling tower before it is returned to the chiller
Data Source
AI summary
A chiller and chiller plant monitoring method that provides real time performance and benchmark parameters using condenser water temperatures and flow rates to determine crucial performance metrics. A customized chiller model developed with algorithms to make comparative analysis for different operating scenarios. By applying a customized model for the supporting equipment, the entire plant can be monitored for performance. Actual operational metrics are compared with bench mark models to provide real time analysis of energy demand. The model also produces a control formula for condenser water reset. And defining the plant as a chilled water production system separate from the distribution system allows comparison with many with dissimilar operations.