new refrigeration measures - fhp status report- & -request for input- september 21, 2010
TRANSCRIPT
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New Refrigeration Measures - FHP Status Report-
& -Request for Input-
September 21, 2010
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Acknowledgements
We would like to thank the following for their support:• Avista Utilities• Bonneville Power Administration• Puget Sound Energy
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Agenda
• Objectives of RTF subcommittee meeting
• New measure update presentation– Floating/Reduced Head Pressure Control
for Stand Alone Refrigeration Compressors
• Next steps
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Floating Head Pressure Control for Stand Alone Refrigeration
Compressors
Michele FriedrichBen Cartwright
Dustin Bailey
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Technology Overview
• This measure requires using controls and/or expansion valve retrofits to change (lower) a fixed head pressure set point
• Allows condenser to operate at a lower temp. depending on ambient conditions and system demand
• Lower condenser temp. operation = less compressor work, more condenser fan energy
• Compressor efficiency increases due to discharge pressure decrease
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Variable Assumptions for SensitivityBase Case Variables Remote condenser with multiple single compressors
Variable Units Min Max Typical
Refrigeration Load per compressor mbtu/h-compressor 10 100 60
Condenser sizing over ref load 1.3 2.1 1.7
Compressor sizing over refrigerant load 1.1 1.3 1.2
Number of condenser fans/ fan size Number / HP 4 / 1.5 6 / 0.5 5 / 1base case Cond head pressure min control setpoint (SCT) Degree F 85 95 90
Suction Temperature (medium and low) Degree F -30 40 15
Climate Zone Snohomish Boise Portland
Non-variable Assumptions Units Min Max Typical
EE Fan control for floating VFD with 10F TD OA drybulb T-stagedEE case Cond head pressure min control setpoint (SCT) Degree F 60 70 70
compressor motor size HP 5
number of compressors per condenser 5
Base case Fan control OA drybulb T-staged OA drybulb T-staged
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Sensitivity for Condenser with Multiple Compressors
Remote Condenser Sensitivity Diagram
0 100 200 300 400 500 600 700 800 900
Condenser setpoint
Suction Temperature
Compressor Oversizing
Number of fans per cond
Cond sizing Factor
Climate Zone
Compressor Efficiency
EE Condenser setpoint
kWh Savings per Year/Compressor hp
85 °F
90 °F
95 °F
40 °F
15 °F
-30 °F
110 %
120 %
130%
4 Fans
5 Fans
6 Fans
210 %
170 %
130%
Snohomish
Portland
Boise
70 °F
60 °F
COP= 3.1
COP= 2.7
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Assumptions for Condenser with Multiple Stand-alone Compressors
Variable Units LT MT Notes
Refrigeration Load per compressor mbtu/h-compressor found size to match comp HP
Condenser sizing over ref load 1.85 1.5 refrigerant schedules for single
comp/ remote cond
Compressor sizing over refrigerant load 1.17 1.13 refrigerant schedules for single
comp/ remote cond
Number of condenser fans/ fan size Number / HP 4/1 4/1 assume 1 HP fans for designbase case Cond head pressure min control setpoint (SCT) Degree F 94.3 94.3 Assume factory set for R22
Suction Temperature (medium and low) Degree F -20 20 GS search for evap temp
Climate Zone Portland Portland weight for climate zones
Non-variable Assumptions Units
EE Fan control for floating OA drybulb T-staged OA drybulb T-stagedCan not use ambient following
on multiple comp.EE case Cond head pressure min control setpoint (SCT) Degree F 70 70 assume balanced port valves
compressor motor size HP 9 7.5 refrigerant schedules for single
comp/ remote cond
number of compressors per condenser 5 5 refrigerant schedules for single
comp/ remote cond
Base case Fan control OA drybulb T-staged OA drybulb T-staged
Only control available for multiple stand alones to one
condenser
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Action Items from Sept 13:Head Pressure Control Valve
• There is no visual indication of the setting on the valve. If it is a non-adjustable valve (the majority on stand alone compressors) then it is factory set at 180 psig +/- 5 psi. For adjustable valves the setting must be made with pressure gauges (no gauges or indicator on valve.) Factory setting is 180 psig +/- 3 psi.
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Action Items from Sept 13:Head Pressure Control Valve
• Analysis assumed 404A refrigerant which has saturated condensing temperature of 82.3oF at 180 psig (194.7 psia) and accuracy is 80.6 to 84.1oF.
• If R22 refrigerant is assumed, it has saturated condensing temperature of 94.3oF at 180 psig (194.7 psia) and accuracy is 92.5 to 96.1oF.
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Action Items from Sept 13:Compressor and Condenser Sizing
• Refrigeration Schedule Search for Stand Alone Compressors: 26 compressors, 6 stores
• Compressor oversize median is 1.15
• Condenser capacity over refrigeration load median is 1.6
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Action Items from Sept 13:Number of fans, Size of fans
• Fan size is dependent on cost and noise, size range from ½ to 1-½ HP.
• 1-½ HP fans cost less than multiple 0.5 HP fans
• ½ HP fans are quieter than 1-½ fans
• Chose 1 HP fans as predominate fan size.
• Refrigration schedule review showed typical is 4 fans.
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Action Items from Sept 13:Fan Control
• Base case fan control for multiple stand alone compressors can only be OA temp control as compressor systems are all separate so you can not control by pressure.
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Action Items from Sept 13:Compressor Efficiency
• Compressor efficiency changes by size even for same type of compressor
• Remote Condenser with multiple compressors, assume 7.5 to 10 HP compressor efficiency (from refrigeration schedule search).
• Condensing Unit – size from ½ HP to 10 HP. Data for compressor HP from GS can weight by compressor size.
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Condensing Units
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Condensing Unit Variable Assumptions for Sensitivity
Base Case VariablesVariable Units Min Max Typical Min Max Typical
compressor COP / motor size None / HP 0.9 / 1/2 1.4 / 5 1.3 / 3 2.0 / 1/2 2.9 / 5 2.8 / 3
Compressor sizing over ref load Degree F 1.1 1.3 1.2 1.1 1.3 1.2
Condenser floodback control setpoint (SCT) Degree F 92 96 94 92 96 94
Climate Zone Snohomish Boise Portland Snohomish Boise Portland
Non-variable Assumptionsnumber of compressors per condenser 1 1
Base case Fan control on/off
w/compon/off
w/compNumber of condenser fans/ fan size #/ HP 1 / 1/2 1 / 1/2Refrigeration Load per compressor mbtu/h-compressor 10250 19083
Suction Temperature (medium and low) Degree F -20 20
Fan control for floatingon/off
w/compon/off
w/compFloating Condenser minimum setpoint (SCT) Degree F 70 70
Condensing unit MTCondensing unit LT
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Condensing Unit- Low TempTornado Diagram
0 100 200 300 400 500 600 700 800 900 1000
Compressor Efficiency (COP)
Refrigeration compressor oversizing(% over Load)
Condenser set point (SCT)
Climate Zone
Energy savings per compressor HP
COP=1.40, 5 HP
COP=1.27, 3 HP
COP=0.94, 1/2 HP
92.5 °F
94.3 °F
96.1 °F
130%
120%
110%
Boise, ID
Portland, OR
Snohomish, WA
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Condensing Unit- Medium TempTornado Diagram
0 100 200 300 400 500 600 700
Comp Eff
Condenser set point (SCT)
Refrigeration compressor oversizing
Climate Zone
Energy savings (kWh/yr-HP)
Boise, ID
Portland, OR
Snohomish, WA
COP=2.889, 5 HP
COP=2.751, 3 HP
COP=1.978, 1/2 HP
92.5 °F
94.3 °F
96.1 °F
130%
120%
110%
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GS Stand-alone Compressor Size Distribution up to 10 HP
HP Frequency1 110 6%2 209 11%3 300 16%4 69 4%5 358 19%6 95 5%7 11 1%
7.5 339 18%8 14 1%9 28 1%10 176 9%
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Remote Condenser 25 expansion valve/condenser Cost
20
EquipmentEquipment
CostLabor Unit
Number of units
Total Notes Source
Adjustable Flood Valve
$ 166.60 $140.00 Per
Condenser1 $ 306.60
1 flood valve per condenser
Sporlan
Bypass valve $ 79.70 $140.00 Per
Condenser1 $ 219.70
1 bypass valve per condenser
Sporlan
Filter drier $ 41.75 $ 17.50 Per
Condenser1 $ 59.25
1 filter drier per condenser
Sporlan, HVAC/R Wholesaler
Balance Port TXV $ 129.64 $ 35.00 Per
evaporator25 $4,116.00
5 low temp cases per compressor. 5 compressors. 25 cases. One evaporator per case. One TXV per evaporator. 25 txvs.
Sporlan, Grainger
Total $4,701.55 per remote condenser
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Condensing Unit 3 expansion valve/condenser Cost
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EquipmentEquipment
Cost Labor UnitNumber of units Total Notes Source
Adjustable Flood Valve $ 166.60 $140.00
Per Condenser 1 $ 306.60 1 flood valve per condenser Sporlan
Bypass valve $ 79.70 $140.00 Per
Condenser 1 $ 219.70 1 bypass valve per condenser Sporlan
Filter drier $ 41.75 $ 17.50 Per
Condenser 1 $ 59.25 1 filter drier per condenser
Sporlan, HVAC/R Wholesaler
Balance Port TXV $ 129.64 $ 35.00 Per
evaporator3 $ 493.92
3 low temp cases. One evaporator per case. One TXV per evaporator. 3 txvs.
Sporlan, Grainger
Total $1,079.47 per condensing unit
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Condensing Unit 2 expansion valve/condenser Cost
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EquipmentEquipment
Cost Labor UnitNumber of units Total Notes Source
Adjustable Flood Valve $ 166.60 $ 140
Per Condenser 1 $ 306.60 1 flood valve per condenser Sporlan
Bypass valve $ 79.70 $ 140
Per Condenser 1 $ 219.70
1 bypass valve per condenser Sporlan
Filter drier $ 41.75 $ 17.50 Per
Condenser 1 $ 59.25 1 filter drier per condenser Sporlan, HVAC/R Wholesaler
Balance Port TXV
$ 129.64 $ 35Per
Evaporator2 $ 329.28
2 medium temp cases .One evaporator per case. One TXV per evaporator. 2 txvs.
Sporlan, Grainger
Total $ 914.83 per condensing unit
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Next Steps
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Next Steps
• Confirm and weight savings
• Finalize costs/hp of compressor
• Calculate BC ratio
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