Efftrack Tech Insert

8/3/2019 Efftrack Tech Insert

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Save your chillerSave energy costs

Save the planet


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ETrack calculates, in real time and continuously, the

actual Coecient o Perormance (COP) o a chiller.

Simultaneously, ETrack calculates the design COP o the

chiller, or those same conditions. We call this Calculated

Part Load Value (CPLV). By comparing CPLV with actual

COP, chiller ineciency can be measured and quantied in

nancial and environmental terms. ETrack then goes on to

automatically generate the service diagnostics responsible

or the prevailing ineciency.

ETrack is based on a six step process to establish the

system and provide a comprehensive support package.

You can ocus on your core business, knowing that yourchillers are continuously being checked against maximum

eciency.

Step 1 Setting Up Design Data

Enter the chiller ull load specications into the ETrack

program. These are ound at the plant or rom the chiller

manuacturer. By ensuring operation within design

parameters, the chiller achieves optimum eciency,

thereore protecting equipment lie.

Step 2 Collecting Chiller Operating Data

ETrack collects operating data, such as evaporator water

temperatures, condenser water temperatures, rerigerantpressures, water fows, running load amps and volts.

Data is automatically collected hourly, via the ETrack data

collection system which includes I/O and data acquisition

boards, plus the appropriate sensors.

Step 3 Processing the Data

Using the proprietary Calculated Part Load Value

(CPLV) and the diagnostics sotware package, ETrack

processes the collected operating data to determine chiller

perormance and provide recommendations or eciency

improvements.

Chiller manuacturers guarantee minimum ull load design

Coecient o Perormance (COP) eciency when a chilleris purchased. However, this eciency is rarely measured

ollowing commissioning. Full load design conditions occur

less than 2% o the time in normal operation.

The real challenge is to measure perormance at less than

ull load design. ETrack meets this challenge. It creates a

CPLV COP prole using a combination o ull load design,

Integrated Part Load Value (IPLV)/Non-Standard Part Load

Value (NPLV) and operating data.

This operating data is compared with the CPLV prole

to measure eciency under all operating conditions.

This provides the oundation or cost and environmental

reporting and diagnostics, to ensure peak perormance o

the chiller system.

Step 4 Developing Operational Reports

The Daily ReportProvides a comprehensive analysis and statistics package

o chiller perormance, including:

Trend Chart

The closer the Actual COP value gets to the CPLV

COP, the more ecient the chiller is operating.

Weighted Average Daily Efciency Pie Chart

Diagnostics

Includes detection o:

Water fow rate problems

Plugged or restricted water fow

High or low rerigerant levels

Rerigerant stacking

Moisture

Oil

Air

Non-condensablesCompressor issues

Heat transer issues

Scaling

Fouling

Limit Alarms

Run Hours

Water Usage

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The Calendar Report

The Calendar Report is the archive o the Daily Reports.

Simply click on any day within the calendar to access the

Daily Report.

The Calendar Report includes:

Create Monthly Report

All data or the month can be aggregated to

produce an executive level monthly perormance

summary.

Export Raw Data to a Spreadsheet

Raw sensor data can be collected automatically

into an Excel le.

Navigate Equipment History

Each day can be investigated to determine

daily perormance.

The Monthly Report

A summary o monthly and year-to-date perormance

statistics are displayed in a concise, single-page PDF.

Month and Year to Date Operating

Averages and Totals

Month and Year to Date Water Usage

Month and Year to Date Run Hours

Weighted Efciency Pie ChartThis is the average chiller eciency achieved or

the entire month.

Operating Costs

Daily Average COP Bar Chart

Daily kWR Produced Bar Chart

The amount o cooling duty provided per day.

Daily Cost Bar Chart

Step 5 Improving Operations

Based on operating data and reports, ETrack signals

issues and recommends responses. The ollowing scenario

demonstrates the events or problem solving with multiple

possible causes.

A chiller technician on a routine service call changed

the rerigerant level controller set point back to a actory

deault setting. This caused the liquid rerigerant level in the

condenser to drop, allowing hot gases to bypass with the

liquid rerigerant, to the evaporator.

The trend chart immediately indicated a COP reduction

with an approximate 15% decrease in eciency.

The only symptoms were a slight increase in evaporator

rerigerant pressure and increased compressor amp loads.

Because the plant was monitoring chiller perormance, the

operators quickly took steps to identiy and correct the

problem.

Temperature sensors and fows were veried, which

suggested the problem may be with the compressor. Anevaluation o the rerigerant level controller revealed that it

was not reading the rerigerant level correctly. Adjustments

were made to compensate or the problem and eciency

returned to normal within 24 hours.

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Efficiency Technologies Australia Pty. Ltd.

Level 2, 395 Collins Street, Melbourne Victoria 3000 Australia

Telephone +61 3 9629 9977 Fax +61 3 9620 0070

[email protected] www.efftec.com.au

Step 6 Measuring Improvements

and Cost Savings

ETrack makes it easy to calculate and identiy the cost

savings o operational improvements. This ensures aclear understanding, at all levels o management, o the

importance o the operations and maintenance program.

As the extract rom the calendar report below shows, on

the 26th, the chiller was operating at 99.9% eciency,

which equated to a loss o $1.20 per day. A problem

occurred on the 27th, and subsequently, daily eciency

dropped and daily loss increased to over $160 per day.

The service issue was corrected on the 11th. Eciency,

and thereore costs, immediately returned to normal.

26

E: 99.9%K: 41634C: $1211.88

L: ($1.20)W: $93.85E: $124.55

27

E: 91.2%K: 13382C: $409.49

L: ($33.19)W: $31.28E: $41.42

28

E: 81.9%K: 36058C: $1164.09

L: ($178.58)W: $92.11E: $121.62

10

E: 78.6%K: 34118C: $1119.54L: ($197.41)

W: $89.21E: $110.77

11

E: 83.7%K: 35303C: $1149.77L: ($161.41)

W: $85.79E: $112.66

12

E: 99.1%K: 39220C: $1183.98L: ($10.62)

W: $94.52E: $121.79

Day Before Problem

Occurred

Day Before Problem

Occurred

Day

Problem Occurred

Day

Problem Occurred

Day After

Problem Occurred

Day After

Problem Occurred

The Importance o CPLV

Q. Why determine eciency and cost using ETracks

CPLV COP versus ull load design COP?

A. Chillers rarely operate at ull load design conditions,and entering condenser water temperatures (ECWT)

vary throughout the year, either o which can greatly

aect overall COP.

The Air Conditioning and Rerigeration Institute (ARI)

has developed the measuring standard 550/590-1998

or Integrated Part Load Value (IPLV) and Non-standard

Part Load Value (NPLV). Its purpose is to refect

the chillers actual operating experience in the eld.

Depending on chiller types, and compressor style,

the IPLV/NPLV COP can vary 10-40% above ull load

design under actual operating conditions. ETrack

uses this ARI standard as a starting point or CPLV.

ETracks CPLV analyses ull load design, actual part

load and actual ECWT to eectively calculate the

outcome o what the actual COP should be. The CPLV

COP is then compared to the Actual COP to determine

eciency and cost. This is vastly more accurate than

comparing strictly to ull load design.

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Efftrack Tech Insert