Patent Grant
11639820
This disclosure is directed to systems and methods for modeling chiller efficiency in multi-chiller systems and controlling the chillers in use based on the modeled efficiency.
Chiller systems can include multiple working fluid circuits to provide cooling to the process fluid of the chiller, such as chilled water that is then used to provide cooling to a space. Each working fluid circuit includes a compressor. As cooling demand varies, the load on the compressors can vary and the number of compressors in use can also vary with demand. Compressor efficiency can change with compressor load and compressor lift (the difference in temperature or pressure between a condenser and an evaporator of the circuit including the compressor). The number of compressors needed to meet cooling demand therefore varies.
This disclosure is directed to systems and methods for modeling chiller efficiency in multi-chiller systems and controlling the chillers in use based on the modeled efficiency.
Performing real-time modeling of compressor efficiency based on chiller demand and the resulting required lift and load can allow for compressor selection to account for the effects of lift and load on compressor efficiency. From the models of compressor efficiency, composite efficiency of the chiller system as a whole can be determined and compressor selection can be based on improving this composite efficiency, improving compressor selection and staging and thus providing increased efficiency for the chiller system.
In particular, using parabolic models for compressor efficiency for particular compressor lift states can simplify calculations while maintaining accuracy. This can enable real-time calculation of compressor efficiency and the models can be readily combined to determine the composite efficiency of a set of compressors being operated to meet a particular chiller demand. The parameters for these parabolic models can be based on observed compressor efficiency during a variety of lift and load conditions for each of the compressors.
In an embodiment, a method of operating a chiller system including a plurality of compressors includes receiving a chiller demand and determining a real time efficiency curve for each of the plurality of compressors of the chiller system that are currently in operation. The method further includes determining a capacity change operation based on the efficiency curves and a chiller demand and operating the chiller system according to the capacity change operation.
In an embodiment, the method further includes determining a real time efficiency curve for one or more compressors of the plurality of compressors that are not currently in operation. In an embodiment, the capacity change operation includes initiating operation of at least one of the one or more compressors of the plurality of compressors that are not currently in operation.
In an embodiment, the capacity change operation includes ceasing operation of at least one of the compressors of the chiller system that are currently in operation. In an embodiment, the capacity change operation includes changing a load of at least one of the compressors of the chiller system that are currently in operation.
In an embodiment, each of the real time efficiency curves is a parabolic function.
In an embodiment, determining the capacity change operation includes determining a composite efficiency curve based on the efficiency curves for each of the plurality of compressors of the chiller system that are currently in operation. In an embodiment, the composite efficiency curve is further based on an efficiency curve for at least one compressor of the chiller system that is not currently in operation.
In an embodiment, determining the capacity change operation includes solving for a staging point, wherein the staging point defines when to initiate operation of a compressor not currently in operation or when to cease operation of a compressor currently in operation.
In an embodiment, the method further includes obtaining selection data by measuring efficiency data for each of the plurality of compressors at each of a plurality of load points within each of a plurality of lift points, wherein determining the real time efficiency curves is based on the selection data.
In an embodiment, a control system for a chiller system including a plurality of compressors includes a controller. The controller is configured to receive a chiller demand and determine a real time efficiency curve for each of the plurality of compressors of the chiller system that are currently in operation. The controller further is configured to determine a capacity change operation based on the efficiency curves and a chiller demand and direct operation of the chiller system according to the capacity change operation.
In an embodiment, the controller is further configured to determine a real time efficiency curve for one or more compressors of the plurality of compressors that are not currently in operation. In an embodiment, the capacity change operation includes initiating operation of at least one of the one or more compressors of the plurality of compressors that are not currently in operation. In an embodiment, the capacity change operation includes ceasing operation of at least one of the compressors of the chiller system that are currently in operation.
In an embodiment, the capacity change operation includes changing a load of at least one of the compressors of the chiller system that are currently in operation.
In an embodiment, each of the real time efficiency curves is a parabolic function.
In an embodiment, the controller is configured to determine a composite efficiency curve based on the efficiency curves for each of the plurality of compressors of the chiller system that are currently in operation, and the capacity change operation is based on the composite efficiency curve.
In an embodiment, the composite efficiency curve is further based on an efficiency curve for at least one compressor of the chiller system that is not currently in operation.
In an embodiment, the controller is configured to solve for a staging point, wherein the staging point defines when to initiate operation of a compressor not currently in operation or when to cease operation of a compressor currently in operation.
In an embodiment, chiller system comprising a plurality of compressors and the control system as described herein.
This disclosure is directed to systems and methods for modeling chiller efficiency in multi-chiller systems and controlling the chillers in use based on the modeled efficiency.
Chiller system 100 is a chiller system for providing a chilled process fluid to provide cooling to a cooling load 114. Chiller system 100 includes a plurality of chiller circuits 102a-n each configured to absorb heat from the process fluid. Any number of the chiller circuits 102a-n can be actively cooling the process fluid at a particular time. In an embodiment, valves and fluid lines can be configured such that chiller circuits 102a-n which are not in operation can be bypassed. The process fluid can be, for example water, glycol, mixtures thereof, or any other suitable fluid for being cooled at chiller circuits 102a-n and absorbing heat at cooling load 114. The process fluid can include one or more additives to, for example, lower a freezing temperature of the process fluid.
Chiller circuits 102a-n are separate refrigeration circuits each configured to absorb heat from the process fluid. Chiller circuits 102a-n can be arranged with respect to flow of the process fluid in any of a series, parallel, or mixed arrangement including some chiller circuits 102a-n being in series and others in parallel. Each of chiller circuits 102a-n respectively include a compressor 104a-n, a condenser 106a-n, and expander 108a-n, and an evaporator 110a-n. In an embodiment, each of chiller circuits 102a-n can include identical components. In an embodiment, at least some of chiller circuits 102a-n differ in at least one component, such as the respective compressors 104a-n having different design and/or characteristics such as capacity or the like.
Each of compressors 104a-n are a compressor configured to compress a working fluid of the respective chiller circuit 102a-n. Each of compressors 104a-n can be any suitable compressor, such as, as non-limiting examples, a centrifugal compressor, a screw compressor, a scroll compressor, or the like. In an embodiment, each of compressors 104a-n are identical to one another. In an embodiment, each of compressors 104a-n can have different rated capacities and/or loading characteristics.
Each of condensers 106a-n is a heat exchanger that is configured to allow working fluid compressed by the respective compressor 104a-n to reject heat. The heat can be rejected to, as a non-limiting example, the ambient environment of that condenser 106a-n or to another fluid circuit such as for example for use in heat recovery.
Each of expanders 108a-n is configured to expand the working fluid after it has rejected heat at the respective condenser 106a-n. The expanders 108a-n can be any suitable structure or structures for expanding the working fluid, such as expansion valves, one or more expansion orifices, or the like.
Each of evaporators 110a-n is a heat exchanger that is configured to allow working fluid expanded at the respective expander 108a-n to absorb heat from process fluid of the chiller system 100. Each of evaporators 110a-n can be connected to the same stream of process fluid such that the process fluid is further cooled by each successive evaporator 110a-n that it passes through. In an embodiment, evaporators 110a-n can be connected to one another using combinations of fluid lines and valves that allow any of evaporators 110a-n to be selectively bypassed.
Chiller process fluid line 112 is a fluid line configured to convey process fluid from the chiller circuits 102a-n to the cooling load 114, and from cooling load 114 back to chiller circuits 102a-n. Cooling load 114 is one or more devices that reject heat to the process fluid. In embodiments, the cooling load 114 can be one or more terminal devices including heat exchangers, which are used to cool air within one or more conditioned spaces that are served by the chiller system 100.
Controller 116 is a controller configured to direct operation of chiller system 100, particularly operating particular compressors selected from among compressors 104a-n. Controller 116 can optionally further be configured to control valves directing process fluid of chiller system 100 such that it is routed only through those evaporators 110a-n of chiller circuits 102a-n that are currently in operation. Controller 116 can include one or more processors, one or more memories, one or more network input/outputs, and storage. It is understood that controller 116 can further include additional components. Controller 116 can be operatively connected to compressors 104a-n such that controller 116 can receive power consumption data and/or issue commands to the compressors 104a-n. Controller 116 can further be operatively connected to valves allowing process fluid to selectively bypass evaporators 110a-n. The operative connections can be any suitable wired or wireless connection allowing data and/or commands to be transferred to or from controller 116 and the connected compressors 104a-n and/or valves. Non-limiting examples of the operative connections include wired communications or wireless communications according any suitable known standard. In an embodiment, controller 116 can further control one or more pumps 118 included in chiller system 100, such as the pumps 118 circulating the process fluid between the cooling load 114 and chiller circuits 102a-n.
In an embodiment, controller 116 can be configured to map each of the compressors 104a-n to operate at various load points and various lift points in order to generate efficiency data. The efficiency data can be, for example, power consumption when operated at the predetermined lift and load points. Controller 116 can further be configured to store the resulting efficiency data for use in subsequent control of operations, for example using it to compute an efficiency curve such as a coefficient of performance which can be used to determine efficiency of that compressor under certain load and lift conditions. The efficiency data can be represented as parabolic curves of efficiency as a function of load under a particular lift condition.
In an embodiment, controller 116 can be configured to use efficiency models of the compressors 104a-n to control the staging of those compressors 104a-n to efficiently address cooling demand by cooling load 114. The controller 116 can use efficiency curves determined by operational testing as described above as the efficiency models, predetermined efficiency models, or any other suitable representation of the efficiency of compressors 104a-n as a function of lift and load. The controller 116 can receive a cooling demand for the cooling load 114. The cooling demand is a value representative of an amount of cooling that the chiller circuits 102a-n must provide to cool the cooling load 114. The cooling demand can, for example, be based on a desired leaving process fluid temperature for the chiller circuits 102a-n and a return process fluid temperature where it is returned from cooling load 114 to the chiller circuits 102a-n and subsequent flow of the process fluid. The efficiency models can be used to control operation of one or more of the compressors 104a-n in order to satisfy the cooling demand. In an embodiment, the control of the compressors 104a-n can include selecting loading levels for compressors 104a-n that are currently in operation. In an embodiment, the control of compressors 104a-n can include selecting one or more compressors 104a-n to operate. In an embodiment, the selection of the compressors to operate can include selecting one or more additional compressors from among compressors 104a-n to be operated alongside currently operated compressors among compressors 104a-n. In an embodiment, the selection of compressors can be based on composite efficiency curves. The composite efficiency curves can be determined based on a combination of efficiency curves for at least some of compressors 104a-n, such as currently operating compressors, currently operating compressors plus a next-to-add compressor, or currently operating compressors except for a next-to-subtract compressor. The selection of compressors to operate can be performed such that the selected compressors in operation reduce or minimize the energy consumption required to meet the cooling demand.
The compressor to be modeled is operated at 202. The operation of the compressor 202 is performed at each of a plurality of various load points and at each of a variety of lift points. The operation at the various load and lift points can be operation at these varied load and lift points that occur over the course of ordinary operation of the compressor. In an embodiment, operation of the compressor may be directed to provide operation at lift and/or load points for which data is desired. The plurality of load points each are predetermined load levels for the compressor to be operated at. The plurality of lift points each represent different compressor lift conditions under which the compressor being modeled can be operated. The lift conditions can be characterized by the difference in temperature or pressure between a condenser and an evaporator of the circuit including the compressor.
Efficiency data is recorded at 204 for operation at each load point and respective lift point. The efficiency data can be, for example, a power consumption by the compressor being modeled when operated under the particular load and lift conditions. In an embodiment, the efficiency data is a coefficient of performance for the compressor.
Efficiency curves for the compressor being modeled can be determined for each lift point at 206. The efficiency curves can be used to model the efficiency of the compressor at various load levels for a variety of different lift points. In an embodiment, each efficiency curve is a discrete curve for a particular lift point. The efficiency curves for a particular compressor may vary in shape as the lift conditions vary. The efficiency curves can represent relationships between the compressor load and compressor efficiency under particular lift conditions. The efficiency curves can be parabolic curves. The method 200 can be performed with each compressor included in a chiller system, such as each of compressors 104a-n in chiller system 100 discussed above and shown in
Chiller demand data is received at 302. The chiller demand is a value indicative of the load required from the compressors to satisfy a cooling load, such as maintaining a leaving temperature for process fluid where it leaves the last of chiller circuits of the chiller system prior to being directed to the cooling load. In an embodiment, the chiller demand data can be based on a set point temperature and a process fluid temperature where the process fluid enters the first of chiller circuits or any other suitable point downstream of the cooling load and subsequent flow of the process fluid.
Efficiency curves are determined for compressors currently being operated at 304. The efficiency curves can be determined based on models of the compressors such as the models generated by way of method 200 described above and shown in
Optionally, efficiency curves can also be determined for compressors not currently being operated at 306. The efficiency curves can be determined for one or more compressors that are identified as potentially being activated to meet the chiller demand received at 302. The efficiency curves can be determined at 306 in the same manner as the efficiency curves are determined at 304 for the compressors currently being operated. In an embodiment, the efficiency curves can be determined at 306 by selecting the relevant efficiency curve for a predicted lift of the compressor if it is put into operation. In an embodiment, the efficiency curves determined at 306 can be combined into a composite efficiency curve also including the efficiency curves determined at 304.
A capacity change operation is determined at 308. The capacity change operation can be any suitable change in operation of the compressors in use to meet the chiller demand received at 302, for example by one or more of changing the loading of one or more compressors currently in operation, initiating operation of a compressor not currently in operation, or ceasing operation of a compressor currently in operation. The capacity change operation can be determined based on the efficiency curves determined at 304 and optionally at 306 to determine an efficient combination and/or operation of compressors to meet the chiller demand received at 302. The efficient combination can be a combination of compressors and their operations that provide increased efficiency and/or decreased energy consumption compared to other possible combinations or operations that can meet the chiller demand received at 302. In an embodiment, the efficient combination is one providing the greatest efficiency and/or the lowest energy consumption of combinations of compressors or operations thereof that meets the chiller demand received at 302. In an embodiment, the combinations of compressors for the capacity change operation can be determined by solving the system of equations defining the efficiency curves to identify staging points at which one or more specific compressors of the chiller system should initiate or cease operations.
The chiller system is operated according to capacity change operation 310. Compressors can be operated or cease operation to achieve the selection of compressors and/or the particular operations of compressors according to the capacity change operation determined at 308. A controller can issue commands directing the compressors of the chiller system to operate in accordance with the capacity change operation. The operation according to the capacity change operation can include ceasing operation of one or more compressors, initiating operation of one or more compressors, and/or selecting particular operational parameters such as speed, load, temperature set points, flow rates within the chiller system, or the like.
A chiller subtraction staging point 406 can be present at the intersection where the current operational curve 400 and the reduced operations curve 402 cross one another. At loads below the chiller subtraction staging point 406, efficiency of the chiller system as a whole, is higher when the next-to-subtract chiller circuit ceases operation. Accordingly, the chiller subtraction staging point 406 can be used to control the chiller system by ceasing operation of the next-to-subtract chiller when load is at or will be lower than the chiller subtraction staging point. In embodiments, the chiller subtraction staging point 406 and/or the curves 400 and 402 from which the chiller subtraction staging point 406 is determined can be dynamically calculated to reflect recent performance for each chiller circuit or compare different combinations of chiller circuits.
Chiller addition staging point 408 can be present at the intersection where the current operational curve 400 and the increased operations curve 404 cross one another. At loads above the chiller addition staging point 408, efficiency of the chiller system as a whole is greater when the next-to-add chiller circuit is added to the chiller circuits currently in operation. Accordingly, the chiller addition staging point 408 can be used to control the chiller system by initiating operation of the next-to-add chiller when the load is or will exceed the chiller addition staging point 408. In embodiments, the chiller addition staging point 408 and/or the curves 400 and 404 from which the chiller addition staging point 408 is determined can be dynamically calculated to reflect recent performance for each chiller circuit or compare different combinations of chiller circuits.
It is understood that any of aspects 1-10 can be combined with any of aspects 11-20.
Aspect 1. A method of operating a chiller system including a plurality of compressors, the method comprising:
receiving a chiller demand;
determining a real time efficiency curve for each of the plurality of compressors of the chiller system that are currently in operation;
determining a capacity change operation based on the efficiency curves and a chiller demand; and operating the chiller system according to the capacity change operation.
Aspect 2. The method according to aspect 1, further comprising determining a real time efficiency curve for one or more compressors of the plurality of compressors that are not currently in operation.
Aspect 3. The method according to aspect 2, wherein the capacity change operation includes initiating operation of at least one of the one or more compressors of the plurality of compressors that are not currently in operation.
Aspect 4. The method according to any of aspects 1-3, wherein the capacity change operation includes ceasing operation of at least one of the compressors of the chiller system that are currently in operation.
Aspect 5. The method according to any of aspects 1-4, wherein the capacity change operation includes changing a load of at least one of the compressors of the chiller system that are currently in operation.
Aspect 6. The method according to any of aspects 1-5, wherein each of the real time efficiency curves is a parabolic function.
Aspect 7. The method according to any of aspects 1-6, wherein determining the capacity change operation includes determining a composite efficiency curve based on the efficiency curves for each of the plurality of compressors of the chiller system that are currently in operation.
Aspect 8. The method according to aspect 7, wherein the composite efficiency curve is further based on an efficiency curve for at least one compressor of the chiller system that is not currently in operation.
Aspect 9. The method according to any of aspects 1-8, wherein determining the capacity change operation includes solving for a staging point, wherein the staging point defines when to initiate operation of a compressor not currently in operation or when to cease operation of a compressor currently in operation.
Aspect 10. The method according to any of aspects 1-9, further comprising obtaining selection data by measuring efficiency data for each of the plurality of compressors at each of a plurality of load points within each of a plurality of lift points, wherein determining the real time efficiency curves is based on the selection data.
Aspect 11. A control system for a chiller system including a plurality of compressors, the control system, comprising:
a controller configured to:
receive a chiller demand;
determine a real time efficiency curve for each of the plurality of compressors of the chiller system that are currently in operation;
determine a capacity change operation based on the efficiency curves and a chiller demand; and direct operation of the chiller system according to the capacity change operation.
Aspect 12. The control system according to aspect 11, wherein the controller is further configured to determine a real time efficiency curve for one or more compressors of the plurality of compressors that are not currently in operation.
Aspect 13. The control system according to aspect 12, wherein the capacity change operation includes initiating operation of at least one of the one or more compressors of the plurality of compressors that are not currently in operation.
Aspect 14. The control system according to any of aspects 11-13, wherein the capacity change operation includes ceasing operation of at least one of the compressors of the chiller system that are currently in operation.
Aspect 15. The control system according to any of aspects 11-14, wherein the capacity change operation includes changing a load of at least one of the compressors of the chiller system that are currently in operation.
Aspect 16. The control system according to any of aspects 11-15, wherein each of the real time efficiency curves is a parabolic function.
Aspect 17. The control system according to any of aspects 11-16, wherein the controller is configured to determine a composite efficiency curve based on the efficiency curves for each of the plurality of compressors of the chiller system that are currently in operation, and the capacity change operation is based on the composite efficiency curve.
Aspect 18. The control system according to aspect 17, wherein the composite efficiency curve is further based on an efficiency curve for at least one compressor of the chiller system that is not currently in operation.
Aspect 19. The control system according to any of aspects 11-18, wherein the controller is configured to solve for a staging point, wherein the staging point defines when to initiate operation of a compressor not currently in operation or when to cease operation of a compressor currently in operation.
Aspect 20. A chiller system comprising a plurality of compressors and the control system according to any of aspects 11-19.
The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
| Number | Name | Date | Kind |
|---|---|---|---|
| 6185946 | Hartman | Feb 2001 | B1 |
| 10241505 | Cohen et al. | Mar 2019 | B2 |
| 10527306 | Boettcher et al. | Jan 2020 | B2 |
| 10852716 | Sayyarrodsari et al. | Dec 2020 | B2 |
| 10921972 | Park et al. | Feb 2021 | B2 |
| 20040144106 | Douglas | Jul 2004 | A1 |
| 20080163642 | Okamoto | Jul 2008 | A1 |
| 20130098084 | Matsuo et al. | Apr 2013 | A1 |
| 20170343267 | Erpelding et al. | Nov 2017 | A1 |
| 20190034066 | Nayak et al. | Jan 2019 | A1 |
| Entry |
|---|
| Hydeman, “Development and Testing of a Reformulated Regression-Based Electric Chiller Model”, American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. Symposium, 10 pages (2002). |
| Extended European Search Report; European Patent Application No. 21215076.7, dated May 16, 2022 (6 pages). |
| Number | Date | Country | |
|---|---|---|---|
| 20220196309 A1 | Jun 2022 | US |
