Optimized Designs October 20, 2016 Presented by Oscar Peraza & Building Efficiency The Large Tonnage Solutions Values are comprised of four major topics. Experience, sustainable solutions, innovation, and customer commitment. The large tonnage solutions group is there for you, to meet the specific needs of your facility. October 20, 2016 Presented by Oscar Peraza Johnson Controls – Milwaukee, WI

Discussions Quick Review of Refrigerant Cycle for Chillers The main components of a chilled water system & their relative size How do chilled water and condenser water temperatures impact system efficiency? When does it make sense to put a VSD on your chiller? Real world example – 500 ton chiller. First Cost & Efficiency Refrigerants – Latest Update 2

Basics: Refrigeration Cycle Purpose of compressor: raise pressure of the refrigerant vapor

Pressure Enthalpy Curve BEST Program - YK Product Overview Pressure Enthalpy Curve Sub-Cooled Liquid Liquid-Vapor Mixture Superheated Vapor Pressure (Abs) Saturated Liquid Saturated Vapor Enthalpy (BTU/lb)

Pressure Enthalpy Curve BEST Program - YK Product Overview Pressure Enthalpy Curve

Basics: Refrigeration Cycle Evaporator Section P H

Basics: Refrigeration Cycle Compressor Section P H

Basics: Refrigeration Cycle Condenser Section P H

Basics: Refrigeration Cycle Metering Device P H

Basics: Refrigeration Cycle Refrigerant Cycle - Review

Centrifugal Chillers in today’s complex buildings How they work BEST Program - YK Product Overview Centrifugal Chillers in today’s complex buildings How they work Prerotation Vanes Impeller Mist Eliminator Diffuser Plate Condenser Flooded Evaporator Subcooler Orifice

Centrifugal Chillers in today’s complex buildings How they work BEST Program - YK Product Overview Centrifugal Chillers in today’s complex buildings How they work Refrigerant rejects heat to atmosphere Refrigerant absorbs heat from load Pressure Condenser Lift (or Head Pressure) Metering Device Compressor CLICK FOR BLUE ARROWS TO APPEAR Evaporator Enthalpy

Basics: Refrigeration Cycle Compressor Section P H

Centrifugal Chillers in today’s complex buildings How they work BEST Program - YK Product Overview Centrifugal Chillers in today’s complex buildings How they work Pressure 95° F 35° C Lift (or Head Pressure) 85° F 29° C 54° F 12° C 44° F 7° C Enthalpy

Basics: Refrigeration Cycle Worksheet Sub-Cooled Liquid Liquid-Vapor Mixture Superheated Vapor Condenser COND Saturated Temperature Leaving COND Temperature 97F Pressure (Abs) 95F LIFT Expansion Compression Leaving EVAP Temperature 44F 42F Evaporator EVAP Saturated Temperature Saturated Liquid Saturated Vapor Enthalpy (BTU/lb)

Basics: Refrigeration Cycle Worksheet Condenser Saturated Temp Condenser Leaving Water Temp Condenser Entering Water Temp Evaporator Entering Water Temp Evaporator Leaving Water Temp Evaporator Saturated Temp 97F Approach 95F 85F LIFT 54F 44F 42F

Basics: Refrigeration Cycle Worksheet R-134a Chiller Evaporator: LWT 44F / EWT 55F Condenser: LWT 95F / EWT 85F R-134a Boils at -15.6F @ 0 psig 118 psig Condensation COND Saturated Temperature 97F Pressure (Abs) 95F Leaving COND Temperature 81 psig Expansion Compression Leaving EVAP Temperature 44F 42F 37 psig Evaporation EVAP Saturated Temperature Enthalpy (BTU/lb)

Real World Energy Performance Capitalizing on Off-Design Conditions BEST Program - YK Product Overview Real World Energy Performance Capitalizing on Off-Design Conditions Lowering Condenser Water Temperature Pressure Condenser Lift (or Head Pressure) Compressor Evaporator Enthalpy

BEST Program - YK Product Overview Real World Energy Performance How Does Leaving Chilled Water Temperature Affect Efficiency Pressure Condenser Lift (or Head Pressure) Compressor Evaporator Raising Chilled Water Temperature Enthalpy

Real World Energy Performance Capitalizing on Off-Design Conditions BEST Program - YK Product Overview Real World Energy Performance Capitalizing on Off-Design Conditions Reduces Energy Consumption Pressure Condenser Lift (or Head Pressure) Reduces Compressor Work Compressor Evaporator Lowers the Lift Raising Chilled Water Temperature Enthalpy

Centrifugal Plants Chilled Water Temps & System Efficiency Chilled Water Plant Components – 500 ton plant Component Chilled Water Pump (850 gpm @ 100ft wpd) Condenser Water Pump (1500 gpm @ 60ft wpd) Cooling Tower Fan(s) Centrifugal Chiller (500-ton) ?? Est. Break Horsepower 25.4 BHP 27.1 BHP 30 BHP _____________ Total = 82.5 BHP 361 BHP Chiller BHP = 4.4x all the other components combined

Centrifugal Plants Chilled Water Temps & System Efficiency What is the best leaving chilled water temperature (lchwt) for system efficiency? 38 44 46 The warmest temperature capable of providing your desired airside leaving air temp 42 40 45

Centrifugal Plants Chilled Water Temps & System Efficiency Warmer leaving chilled water saves energy AND you can still achieve the airside performance you need Chilled Water Design Temp: For every degree the leaving CHW adjusts, the chiller gains/losses about 2% - 2.5% in efficiency On Centrifugal chillers, a higher delta T with the same leaving CHW temp does not impact energy efficiency. “Outside” Temperatures drive chiller efficiency (Leaving Condenser – Leaving Chilled) For example: Energy consumption increases 5% using 42 deg CHW vs 44 deg CHW There is a negligible difference utilizing 44/54 vs 44/60

Centrifugal Plants Chilled Water Temps & System Efficiency Message : With constant equipment cost, you will improve system efficiency with warmer CHW design temps. Example System Assumptions 500 Tons Centrifugal Chiller 85/95 degree condenser water (3 gpm/ton)   ECHWT/LCHWT Efficiency (Kw/ton) Variance (% Efficiency) 42/56 0.603 & 0.363 NPLV 44/58 0.572 & 0.337 NPLV + 5.4% / + 7.7% 45/59 0.561 & 0.325 NPLV + 7.5% / + 11.7% Delta T has little effect on chiller efficiency ECHWT/LCHWT Efficiency (Kw/ton) 42/52 0.606 & 0.363 NPLV 44/54 0.574 & 0.338 IPLV 45/55 0.560 & 0.326 NPLV

What temperature chilled water do I need? 54 deg air is achievable w/ 45 deg Chilled Water Regardless of Entering Air Conditions What temperature chilled water do I need?

Centrifugal Plants Chilled Water Temps & System Efficiency Message: Warmer chilled water temps do not significantly impact airside performance or cost Example Airside Impact 80/67 Entering Mixed Air Temp for AHU cooling Coil 8,000 CFM AHUs @ 500 fpm LAT = Sub 54 (54 db / 53.5 wb) ECHWT/LCHWT LAT db / LAT wb Minimum Cooling Coil Required First Cost vs 42/56 42/56 53.5 / 52.7 5-rows 9 FPI 44/58 53.5 / 52.9 6-rows 9 FPI + $239 45/59 53.6 / 53.1 6-rows 10 FPI + $283 44 deg option increases APD over 42 deg option by only 0.14” 45 deg option increases APD over 42 deg option by only 0.23” Air Pressure Drop Difference 42 vs 45 CHW = 0.16” wpd

Yearly System Energy Savings Assumptions: 500 ton chiller 3,000 yearly operating hours 350-ton average Load $0.10/kwh 13 AHUs running @ 8k CFM (27-tons) = 350 ton average load Airside BHP based on AF Fan @ 4.0” TSP vs 4.16” TSP (0.16” apd increase) Annual Chiller Energy Cost = (Avg Load)(Run Hours)(NPLV kw/ton)($/kwh) Annual Airside Energy Cost = (Qnty AHUs)(Run Hours)(BHP)(0.746 kw/bhp)($/kwh) Chiller: 42/56 design, 0.363 kw/ton NPLV: Chiller: 45/59 design, 0.325 kw/ton NPLV: Airside: 42/56 design, 7.70 BHP per 8k CFM AHU: Airside: 45/59 design, 7.92 BHP per 8k CFM AHU: $38,115 / year $34,125 / year $3,990 reduction/year on Chiller $22,402 / year $23,042 / year $640 extra/year on Airside Net System Energy Savings = $3,350, ~ 5.5% per year

BEST Program - YK Product Overview Real World Energy Performance Capitalizing on Lower Leaving Condenser Water Temperatures Lowering Condenser Water Temperature Pressure Lowers the Lift Condenser Lift (or Head Pressure) Compressor Reduces Compressor Work Evaporator Reduces Energy Consumption Enthalpy

Centrifugal Plants Condenser Water Temps & System Efficiency Colder LEAVING condenser water reduces system energy consumption Condenser Water Design Temp: Entering CW temp has a minimal impact on efficiency. Leaving CW temp drives chiller efficiency. For every degree the leaving CW temp adjusts, the chiller gains/losses about 1.5% - 2% in efficiency Example: A chiller selected for 2 gpm/ton or 85/100 will take a 7.5% to 10% efficiency hit vs 3 gpm/ton

21.7 BHP – System BHP reduction from 3 gpm/ton Centrifugal Plants Chilled Water Temps & System Efficiency Message : With constant equipment cost, you will improve system efficiency with 3 gpm/ton Example System Assumptions 500 Tons Centrifugal Chiller 44/54 degree chilled water   ECWT & Flow Efficiency (Kw/ton) BHP Variance (% Efficiency) 85 & 1500 gpm 0.574 & 0.338 NPLV 361 BHP 85 & 1000 gpm 0.619 & 0.364 NPLV 389 BHP +28 BHP (- 7.8% / - 7.7%) Condenser Water Pump Selection (60 ft WPD) Flow BHP Variance 1500 gpm 27.1 BHP 1000 gpm 20.8 BHP - 6.3 BHP 21.7 BHP – System BHP reduction from 3 gpm/ton

What’s going on with our current refrigerants… INTENT To reiterate what we have covered in a clear message that the refrigerants that JCI utilizes are the best choices for today's market. [Suggested Script] To reiterate what we have covered and the primary take away from this training is that R134a and R410a do NOT have a phase out date. Johnson Controls utilizes these refrigerants, R134a and R410a, because they are efficient, safe, affordable, available and reliable. They are not subject to any bans and will be available for the life of the equipment.

Refrigerant regulations such as EPA SNAP and European F-gas target refrigerants for specific applications based on emissions SNAP – Significant New Alternatives Policy (i.e. R410A) (i.e. R134a, R1234yf) (i.e. R123, R245fa) Source: U.S. EPA

US EPA SNAP Change of Status (De-listing rule) No changes to impact stationary air-conditioning. Applicable to new equipment only.

What’s going on with our current refrigerants… December 31, 2019: No new chillers with R-123 can be manufactured. December 31, 2023: No new chillers with HFC’s can be manufactured, including R-134a and R-410a. December 31, 2029: The end of production and importation of R-123. See below for Phase-Down schedule of HFC. Phase down schedule does not target any individual HFC, but addresses them as a whole. INTENT To reiterate what we have covered in a clear message that the refrigerants that JCI utilizes are the best choices for today's market. [Suggested Script] To reiterate what we have covered and the primary take away from this training is that R134a and R410a do NOT have a phase out date. Johnson Controls utilizes these refrigerants, R134a and R410a, because they are efficient, safe, affordable, available and reliable. They are not subject to any bans and will be available for the life of the equipment.

Summary Warmer chilled water temps improve SYSTEM efficiency Colder leaving condenser water temps improve SYSTEM efficiency 460 volt variable speed drives are no longer expensive Variable Speed Drives save on energy with any reduction in lift Variable Speed Drives save on energy with any reduction in load Make sure you keep up with latest refrigerant regulations, but don’t be intimidated 36

BEST Program - YK Product Overview Question Period

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