BD Medical Salt Lake City

Trane RTHD Chiller Base Line Testing Results June 2014

Tests and report done by: Joel Klobas

Emerging Energy Solutions Technical Director joelk@eeswest.com

[Pick the date] BD Medical Trane RTHD Chiller Test June 2014

Reason for the Test In June of 2014 ETC, an Energy Efficiency Engineering firm located in Salt Lake City, Utah; coordinated with BD Medical to have Emerging Energy Services to conduct a paid demonstration on one of their chillers located in Salt Lake City, Utah. This location is a manufacturing facility which manufacturers medical devices. The chiller designated for the demonstration was a 2006 Trane water cooled RTHD screw chiller used for comfort cooling needs. BD Medical purchased this chiller used in 2012. The facilities personal did a thorough citric acid cleaning of both the Evaporator and Condensing tubes when it was installed. BD Medical had the compressor replaced due to metal filings found in the oil during installation. This chiller is maintained by the facilities personnel at BD and all required PM’s have been done. The hook up of the ClimaCheck took approximately 1 hour. The facilities personnel did assist with the hook up of the CT Clamps and power connection. All the temperature sensors and pressure transducers were hooked by Joel Klobas of Emerging Energy Solutions. After spending about an hour to fine tune the ClimaCheck, we started to see an issue with the evaporator, KW per Ton and the capacity. You will see from the data collected and comparing it to the nominal data provided from Trane and BD Medical that this chiller is experiencing issues with the evaporator. Due to the issues in the evaporator we could only compare the nominal data at 100%.

Chiller Specifications: Chiller Brand: Trane – RTHD series Water Cooled Chiller Model Number: RTHD UB1F XG0U AB1A 2LAL B1A2 LALA VXQA EXAA DXY1 58BG UA4X 4XXX XB Serial Number: U06C06737 Chiller Capacity: 180 tons Refrigerant: R134A Supply Voltage: 480 Electrical Current: (RLA) 158 Electrical, number of phases: 3 phase Inverter control, (Yes or No): No

[Pick the date] BD Medical Trane RTHD Chiller Test June 2014

Data Evaluation

Evaluation:

1. The evaporator approach is high. Nominal data shows an approach of 4.2°F at designed full load conditions. The ClimaCheck measured an approach averaging 12.9°F at full load conditions. See Appendix

Table 1:3. Nominal = 4.2°F (LWTE – SST = 44 – 39.8) * Data provided by Trane

Measured at full load = 12.9°F (LWTE – SST = 46.6 – 33.7) unacceptable See Appendix table 1:1 Every degree of lower evaporation corresponds to approximately 1.5-2% higher energy

efficiency. This problem is diminishing capacity and Performance. This problem can risk the integrity of cooling as it is causing the system to reduce

capacity due to the freeze risk in the evaporator.

2. It is unclear if the gas pump oil return system is working correctly. There is an instability detected in the Discharge temperature. We reviewed the manual forwarded to us and from what we see there is nothing in there to help us understand what the issue may be. It is recommended that this be looked at by a Trane certified technician. See Appendix table 1:2; 1:5

Nominal Data Measured Data

Capacity (Tons) 187.8 140

Unit Power (KW) 112.1 109.2

Efficiency (Kw/Ton) 0.597 0.78

Saturated Suction Temp 39.8 33.7

Saturated Condensing Temp 95.4 95

Evap Entering Temp (F) 55.2 56.3

Evap Leaving Temp (F) 44 46.6

Evap approach (F) (LWTE - SST) 4.2 12.9

Cond Entering Temp (F) 80 80.1

Cond Leaving Temp (F) 90.6 90

Cond approach (F) (SCT - LWTC) 4.8 5

Discharge Temp (F) 114.4 116.6

Discharge Superheat (DT - SCT) 17.2 21.6

* Nominal Data was provided by Trane and BD Medical

* Measurements were done with system at 100% load

* See Appendix Table 1:1

[Pick the date] BD Medical Trane RTHD Chiller Test June 2014

3. The condenser approach. Nominal = 4.8°F (SCT – LWTC = 95.4 – 90.6) * Data provided by Trane.

Measured at full load = 5°F (95 - 90) See Appendix Table 1:1; 1:4

4. Recommended Discharge temperature.

Nominal = 114.4°F at design full load conditions

Measured at full load = 116.6°F See Appendix table 1:1; 1:5 Based on the information provided from Trane, the discharge temperature varies

between 2.5°F - 4°F at 100% load.

KW Per Ton - Nominal Compared to Measured

*Due to the chiller issues measured data was only comparable to nominal data at 100% load.

BD Medical Trane RTHD Chiller Test June 2014

Appendix:

Table 1:1 – Measured Values at 100% Load

Row 1078 was used for this test. System was running at full load during this time frame. See Appendix Table 1:2 for length of testing. Please note time stamp was not set correctly for this time zone. Definition of headings: Sec Evap A in – Entering Water Temperature Evaporator Sec Evap A Out – Leaving Water Temperature Evaporator Ref Evap Midpoint – Saturated Suction Temperature Evaporator SecW Cond A out – Leaving Water Temperature Condenser SecW Cond A in – Entering Water Temperature Ref Cond Midpoint A – Saturated Condensing Temperature Condenser Ref Comp A out – Discharge Temperature Effic. Cool A (KW/RT) – KW Per Ton Cap Cool A (RT) - Capacity

BD Medical Trane RTHD Chiller Test

June 2014

Table 1:2 – Overall Performance at 100% Load

This graph gives us a good view of the system and how it is operating over a 4 hour period.

Instability of Discharge Temp

Compressor power

BD Medical Trane RTHD Chiller Test

June 2014

Table 1:3 – Evaporator Approach

BD Medical Trane RTHD Chiller Test

June 2014

Table 1:4 – Condenser Approach

BD Medical Trane RTHD Chiller Test

June 2014

Table 1:5 – Discharge Superheat

Instability of Discharge Temp

BD Medical Trane RTHD Chiller Test

June 2014

System Efficiency Index and Sub Efficiencies System Efficiency Index for the best chiller is near 50%. This chiller is down to 30% due to the poor performance of the evaporator.

Efficiency Measured value

Acceptable value Chillers

Rating Comment

Eta1 Cycle performance

88.7%

> 85% is normal

Eta2 Compressor efficiency

64.6% > 65% level is OK but some uncertainty due to unstable operation

Eta3 Pressure drop in suction line

100% - not applicable

Eta4co Condenser efficiency

83.5% > 90% is normal

Eta4ev Evaporator efficiency

68.8% > 85% is extremely low need to be investigated Fouling , air or oil in refrigerant is likely causes the later can be caused by excess refrigerant return causing excess oil carry over

Eta4 Combined heat exchanger efficiency

52.7% > 75% is very low

SEI1 Cool

29.5% > 40-45% Low caused by Evaporator

BD Medical Trane RTHD Chiller Test

June 2014

Data Used for SEI Calculations: