Cooling Plant Technologiesto achieve greater reliability and

reduce energy usage

Introduction

Welcome to the Progressive Data Center Summit 1

Guest Speaker:

Paul K Mattingly,PEDirector, ApplicationsSmardt Chiller Group, Inc.Paul.Mattingly@Smardt.com

Major, irreversible market change is driving Technology, Efficiency and Reliability growth> Climate change and energy pricing driving expansion of its

energy efficiency segment (now 30%+) > Energy efficiency, sustainability now fixed on government

agendas, e.g. MEPS > Turbocor oil-free compressor technology increasingly

recognized as market-changing catalyst> Smardt Chiller Group (“SCG”) the major player in this change,

growing strongly.> Smardt rated no 1 in high-efficiency segment in North America

and Asia-Pacific> Customer demand for Redundancy, Reliability, Repeatability

combined with highest overall plant operating efficiencies which result in lower PUE and greater profit margins

Solution Development

In order to identify the solution(s) and technologies that result in the lowest total cost of ownership the entire cooling plant and new additions are modeled using an 8760 Bin Analysis program to develop a baseline.

Several configurations of plant and equipment technologies should analyzed as well as understanding the facilities outdoor environmental operating parameters, redundancy, and load profile.

First Cost

Operating Costs

Life Cycle Costs

Traditional Chiller/Cooling Plant business model> Little technology differentiation> Traditionally 15-20% over-sized> Lowest first cost wins chiller sale> After-market service contracts deliver major

long term returns to chiller manufacturers> End users pay high price in energy costs and

lifetime service costs

Paradigm shift to LCCA

> Large HVAC applications use >30% of total electric power in North America

> Large chillers (over 300 tr) are the category’s major power user

> Smardt oil-free centrifugal chillers offer annual chiller energy savings well over 30%

> Cooling Plant Optimization typically achieves 30% to 50% energy savings

> Annual maintenance costs 50% lower> Total cost of ownership lowest in the world> Smardt & Turbocor catalysing paradigm

change

Smardt, Kiltech and Turbocor New Technology

> Chillers with multiple Turbocor compressors provide built-in redundancy , reducing carbon footprint.

> Economizer and Refrigerant Pumping now available on Water Cooled, Air Cooled, Condenserless ( Evap Condensed) Chillers

> CPECS Cooling Plant Optimization Platform to upgrade existing plants regardless of Chiller Manufacturer

> Turbocor and Smardt/Kiltech fast restart capabilities permit 90 second restarting

> Free Cooling using ThermoSyphon and new energy reduction technologies now available

> Smardt is the only global and wholly oil-free centrifugal chiller brand

> Smardt is DTC’s largest customer worldwide (>30%)

Revolutionary compressor technology

> The permanent magnet motor’s speed varies with the load, from 18,000 to 48,000 RPM.

> The inverter is integrated with the power electronics and control systems.

> Very low starting current - 2 amps rather than a conventional compressor’s 500 amps.

> Magnetic bearings allow very high reliability

> Two-stage centrifugal design> Smardt’s people understand it

better than anyone else

Smardt optimizes Turbocor technology

> Smardt’s chiller control modeling optimizes heat exchanger performance (<1 degC)

> BMS integration enables extra system efficiencies.

> Continued mapping andtesting work

3rd Order Trend Surface

zp( ) x1 x2 Y( )

OFC means major reduction in maintenance costs> Over 70% of chiller field costs are due to

problems with compressor oil return (Sources: Emerson Electric, AHRI)

> Removing oil system removes 70% of field service costs

> US field reports (agg. 2011) confirm reduction in OFC chillers by at least 50% cf lubricated machines

Additional Benefits of Multi Compressor Chiller

> Increased redundancy (a single failed compressor does not leave an entire chiller offline).

> Oil Free Magnetic Bearing chillers have a significantly lower maintenance cost over the lifecycle of the equipment (no rebuilds or scheduled tear downs – important to high run hour applications).

Smardt the pre-eminent oil-free centrifugal chiller range worldwide

> Over 3000 reference sites, worldwide

> Widest chiller product range in – water-cooled, – air-cooled, – condenserless,– evap-boosted air cooled – heat recovery and – compact modular and split models

Smardt water cooled OFC chillers60TR-1200TR

Smardt air cooled range60 TR through 600 TR

Free cooling means spectacular energy efficiencies

Patented thermosyphon system yields extraordinary performance.Available in North America in June 2012.

Free Cooling Using ThermoSiphon

• Uses refrigerant migration to provide cooling effect

• No need for extra coils or fluid coolers

• Oil free design allows eliminates the constraint to maintain oil balance.

Single circuit design

Simple Changeover

Dual circuit design

Allows for simultaneous mechanical and free cooling

Free Cooling Projects

• iCloud Data Center in South Bend • Rep – Bullock Logan• Two 300 ton condenserless

using refrigerant pumping & evap condensing towers

• Ottawa International Airport• Rep – Direct Energy • Two 200 ton air cooled split

systems• Achieved 120+ tons of free

cooling at 25 F

System efficiencies as low as 0.10 – 0.30 kw/ton in off peak ambient conditions

Typical Performance at 75% Capacity

95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -400.000

0.200

0.400

0.600

0.800

1.000

1.200

Series1

• Water cooled using flash economizer• Air cooled using plate economizer

Economizer: Before and After

Air Cooled Economizer

Air Cooled Pictures

Plate heat exchanger located adjacent to evaporator

Water Cooled Economizer

Water Cooled Diagram

Flash economizer located adjacent to heat exchangers

Central Plant Controls

CPECS optimization, automated reporting & condition monitoring.

Definition of OPTIMIZATION: an act, process, or methodology of making something (as a design, system, or decision) as fully perfect, functional, or effective as possible; specifically : the mathematical procedures (as finding the maximum of a function) involved in this

What is optimization?

Kiltech-CPECS Optimization System

• Handles plant control:– Hard wired input/ outputs.– Communication to chillers, VFD’s, air handlers, BAS and

Btu meters.– Delivers total system energy approach sequence of

operations.

• Includes full measurement & verification system.

• Inbuilt enterprise SQL database stores 7yrs data onsite and can be backed up offsite

The System Approach

• High performance components do not necessarily operate at peak performance by themselves.

• Control strategy needs to understand individual equipment requirements as well as a total system level energy consumption.

• Air side integration a must. The left hand needs to know what the right hand is doing!

Optimization - Strategies Applied– Variable primary pumping control with reset based on

weighted AHU & FCU valve position.

– Optimized cooling tower temperature control that utilizes chiller load data and actual cooling tower off design correlations (merkel equations).

– Optimized sequencing of chillers & pumps using 15min buffered data and actual equipment models.

– Variable speed condenser water control for part load optimization.

– Chilled water reset based on AHU fan power, discharge air set point and percentage cooling valve position.

Condition Monitoring & Continuous Commissioning

Keeping the performance up

Hero Buildings – Chicago Mercantile Exchange

1800 Trans Canada HighwayDorval, Quebec H9P 1H7Phone: (514) 426-8989Fax: (514) 416-5757www.smardt.com

• Extremely efficient, low maintenance chillers

• Sophisticated plant optimization controls

Smardt Chiller Group