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It should be noted that this cost savings calculation does not account for an electric peak demand
reduction. If the facility has a peak demand charge, and the chiller operates everyday with on
operational schedule that is coincident with the facilities peak demand, then this estimate slightly
underestimates the cost savings.
Condenser Temperature Reset Energy Savings and Economics Example
Example Synopsis: A water cooled centrifugal chiller currently has an entering condenser
temperature of 55F. After inspection it was determined that the temperature controls can allow
modulation down to 52F during low load periods. The operators estimate that the chiller can
operate at 52F for 3,000hrs per year, and the chiller has an electrical load of 300kW when operating
at these low load conditions. The average electric rate is $0.10/kWh.
The annual energy savings can be estimated as:
The annual cost savings can be estimated as:
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The predominant impact chillers have on water use relates to proper function. An inefficient
chiller will require longer hours of operation to satisfy the load. It is these additional hours that
result in greater water use though evaporation at the cooling tower and any leaks in the system. Any
inefficiency results in a less-than-optimal operation leading to increased resource use water is one of
those resources.
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Description
Maintenance Frequency
Comments
Daily
Weekly
Chiller use/sequencing
Turn off/sequence unnecessary chillers
Overall visual inspection
Complete overall visual inspection to
be sure all equipment is operating and
safety systems are in place
Check setpoints
Check all setpoints for proper setting
and function
Evaporator and condenser
Assess evaporator and condenser coil
fouling as required
Compressor motor
temperature
Check temperature per manufacturers
specifications
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SemiAnnually
Annually
6478#
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Chiller Checklist (contd)
Description
Maintenance Frequency
Comments
Daily
Weekly
SemiAnnually
Annually
Perform water quality test
Check water quality for proper
chemical balance
Leak testing
Conduct leak testing on all compressor
fittings, oil pump joints and fittings,
and relief valves
Check all insulation
Check insulation for condition and
appropriateness
Control operation
Verify proper control function
including:
Hot gas bypass
Liquid injection
Check vane control
settings
Check settings per manufacturers
specification
Verify motor load limit
control
Check settings per manufacturers
specification
Verify load balance
operation
Check settings per manufacturers
specification
Check chilled water reset
settings and function
Check settings per manufacturers
specification
Check chiller lockout
setpoint
Check settings per manufacturers
specification
Clean condenser tubes
Clean tubes at least annually as part of
shutdown procedure
Eddy current test
condenser tubes
As required, conduct eddy current test
to assess tube wall thickness
Clean evaporator tubes
Clean tubes at least annually as part of
shutdown procedure
Eddy current test
evaporator tubes
As required, conduct eddy current test
to assess tube wall thickness
Compressor motor and
assembly
Compressor oil system
Check all alignments to specification
Check all seals, provide lubrication
where necessary
Conduct analysis on oil and filter
Change as required
Check oil pump and seals
Check oil heater and thermostat
Check all strainers, valves, etc.
Electrical connections
Check all electrical connections/
terminals for contact and tightness
Water flows
Assess proper water flow in evaporator
and condenser
Check refrigerant level
and condition
Add refrigerant as required. Record
amounts and address leakage issues.
647D#
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Job Name
Date
Unit Tag
Model #
Time
Serial #
Full Load Design
Operating Condition
__________degF Operating Code
Last Diagnostic
LCHW Setpoint
Current Limit Setpoint
Start #
Run Hours
__________Volts Volts AB
__________Hertz Volts AC
Volts BC
Amps L1
Amps L2
Amps L3
Amps AVG
__________RLA % of RLA
Oil Sump Temperature
Oil Temperature to Bearings
Oil Level
Low Oil Pressure
High Oil Pressure
Net Oil Pressure
Operating Purge Pressure
Operating Purge Oil Level
Purge Starts
Purge Run Hours
_____PSID_____gpm CHW PSID
__________degF CHW Temperature in
__________degF CHW Temperature out
__________degF CHW Temperature Differential
CHW Makeup Water
Evaporator Temperature
Evaporator Pressure
_____PSID_____gpm CW PSI Differential
__________degF CW Temperature in
__________degF CW Temperature out
__________degF CW Temperature Differential
Condenser Temperature
Condenser Pressure
Cooling Tower Makeup Water
CHW Makeup Water
Operator Initials
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6476#
