Calculating chiller and cooling tower refrigeration in

tons

Chiller Refrigeration Tons

A chiller refrigeration ton is defined as:

1 refrigeration ton = 12,000 Btu/h = 3,025.9 k Calories/h

A ton is the amount of heat removed by an air conditioning system that would melt 1 ton of ice in 24 hours.

Cooling Tower Tons

A cooling tower ton is defined as:

1 cooling tower ton = 15,000 Btu/h = 3,782 k Calories/h

Heat Load and Water Flow

A water systems heat load in Btu/h can be simplified to:

h = cp ρ q dt

= (1 Btu/lbm oF) (8.33 lbm/gal) q (60 min/h) dt

= 500 q dt (1)

where

h = heat load (Btu/h)

cp = 1 (Btu/lbm oF) for water

ρ = 8.33 (lbm/gal) for water

q = water volume flow rate (gal/min)

dt = temperature difference (oF)

Example - Water Chiller Cooling

Water flows with 1 gal/min and 10oF temperature difference. The ton of cooling load can be calculated as:

Cooling load = 500 (1 gal/min) (10 oF) / 12,000

= 0.42 ton

The chiller efficiency depends on the energy consumed. Absorption chillers are rated in fuel consumption per
ton cooling. Electric motor driven chillers are rated in kilowatts per ton cooling.

 KW/ton = 12 / EER
 KW/ton = 12 / (COP x 3.412)
 COP = EER / 3.412
 COP = 12 / (KW/ton) / 3.412
 EER = 12 / KW/ton
 EER = COP x 3.412

If a chillers efficiency is rated at 1 KW/ton,

 COP = 3.5
 EER = 12

Cooling Load in - kW/ton

The term kW/ton is commonly used for larger commercial and industrial air-conditioning, heat pump and
refrigeration systems.

The term is defined as the ratio of energy consumption in kW to the rate of heat removal in tons at the rated
condition. The lower the kW/ton the more efficient the system.

kW/ton = Pc / Er (1)

where

Pc = energy consumption (kW)

Er = heat removed (ton)

Coefficient of Performance - COP

The Coefficient of Performance - COP - is the basic parameter used to report efficiency of refrigerant based
systems.

The Coefficient of Performance - COP - is the ratio between useful energy acquired and energy applied and
can be expressed as

COP = Eu / Ea (2)

where

COP = coefficient of performance

Eu = useful energy acquired (btu in imperial units)

Ea = energy applied (btu in imperial units)

COP can be used to define both cooling efficiencies or heating efficiencies as for a heat pumps.

 Cooling - COP is defined as the ratio of of heat removal to energy input to the
compressor
 Heating - COP is defined as the ratio of heat delivered to energy input to the
compressor

COP can be used to define the efficiency at single standard or non-standard rated conditions, or as a weighted
average of seasonal conditions. The term may or may not include the energy consumption of auxiliary systems
such as indoor or outdoor fans, chilled water pumps, or cooling tower systems.

 higher COP - more efficient system

COP can be treated as an efficiency where COP of 2.00 = 200% efficiency. For unitary heat pumps, ratings at
two standard outdoor temperatures of 47oF and 17oF (8.3oC and -8.3oC) are typically used.
Energy Efficiency Ratio - EER

The Energy Efficiency Ratio - EER - is a term generally used to define cooling efficiencies of unitary air-
conditioning and heat pump systems.

The efficiency is determined at a single rated condition specified by an appropriate equipment standard and is
defined as the ratio of net cooling capacity - or heat removed in Btu/h - to the total input rate of electric energy
applied - in watt hour. The units of EER are Btu/Wh.

EER = Ec / Pa (3)

where

EER = energy efficient ratio (Btu/Wh)

Ec = net cooling capacity (Btu/h)

Pa = applied energy (Watts)

This efficiency term typically includes the energy requirement of auxiliary systems such as the indoor and
outdoor fans.

 higher EER - more efficient system

Air condition load, evaporator and condenser water flow rate

The total heat can be expressed as:

h = cp ρ q dt

= 500 q dt (1)

where

h = heat load (Btu/h)

cp = 1 (Btu/lbm oF) for water

ρ = 8.33 (lbm/gal) for water

q = water volume flow rate (gal/min)

dt = temperature difference (oF)

Evaporator water flow rate can be expressed as

qevap = 24 hevap / dt (2)

where

qevap = evaporator water flow rate (gallons per minute - gpm)

hevap = air condition load (tons = 15,000 Btu/h = 3,782 k Calories/h)

Condenser water flow rate can be expressed as

qcond = 30 hcond / dt (3)

where

qcond = condenser water flow rate (gallons per minute - gpm)

hcond = air condition load (tons = 15,000 Btu/h = 3,782 k Calories/h)

Air conditioner efficiency express the ratio between heat removed to

watt of power used - EER and SEER
Cooling equipment systems used in residential and small commercial buildings often express cooling system
efficiency in terms of the Energy Efficiency Ratio - EER - and/or Seasonal Energy Efficiency Ratio - SEER.

For room air conditioners the commonly used efficiency ratio is the

EER - Energy Efficiency Ratio

For central air conditioners the commonly used ratio is

SEER - Seasonal Energy Efficiency Ratio

These ratings are posted on the Energy Guide Label attached to all new air conditioners.

Some air conditioner manufacturers participates in the voluntary Energy Star labeling program where the
Energy Star label indicates higher EER and SEER ratings.

EER - Energy Efficiency Ratio

EER is a measure of how efficiently a cooling system operates when the outdoor temperature is at a specific
level (outdoor conditions commonly used are 95 oF).

 The higher EER the more energy efficient system.

EER can be expressed as

EER = qc / p (1)

where

qc = cooling energy (Btu/hr)

p = power consumption (Watts)

EER is commonly used for room air conditioners ranging 5,000 Btu per hour to 15,000 Btu per hour.

 1 Btu/h = 2.931x10-4 kW = 0.0299 kpm/s = 0.252 kcal/h = 3.986x10-4 hk =

3.939x10-4 hp = 0.2163 ft lb/s

In mild climates air conditioners with EER of at least 9.0 should be selected. In hotter climates air conditioners
with EER over 10.should be selected.

SEER - Seasonal Energy Efficiency Ratio

SEER - Seasonal Energy Efficiency Ratio - can be expressed as

SEER = Qc / P (2)

where

Qc = seasonal cooling energy (Btu)

P = seasonal power consumption (Watt-hours)

SEER should be at least 10 - there are units where SEER reach ate least 17.

Example - EER

A cooling unit operating at 1 kW/ton would have an EER of 12,000 Btu divided by 1000 watts or 12. This is
mathematically equivalent to multiplying the COP by 3.413. Therefore a small cooling unit operating at 1 kW
(1000 watts) per ton is equivalent to a COP of 3.516, or an EER of 12.
The maximum cooling tower efficiency is limited by the wet-
bulb temperature of the cooling air
Cooling towers use the evaporative cooling principle to cool the circulated water, and

 they can achieve water temperatures below the dry bulb temperature - tdb - of the air
cooling air
 they are in general smaller and cheaper for the same cooling loads than other cooling
systems

Cooling towers are rated in terms of approach and range, where

 the approach is the difference in temperature between the cooled-water temperature

and the entering-air wet bulb - twb - temperature
 the range is the temperature difference between the water inlet and exit states

Since a cooling tower is based on evaporative cooling the maximum cooling tower efficiency is limited by
the wet bulb temperature - twb - of the cooling air.
Cooling Tower Efficiency
The cooling tower efficiency can be expressed as

μ = (ti - to) 100 / (ti - twb) (1)

where

μ = cooling tower efficiency - common range between 70 - 75%

ti = inlet temperature of water to the tower (oC, oF)

to = outlet temperature of water from the tower (oC, oF)

twb = wet bulb temperature of air (oC, oF)

The temperature difference between inlet and outlet water (ti - to) is normally in the range 10 - 15 oF.

The water consumption - the make up water - of a cooling tower is about 0.2-0.3 liter per minute and ton
of refrigeration. Compared with the use and waste of city water the water consumption can be reduced
with about 90 - 95%.

There are two main types of cooling towers

 forced draught (using fans)

 natural draught

Both types are based on evaporative cooling.

 Natural draught cooling towers are more dependent on temperature gradients between
air and water and the wind forces than forced draught cooling towers.
 The efficiency of natural draught towers are more variable over time and in general
lower.

Note! Be aware that medium temperature systems like cooling towers are known sources of Legionella!
Good cleaning and maintenance systems are important to minimize the potential damage.
Chilled-water systems formulas - evaporator and
condenser flow rates
In a chilled-water system the air conditioner cools water down to 40 - 45oF (4 - 7oC). The chilled water is
distributed throughout the building in a piping system and connected to air condition cooling units wherever
needed.

Total Heat Removed

The total heat removed by air condition chilled-water installation can be expressed as

h = 500 q dt (1)

where

h = total heat removed (Btu/h)

q = water flow rate (gal/min)

dt = temperature difference (oF)

Evaporator Flow Rate

The evaporator water flow rate can be expressed as

qe = htons 24 / dt (2)

where

qe = evaporator water flow rate (gal/min)

htons = air condition cooling load (tons)

Condenser Flow Rate

The condenser water flow rate can be expressed as

qc = htons 30 / dt (3)

where

qc = condenser water flow rate (gal/min)

htons = air condition cooling load (tons)

Rating performance and efficiency of heat
pumps
Several methods are used to rate heat pump performance and efficiency

COP - Coefficient of Performance

The Coefficient of Performance - COP - is the ratio of heat output to the amount of energy input of a heat
pump.

COP can be expressed as

COP = hh / hw (1)

where

COP = Coefficient of Performance

hh = heat produced (Btu/h)

hw = equivalent electric energy input (Btu/h) = 3413 Pw

where

Pw = electrical input energy (W)

If a heat pump delivers 3 units of heat for every unit of energy input - the COP is 3.
Example - COP Heat Pump

Cooling Cycle
A heat pump delivering 60000 Btu/h with a total input of 9 kW:

COP = 60000 (Btu/h) / 3413 9 (kW)

= 1.95

Heating Cycle
A heat pump delivering 50000 Btu/h with a total input of 7 kW:

COP = 50000 (Btu/h) / 3413 7 (kW)

= 2.1

EER - Energy Efficiency Ratio

The Energy Efficiency Ratio - EER - measures the cooling efficiency of a heat pump.

EER can be expressed as

EER = hc / Pw (2)

where

EER = Energy Efficiency Rating

hc = cooling heat (Btu/h)

Pw = electrical power (W)

Example - EER
An air conditioner or heat pump in cooling modus draws 1000 W to produce 10000 Btu/h cooling. The
EER can be calculated as

EER = (10000 Btu/h) / (1000 W)

= 10
HSPF - Heating Season Performance Factor
The Heating Season Performance Factor - HSPF - is a measure of the overall heating efficiency of a heat
pump.

HSPF = hs / Pws 3413 (3)

where

hs = heat produced during the season (Btu)

Pws = elctrical power consumed during the season (kWh)

The HSPF can be regarded as an "average" COP for an entire heating season. It is common to compare
BTUs of heat output to watts of electrical energy input. HSPF of 6.8 can be compared with an average
COP of 2 and a HSPF in the range of 5-7 is acceptable.

Example - Heat Pump Heating Season Performance Factor

For a heat pump delivering 120,000,000 Btu during the season when consuming 15,000 kWh the HSPF
can be calculated as

HSPF = 120000000 (Btu) / 15000 (kWh) 3513

= 2.3

SEER - Seasonal Energy Efficiency Ratio

Seasonal Energy Efficiency Ratio is a measure of the seasonal cooling efficiency of a heat pump or a
consumer central air conditioning system.

The SEER should be at least 13 to be sold in the United States. SEER above 20 is a very efficient
system.