System analysis of the refrigeration system at Philip Morris Manufacturing Berlin

to develop cost and energy saving potentials

Franziska Dan September 2018

Abstract
With a share of 41% of the total electricity demand of the technical building equipment excluding the air-conditioning
and ventilation systems of the production location Berlin, Philip Morris Manufacturing’s historically grown refriger-
ation structure represents a decisive starting point for the identification of energetic optimization potentials. Within
the framework of this study, holistic solutions for the two main refrigeration plants will be developed considering
all cost and energy intensive main components. As a tool for analyzing the complex interaction of the different
system components, a dynamic annual simulation is used. By means of this simulation, various control strategies
for optimizing system temperatures and switching specifications for the available recooling systems and chillers are
developed. In addition to diverse control concepts, which can be assumed in any case as economically viable, also
the potential of various reconstruction measures with a comparatively higher capital expenditure will be assessed as
another emphasis of investigation. If all the recommended measures derived from this are implemented, significant
energy and cost savings of up to 19% and 22%, respectively, can be achieved within the existing refrigeration supply.
Keywords: control concepts, recooling systems, water treatment costs, turbo compressors, cost and energy efficiency

1 Introduction
A total of seven refrigeration plants cover the year-round
high refrigeration demand at PMMG Berlin. The two re-
frigeration centers KA-001 and KA-008 take over 80% of
this total demand, which was 17.56 GWh in the refer-
ence year 2017. Because they have a higher system ef-
ficiency compared to the other centers, they are deliber-
ately prioritized and can therefore be considered as the
two main refrigeration centers. The ability to combine
dry and wet recooling systems as well as the possibility
of variable setpoint specification gives the basic prerequi-
sites for exploiting further optimization potentials.
The main objective of this study is to identify further
savings potentials for the two main refrigeration plants
and to derive specific recommendations for improved op-
erating practices. The actual problem arises from the
complex interaction between the components. Because a
single component-wise optimization is not automatically
equivalent to an actual system optimization due to reper-
cussions. Rather, potential improvement measures of one
component can simultaneously cause negative energetic
and / or monetary influences elsewhere. The development
of holistic solutions to the system-related cost and energy
saving is therefore the overarching task of this work.
2 Method
The entire system can be visualized as a gear with a va-
riety of screws, in which the influence of reciprocal ef-
fects must always be considered. Oriented on this, the
methodology must also move to an interplay of analyti-
cal, numerical and practical approaches.
Numerical problem solving is done using the simulation
software Modelica/Dymola. The first design part com-
prises the modeling of the individual components and
their interlinking to an overall model. The correspon-
dence between model and reality was ensured by subse-
quent validations as a basic prerequisite for the simulation
in the next work step. It represents the tool for dynamic
and not only static comparative analysis between the ini-
tial state and the operating variations to be examined.
Only by this numerical approach, the reciprocal influence
of all relevant system components by the dynamic speci-
fication of ambient and load conditions can be examined
and thus, an actual system optimization is ensured.
In addition, analytical and practical approaches are also
essential. Based on this combined consideration method-
ology, a wide range of different control strategies and con-
version recommendations has been developed.
3 Optimization measures
This section provides an overview of the recommended op-
timization measures developed for the two main centers.
The simulative and analytical procedure is explained
in part and the main results of the respective partial
analyzes are presented.
3.1 Control-based optimization
Refrigeration machine’s part load behavior
Based on a detailed analysis of the individual plant char-
acteristics of the three identical refrigeration machines
(RM) with turbocompressors available in KA-001, the pos-
itive influence on efficiency (EER) by
 favorable partial load behavior,
 lower cooling water inlet temperatures tin and
 higher cold water flow temperatures tf low
could be identified and quantified. The different parame-
ters influencing the efficiency of the refrigeration machine
can be seen from the EER matrix highlighted in color in
Table 1. The best possible EER value of 11.12 results from
tin =16◦ C and a load of 45-50 %, while under unfavorable
operating conditions at tin =24◦ C and under full load only
an EER value of 5.95 can be achieved.
Table 1: Matrix for describing the refrigeration machine efficiency
(EER) for tf low ≈ 6◦ C generated by data-based function lines.
(orange: lower - green: higher efficiency)
The comparison of these two high-contrast operating
states with an efficiency difference of 87% illustrates the
great potential for optimization through intelligent con-
trolling of the mentioned influencing variables. In view
of the high RM efficiency at the lower capacity range, it
may be advisable in certain cases to switch on another
refrigeration machine even before reaching the maximum
capacity range of the operating one. However, to maintain
the highest possible system efficiency, the entire system,
including the energy-intensive pumps must be considered.
The enormously significant pump energy of 51kW per RM-
cycle has a massive impact on the position of the switch-
ing point optimum. Using a simulation-based systematol-
ogy, the optimal switching points of the second and third
chillers could be differentiated according to tin und tf low .
In Figure 1 the developed systematology is illustrated us-
ing the example of the ideal switching ranges between the
second and third refrigeration machine.
In the left diagram of Figure 1: Optimal switching points depending on tin snd tf low using the example of KM2x to KM3x
Figure 1, the ∆Ptotal,3−2 -
curves of three different
cooling water inlet tem-
peratures tin =18/22/26◦ C
at tf low =6◦ C are applied.
They are determined by
driving the full bandwidth
of the RM2→3 power spec-
trum between 1040kW and
2320kW in the modeled and
simulated overall system.
The difference ∆Ptotal,3−2
is given by subtracting the
total power of two re-
frigeration machines (RM2x )
from the total power of Hier kann ein Bild hin
Figure 2: Left: Procedure for determining the optimal twet−recooler default values using the example
of the cluster area tW etBulb,10...12◦ C at Q̇0,1000kW and tf low,6◦ C .
Right: Extract of three optimized twet−recooler default curves for tf low,6◦ C .
three chillers (RM3x ) un-
der the same conditions.
Due to the intersection
with ∆Ptotal,3−2 =0kW as
an indicator for optimized
switching, it can be seen
that e.g. at tin =26◦ C
it makes sense to con-
nect a third chiller from
Q̇0 =1926kW. This could re-
sult in Ptotal savings of
37kW in the maximum case
at Q̇0,max,2x =2320kW.

From the right diagram it is recognizable that also un-
der other tin - and tf low -conditions, the connection of the
third chiller before reaching Q̇0,max,2x is energetically rec-
ommendable. The greater potential tends to be at higher
tf low - and rising tin −temperatures.
Dry recooling operation
The focus of the second of altogether six different con-
trol strategies in total is on the development of intelligent
switching criteria between dry and wet recooling. With
regard to the often high water treatment costs in con-
nection with the wet recooling operation, a considerable
energy and particularly monetary saving potential can be
exploited by a greater utilization of the capacity limit of
dry recooling plants. However, the amount of savings de-
pends decisively on the specific plant characteristics and
the individual cost factors and requires a differentiated
case-by-case analysis depending on the type of plant. For
the refrigeration plant KA-001 it could be shown that by
optimized switching criteria and the associated improved
control concept an extension of the annual operating time
of the dry recoolers by at least 1400 operating hours can
be achieved. The fundamental approach of this concept is
based on harmonizing both a high dry recooler operating
time and high EER-Values through a sliding tdry−recooler
outlet temperature. For a characteristic period of just
under 1000 hours, an increase in total plant efficiency of
18.1% and a corresponding reduction in operating costs
of 22.4% was demonstrated by means of the simulation.
Wet recooling operation
From the previous analytical and simulative studies it is
known that the chiller’s efficiency can be positively influ-
enced by lower cooling water inlet temperatures. Against
this background it can be stated that the previously stat-
ically at 24◦ C or 26◦ C set twet−recooler -values in the wet
recooling operation require the development of a dynamic
control strategy. In order to meet the objective of increas-
ing system efficiency, a large number of influencing factors
must be taken into account when choosing the optimum
twet−recooler default value. The problem solving therefore
takes place with a simulative solution approach.
Through a systematic twet−recooler -variation in the mod-
eled refrigeration system, the optimal control default val-
ues for every conceivable operating condition were deter-
mined. The principle of clustering usedP12for this purpose
differentiates between the Q̇0 -ranges i=1 i · 250kW, the
P13
tW etBulb -ranges i=0 i + 10◦ C and tf low . For each of the
156 clusters per tf low -variant, the default wet recooler
outlet temperature runs the range from 16◦ C to 27◦ C.
Through the associated Ptotal -curve, an individual opti-
mum can be assigned to each cluster. Figure 2 illustrates
the procedure using the example of one cluster area. The
three determined optimized default values from the left
diagram become transferred to the right diagram along
with other optimization results. The extract illustrates
the tendency that with increasing wet bulb temperature
and cooling load, the optimum wet recooler outlet tem-
perature for the entire system should also be increased.
Flow temperature increase
In contrast to the turbo compressor technology in KA-001
chillers, the screw compressors in KA-008 offer less vari-
ation possibilities. In the partial load case, no signifi-
cant increase in efficiency is detectable and with regard
to the cooling water temperatures, a deviation from the
manufacturer’s default values should be avoided. The de-
velopment of a concept for cold water flow temperature
increase represents a reasonable way to increase efficiency.
The flow temperatures have been permanently set at 6◦ C
on the grounds that in principle, three of the numerous air
conditioning and ventilation systems supplied by KA-008
require dehumidification. However, a detailed analysis of
the critical air conditioning systems has shown that only
in 18% of the almost 7900 operating hours a dehumidi-
fication process would have been required. In all other
times, the flow temperature 9◦ C would suffice to temper
the supply air and even a certain degree of dehumidifica-
tion could be achieved with tf low >6◦ C. Along with such a
flow temperature increase, according to the manufacturer,
a promising EER improvement in the order of ∆EER=0.5
could be achieved.
By linking the relevant cooling valve positions as a funda-
mental approach of the developed concept, it is ensured
that only in case of acute dehumidification, a gradual re-
duction from the new default value tf low =9◦ C is allowed.
The control concept has proved suitable during operation.
Based on a dynamic annual simulation, an increase of the
overall system efficiency of KA-008 by 3% was proven.
Further control-based optimization
In addition, two further control concepts were developed
within the framework of the present study. On the one
hand, it could be shown that the free cooling operating
time can be extended by 11% due to optimized swiching
criteria between free cooling and dry recooling operation.
The simulative study of a characteristic simulation sam-
ple period of 550 operating hours shows that the improved
control concept can achieve an efficiency increase of 8%
for this example period.
On the other hand, the optimization potential regard-
ing the existing outlet temperature control for the only
stepwise controllable wet recooling plant in KA-008 was
analyzed. The present recooling plant can be operated in
wet as well as dry mode by means of five different stages.
Each stage is assigned an individual combination of fan
number, fan stage and spraying. A simulation was used to
investigate the influence of a different stage sequence. As
a result, the superiority of a new stage constellation could
be proven. By adding an energetically and economically
reasonable intermediate stage with a lower spraying pro-
portion, KA-008 can achieve an annual efficiency increase
of 4% and an operating cost reduction of 7%.
3.2 Modification measures
In addition to the economically viable control concepts,
the potential of various reconstruction measures with a
comparatively higher capital expenditure was assessed.
SGV - volume flow controlled refrigeration machine
The focus of this partial analysis is the so-called SGV-
retrofitting of the turbo-compression refrigeration ma-
chines in the main refrigeration plant KA-001. In the
course of such SGV-modification, the power control is im-
plemented by means of a previously not executable vari-
able volume flow control for the purpose of saving pump
energy. Simultaneously, a deterioration of the hitherto
high chillers efficiency in part load cases must also be
taken into account. For a precise quantification of this
non-negligible influence, a systematology was developed
to mathematically describe the modified thermodynamic
behavior. The simulation results for this adapted refriger-
ation system reveal the overall positive impact on the to-
tal efficiency. An increase of 5.3% can already be achieved
by modifying one refrigeration machine circuit thanks to
the significantly reduced power consumption for the mod-
ified pump and despite the simultaneous loss of efficiency
on the part of the chiller.
Weekend shutdown
In the other main refrigeration plant KA-008, the savings
potential by adjusting the distribution of demand were
investigated. Due to minimum loads and distribution
losses, the cooling capacity actually provided was more
Figure 3: Energetic and monetary overall effect of all recommendation measures
than three times the required capacity of a single
consumer group to be supplied exclusively on weekends.
This problem could be circumvented by supplying the
critical consumer group with a local cooling system
instead of using the KA-008 cooling network as before. A
corresponding possibility is offered by the installation of
an efficient climate cabinet. Implementation has already
taken place and the energy and monetary benefits
for KA-008 have been quantified by means of another
simulation. Based on the simulation results, the weekend
shutdown results over the year in a 3% increase in
efficiency and a 13% reduction in operation costs.
Refrigeration machine exchange
The model developed for the purpose to describe the spe-
cific characteristics of such turbocompression refrigera-
tion machines represents the basis for another emphasis of
investigation within the main refrigeration plant KA-008.
System efficiency could be significantly increased if the
outdated existing refrigeration machines were replaced by
the more efficient and rarely operated turbo compression
refrigeration machines of another plant. The results of
the completed annual simulation show that the achiev-
able increase in efficiency within KA-08 amounts to 60%.
Compared to all other investigation measures, the saving
effect of this reconstruction measure is greatest.
4 Conclusions from the dynamic year simulation
As a final result of this study, the overall energetic and
monetary effect should be demonstrated by implementing
all the recommendation measures summarized in Table 2.
Table 2: Overview of all recommended implementation measures. ...
(Control measures in the upper part - rebuilding measures ...
in the lower part of the diagram.)
KA-001 KA-008
X RM part load behavior X drywet recooling
X drywet recooling X tf low increase
X tdry−recooler -optimization X stage constellation
X twet−recooler -optimization
X free coolingdry recooling
X SGV X weekend shutdown
X RM exchange
The achievable savings in the main refrigeration plants
examined are placed in the context of the total electrical
consumption of all seven refrigeration plants measured
in the reference year 2017. The associated operating
costs consist in addition to the electricity costs also of
the calculated water treatment costs. Based on these
consumption and cost values, the classification of the
developed savings potential related to the entire cooling
supply at PMMG in the initial state takes place. The
final results are presented in Figure 3.
The totality of all
recommendations devel-
oped allows significant
reductions in electrical
energy consumption
from 5.7 to 4.6 GWh
and operating costs
from 896 to 697 TA C.
Based on the results of
the annual simulations,
annual energy and mon-
Hier kann ein Bild hin etary savings of 19%
and 22%, respectively,
can be demonstrated. In
each case, an economic
viability of the control
measures and a fast
amortization period of
a maximum of 3.2 years
can be expected for the
conversion measures.