Energy management for refrigeration systems

• US 10,240,836 B2
• Filed: 06/29/2016
• Issued: 03/26/2019
• Est. Priority Date: 06/30/2015
• Status: Active Grant

• Current Assignee: Copeland Cold Chain LP
• Original Assignee: Emerson Climate Technologies Retail Solutions Incorporated (Emerson Electric Company)
• Inventors: Wallace, John, Beltran, Franklin, Wallis, Frank S., Bertie, Keith, Fullenkamp, Paul L.
• Primary Examiner(s): Furdge, Larry L
• Application Number:
  US15/197,121
• Publication Number:
  US 20170089625A1
• Time in Patent Office: 1,000 Days
• CPC Class Codes: F25B 2400/07 Details of compressors or related parts
• CPC Class Codes: F25B 2400/075 with parallel compressors
• CPC Class Codes: F25B 2400/22 Refrigeration systems for supermarkets
• CPC Class Codes: F25B 2500/00 Problems to be solved
• CPC Class Codes: F25B 2500/19 Calculation of parameters
• CPC Class Codes: F25B 2600/00 Control issues
• CPC Class Codes: F25B 2600/02 Compressor control
• CPC Class Codes: F25B 2600/0251 with on-off operation
• CPC Class Codes: F25B 2600/111 of condenser fans
• CPC Class Codes: F25B 2700/15 Power, e.g. by voltage or current
• CPC Class Codes: F25B 2700/151 of the compressor motor
• CPC Class Codes: F25B 2700/171 of the compressor
• CPC Class Codes: F25B 2700/172 of the condenser fan
• CPC Class Codes: F25B 2700/193 of the compressor
• CPC Class Codes: F25B 2700/1931 Discharge pressures
• CPC Class Codes: F25B 2700/1933 Suction pressures
• CPC Class Codes: F25B 2700/21152 at the discharge side of the compressor
• CPC Class Codes: F25B 31/00 Compressor arrangements
• CPC Class Codes: F25B 41/385 Dispositions with two or more expansion means arranged in parallel on a refrigerant line leading to the same evaporator
• CPC Class Codes: F25B 49/00 Arrangement or mounting of control or safety devices
• CPC Class Codes: F25B 49/02 : for compression type machines, plants or systems
• CPC Class Codes: F25B 49/022 : Compressor control arrangements
• CPC Class Codes: F25B 49/027 : Condenser control arrangements
• CPC Class Codes: F25B 5/02 : arranged in parallel

Abstract

A system and method are provided including a system controller for a refrigeration or HVAC system having a compressor rack with a compressor and a condensing unit with a condenser fan. The system controller monitors and controls operation of the refrigeration or HVAC system. A rack controller monitors and controls operation of the compressor rack and determines compressor rack power consumption data. A condensing unit controller monitors and controls operation of the condensing unit and determines condensing unit power consumption data. The system controller receives the compressor rack power consumption data and the condensing unit power consumption data, determines a total power consumption of the refrigeration or HVAC system, determines a predicted power consumption or a benchmark power consumption for the refrigeration system, compares the total power consumption with the predicted power consumption or the benchmark power consumption, and generates an alert based on the comparison.

Claims

1. A system comprising:

a system controller for a refrigeration or HVAC system having a compressor rack with a plurality of compressors and a condensing unit with a plurality of condenser fans, the system controller monitoring and controlling operation of the refrigeration or HVAC system;

a rack controller in communication with the system controller, the rack controller monitoring and controlling operation of the compressor rack; and

a condensing unit controller in communication with the system controller, the condensing unit controller monitoring and controlling operation of the condensing unit;

wherein the system controller determines a startup power demand for each compressor of the plurality of compressors and each condenser fan of the plurality of condenser fans, monitors a total power demand of the compressor rack and the condensing unit, and limits peak power demand of the HVAC system during operation by controlling activation and deactivation of the plurality of compressors and the plurality of condenser fans, based on the monitored total power demand of the compressor rack and the condensing unit and the startup power demand for each compressor of the plurality of compressors and each condenser fan of the plurality of condenser fans, so that the total power demand is below a predetermined power threshold.

2. A method comprising:

monitoring and controlling, with a system controller, a refrigeration or HVAC system having a compressor rack with a plurality of compressors and a condensing unit with a plurality of condenser fans;

monitoring and controlling, with a rack controller in communication with the system controller, operation of the compressor rack;

monitoring and controlling, with a condensing unit controller in communication with the system controller, operation of the condensing unit;

determining, with the system controller, a startup power demand for each compressor of the plurality of compressors and each condenser fan of the plurality of condenser fans; and

monitoring, with the system controller, a total power demand of the compressor rack and the condensing unit; and

limiting, with the system controller, peak power demand of the HVAC system during operation by controlling activation and deactivation of the plurality of compressors and the plurality of condenser fans, based on the monitored total power demand of the compressor rack and the condensing unit and the startup power demand for each compressor of the plurality of compressors and each condenser fan of the plurality of condenser fans, so that the total power demand is below a predetermined power threshold.

3. A system comprising:

a system controller for a refrigeration or HVAC system having a compressor rack with a plurality of compressors and a condensing unit with a plurality of condenser fans, the system controller monitoring and controlling operation of the refrigeration or HVAC system;

a rack controller in communication with the system controller, the rack controller monitoring and controlling operation of the compressor rack; and

a condensing unit controller in communication with the system controller, the condensing unit controller monitoring and controlling operation of the condensing unit;

wherein the system controller monitors a total power consumption of the compressor rack and the condensing unit, receives a signal corresponding to limiting power consumption, and selects at least one compressor from the plurality of compressors and at least one condenser fan from the plurality of condenser fans to operate to provide needed refrigeration capacity while maintaining the total power consumption below a power threshold associated with the signal.

4. The system of claim 3, wherein the signal is received from a utility as a demand shed signal and wherein the power threshold is associated with the demand shed signal.

5. The system of claim 3, wherein the signal is received from an onsite power generation device and wherein the power threshold corresponds to an amount of power generated by the onsite power generation device.

6. The system of claim 3, wherein the signal is received from an onsite power generation device and wherein the power threshold corresponds to a predicted amount of power to be generated by the onsite power generation device.

7. A method comprising:

monitoring and controlling, with a system controller, a refrigeration or HVAC system having a compressor rack with a plurality of compressors and a condensing unit with a plurality of condenser fans;

monitoring and controlling, with a rack controller in communication with the system controller, operation of the compressor rack;

monitoring and controlling, with a condensing unit controller in communication with the system controller, operation of the condensing unit;

monitoring, with the system controller, a total power consumption of the compressor rack and the condensing unit;

receiving, with the system controller, a signal corresponding to limiting power consumption; and

selecting, with the system controller, at least one compressor from the plurality of compressors and at least one condenser fan from the plurality of condenser fans to operate to maximize refrigeration capacity while maintaining the total power consumption below a power threshold associated with the signal.

8. The method of claim 7, wherein the signal is received from a utility as a demand shed signal and wherein the power threshold is associated with the demand shed signal.

9. The method of claim 7, wherein the signal is received from an onsite power generation device and wherein the power threshold corresponds to an amount of power generated by the onsite power generation device.

10. The method of claim 7, wherein the signal is received from an on-site power generation device and wherein the power threshold corresponds to a predicted amount of power to be generated by the on-site power generation device.

11. A system comprising:

a system controller for a refrigeration or HVAC system having a compressor rack with at least one compressor and a condensing unit with at least one condenser fan, the system controller monitoring and controlling operation of the refrigeration or HVAC system;

a rack controller in communication with the system controller, the rack controller monitoring and controlling operation of the compressor rack and determining compressor rack power consumption data; and

a condensing unit controller in communication with the system controller, the condensing unit controller monitoring and controlling operation of the condensing unit and determining condensing unit power consumption data;

wherein the system controller receives the compressor rack power consumption data and the condensing unit power consumption data, receives forecast weather data for a future time period, determines a predicted total power consumption of the refrigeration or HVAC system based on the forecast weather data, compares the predicted total power consumption of the refrigeration or HVAC system with a predetermined power threshold, and performs at least one of generating an alert and modifying operation of the refrigeration or HVAC system when the predicted total power consumption is greater than the predetermined power threshold.

12. The system of claim 11 wherein the system controller performs at least one of pre-cooling a refrigeration case and storing power in an energy storage device.

13. The system of claim 11 wherein the system controller modifies operation of the refrigeration or HVAC system prior to the future time period to reduce power consumption of the refrigeration or HVAC system during the future time period.

14. A method comprising:

monitoring and controlling, with a system controller, operation of a refrigeration or HVAC system having a compressor rack with at least one compressor and a condensing unit with at least one condenser fan;

monitoring and controlling, with a rack controller in communication with the system controller, operation of the compressor rack;

determining, with the rack controller, compressor rack power consumption data for the compressor rack;

monitoring and controlling, with a condensing unit controller in communication with the system controller, operation of the condensing unit;

determining, with the condensing unit controller, power consumption data for the condensing unit;

receiving, with the system controller, the compressor rack power consumption data and the condensing unit power consumption data;

receiving, with the system controller, forecast weather data for a future time period;

determining, with the system controller, a predicted total power consumption of the refrigeration or HVAC system based on the forecast weather data;

comparing, with the system controller, the predicted total power consumption of the refrigeration or HVAC system with a predetermined power threshold; and

performing, with the system controller, at least one of generating an alert and modifying operation of the refrigeration or HVAC system when the predicted total power consumption is greater than the predetermined power threshold and modifying operation of the refrigeration or HVAC system.

15. The method of claim 14 wherein the modifying, with the system controller, operation of the refrigeration or HVAC system includes modifying operation of the refrigeration or HVAC system prior to the future time period to reduce power consumption of the refrigeration or HVAC system during the future time period.

16. The method of claim 15 wherein the system controller performs pre-cooling one or more refrigeration cases.

17. The method of claim 15 wherein the system controller performs modifying defrost schedules of refrigeration cases.

18. The method of claim 15 wherein the system controller performs storing power in an energy storage device.

19. A system comprising:

a system controller for a refrigeration or HVAC system having a compressor rack with a plurality of compressors and a condensing unit with a plurality of condenser fans, the system controller monitoring and controlling operation of the refrigeration or HVAC system;

a rack controller in communication with the system controller, the rack controller monitoring and controlling operation of the compressor rack; and

a condensing unit controller in communication with the system controller, the condensing unit controller monitoring and controlling operation of the condensing unit;

wherein the system controller determines a startup power demand for each compressor of the plurality of compressors and each condenser fan of the plurality of condenser fans and determines a startup sequence, based on the determined startup power demand for each compressor of the plurality of compressors and each condenser fan of the plurality of condenser fans, to limit peak power demand during a startup operation to be below a predetermined power threshold.

20. A method comprising:

monitoring and controlling, with a system controller, a refrigeration or HVAC system having a compressor rack with a plurality of compressors and a condensing unit with a plurality of condenser fans;

monitoring and controlling, with a rack controller in communication with the system controller, operation of the compressor rack;

monitoring and controlling, with a condensing unit controller in communication with the system controller, operation of the condensing unit;

determining, with the system controller, a startup power demand for each compressor of the plurality of compressors and each condenser fan of the plurality of condenser fans; and

determining, with the system controller, a startup sequence, based on the determined startup power demand for each compressor of the plurality of compressors and each condenser fan of the plurality of condenser fans, to limit peak power demand during a startup operation to be below a predetermined power threshold.