Low level central plant optimization

• US 10,101,731 B2
• Filed: 02/27/2015
• Issued: 10/16/2018
• Est. Priority Date: 05/01/2014
• Status: Active Grant

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Asmus, Matthew J., Turney, Robert D.
• Primary Examiner(s): Rodriguez, Carlos Ortiz
• Application Number:
  US14/634,615
• Publication Number:
  US 20150316903A1
• Time in Patent Office: 1,327 Days
• CPC Class Codes: G05B 13/048 using a predictor
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 2219/2639 Energy management, use maximum of cheap power, keep peak load low
• CPC Class Codes: G05B 2219/2642 Domotique, domestic, home control, automation, smart house
• CPC Class Codes: G05B 2219/31414 Calculate amount of production energy, waste and toxic release
• CPC Class Codes: G05B 2219/32021 Energy management, balance and limit power to tools
• CPC Class Codes: G06N 20/00 Machine learning
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 50/06 Energy or water supply
• CPC Class Codes: Y02B 70/3225 Demand response systems, e.g. load shedding, peak shaving
• CPC Class Codes: Y02P 70/10 Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
• CPC Class Codes: Y02P 90/80 Management or planning
• CPC Class Codes: Y04S 20/222 Demand response systems, e.g. load shedding, peak shaving

Abstract

Systems and methods for low level central plant optimization are provided. A controller for the central plant uses binary optimization to determine one or more feasible on/off configurations for equipment of the central plant that satisfy operating constraints and meet a thermal energy load setpoint. The controller determines optimum operating setpoints for each feasible on/off configuration and generates operating parameters including at least one of the feasible on/off configurations and the optimum operating setpoints. The operating parameters optimize an amount of energy consumed by the central plant equipment. The controller outputs the generated operating parameters via a communications interface for use in controlling the central plant equipment.

Claims

1. A controller for a central plant having a plurality of subplants that serve thermal energy loads of a building or building system, the controller comprising:

a processing circuit comprising a processor and memory, wherein the processing circuit is configured to identify a thermal energy load setpoint for a subplant of the central plant, wherein the thermal energy load setpoint is generated by a high level optimization that determines optimum thermal energy load setpoints for each of the plurality of subplants by optimally distributing a predicted thermal energy load for the building across the plurality of subplants;

a low level optimization module comprising a binary optimization module of the processing circuit configured to use binary optimization to determine one or more feasible on/off configurations for equipment of the subplant to achieve the thermal energy load setpoint generated by the high level optimization;

the low level optimization module comprising a setpoint evaluator module of the processing circuit configured to determine optimum operating setpoints for the subplant equipment for each feasible on/off configuration;

the low level optimization module configured to generate a resource consumption curve for the subplant by optimizing an amount of resource consumption by the subplant for several different combinations of thermal energy load and weather conditions, the resource consumption curve indicating a minimum amount of resource consumption by the subplant as a function of a thermal energy load on the subplant;

a subplant control module of the processing circuit configured to generate operating parameters for the subplant equipment, the operating parameters comprising at least one of the feasible on/off configurations and the optimum operating setpoints; and

a communications interface coupled to the processing circuit and configured to output the generated operating parameters for use in controlling the subplant equipment.

2. The controller of claim 1, further comprising a constraints evaluator module configured to identify applicable constraints for the subplant equipment;

wherein each feasible on/off configuration satisfies the applicable constraints and is estimated to result in the subplant equipment meeting the thermal energy load setpoint.

3. The controller of claim 1, wherein the binary optimization module uses a branch and bound method to determine the one or more feasible on/off configurations.

4. The controller of claim 1, wherein the setpoint evaluator module determines the optimum operating setpoints using a nonlinear optimization that minimizes an amount of power consumed by the subplant equipment.

5. The controller of claim 1, wherein the setpoint evaluator module is configured to:

estimate an amount of power consumed by each feasible on/off configuration of the subplant equipment at the optimum operating setpoints; and

identify which of the feasible on/off configurations is estimated to result in a lowest amount of power consumed by the subplant equipment at the optimum operating setpoints.

6. A method for controlling a central plant having a plurality of subplants that serve thermal energy loads of a building or building system, the method comprising:

identifying, by a processing circuit of a controller for the central plant, a thermal energy load setpoint for a subplant of the central plant, wherein the thermal energy load setpoint is generated by a high level optimization that determines optimum thermal energy load setpoints for each of the plurality of subplants by optimally distributing a predicted thermal energy load for the building across the plurality of subplants;

using, by a binary optimization module of the processing circuit, binary optimization to determine one or more feasible on/off configurations for equipment of the subplant to achieve the thermal energy load setpoint generated by the high level optimization;

generating a resource consumption curve for the subplant by optimizing an amount of resource consumption by the subplant for several different combinations of thermal energy load and weather conditions, the resource consumption curve indicating a minimum amount of resource consumption by the subplant as a function of a thermal energy load on the subplant;

determining, by a setpoint evaluator module of the processing circuit, optimum operating setpoints for the subplant equipment for each feasible on/off configuration;

generating, by a subplant control module of the processing circuit, operating parameters for the subplant equipment, the operating parameters comprising at least one of the feasible on/off configurations and the optimum operating setpoints; and

outputting the generated operating parameters via a communications interface coupled to the processing circuit for use in controlling the subplant equipment.

7. The method of claim 6, further comprising:

identifying applicable constraints for the subplant equipment;

wherein each feasible on/off configuration satisfies the applicable constraints and is estimated to result in the subplant equipment meeting the thermal energy load setpoint.

8. The method of claim 6, wherein determining the one or more feasible on/off configurations comprises using a branch and bound method.

9. The method of claim 6, wherein determining the optimum operating setpoints comprises using a nonlinear optimization that minimizes an amount of power consumed by the subplant equipment.

10. The method of claim 6, further comprising:

estimating an amount of power consumed by each feasible on/off configuration of the subplant equipment at the optimum operating setpoints; and

identifying which of the feasible on/off configurations is estimated to result in a lowest amount of power consumed by the subplant equipment at the optimum operating setpoints.

11. A method for determining optimum operating parameters for equipment of a central plant that serves thermal energy loads of a building or building system, the method comprising:

identifying, by a controller for the central plant, a thermal energy load setpoint for a subplant of the central plant, wherein the thermal energy load setpoint is generated by a high level optimization that determines optimum thermal energy load setpoints for each of a plurality of subplants of the central plant by optimally distributing a predicted thermal energy load for the building across the plurality of subplants;

initializing, by the controller for the central plant, a database of possible solutions and a database of feasible solutions that achieve the thermal energy load setpoint generated by the high level optimization;

generating, by the controller, a resource consumption curve for the subplant by optimizing an amount of resource consumption by the subplant for several different combinations of thermal energy load and weather conditions, the resource consumption curve indicating a minimum amount of resource consumption by the subplant as a function of a thermal energy load on the subplant;

retrieving, by the controller, a branch from the database of possible solutions, the branch comprising a specified operating status for one or more devices of the equipment of the central plant;

determining, by the controller, whether the branch satisfies applicable constraints for the equipment of the central plant using the specified operating status;

adding, by the controller, the branch to the database of feasible solutions in response to a determination that the branch satisfies the applicable constraints; and

generating, by the controller, operating parameters for the equipment of the central plant, the operating parameters comprising the operating status specified by the branch in the database of feasible solutions.

12. The method of claim 11, wherein the branch comprises a specified operating status for a first device of the equipment of the central plant and an unspecified operating status for a second device of the equipment of the central plant.

13. The method of claim 12, further comprising:

creating a first expanded branch by specifying a first operating status for the second device, wherein the determining, adding, and generating steps are performed for the first expanded branch;

creating a second expanded branch by specifying a second operating status for the second device; and

adding the second expanded branch to the database of possible solutions for evaluation in a subsequent iteration of the method.

14. The method of claim 13, further comprising, in response to a determination that the first expanded branch does not satisfy the applicable constraints:

determining whether the first expanded branch can possibly satisfy the applicable constraints if an unspecified operating status in the first expanded branch is subsequently specified; and

adding the first expanded branch to the database of possible solutions for evaluation in a subsequent iteration of the method in response to a determination that the first expanded branch can possibly satisfy the applicable constraints.

15. The method of claim 11, further comprising estimating an amount of power consumed by each branch in the database of possible solutions;

wherein retrieving the branch from the database of possible solutions comprises retrieving the branch with the lowest estimated power consumption.

16. The method of claim 11, further comprising estimating an amount of power consumed by each branch in the database of feasible solutions;

wherein the generated operating parameters comprise the operating status specified by the branch in the database of feasible solutions with the lowest estimated power consumption.