Laplace's Transform
Laplace's Transform
Journal of Sensors
Volume 2015, Article ID 954159, 15 pages
http://dx.doi.org/10.1155/2015/954159
Research Article
Design and Implementation of Energy
Efficiency in HVAC Systems Based on Robust PID Control for
Industrial Applications
Muharrem Imal
Mechanical Engineering Department, Kahramanmaras Sutcu Imam University, 46100 Kahramanmaras, Turkey
Copyright © 2015 Muharrem Imal. This is an open access article distributed under the Creative Commons Attribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Energy efficiency in heating, ventilating, and air-conditioning (HVAC) systems is a primary concern in process projects, since
the energy consumption has the highest percentage in HVAC for all processes. Without sacrifice of thermal comfort, to reset
the suitable operating parameters, such as the humidity and air temperature, would have energy saving with immediate effect.
In this paper, the simulation-optimization approach described the effective energy efficiency for HVAC systems which are used in
industrial process. Due to the complex relationship of the HVAC system parameters, it is necessary to suggest optimum settings
for different operations in response to the dynamic cooling loads and changing weather conditions during a year. Proportional-
integral-derivative (PID) programming was developed which can effectively handle the discrete, nonlinear and highly constrained
optimization problems. Energy efficiency process has been made by controlling of alternative current (AC) drivers for ventilation
and exhaust fans, according to supplied air flow capacity and differential air pressure between supplied and exhaust air. Supervisory
controller software was developed by using programmable controllers and human machine interface (HMI) units. The new designed
HVAC control system would have a saving potential of about 40% as compared to the existing operational settings, without any
extra cost.
Figure 2: General view of humidification and air supplier units of controlled system.
(a) (b)
Figure 4: (a) The old conventional control system for single zone, (b) the new designed control system for single zone.
HMI
Switch
Ethernet (TCP/IP)
PLC
Humidifier pump driver
Damper actuators
Temperature sensor
Humidity sensor
Damper actuators
Temperature sensor
Humidity sensor
Damper actuators
Temperature sensor
Humidity sensor
Ventilating fan drivers
was utilized to decide the implementation of free cooling 2.3. Zone Model. According to thermodynamic energy bal-
mode, which would call for the free cooling fan in operation, ance principles, a simple energy equation for a single-zone
with the same speed of the other operating fans. This dynamic HVAC system can be written in (1)
control and operation algorithm was essential to provide the
necessary system response to different loading and climatic
conditions, although this would increase the degree of the 𝑄input + 𝑄generation = 𝑄out + 𝑄accumulation + 𝑄consumption , (1)
nonlinear, constrained, and discrete nature of the system
performance, in particular to the energy efficiency of both
the water side and air side systems. The HVAC optimization where 𝑄input is heat from supply air input, 𝑄generation is gen-
problem hence requires an effective method that could handle erated heat from people, woven machines, light, and so forth,
the nonlinear, discrete, and highly constrained characteris- 𝑄out is heat from exhaust air, 𝑄accumulation is indoor space heat,
tics. and 𝑄consumption is dissipated heat from indoor to outdoor.
Journal of Sensors 5
The heat equation is derived from the first law of thermo- where 𝑚𝑟 , 𝑚𝑜 , and 𝑚𝑠 are mass flow rates of the return,
dynamics and conservation of energy. Any change in energy outdoor, and supplied airs, respectively. This condition has to
Δ𝑄 is proportional to the change in temperature Δ𝑇. That is, be fulfilled by the controlling of these three damper positions.
If the position of 𝐷1 and 𝐷2 dampers is opened at the rate
Δ𝑄 = 𝑓𝑎 𝑐𝑝 𝜌𝑎 Δ𝑇, (2)
of 40%, the position of 𝐷3 damper must be opened at the
3 ∘
where 𝑓𝑎 (m /s) is volume flow rate of air, 𝑐𝑝 (kJ/kg⋅ C) is the rate of 60%. That is, 𝐷1 = 𝐷2 = (100 − 𝐷3). Humidification
is a mass transfer process of water vapor to atmospheric air,
constant pressure specific heat capacity of air, and 𝜌𝑎 (kg/m3 )
which results in an increase of water vapor in the mixture.
is the mass density of air. From the thermodynamic heat
Humidifier model is the same as temperature model and can
equations, the fresh and exhaust heat equations can be written
be derived from mass and energy balance principles as given
as
in [4]
𝑄input = 𝑓sa 𝑐pa 𝜌𝑎 𝑇sa ,
(3)
𝑄out = 𝑓sa 𝑐pa 𝜌𝑎 𝑇𝑖 , 𝑑𝑇ℎ
𝐶ℎ = 𝑓sa 𝑐pa (𝑇sa − 𝑇ℎ ) + 𝛼ℎ (𝑇𝑜 − 𝑇ℎ ) , (8)
3
where 𝑓sa (m /s) is volume flow rate of supplied air: 𝑑𝑡
𝑄generation = 𝑄room ,
where 𝐶ℎ is overall thermal capacitance of the humidifier, 𝑇ℎ
𝑑𝑇 is supply air temperature (in humidifier), and 𝛼ℎ is overall
𝑄accumulation = 𝜌𝑎 𝑐pa V𝑧 𝑖 , (4) transmittance area factor of the humidifier (kJ/s⋅∘ C). Simi-
𝑑𝑡
larly, the rate change of moisture content in the zone is equal
V𝑧 𝑐pa ACH to the difference between the vapor added to and removed
𝑄consumption = (𝑇𝑖 − 𝑇0 ) ,
3600 from the zone. Therefore, humidity zone equation can be
where 𝑄room (W) is heat gains from machines, light, people, written in
and so forth and V𝑧 (m3 ) is volume of the zone. ACH is the air
changes per hour. There are three modes of consumption heat 𝑑𝑊ℎ ℎ (𝑡)
from indoor to outdoor: conduction, convection, and radia- V𝑧ℎ = 𝑓sa (𝑊sa − 𝑊ℎ ) + , (9)
𝑑𝑡 𝜌𝑎
tion. The convection heat equation is defined as follows:
𝑄convection = ℎΔ𝑇,
where V𝑧ℎ is the volume of humidifier, 𝑊ℎ is supply air humid-
𝑄conduction = 𝑘Δ𝑇, (5) ity ratio (in humidifier) in kg/kg (dry air), 𝑊sa is humidity
ratio of supply air (to the humidifier) in kg/kg (dry air), and
𝑄radiation = 𝜀𝜎 (Δ𝑇)4 , ℎ(𝑡) is the rate of moisture air produced in air humidifier.
6 Journal of Sensors
In order to find the transfer function of the controlled Integral terms are
zone, the temperature zone (6)-(7) should be rearranged
according the parameters of 𝑇𝑖 and 𝑇𝑜 : 𝑘𝑐 𝑡
𝑈𝐼 (𝑡) = ∫ (𝑦 (𝜏) − 𝑦 (𝜏)) 𝑑𝑡. (17)
V𝑧 𝑐pa ACH 𝜏𝐼 𝑜 𝑠
𝑑𝑇
V𝑧 𝑐pa 𝜌𝑎 𝑖 + ( + 𝑓sa 𝑐pa 𝜌𝑎 ) 𝑇𝑖
𝑑𝑡 3600 Derivative terms are
(10)
V𝑧 𝑐pa ACH
= 𝑇0 + 𝑓sa 𝑐pa 𝜌𝑎 𝑇sa + 𝑄room , 𝑑 (𝑦𝑠 (𝑡) − 𝑦 (𝑡) )
3600 𝑈𝐷 (𝑡) = 𝑘𝑐 𝜏𝑑 , (18)
𝑑𝑡
𝑑𝑇𝑖 V𝑧 𝑐pa ACH
V𝑧 𝑐pa 𝜌𝑎 +( + 𝑓sa 𝑐pa 𝜌𝑎 ) 𝑇𝑖 where 𝑦𝑠 (𝑡) is the set point of the process output, 𝑦(𝑡) is the
𝑑𝑡 3600
process output, and 𝑈𝑃 (𝑡), 𝑈𝐼 (𝑡), and 𝑈𝐷(𝑡) are the controller
V𝑧 𝑐pa ACH 𝑚𝑟 𝑇𝑖 + 𝑚𝑜 𝑇0 (11) outputs of the proportional, integral, and derivative parts,
= 𝑇0 + 𝑓sa 𝑐pa 𝜌𝑎 ( ) respectively. The constants 𝑘𝑐 , 𝜏𝐼 , and 𝜏𝑑 in (18) are the
3600 𝑚𝑠
proportional gain, integral time, and derivative time, respec-
+ 𝑄room . tively. The total output of the PID controller is a summation
of the three individual outputs in (16)–(18); that is,
In order to simplify (11), 𝜏 and 𝑘 can be defined as follows:
𝑈 (𝑡) = 𝑈𝑝 (𝑡) + 𝑈𝐼 (𝑡) + 𝑈𝐷 (𝑡)
3600V𝑧 𝜌𝑎 𝑚𝑠
𝜏= ,
𝑚𝑠 (V𝑧 ACH + 3600𝑓sa 𝜌𝑎 ) − 3600𝑓sa 𝜌𝑎 𝑚𝑟 = 𝑘𝑐 (𝑦𝑠 (𝑡) − 𝑦 (𝑡))
(12)
𝑚𝑠 V𝑧 ACH + 3600𝑓sa 𝜌𝑎 𝑚𝑜 𝑘𝑐 𝑡
𝑘= . + ∫ (𝑦 (𝜏) − 𝑦 (𝜏)) 𝑑𝑡
(19)
𝑚𝑠 (V𝑧 ACH + 3600𝑓sa 𝜌𝑎 ) − 3600𝑓sa 𝜌𝑎 𝑚𝑟 𝜏𝐼 𝑜 𝑠
Finally, temperature zone (6) has been simplified as 𝑑 (𝑦𝑠 (𝑡) − 𝑦 (𝑡))
+ 𝑘𝑐 𝜏𝑑 .
𝑑𝑇𝑖 𝑑𝑡
𝜏 + 𝑇𝑖 = 𝑘𝑇𝑜 + 𝑄room . (13)
𝑑𝑡 The three constants are the proportional gain, integral time,
𝑄room is heat gains from machines, lights, people, and so forth and derivative time, respectively.
and is a constant. The Laplace transform of (13) is expressed 𝑘𝑐 , 𝜏𝐼 , and 𝜏𝑑 are usually called the parameters of the PID
as controller and should be determined under the dynamic con-
dition of the process. So, the parameters for the improvement
𝜏𝑠𝑇𝑖 (𝑠) − 𝑇𝑖 (0) + 𝑇𝑖 (𝑠) = 𝑘𝑇𝑜 (𝑠) . (14) of the control performance have to be tuned.
Because of the distance between supply air and the measure-
ment point of temperature, there is pure delay time (𝐿) in 2.5. Parameter Tuning. Up to now, numerous tuning meth-
the process. The plant heat transfer function is expressed as ods have been developed, including the Ziegler-Nichols (Z-
follows: N) method, internal model control (IMC), and the integral
of the time-weighted absolute value of the error tuning rule
𝑇𝑖 (𝑠) 𝑘𝑒−𝐿𝑠 for a first-order plus time delay model (ITAE). In this paper,
𝐺𝑝 (𝑠) = = . (15)
𝑇𝑜 (𝑠) 𝜏𝑠 + 1 all three methods were implemented to tune the controller in
the energy efficient HVAC control system. If the model of the
The system is considered as a first-order plus dead time system can be obtained, it is easy to design the PID controller
(FOPDT) structure as shown in (15), where 𝑘 (∘ C⋅s/kg) is the for it.
gain coefficient, 𝜏 is the time constant, and 𝐿 is the time delay The gain coefficients 𝑘𝑝 and 𝑇𝑖 can be achieved model
of the controlled HVAC system. based algorithms such as Ziegler-Nichols (Z-N) or variant
of Z-N tuning rules (Chien-Hrones-Reswick (CHR), Cohen-
2.4. Proportional-Integral-Derivative (PID) Control. The pro- Coon), Wang-Juang-Chan, Zhuang-Atherton optimum PID
portional-integral-derivative (PID) method is used to control controller design, and internal model control (IMC) [7–9, 16–
the air flow and differential pressure by manipulating the 19].
fan speed of the ventilation system. PID controllers are The response of an FOPDT model is shown in Figure 7.
widely employed in feedback control loops in most industrial A large number of systems can be approximately modeled by
process due to their simple structure, robustness, easy imple- (15). If the step response of the system can be experimentally
mentation, and good performance [10–15]. As indicated by measured, the parameters of the 𝑘, 𝐿, 𝑇, and a can be
the name, PID controllers consist of a proportional part, an determined as shown in Figure 7(a). In the same way, if
integral part, and a derivative part as follows [16]. the frequency response of the system can be experimentally
Proportional terms are observed, the crossover frequency 𝜔𝑐 and critical gain 𝑘𝑐 can
be obtained from the Nyquist plot as shown in Figure 7(b),
𝑈𝑝 (𝑡) = 𝑘𝑐 (𝑦𝑠 (𝑡) − 𝑦 (𝑡)) . (16) where 𝑎 = 𝐾𝐿/𝑇 and 𝑇𝑐 = 2𝜋/𝜔𝑐 .
Journal of Sensors 7
y(t) Imaginary
k
1
kc
Real
L T t
(a) (b)
Figure 7: (a) The time response of FOPDT system, (b) the Nyquist plot of FOPDT system.
The critical gain 𝑘𝑐 at the crossover frequency of 𝜔𝑐 is the Table 3: Cohen-Coon method tuning formulas.
first intersection of a Nyquist plot with the negative part of
the real axis as shown in Figure 7(b): Set point regulation
Cont. type
𝑘𝑝 𝑇𝑖 𝑇𝑑
𝑘 (cos 𝜔𝑐 𝐿 𝑖 − 𝜔𝑐 𝑇 sin 𝜔𝑐𝐿 ) 1 1 0.35𝜏
=− . (20) P (1 + )
1 + 𝜔𝑐 2 𝑇2 𝑘𝑐 𝑎 1−𝜏
0.9 0.92𝜏 3.3 − 3𝜏
The Z-N tuning method is a very useful empirical tuning PI (1 + ) 𝐿
𝑎 1−𝜏 1 + 1.2𝜏
formula. The PID controller parameters in Z-N tuning algo-
rithms can be found from Table 1. 1.35 0.18𝜏 2.5 − 2𝜏 0.37 − 0.37𝜏
PID (1 + ) 𝐿 𝐿
The Chien-Hrones-Reswick (CHR) method emphasizes 𝑎 1−𝜏 1 − 0.39𝜏 1 − 0.81𝜏
the set point regulation or disturbance rejection. The CHR
PID controller tuning formulas are summarized in Table 2
with the condition of no overshoot. criterion. If the 𝑘, 𝐿, and 𝑇 parameters of the plant model are
Another Z-N type tuning algorithm is the Cohen-Coon known, the controller parameters are given by
tuning formula. In this algorithm time constant 𝜏 is calculated (0.7303 + (0.5307𝑇/𝐿)) (𝑇 + 0.5𝐿)
as 𝜏 = 𝐿/(𝐿 + 𝑇) and PID parameters are tuned from Table 3. 𝑘𝑝 = ,
𝑘 (𝐿 + 𝑇)
Wang-Juang-Chan tuning method is based on an opti-
mum ITAE (the integral of time multiplied by absolute error) 𝑇𝑖 = 𝑇 + 0.5𝐿,
8 Journal of Sensors
Amplitude
Z-N 13.5 66.6 0.8
Cohen-Coon 14.3 57.9 0.6
0.4
Wang-Juang-Chan 8.4 310 0.2
IMC 7.5 310 0
0 50 100 150 200 250 300 350
Time (s)
Ziegler-Nichols Wang-Juang-Chan
R(s) E(s) U(s) Y(s) Cohen-Coon
+ kp ∑ Gp (s) IMC
−
Figure 9: Comparison of four PID controller methods.
1
Ti s Gc (s)
31∘ C in 12 minutes at the heating position. At same condition,
Figure 8: PI controller diagram for controlled parameters. the temperature decreased from 31∘ C to 28∘ C in only 5
minutes at the cooling position. The heating process was
performed by return air circulation, so the heating process
happened more slowly. The cooling process was performed
3.1. Experimental Results of the Real System Controller. by the fresh air. Therefore, the system response depends on
Modern process control problems in the process industries the outdoor temperature as shown in Figure 12.
are dominated by nonlinear, time-varying behavior, distur- If the outdoor temperature is low, then the cooling
bances, and uncertainties. However, more than 90% of plants process takes place as quickly; on the other side, if the outdoor
are controlled by the well-established PID controllers in temperature is high, then the cooling process is more slowly.
industrial automation and process until today [8, 9]. The If the set point of the temperature is determined as 32∘ C while
control block diagram of the single-zone HVAC system is the outdoor temperature is 34∘ C, then the cooling processes
shown in Figure 8. Four types of PI controllers were designed take place very slowly and heating processes are more rapid as
to control temperature, humidity, air flow, and differential air shown in Figure 12.
pressure. Response of the control system depends on the out-
The cooling process utilizes the temperature of sprayed
door temperature and humidity. If the outdoor temperature is
water by mixing the supplied air from outdoor. Humidity
high, decreasing the temperature of the zone will be very slow
controller has been affected from the outdoor humidity ratio.
and limited. If the outdoor temperature is low, decreasing the
But indeed humidification performance depends generally
temperature is very quick. Humidity controller is altered by
on the capacity of pumps, the structure of control systems,
temperature controller. If the system operates by the returned
and units. Technical specification of the humidifier pumps
air, the increase in humidity becomes quickly. If the system
in designed system is: the flow rate is 78 m3 /h, pump head
runs at the fresh air position the humidity increment becomes
slowly. rate is 3 bar, spray water flow rate is 78 m3 /h, nozzle pressure
Totally 22 PI controllers were developed in a single is 2.1 bar, maximum rotating speed is 3000 rpm, and nozzle
programmable controller. These controller parameters were diameter of each unit is 6 mm.
adjusted by using Z-N tuning method. A software program Two experiments were done to test the performance of the
was developed for quickly tuning the PID parameters of the humidity controller. The first experiment has been performed
controllers. The Z-N based tuning algorithm of the developed at the condition of 36% outdoor humidity ratios. The desired
software is shown in Figure 10. The developed software is able set point humidity has been obtained in 15 minutes. The
to communicate with the programmable controller, selectable humidity of the zone rose from 62% to 70% in this time
of control type (auto/manual control), and able to store interval. Decreasing the humidity again from 70% to 62% was
control output data into database system and perform online carried out in 10 minutes as shown in Figure 13. The second
analysis graphically as shown in Figure 11. experiment has been done at the 28% outdoor humidity ratio.
The complete HVAC system can be controlled by a HMI The desired set point value has been reached in 18 minutes
unit. An operator can enter the temperature, humidity, air and the old humidity ratio has been reached in 8 minutes.
flow, and differential air pressure set points values from the Eventually, the humidity ratio is affected by outdoor humidity
software. After the set points are determined by the operators, ratio as shown in Figure 13.
the controllers hold the system parameters at the desired set Differential pressure controller has been carried out by
point values. The following experiments have been carried setting the speed of 37 kW exhaust fans according to mea-
out to observe the performance of the controlled system. sured value from differential air pressure transmitter. The
As stated early, the responses of the controller depend on differential pressure transmitter measures the difference
the outdoor climatic conditions. While the outdoor tempera- between indoor and outdoor air pressure. Figure 14 shows the
ture was 21∘ C, the system temperature increased from 28∘ C to air pressure deviation measured from differential air pressure
10 Journal of Sensors
Tc
Process variable
Process variable
Process variable
t t t
Temperature
Temperature control Temperature control
Temperature
31 37
30 35
(∘ C)
(∘ C)
29 33
28
27 31
0 10 20 30 40 50 60 70 80 90 100 110 120 130 0 10 20 30 40 50 60 70 80 90 100 110
(min) (min)
(a) (b)
∘
Figure 12: The temperature controller response of the outdoor condition at 21 C (a) and the temperature controller response of the outdoor
condition at 34∘ C (b).
Humidity
68 68
(%)
(%)
64 64
60 60
5 15 25 35 45 55 65 75 85 95 5 15 25 35 45 55 65 75 85 95 105
(min) (min)
(a) (b)
Figure 13: The humidity controller response of the outdoor condition at 36% humidity (a) and the humidity controller response of the outdoor
condition at 28% humidity (b).
Power consumption in old conventional system Power consumption after the designed control system
Date Hour kW Date Hour kW
14.11.2013 10:30:00 108.21 05.01.2014 19:00:00 59.08
14.11.2013 11:00:00 109.53 05.01.2014 19:15:00 67.05
14.11.2013 11:30:00 108.87 05.01.2014 19:30:00 65.72
14.11.2013 12:00:00 109.2 05.01.2014 19:45:00 65.06
14.11.2013 12:30:00 108.87 05.01.2014 20:00:00 60.74
14.11.2013 13:00:00 108.21 05.01.2014 20:15:00 65.72
14.11.2013 13:30:00 108.87 05.01.2014 20:30:00 65.72
14.11.2013 14:00:00 108.54 05.01.2014 20:45:00 65.39
14.11.2013 14:30:00 108.87 05.01.2014 21:00:00 65.72
14.11.2013 15:00:00 108.54 05.01.2014 21:15:00 65.06
14.11.2013 15:30:00 108.54 05.01.2014 21:30:00 67.05
14.11.2013 16:00:00 109.2 05.01.2014 21:45:00 66.05
14.11.2013 16:30:00 108.87 05.01.2014 22:00:00 63.06
14.11.2013 17:00:00 109.53 05.01.2014 22:15:00 65.72
14.11.2013 17:30:00 108.87 05.01.2014 22:30:00 65.39
14.11.2013 18:00:00 109.53 05.01.2014 22:45:00 66.38
14.11.2013 18:30:00 109.2 05.01.2014 23:00:00 67.05
14.11.2013 19:00:00 105.55 05.01.2014 23:15:00 66.38
14.11.2013 19:30:00 105.88 05.01.2014 23:30:00 65.39
14.11.2013 20:00:00 106.88 05.01.2014 23:45:00 66.05
14.11.2013 20:30:00 109.2 05.01.2014 00:00:00 66.05
14.11.2013 21:00:00 108.87 05.01.2014 00:15:00 65.39
14.11.2013 21:30:00 108.87 05.01.2014 00:30:00 65.72
Average 108.55 Average 65.26
Average power consumption: old = 108.55, new = 65.26, and profit = 39.88%.
12 Journal of Sensors
Power consumption in old conventional system Power consumption after the designed control system
Date Hour kW Date Hour kW
13.07.2013 10:00:00 107.7 06.01.2014 10:30:00 79.99
13.07.2013 11:00:00 106.7 06.01.2014 10:45:00 80.32
13.07.2013 12:00:00 104.2 06.01.2014 11:00:00 79.66
13.07.2013 13:00:00 107.5 06.01.2014 11:15:00 82.65
13.07.2013 14:00:00 107.4 06.01.2014 11:30:00 76.67
13.07.2013 15:00:00 107,7 06.01.2014 11:45:00 75.35
13.07.2013 16:00:00 108.3 06.01.2014 12:00:00 75.01
13.07.2013 17:00:00 108 06.01.2014 12:15:00 71.36
13.07.2013 18:00:00 108.4 06.01.2014 12:30:00 72.03
13.07.2013 19:00:00 108.2 06.01.2014 12:45:00 71.69
13.07.2013 20:00:00 107.9 06.01.2014 13:00:00 71.69
13.07.2013 21:00:00 107.9 06.01.2014 13:15:00 72.03
13.07.2013 22:00:00 108.4 06.01.2014 13:30:00 74.02
13.07.2013 23:00:00 107.8 06.01.2014 13:45:00 74.68
13.07.2013 00:00:00 107.9 06.01.2014 14:00:00 74.68
13.07.2013 01:00:00 107.2 06.01.2014 14:15:00 75.68
13.07.2013 02:00:00 106.7 06.01.2014 14:30:00 75.01
13.07.2013 03:00:00 106.3 06.01.2014 14:45:00 76.34
13.07.2013 04:00:00 106.5 06.01.2014 15:00:00 74.68
13.07.2013 05:00:00 106.8 06.01.2014 15:15:00 75.35
13.07.2013 06:00:00 106.8 06.01.2014 15:30:00 75.35
13.07.2013 07:00:00 106.2 06.01.2014 15:45:00 75.01
13.07.2013 08:00:00 106.2 06.01.2014 16:00:00 75.01
Average 107.25 Average 75.4
Average power consumption: old = 107.25, new = 75.40, and profit = 29.69%.
15
Differential pressure of 32 kW has been obtained for plant 2, 41 kW in plant 3,
Pressure
10
(mbar)
5
and 24 kW in plant 4, respectively. The money spent for plant
0 1, plant 2, and plant 3 was approximately 39450 USD and
−5
−10 8331 USD for plant 4. The total energy efficiency has been
20 60 100 140 180 220 260 300 340 380 420 460 500
measured as 140 kW. The total cost of 47781 USD has been
(min)
spent of the whole system.
Figure 14: The differential air pressure of supply and exhaust air in
the period of 9 hours.
5. Conclusion
Air flow
20
This paper describes a novel simulation-optimization tech-
Air flow
(m3 /s)
15 nique that was applied to devise a reset scheme of air flow for
10
5 air temperatures and differential air pressure for supply and
0
10 40 70 100 130 160 190 220 250 280 310 340 370 400 exhaust air of the HVAC control system in fabric manufactur-
(s) ing plants in industry. Due to the complex relationship of the
HVAC system parameters, it is necessary to suggest optimum
Figure 15: The air flow capacity controller response. settings for different operations in response to the dynamic
cooling loads and changing weather conditions during a year.
Proportional-integral-derivative (PID) programming was
energy consumption in old conventional control system for developed which can effectively handle the discrete, nonlin-
plant 1 was measured as the average of 108 kW. For the energy ear, and highly constrained optimization problems. To solve
consumption in the new designed system, this value was this problem, a HVAC control system has been successfully
decreased to average of 65 kW. The energy efficiency has been designed and the dynamic model of the controlled zone has
obtained as 43 kW per hour for plant 1. The energy efficiency been derived accurately for an integrated big plant in Turkey.
Journal of Sensors 13
Power consumption in old conventional system Power consumption after the designed control system
Date Hour kW Date Hour kW
16.11.2013 10:30:00 85.64 06.01.2014 18:00:00 43.81
16.11.2013 11:00:00 85.3 06.01.2014 18:30:00 43.81
16.11.2013 11:30:00 85.64 06.01.2014 19:00:00 43.48
16.11.2013 12:00:00 84.97 06.01.2014 19:30:00 42.82
16.11.2013 12:30:00 84.97 06.01.2014 20:00:00 43.15
16.11.2013 13:00:00 84.97 06.01.2014 20:30:00 48.13
16.11.2013 13:30:00 84.97 06.01.2014 21:00:00 43.48
16.11.2013 14:00:00 83.64 06.01.2014 21:30:00 43.81
16.11.2013 14:30:00 84.31 06.01.2014 22:00:00 40.83
16.11.2013 15:00:00 83.98 06.01.2014 22:30:00 42.15
16.11.2013 15:30:00 83.64 06.01.2014 23:00:00 49.12
16.11.2013 16:00:00 83.64 06.01.2014 23:30:00 43.81
16.11.2013 16:30:00 83.64 06.01.2014 00:00:00 43.15
16.11.2013 17:00:00 83.64 06.01.2014 00:30:00 44.81
16.11.2013 17:30:00 83.64 06.01.2014 01:00:00 39.5
16.11.2013 18:00:00 83.64 06.01.2014 01:30:00 43.81
16.11.2013 18:30:00 83.31 06.01.2014 02:00:00 39.5
16.11.2013 19:00:00 83.98 06.01.2014 02:30:00 44.15
16.11.2013 19:30:00 83.64 06.01.2014 03:00:00 36.51
16.11.2013 20:00:00 83.64 06.01.2014 03:30:00 38.83
16.11.2013 20:30:00 83.98 06.01.2014 04:00:00 41.16
16.11.2013 21:00:00 84.31 06.01.2014 04:30:00 42.15
16.11.2009 21:30:00 83.98 06.01.2014 05:00:00 38.83
Average 84.22 Average 42.64
Average power consumption: old = 84.22, new = 42.64, and profit = 49.37%.
The simulation and the real controller responses have been Nomenclature
observed, respectively. When the results have been compared,
either of the system responses has been obtained similarly. 𝑓𝑎 : Volume flow rate of air (m3 /s)
Supervisory control software was developed to control overall 𝑐𝑝 : Specific heat capacity of air (kJ/kg⋅∘ C)
system using a host computer and programmable controllers. 𝜌𝑎 : Mass density of air (kg/m3 )
All of the control units could communicate with the host V𝑧 : Volume of the zone (m3 )
computer by the MODBUS TCP/IP Ethernet protocol. Thus, ACH: Air changes per hour
the system parameters could be observed and controlled on ℎ: Convection heat transfer coefficient,
the single central point by the host computer and an operator. (W/m2 ⋅∘ C)
The approximately 40% energy efficiency was gained by ℎ𝑤 : Rate of moisture air produced in air
the designed control system. This energy efficiency amount humidifier
was clearly verified by measuring of energy consumption of 𝑘ℎ : Conduction heat transfer coefficient
each plant as shown in Table 6 through Table 9. Finally the (W/m⋅∘ C)
following beneficial results have been obtained: 𝑘: Gain coefficient (∘ C⋅s/kg)
𝜀: Emissivity constant
(i) total money spent to control system = 47781 $; 𝜎: Boltzmann constant (W/m2 ⋅∘ C)
𝑚: Mass flow rates
(ii) total energy efficiency per hour = 140 kW;
𝐶ℎ : Overall thermal capacitance of the
(iii) 1 kW electricity cost = 0.087 $/kWh; humidifier
𝑇ℎ : Supply air temperature (∘ C)
(iv) energy efficiency per month = 140 kWh ∗ 24 hours ∗ 𝛼ℎ : Overall transmittance area factor of the
30 days ∗ 0.087 $/kWh = 8770 $; humidifier (kJ/s⋅∘ C)
(v) depreciation time of the system = 47781/8770 = 5.44 V𝑧ℎ : Volume of humidifier
months. 𝑤ℎ : Supply air humidity ratio (kg/kg)
14 Journal of Sensors
Power consumption in old conventional system Power consumption after the designed control system
Date Hour kW Date Hour kW
17.11.2013 10:30:00 46.8 07.01.2014 11:00:00 22.24
17.11.2013 11:00:00 46.8 07.01.2014 11:15:00 22.24
17.11.2013 11:30:00 46.47 07.01.2014 11:30:00 22.24
17.11.2013 12:00:00 46.47 07.01.2014 11:45:00 22.24
17.11.2013 12:30:00 46.47 07.01.2014 12:00:00 20.25
17.11.2013 13:00:00 47.8 07.01.2014 12:15:00 19.92
17.11.2013 13:30:00 44.81 07.01.2014 12:30:00 19.92
17.11.2013 14:00:00 46.47 07.01.2014 12:45:00 22.24
17.11.2013 14:30:00 46.47 07.01.2014 13:00:00 22.24
17.11.2013 15:00:00 45.81 07.01.2014 13:15:00 22.24
17.11.2013 15:30:00 45.81 07.01.2014 13:30:00 22.24
17.11.2013 16:00:00 46.47 07.01.2014 13:45:00 22.24
17.11.2013 16:30:00 46.14 07.01.2014 14:00:00 22.24
17.11.2013 17:00:00 45.81 07.01.2014 14:15:00 22.24
17.11.2013 17:30:00 43.81 07.01.2014 14:30:00 23.9
17.11.2013 18:00:00 45.81 07.01.2014 14:45:00 22.24
17.11.2013 18:30:00 45.14 07.01.2014 15:00:00 22.24
17.11.2013 19:00:00 45.14 07.01.2014 15:15:00 22.24
17.11.2013 19:30:00 45.14 07.01.2014 15:30:00 22.24
17.11.2013 20:00:00 45.47 07.01.2014 15:45:00 19.92
17.11.2013 20:30:00 45.47 07.01.2014 16:00:00 20.25
17.11.2013 21:00:00 43.48 07.01.2014 16:15:00 21.78
17.11.2013 21:30:00 45.14 07.01.2014 16:30:00 21.78
Average 45.79 Average 21.8
Average power consumption: old = 45.79, new = 21.80, and profit = 52.39%.
𝑤sa : Humidity ratio of supply air (kg/kg) [5] J. Teeter and M.-Y. Chow, “Application of functional link neural
𝜏: Time constant network to hvac thermal dynamic system identification,” IEEE
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Conflict of Interests control of HVAC system,” in Proceedings of the IEEE Interna-
The author declares that there is no conflict of interests tional Conference on Mechatronics and Automation (ICMA ’08),
pp. 678–683, Takamatsu, Japan, August 2008.
regarding the publication of this paper.
[7] K. F. Fong, V. I. Hanby, and T. T. Chow, “HVAC system opti-
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