Federal

Technology
Alert
Refrigerant Subcooling
A publication series Technology for improving cooling system performance
designed to speed the
adoption of energy- Refrigerant subcooling is proving to
be a reliable energy-saving alternative
based on the properties of refrigerants,
which absorb latent heat until they
efficient and renewable to increasing the cooling capacity of air- vaporize. The subcooling increases
conditioning systems in many facilities. refrigerant cooling capacity, and use
technologies in the As shown below, the technology of an external heat sink (either mini-
Federal sector modifies a standard direct-expansion,
vapor-compression refrigerant system
cooling tower or ground-source water)
reduces compressor power. Although
with the addition of a heat exchanger in detailed operation and maintenance
the liquid line of the system. data are generally lacking, the technolo-
Prepared by the This Federal Technology Alert gy is proving particularly applicable in
(FTA), one of a series on new technolo- direct-expansion vapor-compression
New Technology gies, describes the theory of operation, air-conditioning equipment, especially
energy-saving mechanisms, range of where old units are being replaced or
Demonstration Program applications, and field experience for where new construction/expansion or
the refrigerant subcooling technology. new installation is planned.
Featured is a subcooling device with an
external heat sink. One such subcooling Technology Selection
device, called the Fisher Tri-Temp Refrigerant subcooling is one of
System (FTTS), is patented by many energy-saving technologies to
Ralph H. Fisher. emerge in the last 20 years. The FTA
series targets technologies that appear
Energy-Saving Mechanism to have significant untapped Federal-
A refrigerant subcooling unit sector potential and for which some
provides additional cooling capacity Federal installation experience exists.
and can also reduce energy consumption New technologies were identified
for increased overall system efficiency. through advertisements for technology
It works best where year-round outdoor suggestions in the Commerce Business
temperatures are high and constant. Daily and trade journals, and through
Effectiveness of the technology is direct correspondence. Numerous
The U.S. Department of Energy
requests that no alterations be
made without permission in any Desuperheat Condensing
reproduction of this document. Desuperheat
Condenser

Condenser

Condensing

Subcooled
Heat Exchanger
Superheat Superheat
Subcooled

Evaporating
Eva orator

Evaporating
Evaporator

S9506041.1
TEV TEV

Normal System System with Subcooler

responses were obtained from manu- pump systems (split or packaged associated with the external heat sink
facturers, utilities, trade associations, systems) or reciprocating, screw (mini-cooling tower). In general,
research institutions, Federal sites, and or scroll chillers reduction in cost of maintaining the air-
other interested parties. conditioning system is offset by the
• where chillers, split systems or
Technologies suggested were additional cost for maintaining the mini-
packaged systems are to be
evaluated in terms of potential energy, cooling tower. The general maintenance
replaced (equipment that is
cost, and environmental benefits to the of the air-conditioning system with an
15 years or older or where new
federal sector. They were also catego- external heat sink subcooling device is
construction/expansion or new
rized as those that are just coming to similar to a conventional system. The
installation is planned).
market and those for which field data mini-cooling towers will need periodic
already exist. Technologies classified as External heat sink subcooling devices maintenance, such as checking the pre-
just coming to market are considered for (such as FTTS) are not recommended filter on the makeup water and cleaning
field demonstration through the U.S. for the following applications: the sump.
Department of Energy s Federal Energy • as add-on devices
Management Program (FEMP) and Case Study
• large centrifugal chillers
industry partnerships. Technologies for A qualitative analysis was performed
which some field data already exist are • off-peak cold storage on the basis of whole-building utility
considered as topics for FTAs. The • low-temperature applications billing information from one private-
refrigerant subcooling technology was • insufficient space for a mini- sector site. Southeastern University
found to have significant potential for cooling tower (SU), in Washington, D.C., has a
federal-sector savings. 22-year-old, 100-ton (352-kW) chiller
• in some cases a system with a
system with a cooling tower. This
Potential water-cooled or evaporatively
system was replaced with two 20-ton
Analysis of a large sample (nearly cooled condensers may be as
(70-kW) remote condensing units, each
25% by floor area) of Federal facilities effective as external heat sink
fitted with an external heat sink
indicates a major, untapped energy subcooling devices.
subcooling device, including two mini-
conservation potential in the Federal Field Experience cooling towers. Comparison of utility
sector. The subcooling technology not More than 12 systems have been bills from pre- and post-replacement
only provides for additional cooling fitted with external heat sink subcooling periods indicated savings in demand
capacity but can also reduce compressor devices, seven of these in the Federal charges and energy charges of
power, leading to higher overall system sector (IRS headquarters in Washington, $5,819/year. On the basis of whole-
efficiency. Besides saving energy, D.C.). Detailed performance of the building utility billing data alone,
subcooling benefits the environment technology has not been monitored it is difficult to quantify the actual
through reduced emissions of sulfur and at any of the sites. Building owners/ savings. Because there was no other
nitrogen oxides and carbon dioxide operators have noticed reduced electric change to the building during the one-
associated with power generation. consumption after the retrofit. The year period (peak demand and energy
Application operator at the IRS site is satisfied with consumption remained unchanged
Qualitative field testing and theoreti- the performance of the retrofits and is during winter months), significant
cal analyses have shown the subcooling considering installing another one at that portion of the energy and demand
technology to be technically valid and site. reduction can be attributed to the
economically attractive. The technology Typical installation cost is $700/ton replacement system with an external
is generally applicable to direct- (approximately $200/kW) of cooling heat sink subcooling device.
expansion vapor-compression equip- capacity. A typical yearly maintenance Implementation Barriers
ment with or without head pressure cost for the air-conditioning system is
There are no known barriers for
control. Potential Federal-sector about $25/ton to $35/ton, and for the
implementing the subcooling technol-
applications for refrigerant subcooling mini-cooling tower (external heat sink)
ogy. Federal energy managers who are
include direct-expansion vapor- it is about 2% of the cost of the cooling
familiar with refrigerant subcooling
compression air-conditioning equip- tower. When an external heat sink
systems are listed in this FTA. The
ment. The subcooling technology with subcooling device, such as an FTTS,
reader is invited to ask questions and
external heat sink is especially useful is installed with the air-conditioning
learn more about the technology.
under the following conditions: system the outdoor unit is downsized;
therefore, the general maintenance of the
• for high-temperature(a) applica-
air-conditioning system decreases and
tions, generally in conjunction
there is an additional maintenance
with air-conditioning and heat

(a) Low-temperature application refers to applications with evaporator temperatures less than -10¡F, medium-temperature refers to -10¡F to 30¡F
evaporator temperatures, and high-temperature refers to evaporator tempertures greater than 30¡F.
16 This page left blank intentionally
About the Federal Technology Alerts
The Energy Policy Act of 1992, and already entered the market and have The information in the Technology
subsequent Executive Orders, mandate some experience but are not in general Alerts typically includes a description
that energy consumption in the Federal use in the Federal sector. Based on of the candidate technology; the
sector be reduced by 30% from 1985 their potential for energy, cost, and results of its screening tests; a descrip-
levels by the year 2005. To achieve environmental benefits to the Federal tion of its performance, applications
this goal, the U.S. Department of sector, the technologies are considered and field experience to date; a list of
Energy s Federal Energy Management to be leading candidates for immediate potential suppliers; and important
Program (FEMP) is sponsoring a Federal application. contact information. Attached appen-
series of programs to reduce energy The goal of the Technology Alerts dixes provide supplemental informa-
consumption at Federal installations is to improve the rate of technology tion and example worksheets on the
nationwide. One of these programs, transfer of new energy-saving tech- technology.
the New Technology Demonstration nologies within the Federal sector and FEMP sponsors publication of the
Program (NTDP), is tasked to acceler- to provide the right people in the field Federal Technology Alerts to facilitate
ate the introduction of new energy- with accurate, up-to-date information information-sharing between manufac-
saving technologies into the Federal on the new technologies so that they turers and government staff. While
sector and to improve the rate of can make educated judgments on the technology featured promises sig-
technology transfer. whether the technologies are suitable nificant Federal-sector savings, the
As part of this effort, FEMP, in a for their Federal sites. Technology Alerts do not constitute
joint venture with the Department of Because the Technology Alerts are FEMP s endorsement of a particular
Defense s Strategic Environmental cost-effective and timely to produce product, as FEMP has not indepen-
Research and Development Program (compared with awaiting the results dently verified performance data
(SERDP), is sponsoring a series of of field demonstrations), they meet provided by manufacturers. FEMP
Federal Technology Alerts (FTAs) that the short-term need of disseminating encourages interested Federal energy
provide summary information on information to a target audience in and facility managers to contact the
candidate energy-saving technologies a timeframe that allows the rapid manufacturers and other Federal sites
developed and manufactured in the deployment of the technologies a n d directly, and to use the worksheets in
United States. The technologies ultimately the saving of energy in the the Technology Alerts to aid in their
featured in the Technology Alerts have Federal sector. purchasing decisions.

Federal Energy Management Program Strategic Environmental

R&D Program
The Federal Government is the largest energy consumer in the nation. Annu-
ally, in its 500,000 buildings and 8,000 locations worldwide, it uses nearly The Strategic Environmental Research
two quadrillion Btu (quads) of energy, costing over $11 billion. This repre- and Development Program, SERDP, co-
sents 2.5% of all primary energy consumption in the United States. The sponsor of these Federal Technology
Federal Energy Management Program was established in 1974 to provide Alerts, was created by the National
direction, guidance, and assistance to Federal agencies in planning and Defense Authorization Act of 1990
implementing energy management programs that will improve the energy (Public Law 101-510). SERDP’s primary
efficiency and fuel flexibility of the Federal infrastructure. purpose is to "address environmental
matters of concern to the Department of
Over the years several Federal laws and Executive Orders have shaped Defense and the Department of Energy
FEMP’s mission. These include the Energy Policy and Conservation Act of through support for basic and applied
1975; the National Energy Conservation and Policy Act of 1978; the Federal research and development of technolo-
Energy Management Improvement Act of 1988; and, most recently, Executive gies that can enhance the capabilities of
Order 12759 in 1991, the National Energy Policy Act of 1992 (EPACT), and the departments to meet their environ-
Executive Order 12902 in 1994. mental obligations." In 1993, SERDP
made available additional funds to
FEMP is currently involved in a wide range of energy-assessment activities, augment those of FEMP, for the purpose
including conducting New Technology Demonstrations, to hasten the penetra- of new technology installations and
tion of energy-efficient technologies into the Federal marketplace. evaluations.
For More Information

FEMP Help Desk

(800) 363-3732
International callers please use (703) 287-8391
Web site: http://www.eren.doe.gov/femp/

General Contact
Ted Collins
New Technology Demonstration Program
Program Manager
Federal Energy Management Program
U.S. Department of Energy
1000 Independence Avenue, SW, EE-92
Washington, DC 20585
(202) 586-8017
Fax: (202) 586-3000
theodore.collins@hq.doe.gov
Steven A. Parker
Pacific Northwest National Laboratory
P.O. Box 999, MSIN: K5-08
Richland, Washington 99352
(509) 375-6366
Fax: (509) 375-3614
steven.parker@pnl.gov

Produced for the U.S. Department of Energy

by the Pacific Northwest National Laboratory

Reprinted March 1999

(originally printed November 1995)
Printed with a renewable-source ink on
paper containing at least 50% wastepaper,
including 20% postconsumer waste