building efficiency – services june 2007 sample...
TRANSCRIPT
CPES – CPS Ph II
Practical ways to save energy from chiller plants
Optimize & Modernize your Plant Room
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CPES – CPS Ph II 4
CPES: Energy Conservation Measures
VSD optimization for Chilled water Pumps
Condenser pump retrofit
VSD optimization for Condenser pump
VSD optimization for CTs
Chilled water temperature reset
Demand control through operational improvement
Pressure drop reduction across pumping circuit
Motorized butterfly valves for equipments
Rectification of abnormalities of water circuit (Piping etc)
Chiller plant automation
VSD optimization for chillers
And many more……as every site is unique……
CPES – CPS Ph II 19
Confidential and Proprietary
Remote Monitoring & Diagnostic (RMD)
Better Information
= Sum() A Satisfied Customer
= Better Decisions
= Better Results
CPES – CPS Ph II
What is “RMD”?
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Essentially diagnostics is the same practice as a doctor diagnosing health, but in our case its all about “Keeping
The Chiller Healthy.”
CPES – CPS Ph II
Ball Tech System
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Automatic Tube Cleaning System
BTS is an hydro-mechanical system, circulate sponge balls through condenser's tubes and
keeps them absolutely and permanently clean.
CPES – CPS Ph II
NEW chiller
After some time…
Organic
Sludge
Blockage Rust & Scaling
Automatic Tube Cleaning System
CPES – CPS Ph II 23
Relative
Watts
Per T.R
0 0.001 0.0015 0.002 0.0025 0.0030.0005
Fouling Factor
100%
120%
140%0 0.33 0.50 0.67 0.88 1.000.17
Scale Thickness mm
The Increasing of Power Consumption
due to Fouling of Heat Exchanger
Automatic Tube Cleaning System
CPES – CPS Ph II
SELECT CITY WALK, NEW DELHI
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MULTIPLEXES, HOTEL & SHOPPING MALL
Air-Conditioning System Retrofit to improve operational efficiency & reliability
CPES – CPS Ph II
SELECT CITY WALK, NEW DELHI
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CHALLENGES:
-Condenser entering Water
temperature always remains high
throughout the year.
-The rate of Fouling in Condenser
is high.
-Standby Chiller also runs for 2
months during peak load killing
the reliability.
PLANT CONFIGURATION
3 Nos. x 600 TR VSD
Centrifugal Chiller & 2 Nos. x
300 TR Screw Chiller
CPES – CPS Ph II
SELECT CITY WALK, NEW DELHI
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OUR APPROACH & FINDINGS:
-Cooling Tower approach varies
from 12 Deg F to 18 Deg F though
the fills are changed regularly.
-Distance between Cooling
Towers is very less.
-Water is sourced from Tankers,
quality of which is bad and varies
daily.
-Spray Nozzles gets choked
frequently.
Cooling Tower Basin Cooling Tower Fills
- Condenser entering Water temperature goes as high as 101 Deg F in monsoon.
Existing Cooling Tower Installation
CPES – CPS Ph II
SELECT CITY WALK, NEW DELHI
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SOLUTIONS:
-Gravity Feed Cooling Towers
were offered with higher heat
rejection (by calculating Cooling
Tower Effectiveness) keeping in
mind de-ration of cooling towers.
-Suction of Air is only from 2
sides free from restriction.
-Pot Strainers were also installed
in outlet of each cooling tower
which were not present
previously.
Gravity Feed Cooling Tower
Cooling Tower
Suction
CPES – CPS Ph II
SELECT CITY WALK, NEW DELHI
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SOLUTIONS:
-Automatic Tube Cleaning
system was installed on each
chillers to keep a check on
increasing approach.
-All Chillers are connected to
our RMD Centre so that high
operational efficiencies are
maintained and any minor or
major breakdown can be
avoided.
Automatic Tube Cleaning System
CPES – CPS Ph II
SELECT CITY WALK, NEW DELHI
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SOLUTIONS:
-Investment of Rs 8 million.
-Estimated Payback of 2 years.
-Project completed in May 2013. Customer has already saved 6 million in 1 year of
operation.
Lower operational costs
Sustainable solutions
Occupant & Human Comfort
Reduce Maintenance Cost
CPES – CPS Ph II
PSRI HOSPITAL, NEW DELHI
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CHALLENGES:
-High Down time.
-High Maintenance as well as Energy
cost.
-Inside Conditions not met.
-Future Expansion coming up.
-
CPES – CPS Ph II
PSRI HOSPITAL, NEW DELHI
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OUR APPROACH & FINDINGS:
-Carried out the measurements at site and found that:
-Chillers working at 1.45 KW/TR.
-Inefficient Mono-block pumps.
-Minimum Chilled water outlet temperature never lowers below 9 Deg C.
-Heating up of Electrical Panel.
-Cooling Tower Heat rejection much lower than designed.
CPES – CPS Ph II
PSRI HOSPITAL, NEW DELHI
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SOLUTIONS:
-Water Cooled Screw Chillers of
200 TR with 6.17 COP IKW/TR
supplied with SSS.
-Cooling Towers selection
complying with CTI certification
standards.
-Primary Secondary Pumping
System with VFD Mounted
Intelligent Secondary Pumps
used.
-Chillers connected to RMD
Centre.
CPES – CPS Ph II
PSRI HOSPITAL, NEW DELHI
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SOLUTIONS:
-Complete contract of Rs 16.5 million including associated Piping Works and
Electricals.
-Payback of 3 years.
-Project completed in April 2013. Customer has saved 7 million in 1.5 years of
operation.
Lower
operational costs Sustainable
solutions Occupant & Human
Comfort Reduce
Maintenance Cost
CPES – CPS Ph II
INTEGRAL BIOSCIENCES, NOIDA
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CHALLENGES:
-Temperatures not maintained.
-Maintenance cost high as well as High Energy Costs.
-Winter Heating through Strip heaters in AHU’s with minimal heating effect.
-
CPES – CPS Ph II
INTEGRAL BIOSCIENCES, NOIDA
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OUR APPROACH & FINDINGS:
-Carried out the measurements at site and found that:
-Air Cooled Scroll Chillers installed at wrong place i.e. between 2 high rise
buildings hence creating well.
-Temperature near chiller was found 50 Deg C when Ambient was 43 Deg C.
-Scroll Chillers trips compressor to handle the discharge pressure problem thus
delivering less capacity at peak loads..
-Strip heaters in AHU’s used for heating consumed higher energy and desired
temperatures not maintained.
CPES – CPS Ph II
INTEGRAL BIOSCIENCES, NEW DELHI
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SOLUTIONS:
-Installed Highly Efficient Air
Cooled Screw Chiller with VSD
which was placed on the terrace
of the building.
-Calculated the heating load and
installed Reversible heat pumps
which would do heating in
Winters as well as serve as a
chiller in Summers.
Air Cooled VSD Screw Chiller
Air Cooled Reversible Heat Pump
CPES – CPS Ph II
INTEGRAL BIOSCIENCES, NEW DELHI
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SOLUTIONS:
-Complete contract of Rs 7 million including Low side Works.
-Payback of 2.5 years.
-Project Completed in January 2013.
Lower operational costs
Sustainable solutions
Occupant & Human Comfort
Reduce Maintenance Cost
CPES – CPS Ph II
Escorts Corporate Center, Faridabad
Challenges
Old Chillers and Constant primary only chilled water pump
configuration.
Unhealthy working conditions during monsoon seasons.
Chilled water out never went below 10 Deg C.
Solutions
Replaced reciprocating chillers with high efficiency Screw
Chiller
Changed the conventional pumping system to Primary
Secondary pumping system.
Replaced Existing AHU’s with new ones with TiO2 filters for
maintaining Indoor Air Quality.
Total Project Cost – Rs 20 million.
Payback of 3.5 years.
Project Completed in April 2011.
Results
Energy consumption reduced by 22 - 24%.
Temperature problems have been solved and Air quality
improved.
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CPES – CPS Ph II
Max Healthcare Pitampura & Noida, Delhi/NCR
Challenges
Compressor failures.
Leakages in condenser coils and severe complaints of
temperatures not being met.
Solutions
Johnson Controls replaced Air Cooled reciprocating chillers
with high efficiency Water Cooled Screw Chillers.
Water Cooled Chiller, Cooling tower, Condenser & Chilled
water pumps along with Low side works at Max, Pitampura.
Water Cooled Chiller, Cooling tower, Condenser & Chilled
water pumps along with Low side works at Max, Noida.
Results
Energy consumption reduced by 40%.
Internal Condition improved.
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CPES – CPS Ph II
IBM: RETROFIT OF OLD AIRCOOLED RECIP CHILLERS WITH HIGH
EFFICIENCY CHILLERS:
Challenges
Existing plant’s energy consumption.
High maintenance cost & issues with existing chillers.
.
Increased internal load.
Solutions
Conducted a detailed audit of Chillers and found that Air
Cooled chillers were running on 2 IKW/TR
High Efficiency Air Cooled VSD Chillers supplied, 3.3 COP
and 5.5 IPLV Chillers. ( Full Load of 1.06 IKW/TR and 0.64
IKW/TR.
Results
30% Savings in Energy.
Augmented capacity & redundancy.
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CPES – CPS Ph II
ITC: Retrofit of Air Handling System for Tobacco Processing Unit:
Challenges
OLD masonry AHU's with leakages and performance issues.
Existing AHU's incapability of attaining set temperatures.
Leakages.
Solutions
We had offered EUROVENT certified 12 Nos. x 37500
CFM AHUs.
AHU’s with all SS Construction.
Double Decker AHU construction to meet site constraints.
High Efficiency Fan and Motor.
90% efficiency Wet Deck Humidifier.
Results
AHU’s supplied, under installation.
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CPES – CPS Ph II
Energy Retrofits for Chiller Plants
P & G, Mandideep, Madhya Pradesh
ROI: One year (Replacement of existing old reciprocating chiller with energy efficient 200TR screw chiller)
Bharat Serums, Ambarnath
ROI: 1.4 Years (Replacement of existing old reciprocating chiller with energy efficient 170TR screw chiller)
Galaxy Surfactants, Taloja, Thane
ROI: One year (Replacement of existing old reciprocating chiller with energy efficient 100TR screw chiller)
Softesule Pvt Ltd, Mulund, Mumbai
ROI: One year (Replacement of existing old reciprocating chiller with energy efficient 130TR screw chiller)
Gadre Marine Exports, Veraval, Gujarat
ROI: 1.5 year (Replacement of existing old reciprocating chiller with energy efficient 200TR screw chiller)
Tech Mahindra, Pune, Maharashtra
ROI: 1.5 year (Replacement of existing old pumping with Energy efficient Eff 1 pumps.)
Aurigine, Bangalore.
ROI: 2 years (Replacement of existing Air cooled chiller with High efficient Air cooled Chiller)
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