CPES – CPS Ph II

Building

Efficiency

Helping people

achieve

2

Speakers

- Amit

- Shubham

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 24

Automatic Tube Cleaning System

Before Installation After Installation

CPES – CPS Ph II

Case Studies

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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

Retrofit of Complete Air-Conditioning system

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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

Inefficient Cooling &

Heating System

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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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CPES – CPS Ph II 47

Q&A

AMIT SINGH

#9711200916