AMRI Global Final Presentation Chillers

Detailed Energy Audit at AMRI,
Hyderabad
25th April, 2012
Confederation of Indian Industry

CII – Godrej Green Business Centre, Hyderabad, India
At the outset
Thank you for
 Opportunity
 Support
© Confederation of Indian Industry

Objective
AMRI ,Hyderabad
 Achieve Maximum Energy Saving
 Improve on a continuous basis to
achieve Green Building status

Methodology
Data Collection
Measurements
Discussion
And Now…
Presentation

Past Energy Conservation activities
 Installation of VFD for chilled water pumps

 Installation of VFD for AHU fans
 Use of actuators for controlling chilled water flow
 And many more…
Committed Team

ROLE OF CII
 Catalyst / Facilitator role
 Supplement in-house activities
 Identify energy saving proposals
 All possible assistance
 Monitoring
 Vendor identification
Not fault finders !!

Major energy consumers
 Air conditioning system
 Chillers
 Chilled water pumps
 Air handling units
 Scrubber system
 Lighting

Presentation flow
 Chiller system
 Chilled water pumps
 Air handling units
 Scrubber units
 Compressed air system
 Electrical system
 Lighting
 UPS

Air conditioning system
 Two chillers installed for catering air conditioning
load of facility
 Normally only one chiller in operation
 Three chilled water pumps installed for pumping
chilled water from chiller to AHU
 13 number of air handling units
 For writing area
 For labs

Avoid flow through idle chiller
13.70C 8.60C
Return Chiller
Water from Supply to
AHU AHU
Chiller 12.30C
13.70C
Chilled water pumps

 Normally, one chiller in operation for catering air
conditioning load of facility
 Flow measurements taken:
 Flow through working chiller : 82.5 m3/hr
 Flow through idle chiller : 76.5 m3/hr
 Return water from AHU is pumped to both the
chillers (through idle chiller also)
 AHU return water temp0 : 13.70C
 Chilled water temp0 from working chiller : 8.60C
 Water temp0 from idle chiller : 13.70C
 Chilled water temp0 to AHU (after mixing) : 12.30C
 Due to mixing of water from idle chiller,
temperature of chilled water increases from 8.6 to
12.30C
 Almost 40C is lost because of mixing of water from
idle chiller
 Fro every 10C temperature change, chiller power
consumption changes by 4%
 Trial taken:
 Closed valve of idle chiller
 Water allowed to pass only through working chiller
 Chiller working observed carefully
13.30C 10.40C
Return Chiller
AHU AHU
Chiller 10.40C
Chilled water pumps

 In this scenario, heat removed from system is
higher than previous scenario
 Improved temperature conditions in user space
 Better user comfort
 Recommendations:
 Avoid flow through idle chiller
 Effectively utilize energy used for chiller

Effective utilization - Rs 3.36 Lakhs

Effective energy utilization - 16 kW

Switch off one chilled water pump
ON
Return ON Chiller
AHU AHU
Chiller
Chilled water pumps

 Two pumps in operation for pumping chilled
water to AHU
 Pump design:
 Flow : 71 m3/hr
 Head: 35 m
 Flow measurements taken:
 Flow through working chiller : 82.5 m3/hr
 Flow through idle chiller : 76.5 m3/hr

 Trail taken:
ON 13.30C 10.40C
Return OFF Chiller

AHU AHU
Chiller
10.40C
Chilled water pumps

 Trail taken:
 Valve closed for idle chiller
 Water allowed only through one chiller
 Switched off one pump
 As a rule of thumb, for air cooled chiller of this
capacity requires 2 gallons per minute / TR
 Running one pump will suffice the requirements

 Recommendations:
 Allow water only through one chiller
 Operate only one chilled water pump
 Switch off the other pump
 11 kW can be saved
Annual Saving - Rs 2.30 Lakhs

Replace the existing chiller pump with
higher efficiency pump
 Current Scenario
 2 Pumps – Running
 1 Pump - Standby

Replace the existing chiller pump
with higher efficiency pump
 Design Specification
 Flow - 71 m3/ hr
 Head - 35 M
Parameter Unit 1 Pump 2 Pump

Head meter 17 27
Flow m3/ hr 104 146
Power kW 11 22
Efficiency % 48 54
 Recommendation
 Install 2 Pumps
 Smaller Pump – 1 chiller operation
• Flow – 80 m3/ hr
• Head – 17 m
• Power - 6 kW
 Bigger Pump – 2 chiller operation
• Flow – 150 m3/ hr
• Head – 17 m
• Power - 11 kW

 Savings
 1 small pump & 1 chiller running - 5 kW
 1 bigger pump & 2 chillers running - 11kW

Annual savings
1 small Pump, 1 chiller - Rs. 1.00 Lakhs
1 bigger Pump, 2 chiller - Rs. 2.31 Lakhs
Investment
Small Pump - Rs. 0.26 Lakhs
Bigger Pump - Rs. 0.47 Lakhs
Payback
Small Pump - 4 months
Bigger Pump - 3 months

Install ECOMESH for Chillers
 Air cooled system
 Lower heat transfer coefficient
 Higher will condenser temperature
 Lower COP, Higher power consumption
 > 1.0 kW/TR
 Water cooled system
 Higher heat transfer coefficient
 Lower condenser temp, higher COP
 Lower power consumption, < 1.0 kW/TR
 Good savings potential
 Air cooled to water cooled
 Latest trend
 Installation of ECO MESH for air cooled system
 ECO MESH
 Fine spray of water
 Lower air temperature achieved
 Lower condenser temperature

Fine Water Fine Water

spray spray
Air Cooled CT
Cooled air
Spray Pump

 At least 5oC reduction in air temperature
 At least 10% reduction in power
 Reduction in kW/TR
 Attractive pay back
 16 kW can be saved

Investment - Rs 7.00 Lakhs
Payback - 25 months

Operation of faulty actuators
Chilled water supply
Actuator AHU
By pass line
Chiller

 Actuators installed at all the users at AHUs
 For Chilled water flow control
 Few actuators only in operation
 Recirculation valve fully open
 Recirculating back to return line through
bypass
 Recirculation increases the power
consumption of pump
 Good potential to optimise the recirculation
 Recommendation:
 Replace faulty actuators
 Close recirculation line
 Recirculation reduces, back pressure
increases
 Give back pressure as feedback for chilled
water pump VFD
 Operate the VFD in closed loop based on
 Pump discharge pressure

 3 kW can be saved

Operate corporate & reception AHU with
VFD
 VFD installed in corporate and reception AHU
 Static pressure is given as feedback for AHU fan
VFD
 Presently, VFD operated in manual mode
 Normally, AHU fan VFD is operated with return air
temperature feedback
 Recommended to operate fan with return air
temperature as VFD feedback
 Finer temperature control ca be achieved
Operate corporate & reception AHU
with VFD
 1 kW can be saved

Optimizing scrubbing air flow
operation
RETURN AIR FLOW

+110 mmwc +7mm
B
SCRUBBER FAN
FAN

operation
Unit FF Lab GF Lab Kilo - 2

Flow
Before m3/s 10.65 5.46 0.75
Flow
After m3/s 8.25 4.92
Difference % 22.50 9.76
Power Savings kW 7.80 5.40 5.50

operation
 Recommendation
 Switch OFF scrubber fans for FF, GF and
kilo 2 Lab
 Total savings – 18 kW

operation
Annual savings - Rs. 3.90 Lakhs

Investment - NIL

ELECTRICAL

Optimize the pressure of compressed
air
 Pressure Setting:
 11 kW compressor
 Loading : 8 bar
 Unloading : 9 bar
 Loads connected
 NMR – Major load
 Requires 4.5 – 5 bar maximum
 Cleaning purpose inside the lab
 Requires less than 3kg/cm2
 Higher compressed air pressure
 Higher energy consumption
Optimize the pressure of compressed
air
 Recommended to optimize the
compressed air pressure to 5 bar
Annual savings - Rs. 0.55

lakhs

Optimize UPS system
 To provide uninterruptible power for critical loads
 Inherent loss in system
 Efficiency : 80% - 94%
 Present load
 Servers, desktops
 Critical equipment in labs
 Factors
 Redundancy
 Energy efficient

Load vs. Efficiency

UPS system – Approach
Loading optimization
Two pronged
Approach
Only critical load

function
Optimize UPS system
 Present loading
Around 15%
Total kVA - 50 kVA
 Optimum loading for the UPS
 70%-100%
 Automatic transfer switch system
 Keeps the UPSs in hot stand by
 Switches ON additional UPS if the load
increases
Optimize UPS system
 Recommended to maintain 70-100%
load on the UPS by installing ATS

Payback period - 24 Months

Replace 250W HPSV and Metal halide
lamps with solar street light LEDs
 250W HPSV and Metal halide
lamps
 Exclusively for street
lighting
 16 nos.
 Good potential to replace

 Solar based LED lighting
 Low wattage
 Less operating cost

Replace 250W HPSV and Metal halide
lamps with solar street light LEDs
 Recommend to replace 250W HPSV and
Metal halide lamps with solar street light
LEDs

Payback period - 58 Months

Bypass the identified VFDs running at
50 Hz
Name Motor power
(kW)
AHU – 7 2
Exhaust Scale up 6
lab
AHU – 8 2
Corporate AHU 4
CWP – 1 11
GF Lab AHU 11

Bypass the identified VFDs running at
50 Hz
Name Motor power
(kW)
Exhaust Synthetic 8
Chem lab FF
Exhaust Synthetic 9
Chem lab
AHU-2 Scale up 12
lab

Bypass the following VFDs running at
50 Hz
 Efficiency of VFDs
 96-98%
 VFDs at Full speed
Atleast 2% loss

Bypass the following VFDs running at
50 Hz
 Recommend to bypass the VFDs
running at full speed
Annual savings - Rs. 0.25

lakhs

Long Term Projects

Install 50kWp Solar Photovoltaic for
building lighting
 Lighting
 Connected load - 62 kW
 Measured lighting load - 29 kW

Install 50kWp Solar Photovoltaic for
building lighting
 Recommend to install solar photovoltaic
for lighting


SUMMARY OF FINDINGS
Parameters No. of Projects Rs. Lakhs
Total Annual Savings

11 16.84
Annual Savings – Without
investment 7 11.19x
Annual Savings
- with inv. 4 5.65
Investment required 4 12.16

Average Simple Payback
Period 26 months **
** For capital proposals only
To Sum-up
 AMRI - Done well in the past
 AMRI & CII- Energy Audit indicates

further Potential
 AMRI – To implement and reap the

potential
 CII – Assist in implementation

Thank you

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Detailed Energy Audit at AMRI,

Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

 Installation of VFD for chilled water pumps

© Confederation of Indian Industry

Not fault finders !!

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

Chilled water pumps

© Confederation of Indian Industry

© Confederation of Indian Industry

Effective utilization - Rs 3.36 Lakhs

© Confederation of Indian Industry

Chilled water pumps

© Confederation of Indian Industry

© Confederation of Indian Industry

Return OFF Chiller

© Confederation of Indian Industry

© Confederation of Indian Industry

Annual Saving - Rs 2.30 Lakhs

© Confederation of Indian Industry

© Confederation of Indian Industry

Parameter Unit 1 Pump 2 Pump

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

© Confederation of Indian Industry

Fine Water Fine Water

© Confederation of Indian Industry

Annual Saving - Rs 3.36 Lakhs

© Confederation of Indian Industry

Chilled water supply

© Confederation of Indian Industry

© Confederation of Indian Industry

Annual Saving - Rs 0.63 Lakhs

© Confederation of Indian Industry

Annual Saving - Rs 0.20 Lakhs

© Confederation of Indian Industry

RETURN AIR FLOW

© Confederation of Indian Industry

Unit FF Lab GF Lab Kilo - 2

Power Savings kW 7.80 5.40 5.50

© Confederation of Indian Industry

© Confederation of Indian Industry

Annual savings - Rs. 3.90 Lakhs

© Confederation of Indian Industry

© Confederation of Indian Industry

Annual savings - Rs. 0.55

© Confederation of Indian Industry

 Critical equipment in labs

© Confederation of Indian Industry

© Confederation of Indian Industry

Only critical load

Annual Saving - Rs 0.45 Lakhs

© Confederation of Indian Industry