10.chiller Case Studies-2

CHILLER SYSTEM ANALYSIS AND CASE STUDIES
WWW.RBS-ENGINEERS.COM
Chiller Case Analysis
CASE STUDY:
PLANT : CHILLER SYSTEM REPLACEMENT TO

HIGHER EFFICIENCY
SAVINGS OF PHP1.31M PER MONTH

OR PHP15.74M PER YEAR.
BUILDING AT AYALA
CENTER, AYALA
CHILLER SYSTEM REPLACEMENT TO

HIGHER EFFICIENCY
SAVINGS OF PHP1.31M PER MONTH
OR PHP15.74M PER YEAR.
MANILA COATS
HVAC SYSTEM
CMBI SPINNING PLANT
FINAL REPORT
Troubleshooting & Analysis
August 30, 2006
DATA GATHERING
…CMBI SPINNING PLANT
DATA GATHERING
DATA GATHERING
R-134A ENTHALPHY
FOR COATS
CMBI SPINNING PLANT
Baseline Readings
COOLING TOWER
North
CMBI SPINNING PLANT
(Maintenance Workshop)
COOLING TOWER
MANILA COATS INC, MARIKINA
THE DUBAI BURJ TOWER
THE DUBAI BURJ TOWER
POOR CHEMICAL TREATMENT

LOW DELTA T
COOLING TOWER
PRIMARY SECONDARY PUMPING
PUMPS IN PARALLEL VS. SINGLE PUMPS
Chilled Waters Systems
SUMMARY
Measurements and verified by accurate data…

and ANALYZED properly
With a dynamic math model simulation of a
system
… is the first and necessary step in improving ENERGY
EFFICIENCY, or improve operational performance or
modifying an existing system for increased capacity and
relaibility.
CASE STUDY:
PLANT : A NEW CHILLER PLANT REPLACING OLD

CONDENSER WATER PACKAGED UNITS.
MALL OF 3400 TONS. SAVINGS OF

PHP3 TO 4 M PER MONTH
ENERGY CASE STUDIES
HVAC UPGRADE
PROJECT,
Muntinlupa
MERALCO BILL
JUNE 2013
PHP4M A MONTH IN SAVINGS.
MERALCO BILL
JULY 2013
PHP4M A MONTH IN SAVINGS.
ENERGY SAVINGS
MERALCO BILL
AUGUST 2013
PHP4M A MONTH IN SAVINGS
YEAR BEFORE - ACTUAL MERALCO BILLS
CASE STUDY:
PLANT : CHILLER SYSTEM REPLACEMENT FROM

IMPROPER SELECTION AND DESIGN OF CHILLERS,
PUMPS AND COOLING TOWERS
MALL OF 1500 TONS. SAVINGS OF

PHP1.5 TO 2 M PER MONTH
Design & Consultancy
UPGRADE PROJECT, EDSA,

Mandaluyong City.

Mandaluyong City.
OLD TOWER

Mandaluyong City.
NEW TOWER

Mandaluyong City.
NEW CHILLERS

Mandaluyong City.
SMALLER PUMPS

Mandaluyong City.
A MERALCO SAVINGS
STARMALL EDSA HVAC

Mandaluyong City.
ENERGY SAVINGS
THIS WAS DONE THROUGH INNOVATIONS IN

ENGINEERING.
LOWEST MERALCO BILLS IN AIRCON:
PHP1.5-2M A MONTH IN SAVINGS
INNOVATIONS: NO BALANCING VALVES ON CIRCUITS.
FILINVEST
SUPERMALL
95,000 sqm air-
conditioned area
of new mall (12 Ha.)
First mall in Philippines
with a river flowing RBSANCHEZ INC, was subcontracted by
AECOM INC to serve as its:
inside the mall.
PRINCIPAL HVAC and FIRE
Design Engineer For Mall
project (Year 2011-2012)
. .
CASE STUDY:
PLANT : CHILLER SYSTEM REPLACEMENT FROM

DX SPLIT TYPES
WAREHOUSE OF 500 TONS. SAVINGS OF PHP0.985M

PER MONTH
SWOT Analysis- Current Air Cooled Chiller
System
WEAKNESSES
STRENGTHS
-Lower cost to acquire air cooled -Large no. of chillers in operation
air conditioning system. high cost maintenance parts and frequency
-Easily installed and operated -high energy cost
-higher manpower time and cost

OPPORTUNITIES - maintenance
-Available expert engineering design firms. THREATS
Current chiller technologies has achieved less than -increasing power rates
0.55kw/ton efficiencies
-possible government ban on old
-Aircon suppliers manufacture specific designed inefficient chillers
chillers for individual customers
-World bank incentive to convert old chillers

15% rebate .
- Bank leasing option to acquire asset

Recommendation
Convert to water cooled air conditioning system
Baseline Assumptions -current

temperature 23- 25C
humidity
cooling efficiency
We shall maintain the current baseline assumptions but achieve

energy savings and cooling efficiency.
Other requirements:
Installation of fans in warehouse

Air condition in admin offices during off normal schedule
Excluded in project cost but can be included if requested”

Financial
1.Asset acquisition
Project cost - 40,000,000.
estimate 400TR 00
monthly savings
minimum 110,200.00 KWH 985,000.00
net monthly maintenance cost
savings 40,000.00
depreciation 120 months (333,333.33)
net savings 691,666.67
Pay back- years (Cash flow) 3.25

Financial
2. Operating lease
Project cost -estimate 400 TR 40,000,000.0

0
Security deposit 10%

4,000,000.00
Amount financed 36,000,000.0

0
Monthly rate for 5 years term 0.018964
Monthly amortization
(758,560.00)
Financial
Savings
110,200.00
Monthly savings minimum KWH 985,000.00
Net monthly maintenance 40,000.00
cost savings
Net savings 1,025,000.00
Net savings after

amortization 266,440.00
Pay back period- deposit 1.25

Implementation timeline
6-8 months total lead
time 1 2 3 4 5 6 7 8
Approval
Down payment
Schematic design
Detailed design
Final Approval
Down payment
Bank processing and
approval
Construction
Import of chillers
Installation
Electrical
Commissioning
Testing
Training
Turn over
New Chiller Developemts
HOW?
Chiller Operation and Analysis
Take Baseline data

Taking past chiller logs and entering the data
establishes a starting point for analysis.
Any improvements or operational changes,

past or present, are recorded for review.
CHILLER SYSTEM ANALYSIS
Ensure accurate data
The best way to provide precise data, obtain concrete

results, and minimize problems is to verify flow rates to
the chiller for tonnage measurements and other
calculations to determine efficiency.
Four methods for determining flow are inline flow meter,

external flow meter, delta pressure, and delta
temperature.
Flow meters—turbine type, magmeter (inline), or
ultrasonic (external)—provide the most accurate flow
readings in gallons per min (gpm).
Adjust water temperature SETPOINTS
For constant speed chillers, every 1 deg F increase in

chill water temperature can increase chiller energy
efficiency 1-2 percent.
Take advantage of wet bulb conditions in the cooling

tower system to lower the chiller’s entering
condenser water temperature. This can result in a 1-
1.5 percent efficiency improvement for every 1 deg F
below the chiller full load design.
Treat water aggressively
A good water treatment program is a necessity for

efficiency. The results can provide significant energy
savings with greater chiller efficiency, maximized
equipment life, and reduced overall maintenance
costs.
Curb noncondensable gasses
When a leak develops in the evaporator, air and

moisture are pulled in, which affects the compressor
and reduces heat transfer efficiency. The compressor
is working to move the noncondensable but getting
no refrigerant effect.
Noncondensables can blanket tubes in the condenser
lowering the overall efficiency up to 6-8 percent at
60 percent load and 8-14 percent at full load.
Maintain refrigerant levels
Low levels cause the compressor to work harder and less

efficiently
Trending refrigerant levels will help determine if the

chiller has a leak(s), a bad purge unit, or refrigerant
carryover.
Regular refrigerant analysis is an important part of

determining chiller inefficiencies. If oil content in the
refrigerant is above the chiller manufacturer’s guidelines,
it may be reducing heat transfer.
Monitor refrigerant approach temperature

One of the earliest signs of chiller inefficiency is an increase in
refrigerant approach temperature (RAT).
The RAT is determined by calculating the difference between

the leaving fluid (water) and the saturated temperature of the
refrigerant being heated (evaporator) or cooled (condenser).
Every chiller has a manufacturer design RAT. When it is exceeded, a

problem with heat exchange in the chiller exists. Problems
associated with high RAT include low refrigerant level,
noncondensable gasses, low/high flow rates, part loads at low
ECWTs, and finally, a scaled or fouled chiller.
Analyze Oil and Refrigerant

Annual chemical analysis of oil and refrigerant can
aid in detect chiller-contamination problems before
they become serious. Testing consists of
spectrometric chemical analysis to determine
contaminants, including moisture, acids and metals,
which hamper performance and efficiency.
Oil analysis can help detect other chiller

problems. For example, high moisture content in the
oil can signal problems with the purge unit, and
changes in oil characteristics can signal the
development of unacceptable compressor wear.
The Point is:

Chiller systems are complex and
cannot be covered in a 1/2 day
course.
We cannot list all possible
problems and make them as
examples…But…
We can discuss your …

CHILLED WATER SYSTEM
CASE STUDIES!!!
NEW DEVELOPMENTS…
Smaller Centrifugal Compressor
72
Oil-less Centrifugal Chillers

Advanced designs enable new centrifugal chillers to
operate without using gears — a direct-drive system
— allowing the units to operate without oil.
This advance eliminates the risk of oil contamination

and the resulting loss of operating efficiency.
Oil-less Centrifugal Chillers

One problem that cuts into the operating efficiency
of many centrifugal chillers is oil contamination of
the refrigerant circuit. The drive systems of most
centrifugal chillers use a series of gears, which
requires lubrication. In normal operation, only a
small amount of this oil ever ends up in the
refrigerant circuit.
Accurate analysis
needed
A coil utilising micro-channel tubes has better

heat transfer than standard coil construction.
SUMMARY
Taken together, the recent advances in chiller design

means significant savings for institutional and
commercial facilities. Managers that take advantage
of new technologies and design features can expect
these systems to use only 50-60 percent of the
energy required by systems installed as recently as
10-15 years ago
CONCLUSIONS:
ENGINEERS!
EMPOWER YOURSELF !
CONCLUSIONS:
WHY? BEING AN ENGINEER,

YOU HAVE AN ACCOUNTABILITY
TO THE PUBLIC AND THE
NATION BEYOND THE
ENGINEERING ANALYSIS.
CONCLUSIONS:
…. YOU HAVE TO DELIVER

ENERGY SAVINGS AND HELP
MOTHER EARTH!
THANK YOU
-END-

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CHILLER SYSTEM ANALYSIS AND CASE STUDIES

PLANT : CHILLER SYSTEM REPLACEMENT TO

SAVINGS OF PHP1.31M PER MONTH

CHILLER SYSTEM REPLACEMENT TO

POOR CHEMICAL TREATMENT

Measurements and verified by accurate data…

PLANT : A NEW CHILLER PLANT REPLACING OLD

MALL OF 3400 TONS. SAVINGS OF

PLANT : CHILLER SYSTEM REPLACEMENT FROM

MALL OF 1500 TONS. SAVINGS OF

UPGRADE PROJECT, EDSA,

UPGRADE PROJECT, EDSA,

UPGRADE PROJECT, EDSA,

UPGRADE PROJECT, EDSA,

UPGRADE PROJECT, EDSA,

UPGRADE PROJECT, EDSA,

STARMALL EDSA HVAC

THIS WAS DONE THROUGH INNOVATIONS IN

LOWEST MERALCO BILLS IN AIRCON:

PHP1.5-2M A MONTH IN SAVINGS

PLANT : CHILLER SYSTEM REPLACEMENT FROM

WAREHOUSE OF 500 TONS. SAVINGS OF PHP0.985M

-Easily installed and operated -high energy cost

-higher manpower time and cost

-Available expert engineering design firms. THREATS

-World bank incentive to convert old chillers

- Bank leasing option to acquire asset

Baseline Assumptions -current

We shall maintain the current baseline assumptions but achieve

Installation of fans in warehouse

Excluded in project cost but can be included if requested”

depreciation 120 months (333,333.33)

net savings 691,666.67

Pay back- years (Cash flow) 3.25

Project cost -estimate 400 TR 40,000,000.0

Security deposit 10%

Amount financed 36,000,000.0

Net savings after

Pay back period- deposit 1.25

Take Baseline data

Any improvements or operational changes,

Ensure accurate data

The best way to provide precise data, obtain concrete

Four methods for determining flow are inline flow meter,

Adjust water temperature SETPOINTS

For constant speed chillers, every 1 deg F increase in

Take advantage of wet bulb conditions in the cooling

Treat water aggressively

A good water treatment program is a necessity for

Curb noncondensable gasses

When a leak develops in the evaporator, air and

Maintain refrigerant levels

Low levels cause the compressor to work harder and less

Trending refrigerant levels will help determine if the

Regular refrigerant analysis is an important part of

Monitor refrigerant approach temperature

The RAT is determined by calculating the difference between

Every chiller has a manufacturer design RAT. When it is exceeded, a

Analyze Oil and Refrigerant

Oil analysis can help detect other chiller

The Point is:

We can discuss your …