Energy Conservations

in
HVAC
Prof. B A Shah,
Assistant Professor,
Mechanical Engineering Department
Institute of Technology,
Nirma University
Courtesy GIFT city and GEDA
Outline of Presentation
• ICAP (India Cooling Action Plan)
• Strategies to reduce energy consumption in HVAC
• Inverter AC Technology
• GIFT City District Cooling System (DCS)
• Other Strategies
Introduction- EC in HVAC
• The main power consumers in most buildings are lighting and the
heating, ventilation and air-conditioning (HVAC) systems.
• Substantial savings can be achieved by optimising the heating,
ventilation and air-conditioning (HVAC) system and by upgrading
plant with energy efficient technology.
• Poor maintenance, lack of knowledge on how to use them efficiently,
overuse, and the large number of old and inefficient systems at work
in the sector make HVACs a significant contributor to the country’s
demand for energy.
Strategies to reduce energy consumption
• Reduce Cooling Load
• Use energy efficient HVAC system
• Use of BMS(Building Management System)
• Use VSD(Variable Speed Drive) and inverter technology
• Use Renewable Energy
HVAC System Components

Fig. 1 HVAC system components

Inverter AC Technology
• What is Inverter Technology and how is it different from Non-
Inverter Technology?
• An inverter is a device for converting frequency. The technology is used in
many home appliances and controls electric voltage, current and frequency.
Inverter air-conditioners vary their cooling/heating capacity by adjusting the
power supply frequency of their compressors.
• An inverter type air-conditioner adjusts the speed of the compressor to
control the refrigerant (gas) flow rate, thereby consuming less current and
power. An inverter has precise temperature control and as the set
temperature is attained, the unit adjusts its capacity to eliminate any
temperature fluctuations.
Inverter AC Technology
• In contrast, non-inverter air conditioners have a fixed cooling/ heating
capacity and can only control the indoor temperature by starting or
stopping their compressors.
• Non-inverter air-conditioners stops and starts repeatedly. The power
consumption and current goes down when the operation stops, but it goes
up sharply at the time of restart and thus it has high average power
consumption and temperature variations. As a result, inverter air
conditioners are more energy-saving and comfortable than non-inverter
air-conditioners.
• Let’s take an example of 1.5 Ton AC. Inverter AC can work from 0.3 to 1.7
ton based on cooling requirement. Non-inverter AC can work at 1.5 ton
only (fixed capacity).
Inverter power control

Non-inverter type air-conditioner

• Inverter air-conditioners are able to vary their operating

capacity. Non-inverter air-conditioners can only operate at a
fixed capacity.
Scenario: Indoor Temperature: 22o, Set Temperature: 22o
Inverter air-conditioner

Non-inverter air-conditioner
What are the benefits of Inverter Air-Conditioners?
India’s 1st IFSC
Operational Greenfield Smart City
Air Conditioning System at GIFT
• District Cooling System (DCS) is going to be used in India’s first smart
city – GIFT City.
• Overall 35% energy saving have been claimed by using DCS in GIFT
City.
• No Split ACs or separate Building based chillers will be used, All
buildings including commercial and residential will be provided air
conditioning through DCS only.
WHAT IS DISTRICT COOLING SYSTEM

The Central DCS Plant will include Chiller, Primary Pump, Secondary
Pump, Condenser Pump, Cooling Tower, Thermal Energy Storage and
Distribution network of CHW.
The consumer system would usually comprise of energy transfer
station, tertiary Pumps & chilled water piping and air handling units in
the building.
…District Cooling
What is District Cooling ?
• A DCS consists of three primary components:
• The Central Plant
• The Distribution Network
• The Consumer System
DISTRICT COOLING SYSTEM IN GIFT

A centralized Plant (DCP) which generates chilled water at 5 Deg C with

the help of Centrifugal electrical driven Chillers and associated
equipments.
Thermal Energy Storage Tank (TES Tank) which stores chilled water during
the night and discharge chilled water during day operation.

Distribution piping Network of chilled water supply and return pipes

installed in utility tunnel with branch connections and valves for the
individual buildings.

Energy Transfer Station (ETS) at individual building level which consists of

heat exchangers, control valves and BTU meters.
 225000 TR/ 250 MW
Chiller at Building

Heat load in TR 180000 TR/ 160 MW

District Cooling

6 am 10 am 12 am 4pm 8pm 0 4 am 6am

 180000 TR/ 160 MW

Heat load in TR
150000 TR/ 135 MW

Availability of
Chillers Availability of Chillers
Can be use for Can be use for TES Charging
TES Charging

6 am 10 am 12 am 4pm 8pm 0 4 am 6am

 How DCS Beneficial
POWER DEMAND
Building based Chiller system DCS System

250 MW

135 MW

WATER DEMAND
Building based Chiller system DCS System

25 MLD
20 MLD

22
•Counter series Chillers
•Effective CHW Distribution
•Thermal Energy Storage Tank

23
Counter Series Chillers
35⁰C

10 ⁰C 35 ⁰C 10 ⁰C

38 ⁰C 6 ⁰C
14⁰ C 32 ⁰C

24
Thermal Energy Storage

25
…District Cooling
• District Cooling Advantages
• Less operating costs for System owners
• Easy to operate from centralized Control Room
• Improved supply reliability
• Building owner ends up with more space available for other purposes. A heat exchanger is
needed at the building site instead of a complete cooling system.
• System flexibility makes it possible to adjust cooling capacity to varying demands
• Eliminates the need for building owner to buy, service or maintain cooling equipment
• Environmentally friendly refrigerants are kept contained in one central system
• Optimum number of standby equipment requirements
• Lower operating manpower for centralized maintenance facility
27
CHW Distribution through tunnel 28
 Operating Cost comparison in Gift City
System Operating cost per TR Remarks
DCS Rs. 8 Break even reached @ 3500 TR
(0.8 KW/TR) which is 2% of total city demand

Building based water cooled chiller Rs. 11 Space for chiller & Cooling tower
(1.1 KW/TR) required
Diversity Not applicable
Air cooled chillers Rs. 12 Space for heat rejection not
(1.2 KW/TR) possible in high rise towers

VRF Rs. 14 Not feasible , large no. of ODU

(1.4 KW/TR) installation required

Split AC units Rs. 16 ODU installation not feasible.

(1.6 KW/TR)
29
Cooling load

The first step in energy savings on HVAC systems is to reduce the

cooling load. The amount of electricity air-conditioning systems use
also depends on the cooling load – the amount of heat the system has
to remove. There are several steps to reducing cooling load.
Steps to reduce Cooling Load
Insulate the cooled space
• This involves implementing various measures such as ceiling insulation,
window glazing, blinds, sunshades and door sweeps. All will contribute to
creating a thermally efficient shell that can dramatically reduce the cooling
load on HVAC systems while ensuring that comfortable internal
temperatures are maintained.
Minimise the use of appliances and lighting
• All lights emit heat, so lights and equipment that are not required at any
particular time should be switched off to help to reduce the cooling load.
Replacing standard motors with high-efficiency motors results in lower
losses and less emitted heat. Investing in variable speed drives (VSDs) for
motors to match speed with output demand results in lower energy usage
and heat load.
Steps to reduce power consumption by HVAC
System
• Ensure that controls are in place and HVAC operation reflects demand
• HVAC loads vary at different times and in different parts of a building throughout
the day. Well set time and occupancy controls should ensure that systems only
operate when and where required during core business hours. It is also crucial to
check settings regularly – many systems are set incorrectly because of forgotten
short-term adjustments. Installing a building energy management system (BMS or
BEMS) which offers close control and monitoring of building services
performance, including HVAC, allows automatic control of the HVAC system.
BEMS can reduce energy costs by allowing system performance to be monitored
and settings to be changed.
• Variable Speed Drives(VSD) on HVAC fans and pumps
• This allows motor-driven loads such as fans and pumps to operate in response to
varying load requirements instead of simply operating in “on/off” mode.
HVAC Systems
• HVAC systems account for more than 50% of a facility’s energy usage [1]. After
the cooling load has been reduced and the HVAC system has been optimised in
terms of airflow, environmental controls and sensors, there still remain major
areas of possible energy savings in the major components that form the basis of
the system.
• Most HVAC systems are designed to handle the maximum cooling or heating load
required by the building. This maximum only occurs for a short period in the year
and, for most of the time, the system is faced with a load below the maximum,
and operates below full capacity. Operating below capacity generally means
inefficient operation, and energy savings can be achieved by the use of systems
that optimise operation under conditions below full capacity.
HVAC Systems
The HVAC system consists of the following components:
• Central chilled water plant.
• Chilled water circulation system.
• Air cooling (handling) and circulation system.
• In addition to these units, there are numerous pumps and fans, each
of which contributes to the energy demand, and each of which can be
configured to run energy-efficiently.
Central chilled water plant
The central chilled water plant can consume more than 35% of the energy
required to run a building [2]. Improving the efficiency of the central plant
allows better management of energy usage and cost savings. The chilled
water plant consists of the following components:
• The compressor.
• The condenser.
• The evaporator.
• Cooling water supply (in a water cooled condenser system).
• Chilled water distribution system.
• In addition there are numerous water pumps and fans, depending on the
type of system used. Most building types will offer a varying heat load to
the chiller, and this can result in the plant running at lower than full cause
inefficient operation.
Compressor

• There are two types of compressor drive: Fixed speed and variable
speed. The fixed speed chiller operates at a constant speed and is
designed to deliver a constant quantity of compressed gas
irrespective of the load. Variations in load are accommodated by
several methods:
• Cycling operation (on-off): When the required conditions have been
met, the compressor switches off or goes into idle or bypass mode.
• Using a variable speed drive allows matching the compressor
operation with the load in an efficient and energy saving manner. This
is especially relevant at low loads.
Comparison of fixed and variable speed drives

Fig. 2 Comparison of fixed and variable speed drives[5]

Energy saving in compressor
• Fig. 2 shows the difference between a fixed speed and a variable speed
compressor at different loads.
• Many compressor manufactures offer a variable speed drive matched to
the compressor and mounted on the same frame as the compressor.
Alternatively, a separate VSD may be retrofitted to existing equipment.
Variable speed compressors can operate in the range from very low load
(≈10%) to full load.
• Other improvements include the use of permanent magnet synchronous
motors, which are particularly suited for VFD systems. These offer
improved efficiency over induction motor-driven units (see Fig. 3). Other
compressor improvements include oil-free magnetic bearing drives that
reduce oil usage, have a lower number of parts and, therefore, lower
maintenance requirements
Fig. 3: Energy gains at low speed for permanent magnet synchronous motors [2].
Evaporator
• The evaporator is used to lower the temperature of the chilled water returned
from the water circulation system. The water is passed through the evaporator in
pipes surrounded by condensed refrigerant. The heat from the water evaporates
the refrigerant and the water is cooled in the process. The flooded evaporator
(see Fig. 5) was commonly used in the past. In the flooded type, the refrigerant
covers the tubes completely and evaporation of the mass of refrigerant takes
place when returned chilled water is passed through the tubes.

Fig. 5 Evaporator Configurations

Falling film type heat exchanger (evaporator)

• In the falling film evaporator, the surface of the tubes in the upper portion
of the evaporator is covered with a thin film of refrigerant, giving a very
effective heat transfer mechanism. In the mixed falling film type evaporator
(see Fig. 5), a thin film of refrigerant is sprayed over the top tubes. Some of
this evaporates and the gas passes on to the compressor. The remaining
refrigerant covers the bottom tubes and evaporates as well. The FF-type
offers higher heat transfer efficiency and requires a lower charge of
refrigerant than the flooded type evaporator In the full falling film
evaporator (see Fig. 5), the film covers all the tube and the remaining
refrigerant collects in the bottom of the evaporator. Only the evaporator
bottom has a small amount of liquid refrigerant so that refrigerant charge
is less, complying with environment protection.
• The mixed falling film is claimed to use 15% less refrigerant than the
flooded type. The full falling film type is claimed to use 40%
refrigerant less than the full flooded type. Less refrigerant implies less
energy usage in compressing and pumping the refrigerant around the
cooling circuit.
Condensers

• Water is used to cool condensers to allow condensation of the

compressed gas. Water is circulated though the condenser and then
goes to a cooling tower where the heat is released to the
atmosphere. However, in recirculation, the power required to pump
the water to the cooling tower and to run the cooling tower fans
contributes to the total energy consumption of the HVAC system.
Optimisation of these improves the overall efficiency of the
system. VFDs reduce energy usage by the cooling tower by reducing
the fan speed to match the rejected heat load requirements.
Air distribution systems

• Constant air volume (CAV) systems

• Constant air volume systems feed a constant flow of air and regulate the air
temperature to the heat load.
• Variable volume air system
• The variable air volume system has advantages over the constant air volume
system, but in the basic version has several drawbacks. In a variable air
volume system, the air temperature is kept constant and the flow is varied to
meet the heat load requirements. The basic method of control is to use a
constant speed fan and a damper to regulate air flow. This provides the fan
motor with a constant load irrespective of the air flow rate. Using a variable
speed drive varies the load on the fan motor with variations in air speed and
achieves energy savings as a result.
Central plant optimisation and energy efficient
operation
• HVAC systems consist of a complex arrangement of different
components, all of which must be controlled to work together. In a
manually controlled system, each of the systems is set to its optimum
condition, which might not be optimum for the system as a whole.
• Take, for instance, the air handling unit. There are two flows that can
be controlled, the rate of air flow and the rate of water flow. The
water temperature will depend on the evaporator settings, which also
depend on the compressor and condenser settings. Optimisation will
require adjustment of the operation of all these units to achieve best
efficiency.
Continue…
• Optimising energy usage in the HVAC system involves optimising
every element and the system as a whole. The operation of the
system as a whole can be optimised to ensure further energy savings
even once the individual items have been set for maximum economy.
Central plant optimisation can achieve further gains after equipment
and motor drive upgrades. Up to 60% energy saving are claimed
compared to the existing plant in a plant retrofitted with VSD and
energy efficient equipment[3].
Pumps and pump controllers
• There are numerous pumps in the system and all play a part in energy
savings. When operating at below full capacity, the amount of
refrigerant and cooling liquids required to be moved through the
system is reduced. This is accomplished by controlling the pump
system. Traditional means of controlling the pump output involve
dissipating or diverting the output of the pump running at full speed
by means of bypass and throttle valves, which meant that the pump
was still running at full load or close to full load. VSD drives allow flow
control by varying the speed or other parameters of the pump to
achieve the required flow rate.
Fans and fan controllers

• Energy saving on fans is much greater than on other equipment. On fan loads, the
power requirement varies as the cube of the speed, so the slower the fan speed,
the less energy required. A fan running at 80% speed will consume 50% of the
energy at 100% speed. Modern fan controls consist of much more than just speed
controls and variable speed drives.
• Key to identifying the energy savings opportunities of VSDs in HVAC systems is an
understanding of the operating cycle of the system versus the heating and cooling
needs actually required. Most HVAC systems are designed to keep the building
cool on the hottest days and warm on the coldest days. Therefore, the HVAC
system only needs to work at full capacity on those days.
• For the rest of the year, the HVAC system can operate at reduced capacity. This is
where a variable air volume system with variable speed drives (also-called
variable frequency drives, or VFDs) can be used to match air flow to actual
heating and cooling demands. The VSD can reduce the motor speed when full
flow is not required, thereby reducing the power and the electrical energy used.
 VAPOUR ABSOBPTION SYSTEM

◼ Lithium Bromide and Water System for temperature up to 60C

◼ Water (absorbent) and Ammonia (refrigerant) for temperature
System less than 00C.
◼ Saves 90% power but heat input is quite significant
◼ Overall economics depend on cost of heat supplied
 VAPOUR COMPRESSION SYSTEM
◼ COP = COEFFICIENT OF PERFORMANCE
◼ = REFRIGERATION EFFECT/ WORK DONE
◼ VALUE- 4.0 TO 6.0 for VAPOUR COMPRESSION
◼ 1.0 for VAPOUR ABSORPTION
◼ SPECIFIC POWER CONSUMPTION
◼ KW/TON 0.6 TO 1.0 FOR CHILLED WATER AT 80C
◼ EER= Energy Efficiency Ratio
◼ EER = BTU/HR REFRIGERATION EFFECT/WATTS
◼ 9 TO 13 FOR AIR CONDITIONER
 EFFECT OF TEMPERATURE
EVAPORATOR CONDENSER
TEMPERATURE TEMPERATURE
+400 +500
TR 143 127
+50C POWER 102 117
KW/TR 0.72 0.93
TR 118 104
00C POWER 96.8 108.9
KW/TR 0.82 1.05
TR 96 84
-50C POWER 89.6 99.4
KW/TR 0.93 1.19
Operate at highest possible evaporator temp.
Operate at lowest condenser temp.
ENERGY SAVING OPPORTUNITIES
◼ Optimum temp setting
◼ Each 10C temperature increase in air condition
space reduces power by 2% to 3%
◼ Set A.C. temperature at 270C to 300C
◼ Use fans for circulation
◼ For cold storage better and equal air distribution
allows higher temp.
◼ Better heat exchangers
 REDUCTION IN HEAT LOAD
◼ Provide air conditioning in used area
◼ Provide false ceiling
◼ Reduce outside heat by insulation, sun control films
etc.
◼ For vegetables 50C required
◼ For ice creams -300 C required
◼ Segregate such load
◼ Keep motors, heating devices outside conditioned
space
◼ Air curtains, automatic door closures

PAGE 8.8
LARGER HEAT EXCHANGER
◼ Larger heat exchanger, condenser and
evaporators allow higher evaporator
temperature and lower condenser
temperature
◼ Regularly clean all heat exchanger
◼ Provide proper water treatment
◼ Performance can drop by 50% in absence of
cleaning and water treatment
 NEW TECHNOLOGY
◼ Thermal storage to take advantage of
cheap power at night
◼ Tariff as well as temperature favourable
◼ Heat recovery systems
◼ Heat pipes, heat wheels variable speed
drives heat pumps
References
[1] http://www.ee.co.za/article/energy-saving-in-hvac-systems.html
[2] J Eldridge: “Variable speed compressor technology and
applications”, Daikin.
[3] SEW Eurodrive: “LTP-B Eco HVAC pump control”, www.sew-
eurodrive.co.za
[4] A Lynegar: “Smarter VSDs improve centrifugal pump
operation”, Flow control, March 2017.
[5] York: “York Variable Speed Drives”, www.johnsoncontrols.com
Thank You