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Title: Optimization of Central Air-conditioning Chillers System

Title: Optimization of Central Air-conditioning Chillers System. Project No. OAS-06-003 (2W). Team: Leader: Joselito Mendez Assistant: Oscar Roman Members: Manny Mabalot George Villamor Gabriel Custodio - BCC Jojo Placer – Trane Philippines

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Title: Optimization of Central Air-conditioning Chillers System

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  1. Title: Optimization of Central Air-conditioning Chillers System Project No. OAS-06-003 (2W) Team: Leader:Joselito Mendez Assistant: Oscar Roman Members: Manny Mabalot George Villamor Gabriel Custodio - BCC Jojo Placer – Trane Philippines Champion: Chatiya Nantham

  2. DEFINE Project Charter The operation of air-conditioning is the largest energy user in ADB HQ utilizing about 44% of the total energy consumption. Operation of Chiller plant is a major component of the high energy consumption of the whole air-conditioning system.Improving the operating efficiency range of the chillers operation is a key energy saving opportunity. As part of EHSMS, energy conservation from this project certainly contribute to reduction of air pollution in the local environment particularly fuel exhaust emission from thermal power plant. Business Case:

  3. DEFINE Problem Statement: The central chiller plant serves the 24/7 cooling requirement of the building ranging from 200 to over 1,800 tons. Data shows that the plant has the capability to operate from 0.74 – 0.80 kW/ton efficiency range to deliver this cooling demand. However, it also operates inefficiently to an undesirably low value of 1.10 kW/ton. This clearly indicates that there are factors that affect the overall performance efficiency of the plant. Project Goal: Improve and maintain Chiller plant operating efficiency not more than 0.75 kW/ton to realize energy saving without sacrificing the quality of air-conditioning services.

  4. Illustration of Basic Chiller Plant Operation Amount of heat in the space = Air-conditioning load which expressed in Tons Efficiency = KW / TON Space heat load Chiller Automation System CP ChwP CT Chiller Plant

  5. Subtract 1-Chiller (350T) Add 1-Chiller (700T) > 1750 A 3 x 700T Start Chiller-5 (350T) 6:30 am Add 1-Chiller (700T) Monitored Load >1050T Add 1-Chiller (700T) Load ? Maintain Operating Chillers >/ = 1750 B 2 x 700 T 1 x 350 T Automation System Subtract 1-Chiller (350T) = 1400 2 x 700 C 24/7 Operation Subtract 1-Chiller (700T) Subtract 1-Chiller (700T) = 700 = 1400 Subtract 1-Chiller (700T) Monitored Load = 350T A A Subtract 1-Chiller (700T) = 700 Load ? Subtract 1-Chiller (350T) = 1400 Load ? B B Subtract 1-Chiller (700T) Subtract 1-Chiller (700T) = 350 = 700 C C

  6. C h i l l e r s O p e r a t i o n Legend: ChwP – Chilled Water Pump (4-units) CP – Condenser Water Pump (5-units) CT – Cooling Tower (4-units)

  7. S I P O C D i a g r a m SIPOC Diagram

  8. Translation to Savings ( Illustration ) Present: Ave. Eff. = 0.75 kw/ ton Improved by 7.5%: 0.70 kw/ Ton Savings for every 100 Tons 100 tons x (0.75 – 0.70) Kw/ton x Php 7.00/Kw-hr = Php 35.00 per 100 ton/hr Load, tons x (1.0 - .75) kW/ton x 8 hrs x Php 7 =

  9. Measure Data Collection and Consolidation: • Retrieve/ download 2005 data from Chillers Automation System (Trane Tracer Summit). • Average 24-hrs operation efficiency of central chiller plant. • Initially use 5-months (March – July 2005) as sample data to measure the process capability.

  10. Measurement HistoricalData/Chiller Operation

  11. Measure Is data NORMAL? For Normal Data: P-Value > 0.05 Mean = Median For this Normality Test: P-Value < 0.005 Mean (0.81660) not equal to Median (0.78000)

  12. Measure Normality Test Data is not in the straight line pattern

  13. Measure Process Capability Zlt = Ppk x 3; -0.13 x 3 = 0.39 Zst = Zlt + 1.5; -0.39 + 1.5 = 1.11 sigma

  14. Measure Pareto Diagram for Chiller Plant Efficiency Diagram shows that the plant operates at the region of 0.74 – 0.78kW/ton most of the days.

  15. Measure

  16. Analyze Cause and Effect Diagram for Chiller Plant Operation

  17. Analyze Verify Efficiency Behavior at Different Load Range

  18. Analyze

  19. Analyze

  20. Analyze

  21. Analyze

  22. Analyze

  23. Analyze

  24. Analyze

  25. June 30, 2005

  26. June 30, 2005

  27. June 30, 2005

  28. Chiller no.3 Chiller no.2 Chiller no.2 June 30, 2005 Chiller no.3 Chiller no.2 Chiller no.2 Chiller no.3

  29. June 30, 2005

  30. June 30, 2005

  31. June 25 & 26, 2005

  32. Mar 05 Mar 26 Mar 26 Mar 05

  33. Analyze

  34. After Office Hour Operation

  35. Chiller System ( kW, TONS) PLANT OUTPUT Building Cooling Demand LOAD Chilled Water Pump (kW) Tons Chilled Water (Flow, Temp.) COMPRESSOR kW Efficiency EVAPORATOR Tons Power CONDENSER Condenser Water Pump (kW) . Cooling Tower ( kW ) Chiller Automation System CHILLER PLANT LAY-OUT

  36. Analyze Cause and Effect Diagram for Chiller Plant Operation OPERATION PEOPLE Technology operating chillers vs. demand load C qualification C chillers vs. pumps, cooling tower requirements C common knowledge Chiller Obsolency C N timely start-up/ shut-down of chillers C training Chiller Plant Eff. Variation C Chiller Automation chillers combination attitude C C N chilled water flow C reporting of abnormalities C C chiller out chilled water temp. guides on decision making difference N C bms c.t. out C data monitoring and indepth analysis C condenser water temp. difference field C regular maintenance N C condenser water flow C timely correction/ adjustment of weather approach temperature N C C malfunctioning control devices load N – can’t be controlled N BEST PRACTICES PARAMETERS C – can be controlled

  37. I. Covered in the previous reviews - Analyze Phase: • a. Chillers load vs. efficiency profile at different operating time frames: • office hours operation • after office hours operation • night operation • Saturday and Sunday operation b. Chiller plant’s load and efficiency trends for (5) five months (March – July 2005) operation; c. Verification of individual chiller performance. d. Cause and effect diagram for chiller plant operation. II. Last review - Analysis Phase: • Trending of chillers operating parameters to verify whether these are • within or outside normal range.

  38. Chiller No. 3 design: 0.8 deg C Chiller No. 2 Chiller No. 2 clean: 1.4 deg C design: 0.77 deg C Chiller No. 3

  39. Illustration of Approach Temperature 6 deg C Refrigerant temp. 6.8 deg C Tube Scale Water Fouled Tube Clean Tube Approach Temp. = Water temp. – Ref. temp. Say: Refrigerant Temp = 6 deg C Water Temp. = 6.8 deg C Approach Temp. = 6.8 – 6 = 0.8 deg C

  40. Chiller No. 2 Chiller No. 3 Active setting: 6.5 deg C design: 31.11 deg C

  41. chillers shut-down transition upper limit: 5400lpm design: 5110lpm lower limit: 4800lpm

  42. Upper Limit Design at full operation Lower Limit VSD Pump in operation Condenser Design App. Temp. = 0.61 deg C Evaporator Design App. Temp = 0.44 deg C

  43. ChW Active temp set pt. = 6.5 deg C Cond. In Temp. - design Design Condenser Temp.: In = 31.11 deg C Out = 36.29 deg C

  44. Analyze The analyzes show that: • With the operation of chiller no.1, the chiller plant efficiency goes to undesirably low value of more than 1kW/Ton. • 2. Chiller no.4 is not efficient to operate below 650-Tons load and this contributes in not achieving the target of 0.75kW/ton. However, it was found that although this chiller is rated 700-tons but it can efficiently handle the load up to 800-tons. • 3. Chillers nos. 2 and 3 are identical machine but the latter is more energy efficient than the former. • 4. Chiller no.2 is exhibiting relatively higher condenser approach than chiller no.3. This could be one factor that affects the performance of chiller no.2. • Higher percentage of over 0.75kW/Ton chiller plant efficiency is in the load range of 701 - 900 tons which normally occurs outside regular office hours. This air-conditioning load is shared by 2 x 700-tons chillers which are operating at their lower efficiency zone. • 6. Interview with Chiller and BMS operators revealed that their awareness on the chillers and Tracer operations is not consistent.

  45. Improve • Short-term: Improve Best Practices: • 1. Maintain the following chillers combination during office hours: • a. chillers no. 2 + no. 3 at cooling demand range of 700+ – 1400 Tons; • b. chillers no. 2 + no.3 + no. 5 at cooling demand range 1400+ – 1750 Tons • c. either chiller no. 2 or 3 + no. 5 + no. 4 when cooling demand is in the • range 1,750+ - 1,900 Tons. • Run either chiller no.2 or no. 3 on Saturday instead of chiller 4 which is programmed to run every Saturday. • 3. Run chiller no.4 when it can be loaded by 650 – 850 Tons. • 4. Coincide the operational test run of chiller no. 1 during weekly Genset operation on Sunday. This is more practical because the standby Generator units can be used more efficiently and stored diesel can also be gradually replaced rather its quality degrade overtime. This can bring savings from wastage of diesel, and payment to Meralco on energy used. This is possible because the Gensets are already undergoing regular preventive maintenance. • 5. Maintain chillers operating parameters within the design tolerable range.

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